Planar Electrode High Frequency Sewing Machine Bonding
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Solution Overview
Problem
Conventional high frequency sewing machines face issues with achieving uniform bonding strength and handling curvilinear or stretchable fiber clothes, often resulting in defective products due to heat concentration and reduced processing efficiency.
Innovation Solution
A high frequency sewing machine design featuring a work material mounting plate, intermittent transfer device, presser foot, and planar electrodes that allow for intermittent transfer and heat distribution, enabling uniform bonding of thermoplastic resin tapes between fiber cloth overlaps, while accommodating curvilinear and stretchable materials without excessive clamping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high frequency power is enhanced to obtain assured bonding strength under line or point contact, then bonding strength is improved, but the work material is susceptible to insulation breakdown causing burn and burn holes
Solution Approach 1:
The invention transitions from line contact or point contact to surface contact by using planar electrodes with contact surfaces extending in the transfer direction of the work material. This dimensional change distributes the high frequency power over a larger area, preventing heat concentration while maintaining bonding strength.
Solution Approach 2:
The electrode contact portions are designed with specific surface properties and dimensions tailored for heat distribution. The planar electrodes have contact surfaces with areas of 10mm² or more, providing localized quality improvement in heat dissipation and bonding uniformity.
2Manufacturing precision
If transfer rate of the work material is decreased to obtain assured bonding strength with low high frequency power, then bonding quality is improved, but processing efficiency is extremely deteriorated
Solution Approach 1:
By changing from line/point contact to surface contact with planar electrodes, the invention enables adequate heat distribution at normal transfer rates. The increased contact area allows sufficient bonding without requiring reduced transfer speed, thus maintaining processing efficiency.
3Device complexity
If conventional electrode rollers with line or point contact are used, then device structure is simple, but uniform bonding strength cannot be achieved and defective products occur
Solution Approach 1:
The invention uses planar electrodes with surface contact instead of conventional roller electrodes with line or point contact. This simple dimensional change from 1D line contact to 2D surface contact achieves uniform bonding without complicating the overall device structure.
4Ease of operation
If conventional high frequency sewing machines are used for curvilinear portions or stretchable fiber clothes, then linear transfer is simple, but the machines cannot sufficiently handle curvilinear portions and stretchable materials
Solution Approach 1:
The planar electrode configuration with surface contact provides universal applicability for both linear and curvilinear portions, as well as for stretchable and non-stretchable materials. The design accommodates various work material types without requiring specialized mechanisms.
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 design ensures uniform bonding strength, prevents heat-related defects, and efficiently handles curvilinear and stretchable fiber clothes, producing high-quality apparel products with improved processing efficiency and reduced component complexity.
Implementation Method 1
the overlapped portions of the fiber cloth are continuously bonded together by allowing the thermoplastic resin tape to melt under high frequency dielectric heating by applying high frequency power between the paired upper and lower planar electrodes
Implementation Method 2
allowing the thermoplastic resin tape to melt under high frequency dielectric heating
Data Source
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AI summary
While intermittently transferring a work material mounted on a work material mounting plate by cooperation between feed dogs performing synthetic circular movement in horizontal and vertical directions and a presser foot, the overlapped portions of a fiber cloth can be continuously bonded together by allowing a thermoplastic resin tape held between the overlapped portions of the fiber cloth in the work material to melt under high frequency dielectric heating by applying high frequency power between a pair of planar electrodes respectively disposed above and below the work material during the time when the transfer by these feed dogs is stopped. The occurrence of defective products having burn or the like due to heat concentration can be prevented while obtaining assured uniform bonding strength by using the high frequency power. Additionally, the bonding of curvilinear portions and the bonding of stretchable fiber clothes can be sufficiently handled.