Method for producing a layered article
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Solution Overview
Problem
The production speed of layered articles using non-woven fabrics is hindered by variations in fusion strength during the fusing process, leading to inconsistent product quality.
Innovation Solution
The method involves ultrasonic welding of non-woven fabrics with fiber diameters of 100 µm or less using a heated rotating anvil, with controlled temperature fluctuations and embossed patterns to optimize fusion strength and production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fusing step is adopted to hold the layered structure, then the layered article can be produced, but the production speed is not increased and variation in fusion strength occurs
Solution Approach 1:
The invention changes the temperature parameter by heating the rotating anvil to a specific range (30°C to 150°C), which optimizes the fusion process. This temperature control ensures consistent fusion strength while enabling continuous production, thereby resolving the contradiction between reliability and productivity.
Solution Approach 2:
The invention applies preliminary heating to the rotating anvil before the ultrasonic welding process. This preliminary thermal preparation ensures that the material is at the optimal temperature for fusion, leading to consistent fusion strength and enabling continuous high-speed production without variation in quality.
2Device complexity
If ultrasonic welding is performed without heating the rotating anvil, then the process is simpler, but variation in fusion strength occurs and production speed is limited
Solution Approach 1:
The invention introduces temperature as a controlled parameter by heating the rotating anvil to 30°C to 150°C. This parameter change ensures consistent material properties during ultrasonic welding, eliminating fusion strength variation while maintaining a relatively simple process structure.
Solution Approach 2:
The invention replaces purely mechanical ultrasonic welding with a combined thermal-mechanical process by heating the rotating anvil. This substitution provides more stable fusion results through thermal control, improving manufacturing precision without significantly increasing process complexity.
3Ease of manufacture
If the fiber diameter is larger than 100 μm, then the non-woven fabric is easier to manufacture, but the flexibility and touch feeling of the layered article deteriorate
Solution Approach 1:
The invention changes the fiber diameter parameter to 100 μm or less, which improves flexibility and touch feeling. The heated rotating anvil compensates for the manufacturing difficulty of fine fibers by providing optimal thermal conditions that facilitate handling and processing of these finer materials.
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 approach enhances production speed while reducing variations in fusion strength, resulting in improved product quality and flexibility with a satisfactory touch feeling.
Implementation Method 1
wherein the rotating anvil is heated
Implementation Method 2
through ultrasonic welding
Data Source
Figure 1
Figure 2
AI summary
Provided is a method of producing a layered article by which a sufficient production speed can be achieved, and preferably, a variation in fusion strength can be suppressed and hence a variation in product quality can be reduced. The method of producing a layered article of the present invention includes fusing at least part of a single-layer body or a laminate including at least one layer including a non-woven fabric of fiber having a fiber diameter of 100 µm or less through ultrasonic welding.