Flexible Anvil Ultrasonic Web Bonding for Uniform Consolidation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for thermally treating webs with thermoplastic materials face challenges in creating uniform consolidation regions due to material variability and rigidity in the energy transmission system, leading to issues like incomplete consolidation and 'burn through' during bonding processes.
Innovation Solution
An apparatus with a flexible elongated anvil element, supported by a harder anvil structure, is used to create consolidation regions with non-circular elliptical or cylindrical shapes, allowing for adjustable gap width and pressure to buffer material fluctuations and improve bonding patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rigid energy transmission system is used for thermal treatment, then energy transmission accuracy is improved, but adaptability to material variability deteriorates
Solution Approach 1:
The anvil is designed with dynamic characteristics, allowing it to flex and adapt to variations in web thickness and material properties during the bonding process. This dynamic anvil configuration enables the system to maintain consistent bonding pressure and energy transmission across different material conditions without requiring a completely rigid structure.
Solution Approach 2:
The system allows for changes in physical parameters such as anvil flexibility, gap width, and pressure to accommodate material variability. By adjusting these parameters, the system can optimize energy transmission for different web thicknesses and material compositions while maintaining bonding quality.
2Strength
If consistent pressure is applied during bonding, then bonding strength is improved, but risk of burn through increases
Solution Approach 1:
The system incorporates cushioning elements and flexible anvil designs that absorb excess pressure and energy before they can cause burn through. This cushioning effect protects the web material from harmful over-compression while maintaining sufficient bonding pressure, preventing burn through during the bonding process.
3Manufacturing precision
If rigid bonding structures are used, then bonding precision is improved, but tactile softness deteriorates
Solution Approach 1:
The bonding system employs flexible anvil elements and thin film structures that can deform under pressure to conform to the web surface. This flexibility allows the system to maintain precise bonding patterns while producing a softer tactile surface on the finished product, eliminating the harshness associated with rigid bonding structures.
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 flexible anvil system enables more uniform and reproducible consolidation regions, enhancing tactile softness and strength while maintaining water impermeability, even in webs with varying properties.
Implementation Method 1
by employing a thermal energy source, such as ultrasonic energy
Implementation Method 2
one or more energy source(s) for increasing the temperature at least of the region(s) of the web(s)
Data Source
AI summary
An apparatus and methods for thermally treating webs having thermoplastic respectively meltable compounds, thereby creating cylindrical or elliptic consolidation regions which may optionally have an aperture by employing a thermal energy source, such as ultrasonic energy, as well as to webs with elliptic consolidation regions. In a particular, the apparatus and methods create consolidation regions by using an anvil with a flexible elongated member, such as a wire, a chain or a tubular anvil with circumferential ribs.