Rotating Drum Energy Transfer for Longer Ultrasonic Bond Dwell
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ultrasonic bonding equipment often fails to provide sufficient dwell time for effective energy transfer, leading to less than desirable bond strength, especially in high-speed manufacturing processes, and existing solutions involve complex systems for manipulating materials.
Innovation Solution
An energy apparatus with a first energy mechanism fixedly coupled to a rotatable drum and a second energy mechanism that rotates around the drum, utilizing a translation system to move the second energy mechanism to an end position for precise energy delivery without relative motion, allowing for increased dwell time and improved bond strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manufacturing speed is increased, then productivity improves, but bond strength deteriorates due to insufficient dwell time
Solution Approach 1:
The patent applies dynamics by making the anvil movable relative to the ultrasonic horn. The anvil can dynamically adjust its position between engaged and disengaged states, allowing the system to adapt to different operating conditions. This enables prolonged dwell time during bonding while maintaining high manufacturing speed capability.
Solution Approach 2:
The patent implements periodic action through the reciprocating motion of the anvil. The anvil periodically engages with the ultrasonic horn to perform bonding operations, then disengages to allow web advancement. This periodic engagement-disengagement cycle enables sufficient energy transfer during each bonding event while maintaining continuous high-speed production.
2Strength
If dwell time is increased to improve bond strength, then manufacturing speed decreases
Solution Approach 1:
The movable anvil creates a dynamic system where dwell time can be precisely controlled. The anvil remains engaged with the ultrasonic horn for the exact duration needed for effective bonding, then quickly disengages. This dynamic control allows prolonged energy transfer without permanently reducing manufacturing speed, as the system efficiently transitions between bonding and advancement phases.
3Device complexity
If the anvil is made stationary to simplify the system, then device complexity reduces, but the ability to provide sufficient dwell time is lost
Solution Approach 1:
Rather than making the anvil stationary, the patent makes it movable through a relatively simple mechanism. This dynamic anvil can engage and disengage from the ultrasonic horn, providing the necessary dwell time for effective bonding. The movement mechanism is designed to be straightforward, avoiding excessive complexity while achieving the required functional improvement.
4Strength
If material manipulation components are added to increase dwell time, then bond strength improves, but device complexity increases
Solution Approach 1:
The patent uses the dynamic movement of the anvil itself as the primary mechanism for increasing dwell time, rather than adding separate material manipulation components. The anvil's ability to engage and remain engaged with the ultrasonic horn provides the necessary prolonged contact time for effective bonding. This approach improves bond strength while minimizing additional system complexity.
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 solution enhances bond strength by ensuring consistent and prolonged energy transfer during the bonding process, improving the quality of absorbent articles and other manufactured goods.
Implementation Method 1
transferring ultrasonic energy from respective components of an ultrasonic bonding apparatus commonly referred to as an anvil and an ultrasonic horn across the web of material
Implementation Method 2
a translation system coupled to the second energy mechanism and configured to move the second energy mechanism to an end position that allows the second energy mechanism and the first energy mechanism to provide energy to the item while there is no relative motion between the first energy mechanism and the second energy mechanism
Data Source
AI summary
An energy apparatus can be configured for providing energy to an item being transferred over a rotatable drum. The energy apparatus can include a first energy mechanism configured to be fixedly coupled to the rotatable drum and rotate with the rotatable drum. The energy apparatus can also include a second energy mechanism configured to rotate around a circumference of the rotatable drum. The energy apparatus can additionally include a translation system coupled to the second energy mechanism and configured to move the second energy mechanism to an end position that allows the second energy mechanism and the first energy mechanism to provide energy to the item while there is no relative motion between the first energy mechanism and the second energy mechanism. Methods of providing energy to an item utilizing an energy apparatus are also disclosed.