Lateral-Mounted Sonotrode for Uniform Ultrasonic Sealing Force
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Solution Overview
Problem
Existing ultrasonic vibration systems face issues with bending distortion and non-uniform sealing force due to mounting via converters, limiting their application to high welding forces and requiring excessive space, especially when using in-plane vibration for friction welding.
Innovation Solution
The ultrasonic vibration system is mounted via a material-bonded joint engaging the lateral surface, using a flexible element to decouple the machine stand and allow for separate mounting components, reducing bending distortion and enabling more efficient vibration transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sonotrode is mounted by way of a converter arranged symmetrically relative to the longitudinal centre line, then the sonotrode can be held and excited, but welding forces cause bending distortion and non-uniform sealing force
Solution Approach 1:
The patent transitions from symmetric end-face mounting to asymmetric lateral surface mounting. The mounting is positioned at a specific location on the lateral surface rather than at the end faces, changing the spatial dimension of mounting attachment. This dimensional change allows the mounting to engage the sonotrode in a way that prevents bending distortion while maintaining sealing force uniformity during welding operations.
Solution Approach 2:
The patent introduces a mounting as an intermediary component between the converter and the sonotrode. This mounting serves as a mediator that transfers forces more effectively, allowing the converter to excite the sonotrode while the mounting handles the welding forces separately. This intermediary structure prevents the welding forces from causing bending distortion that would affect sealing uniformity.
2Reliability
If the sonotrode is made longer to accommodate converter mounting, then the converter can be arranged symmetrically, but user-specific structural space demands cannot be met
Solution Approach 1:
The patent moves the mounting attachment from the longitudinal ends (end faces) to the lateral surface of the sonotrode. This spatial repositioning allows the converter to be mounted without extending the longitudinal length of the sonotrode, as the mounting now utilizes the lateral dimension rather than requiring additional longitudinal space.
3Adaptability or versatility
If the sealing surface performs in-plane vibration for friction welding, then certain welding applications are enabled, but the sealing surface exhibits additional vibration components perpendicular to the surface
Solution Approach 1:
The mounting acts as an intermediary that stabilizes the sonotrode during in-plane vibration. By providing a stable mounting point on the lateral surface, it prevents the development of unwanted perpendicular vibration components, thereby maintaining vibration pattern uniformity while enabling friction welding applications.
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 solution allows for reliable mounting and improved vibration performance by minimizing the influence of mounting on the ultrasonic vibration system, enabling uniform sealing force and reduced system length, suitable for applications requiring higher welding forces without compromising in-plane vibration.
Implementation Method 1
a flexible element (17) which connects the fixing beam (16) and the wing element (4), wherein the flexible element (17) has a length which is less than the length of the webs (5, 6)
Implementation Method 2
an in-plane vibration is impressed on the sealing surface so that the sealing surface moves to and fro on the material to be processed and friction welding takes place
Implementation Method 3
to excite the sonotrode with a kind of flexural vibration so that the core element and the wing element move in opposite relationship
Implementation Method 4
the core element is excited and by virtue of the connection of the wing elements by way of the plurality of webs, that results in opposite movement of the sealing surface mounted on the wing element
Implementation Method 5
the sealing surface moves to and fro on the material to be processed and friction welding takes place
Data Source
AI summary
The present invention concerns an ultrasonic vibration system comprising a sonotrode which has two sonotrode end faces and a circumferentially extending lateral surface connecting the two sonotrode end faces together, wherein the sonotrode has an elongate core element and at least one wing element, wherein core element and wing element respectively extend from the one sonotrode end face to the other sonotrode end face in a longitudinal direction, wherein the wing element has a sealing surface which is provided to come into contact with a material for processing thereof and is connected to the core element by way of a plurality of webs spaced from each other in the longitudinal direction of the core element, and a converter which is optionally connected to the sonotrode by way of an amplitude transformer. According to the invention it is proposed that the ultrasonic vibration system is connected to a machine stand by way of a mounting connected to the lateral surface.