Ultrasonic Sealing Anvil Step and Groove Misalignment Compensation
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Solution Overview
Problem
Current ultrasonic sealing anvils either apply suboptimal pressure to the overlap part when aligned or excessive pressure when misaligned, leading to potential damage and leakage of packaging materials.
Innovation Solution
An ultrasonic sealing anvil with a step and grooves on both sides, allowing for optimal pressure application when aligned and mitigating pressure when misaligned, ensuring uniform sealing without damaging the packaging material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the anvil uses continuous grooves to prevent leakage during misalignment, then reliability is improved, but the pressure applied to the overlap part is reduced and the anvil abutting area is small, requiring stronger pressure that may damage the packaging material
Solution Approach 1:
The anvil surface is segmented into distinct functional zones: a recessed portion for normal sealing and a protruding portion for misalignment compensation. This segmentation allows each zone to serve its specific purpose without interfering with the other, enabling the system to maintain reliability while avoiding damage to the packaging material.
Solution Approach 2:
Different regions of the anvil are given different geometric properties: the recessed portion provides concentrated pressure for effective sealing, while the protruding portion provides distributed pressure for misalignment protection. This local differentiation of quality allows the anvil to adapt its pressure characteristics based on the sealing condition.
2Productivity
If ultrasonic sealing speed is increased to improve productivity, then productivity is improved, but positioning accuracy between the recess of the anvil and the sealing part deteriorates, causing misalignment
Solution Approach 1:
The anvil structure dynamically adapts to positioning variations through its dual-portion design. During high-speed operation, if misalignment occurs, the protruding portion automatically engages to compensate, allowing the system to maintain sealing quality across a range of positioning accuracies without reducing productivity.
Solution Approach 2:
The anvil geometry is designed with specific dimensional parameters: the recessed portion has a depth and width optimized for normal sealing, while the protruding portion has height and width optimized for misalignment compensation. These parameter variations enable the anvil to function effectively under different positioning conditions.
3Reliability
If discontinuous pressure is applied to the overlap part, then misalignment is compensated, but the pressure is reduced and optimal pressure cannot be applied even when aligned
Solution Approach 1:
The pressure application is segmented into two distinct modes: concentrated pressure through the recessed portion when aligned, and distributed pressure through the protruding portion when misaligned. This segmentation allows optimal pressure to be applied in both scenarios without compromise.
Solution Approach 2:
The protruding portion acts as an intermediary element that engages when misalignment occurs, mediating between the horn and the overlap part to provide compensatory pressure distribution without interfering with the primary sealing function of the recessed portion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The anvil effectively applies optimal pressure to the overlap part without misalignment and prevents excessive pressure during misalignment, enhancing sealing quality and reducing the risk of leakage.
Implementation Method 1
Ultrasonic sealing provides vibrational energy to the sealing part via the horn simultaneously with application of pressure, and melts the thermoplastic resin on the inner surfaces of the packaging material to fuse them together
Implementation Method 2
Ultrasonic sealing provides vibrational energy to the sealing part via the horn simultaneously with application of pressure, and melts the thermoplastic resin
Data Source
AI summary
An ultrasonic sealing anvil is provided which is capable of applying an optimal pressure to an overlap part in the absence of misalignment between the overlap part and the anvil, and preventing application of an excessive pressure in the occurrence of misalignment. An ultrasonic sealing anvil is configured to seal a tubular material having an overlap part extending in one direction, in a sealing direction crossing the overlap part. The anvil is provided with a step that can be abutted with the overlap part R, and a pair of grooves arranged sandwiching the step in the sealing direction.