Rotating Drum Ultrasonic Bonding for Longer Dwell Time
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Solution Overview
Problem
Current ultrasonic bonding equipment often fails to provide sufficient dwell time for optimal bond strength, especially at increased manufacturing speeds or complex absorbent article configurations, leading to less than desirable bond quality.
Innovation Solution
The energy apparatus features a rotatable drum with integrated first energy mechanisms and a second energy mechanism that moves radially and axially to ensure proper alignment and increased dwell time for ultrasonic bonding, enhancing bond strength and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic bonding equipment operates at increased manufacturing speeds, then productivity is improved, but dwell time decreases leading to reduced bond strength
Solution Approach 1:
The anvil is designed to be movable rather than fixed, allowing it to dynamically adjust its position and maintain contact with the material web during high-speed operation. This dynamic configuration enables the bonding apparatus to adapt to varying speeds while preserving adequate dwell time for ultrasonic energy transfer, resolving the contradiction between increased productivity and maintained bond strength.
2Duration of action of moving object
If ultrasonic bonding equipment uses complicated systems with multiple components to increase dwell time, then bond strength is improved, but device complexity increases
Solution Approach 1:
The bonding apparatus is segmented into distinct functional components: a fixed ultrasonic horn, a movable anvil, and a translation system. This segmentation allows the anvil to be independently controlled to provide the necessary dwell time through radial and axial movements, while the overall system remains manageable through modular design rather than requiring complex multi-component manipulative systems.
Solution Approach 2:
A translation system acts as an intermediary mechanism between the fixed horn and the material web, enabling the anvil to move radially and axially to maintain optimal contact and dwell time. This intermediary system simplifies the overall architecture by providing a dedicated mechanism for dwell time control rather than requiring complex coordination of multiple manipulative components.
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 configuration allows for improved bond strength and consistency by increasing dwell time and ensuring precise energy transfer, even at higher manufacturing speeds and complex configurations.
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
Data Source
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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.