Deformable Sonotrode Bearing for Stable Ultrasonic Welding

Solution Overview

Problem

Existing ultrasonic welding devices face challenges in miniaturization and weight reduction due to insufficient pretensioning forces in screw-based connections, leading to unwanted movements and rotations of the sonotrode, which affect the welding process, and generate heat and lost channels.

Innovation Solution

A self-regulating sonotrode bearing with a deformable frame that fixes the sonotrode by moving a second section into an opening under load, utilizing a lever mechanism to enhance clamping and minimize couplings, reducing weight and size without screws.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If screw-based connections are used to fix the sonotrode, then the sonotrode is secured against movements and rotations, but the device cannot be miniaturized and weight reduction is limited

Engineering Contradiction:

Improvesonotrode fixation stabilityVSAvoiddevice weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention extracts and eliminates the screw-based fixation system from the device. Instead of using screws and countermasses, the patent employs a screwless bearing with a deformable frame that secures the sonotrode through elastic deformation, removing the heavy fastening components entirely while maintaining reliable fixation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical screw-based fastening system with an elastic-mechanical system. The deformable frame utilizes elastic deformation to generate clamping force on the sonotrode, substituting the traditional mechanical connection with an elastic field-based solution that achieves the same fixation function with reduced weight.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If screw-based connections are used to fix the sonotrode, then the sonotrode is secured against movements and rotations, but the device size increases and miniaturization is prevented

Engineering Contradiction:

Improvesonotrode fixation stabilityVSAvoiddevice volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The invention extracts and eliminates the screw-based fixation system from the device. Instead of using screws and countermasses, the patent employs a screwless bearing with a deformable frame that secures the sonotrode through elastic deformation, removing the heavy fastening components entirely while maintaining reliable fixation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The deformable frame is designed to nest around the sonotrode in a compact configuration. The frame's elastic structure allows it to conform closely to the sonotrode's geometry, creating a nested arrangement that minimizes the overall device volume while maintaining effective fixation.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If screws and countermasses are used for sonotrode fixation, then the sonotrode is held securely, but lost channels are formed and heat is generated

Engineering Contradiction:

Improvesonotrode holding forceVSAvoidvibration loss and heat generation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention extracts and eliminates the screw-based fixation system from the device. Instead of using screws and countermasses, the patent employs a screwless bearing with a deformable frame that secures the sonotrode through elastic deformation, removing the heavy fastening components entirely while maintaining reliable fixation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The deformable frame acts as a flexible elastic structure that conforms to the sonotrode. This flexible shell approach allows the frame to apply uniform clamping force through elastic deformation, creating a smooth contact interface that minimizes vibration losses and heat generation compared to rigid screw connections.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables reliable ultrasonic welding in smaller spaces with reduced weight, simplified sonotrode replacement, and minimized heat and vibration losses, while maintaining stability and precision.

Implementation Method 1

the frame is designed in such a way that, by the action of a force from the sonotrode on a first section of the frame, the frame deforms in such a way that a second section of the frame is thereby moved into the opening

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12472579B2Sonotrode bearing for an ultrasonic welding device

Publication Date: 2025.11.18 NOVATEC GMBH INNOVATIVE TECH

AI summary

This invention relates to a sonotrode bearing for an ultrasonic welding device. The bearing comprises: a frame, wherein the frame at least partially delimits an opening for receiving the sonotrode; wherein the frame is designed in the region of the opening to support the sonotrode in the opening; wherein the frame is designed in such a way that, by the action of a force from the sonotrode on a first section of the frame, the frame deforms in such a way that a second section of the frame is thereby moved into the opening, wherein the second section is different from the first section. The invention also relates to a kit, a sonotrode, an ultrasonic welding device, a method for retrofitting an ultrasonic welding device and a use of the bearing or of the kit for supporting a sonotrode of an ultrasonic welding device.