Ultrasonic Welding Anvil Segmentation for Diaper Closure Systems
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Solution Overview
Problem
Ultrasonic welding in diaper closure systems causes thermal deformation of adhesive closure elements, leading to a loss of adhesive force and compromising the security of the diaper closure, necessitating limited weld points that are costly and inefficient.
Innovation Solution
The method employs a block tool with anvil parts spaced to match the row spacing of closure elements, using guide strips to position welds between rows, ensuring parallel weld lines that minimize thermal impact and maintain adhesive force while forming a secure, large-area connection between the carrier and fixing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to connect carrier part and fixing part, then secure connection is achieved, but thermal deformation of closure elements occurs leading to loss of adhesive force
Solution Approach 1:
The anvil is segmented into multiple anvil parts, each with a free end that can be positioned in spaces between adjacent rows of closure elements. This segmentation allows selective positioning of welding zones away from closure elements while maintaining overall connection strength.
Solution Approach 2:
The free ends of anvil parts act as intermediaries that guide the welding process. By positioning these free ends in spaces between closure element rows, they mediate between the need for secure welding and the need to protect closure elements from thermal damage.
2Reliability
If weld points are limited to avoid thermal deformation, then adhesive force is preserved, but connection security and production efficiency are impaired
Solution Approach 1:
The anvil is divided into multiple anvil parts that can be independently positioned. This segmentation enables the creation of multiple parallel weld lines between closure element rows, increasing overall connection area and production efficiency without compromising adhesive force at closure element locations.
3Area of stationary object
If welds are formed between adjacent rows of closure elements, then large-area connection is achieved, but thermal impact on closure elements increases
Solution Approach 1:
The anvil parts are designed with specific local qualities - their free ends are positioned in spaces between closure element rows rather than directly adjacent to them. This local positioning strategy allows welding to occur in close proximity to closure elements without directly impacting them, achieving large-area connection while minimizing thermal harm.
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 approach allows for a secure and efficient welding process that maintains the closure system's integrity without damaging the closure elements, ensuring reliable anchoring and easy opening of the diaper fastener.
Implementation Method 1
a) a carrier part (18) provided with closure elements (22) which protrude in the direction of the fixing part (16) and are arranged in rows with a definable distance from one another, has a fixing part (16) fed to its rear side and connected to the carrier part (18) by means of an ultrasonic welding process
Implementation Method 2
the thermal effect occurring in the welding area on the protruding adhesive closure elements leads to their deformation in the welding area
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed is a method for manufacturing closing systems for hygiene articles, in particular diaper closing systems, wherein an attachment part (16) is fed to the rear face of a substrate part (18) comprising protruding closing elements (22) which are arranged in rows at a predefined distance from each other, and the attachment part (16) is joined to the substrate part (18) along welding points using an ultrasonic welding process, at least some of the welding points being introduced in such a way as to extend along weld seam lines (46) between adjoining rows of closing elements (22) and extend at least partially in parallel to said rows of closing elements (22).