Composite Sheet Manufacturing via Ultrasonic Bonding and Embossing

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Solution Overview

Problem

Conventional methods for manufacturing composite sheets with fusion bonds and through-holes face issues such as displacement of fusion bonds and through-holes, and high maintenance burdens due to wear of small projections on rollers.

Innovation Solution

A method and apparatus that use embossing rollers with projections and depressions to deform the first sheet, followed by ultrasonic processing to form fusion bonds with through-holes, reducing displacement and maintenance by preheating the sheets to controlled temperatures and applying precise ultrasonic vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional rollers with small projections are used to form fusion bonds with through-holes, then fusion bonds and through-holes can be formed simultaneously, but displacement between fusion bonds and through-holes occurs and maintenance burden increases due to wear of small projections

Engineering Contradiction:

Improvesimultaneous formation of fusion bonds and through-holesVSAvoiddisplacement between fusion bonds and through-holes

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The process is divided into two separate operations: first forming fusion bonds using embossing rollers, then forming through-holes using ultrasonic processing. This segmentation eliminates the displacement problem between fusion bonds and through-holes that occurs when both are formed simultaneously by the same roller, while maintaining ease of manufacture through a systematic two-step approach

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical system of using small projections on embossing rollers to punch through-holes is replaced with an ultrasonic processing system. This substitution eliminates wear of the small projections (reducing maintenance burden) while precisely forming through-holes at the fusion bond locations without displacement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If small projections on embossing rollers are used to form through-holes, then fusion bonds with through-holes can be created, but the small projections wear quickly requiring frequent maintenance

Engineering Contradiction:

Improveformation of fusion bonds with through-holesVSAvoidmaintenance burden due to wear of small projections

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The mechanical punching action of small projections on embossing rollers is replaced with ultrasonic vibration processing. This substitution eliminates the wear problem of the small projections entirely, as ultrasonic horns do not experience the same mechanical wear, thereby reducing maintenance burden while maintaining the capability to form fusion bonds with through-holes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Ultrasonic vibration serves as an intermediary mechanism between the embossing roller and the sheet material for forming through-holes. Instead of direct mechanical contact and wear between the roller's small projections and the material, ultrasonic vibrations mediate the hole-forming process, reducing wear and maintenance requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method effectively forms composite sheets with alternating projections and fusion bonds, providing comfort and preventing liquid spread while reducing the risk of displacement and maintenance issues.

Implementation Method 1

pinch the overlapped first and second sheets between the projections of the first roller and an ultrasonic horn of an ultrasonic bonding machine to apply ultrasonic vibrations to the sheets

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

deform the first sheet to have depressions and projections

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Data Source

PatentEP3517278B1Composite sheet manufacturing method and manufacturing apparatus

Publication Date: 2021.04.14 KAO CORP

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AI summary

A method for manufacturing a composite sheet has a step to introduce a first sheet (1) to an engaging part (33) of a first roller (31) and a second roller (32) having projections and depressions engaging with each other on the peripheral surfaces to deform the first sheet to have depressions and projections while rotating the rollers; a step to conveys the deformed first sheet (1) having depressions and projections while holding the first sheet on the first roller (31), and overlaps the second sheet (2) with the first sheet (1) being conveyed; and a step to pinches the overlapped first and second sheets (1, 2) between projections (35) of the first roller (31) and an ultrasonic horn (42) of an ultrasonic bonding machine to apply ultrasonic vibrations to the sheets. In the method, fusion bonds (4) having through-holes (14) are formed during the application of the ultrasonic vibrations.