Ultrasonic Web Processing Device with Oscillating Horn and Anvil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultrasonic processing systems for webs face challenges in forming seams perpendicular to the machine direction and suffer from resin agglomerations that can hinder processing and cause skin irritation due to the stationary nature of the thermal energy application device.
Innovation Solution
A system and method where first and second mechanical elements, such as an ultrasonic horn and anvil, move forward and backward across the web, cooperating to apply ultrasonic processing while ensuring the agglomerations are removed by their movement, preventing interference with the processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stationary thermal energy application device is used for ultrasonic processing, then the web can be processed consistently, but resin agglomerations accumulate on the device and hinder processing
Solution Approach 1:
The patent applies the dynamics principle by making the thermal energy application device movable rather than stationary. The device moves in the width direction of the web during processing, which prevents resin agglomerations from accumulating on the device surface. This movement maintains consistent processing while eliminating the harmful accumulation effect.
2Productivity
If an ultrasonic horn rotates around an axis perpendicular to the web, then continuous welding is achieved, but sealing portions extending in the cross direction cannot be formed
Solution Approach 1:
The patent uses the dynamics principle by enabling the ultrasonic processing device to move in the width direction of the web, allowing it to create sealing portions in the cross direction while maintaining continuous processing capability. This dynamic movement provides both continuous welding and cross-directional sealing.
Solution Approach 2:
The patent applies dimensionality change by adding width-direction movement capability to the processing device. This allows the device to operate in two dimensions (machine direction and width direction), enabling it to form sealing portions in the cross direction while maintaining continuous processing productivity.
3Ease of manufacture
If the first thermal energy application device is secured to the drum, then the web can be processed, but agglomerations grow and eventually cause processing failures
Solution Approach 1:
The patent applies the dynamics principle by making the thermal energy application device movable in the width direction rather than fixed to the drum. This movement prevents resin agglomerations from accumulating and growing, thereby maintaining processing continuity while keeping the mounting structure relatively simple.
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 allows for reliable formation of seams perpendicular to the machine direction and prevents resin agglomerations from interfering with the processing, ensuring consistent ultrasonic treatment and comfort by avoiding skin irritation.
Implementation Method 1
an ultrasonic apparatus disclosed in the Patent Literature 1 includes an ultrasonic horn applied with ultrasonic oscillation
Implementation Method 2
one of the first and second thermal energy application devices is a horn applied with ultrasonic oscillation
Data Source
AI summary
An ultrasonic processing system adapted to subject a web running in a machine direction to ultrasonic processing includes a first mechanical element defined by one of an ultrasonic horn and an anvil and a second mechanical element defined by a remainder. The web placed on an outer peripheral surface of a rotary drum moves conforming to the drum in a machine direction. The first mechanical element is provided on the inner side of the drum and the second mechanical element is provided on the outer side of the drum. The first and second mechanical elements repeat a step of forward movement and a step of backward movement in a direction intersecting the machine direction across the web. In both steps, the first and second mechanical elements come in close contact with each other by the intermediary of the web and thereby subject the web to the ultrasonic processing.