Composite-Material Ultrasonic Welding With Movable Anvil Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultrasonic welding devices face challenges in maintaining a constant pressure distribution and energy input along the weld seam due to tool deflection or flexion, especially when dealing with composite materials that require dynamic adjustments during the welding process.
Innovation Solution
The device allows for flexible adjustment of the tools' position and orientation by enabling a changeable axis of rotation and joint configuration, such as hinge or leaf spring mechanisms, to maintain consistent welding pressure and seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the tools are made rigid to maintain stable welding pressure, then the structural stability is improved, but the ability to adapt to dynamic changes in material thickness and shape deteriorates
Solution Approach 1:
The anvil is designed with a movable mounting that allows it to rotate about a vertical axis and move along the feed direction. This dynamic mounting enables the anvil to automatically adapt its position and orientation in response to changes in material thickness and shape during the welding process, while the spring mechanism maintains constant welding pressure by compensating for these variations.
Solution Approach 2:
The system changes the position and orientation parameters of the anvil dynamically during welding. The anvil can rotate about a vertical axis to adjust its angular position and move along the feed direction to adjust its linear position, allowing the welding pressure parameters to remain constant despite changes in material dimensions.
2Device complexity
If the gap width is fixed to simplify the device structure, then the device complexity is reduced, but the ability to weld different material thicknesses deteriorates
Solution Approach 1:
The gap width between the sonotrode and anvil is made dynamically adjustable through the movable mounting of the anvil. The anvil can move along the feed direction, allowing the gap width to be changed automatically in response to different material thicknesses without requiring a complex manual adjustment mechanism.
3Adaptability or versatility
If the tools are mounted to allow movement along the feed direction to adapt to material variations, then the adaptability is improved, but the control precision of welding parameters deteriorates
Solution Approach 1:
The spring mechanism provides a feedback system that automatically adjusts the anvil position based on the material thickness. As the material thickness changes, the spring compresses or extends, moving the anvil along the feed direction to maintain constant welding pressure, thereby ensuring consistent welding parameters despite material variations.
Solution Approach 2:
The movable mounting system with spring mechanism enables the anvil to self-adjust its position automatically in response to material thickness changes. The system uses the material's own dimensions to trigger the appropriate adjustment, eliminating the need for external control systems.
4Manufacturing precision
If the anvil is made movable to maintain constant welding pressure, then the welding quality is improved, but the device complexity increases
Solution Approach 1:
The anvil mounting is designed with two degrees of freedom: rotation about a vertical axis and movement along the feed direction. This dynamic mounting allows the anvil to adjust its position and orientation automatically, maintaining constant welding pressure while distributing the complexity of the adjustment mechanism across two independent motions rather than requiring a complex single mechanism.
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
This design ensures a constant welding pressure and energy input along the seam, even with dynamic changes in material thickness or shape, resulting in high-quality welds without compromising the integrity of the seal.
Implementation Method 1
The welding process occurs when the sonotrode transmits its ultrasonic vibrations to the area of the packing shell to be welded (typical frequency range of ultrasonic vibrations: 20 kHz to 10 GHz)
Implementation Method 2
The energy introduced into the packing shell in this way causes the inner layer of material, often a thermoplastic, to melt and bond together
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The invention relates to a device (1) for the ultrasonic welding of composite material, e.g., packaging (2), comprising two tools (5, 6) for ultrasonic welding, more particularly a sonotrode (5) and an anvil (6), the functional surfaces (5A, 6A) of the tools (5, 6) being oriented parallel to each other so that a gap (7) having an approximately horizontal seam direction (8) is created, and the width (B) of the gap (7) can be changed by moving the tool (5) in an advancement direction (9). The device further comprises a joint (10A) having a movable axis of rotation (11A) so that the tool (5) can be rotated. Ideally, the axis of rotation (11A) can move along the seam direction (8) in translational fashion, allowing for better adjustment or self-alignment of the angular orientation of the tool (5) at the gap (7).