Manual Sonic Welding Device for Multi-Label Alignment
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Solution Overview
Problem
Sewing contractors face difficulties in aligning and handling multiple product labels simultaneously, leading to decreased production efficiency and sewing speed, as existing methods require continuous adjustment and rearrangement.
Innovation Solution
A manual sonic welding device that uses ultrasonic welding with a knurled head to align and bond multiple labels into a single packet, featuring an anvil, sonic horn, power supply, and dual safety switches, allowing for adjustable weld strength and easy handling during the sewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple labels are handled simultaneously during sewing, then production capability should increase, but label alignment becomes difficult resulting in decreased production capability
Solution Approach 1:
The patent applies preliminary action by bonding multiple labels together before the sewing process. The label bonding device attaches labels to a carrier tape in advance, creating pre-aligned label packets that maintain their positioning during subsequent sewing operations, thereby eliminating alignment difficulties while preserving productivity gains
2Productivity
If multiple labels are handled at one time, then sewing speed should increase, but continuous adjustment and rearrangement are required resulting in decreased sewing speed
Solution Approach 1:
The invention performs preliminary arrangement by bonding labels in their final positions on the carrier tape before sewing. This pre-positioning eliminates the need for continuous adjustment and rearrangement during the sewing process, making label handling easier while maintaining increased sewing speed
Solution Approach 2:
The carrier tape serves as an intermediary that holds multiple labels in fixed positions. This mediator allows labels to be transported and positioned without requiring direct manual handling and adjustment during sewing, thereby improving ease of operation while preserving productivity
3Manufacturing precision
If labels are bonded together, then alignment is maintained during sewing, but weld strength must be adjustable to allow label removal without destruction
Solution Approach 1:
The patent applies parameter changes by making the weld strength adjustable through controllable bonding parameters. The label bonding device allows adjustment of bonding conditions to create welds with appropriate strength - strong enough to maintain alignment during sewing but weak enough to allow label removal without destruction, thereby achieving both alignment precision and adaptability
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 device effectively aligns and bonds multiple labels, increasing sewing speed by maintaining label alignment and allowing for easy installation into garments without continuous adjustment, while the adjustable weld strength enables the top or bottom label to be removed without damaging the others, even during washings or dry cleanings.
Implementation Method 1
The converter converts the electrical signal into a mechanical vibration, and the sonic horn applies the mechanical vibration to the labels to be welded
Implementation Method 2
The manual sonic welding device welds multiple labels or other articles together using ultrasonic welding
Data Source
AI summary
A system and method is presented that provides a manual sonic welding device for welding multiple labels or other articles together. The manual sonic welding device includes an anvil and a head. The anvil is where the labels are placed on the welding device and allows the high frequency vibration from the welding device to be directed to the proper interfaces of the labels. The head allows the multiple labels to be assembled under pressure. Additionally, the manual sonic welding device includes a converter, a sonic horn, and a power supply to seal the multiple labels together. The power supply delivers a high power AC signal, the converter converts the electrical signal into a mechanical vibration, and the sonic horn applies the mechanical vibration to the labels to be welded. The manual sonic welding device also includes dual safety switches which activate the device.