Ultrasonic Welding Ribs for Plastic Closure Delamination
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Solution Overview
Problem
Existing plastic closure devices for tubular bags made of multi-layer plastic films fail to achieve a strong and durable welded connection, leading to delamination issues during tilting tests, where the flange separates easily from the film despite passing tensile and twist tests.
Innovation Solution
The use of an energy-introducing arrangement on the flange underside with multiple concentric and radially arranged energy-conducting ribs during ultrasonic welding, optimizing the distribution of melted material for improved bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is performed with conventional energy-conducting ribs, then the welded connection passes tensile and twist tests, but the flange separates easily from the film during tilting tests due to delamination
Solution Approach 1:
The energy-conducting rib structure is segmented into multiple concentric ribs (first, second, and third concentric energy-conducting ribs) with different radial positions and configurations. This segmentation allows different zones of the flange to receive optimized ultrasonic energy distribution, creating varied welding patterns that prevent delamination across the entire bonding interface while maintaining passage through tensile and twist tests.
2Strength
If the welded connection is strong enough to pass tensile and twist tests, then the connection appears durable, but delamination occurs during tilting tests
Solution Approach 1:
Different concentric energy-conducting ribs are designed with varying properties: the first concentric rib has a specific pattern, the second concentric rib has a different pattern, and the third concentric rib has yet another pattern. This local differentiation creates zone-specific welding characteristics that collectively enhance both the overall strength (passing tensile and twist tests) and the layer bonding stability (preventing delamination during tilting tests).
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 enhanced arrangement significantly improves the bonding between the plastic closure device and the multi-layer plastic film, preventing delamination and ensuring a strong, durable connection that withstands tilting tests.
Implementation Method 1
a flange with a flange underside on which an energy-introducing arrangement is arranged, which can be connected to a plastic layer by means of ultrasonic welding
Implementation Method 2
The energy-introducing arrangement comprises at least one energy-conducting rib running concentrically to the flange edge
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
A plastic closure device (1) must be welded by means of ultrasound onto a tubular bag (2) consisting of a multilayer plastic film (20). For this purpose, an energy introduction arrangement (182) on the underside (180) of a flange (18) is proposed, in which at least one energy conduction rib (183) concentric with the outer edge (181) of the flange is present, as well as a plurality of outwardly-directed energy conduction ribs (184). These energy conduction ribs can intersect in the region of intersection (185) or they can be interrupted in the region of intersection.