Method for producing layered article

The patent replaces conventional thermal fusing methods with ultrasonic welding technology. The ultrasonic welding device uses high-frequency mechanical vibrations (ultrasonic waves) to fuse the non-woven fabric layers, eliminating the need for thermal fields and complex heating systems. This substitution enables continuous high-speed production while maintaining consistent fusion strength, as the mechanical vibration energy is precisely controlled and rapidly applied across the entire bonded surface.

The patent changes the fundamental parameter of the fusing process from thermal energy (temperature) to mechanical energy (ultrasonic vibration frequency and amplitude). By operating at ultrasonic frequencies (typically 20-40 kHz), the system achieves rapid heating localized at the interface between layers, enabling fast fusion cycles that match high production speeds while ensuring uniform fusion strength through precise control of vibration parameters.

The patent replaces thermal fusing systems with ultrasonic welding, which uses controlled mechanical vibrations to create uniform fusion. The ultrasonic horn distributes vibration energy evenly across the bonding surface, ensuring consistent fusion strength throughout. This mechanical approach eliminates the temperature gradients and heat distribution issues inherent in thermal fusing methods, thereby improving manufacturing precision while enabling faster production cycles.

The ultrasonic welding process operates continuously at high frequency, maintaining constant energy input across the bonding interface throughout the fusion cycle. This continuous action ensures uniform fusion strength without the variations that occur in batch thermal fusing processes, where temperature fluctuations and heat transfer inefficiencies can cause inconsistency. The continuous ultrasonic vibration enables both high productivity and consistent quality.