Rotatable Anvil Alignment for Uniform Ultrasonic Welding
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Solution Overview
Problem
Existing ultrasonic welding apparatuses face challenges in achieving parallelism between the horn and anvil, leading to misalignment, uneven welding, and reduced horn lifespan due to uneven wear, complicating the process and increasing production costs.
Innovation Solution
An ultrasonic welding apparatus with a rotatable anvil that allows for easy alignment of the anvil's upper surface to be parallel with the horn's welding surface, using a support portion to maintain the anvil's position and minimize friction, ensuring consistent contact and preventing uneven wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the anvil is fixed to the main body, then there is no misalignment at the time of setting, but the horn gets slightly out of place during horizontal setting adjustment
Solution Approach 1:
The anvil is designed to be rotatable relative to the main body, transforming from a static fixed structure to a dynamic adjustable structure. This allows the anvil to be rotated during horizontal setting to achieve proper parallelism with the horn, and then locked in position during welding to eliminate misalignment.
2Ease of operation
If the horn is connected to the cylindrical booster, then the horn can be adjusted horizontally, but the horn gets slightly out of place in the process of checking and fixing
Solution Approach 1:
The patent replaces manual visual checking and bolt fixing with a rotational adjustment mechanism. The anvil can be rotated to achieve parallelism, and a locking mechanism (such as a clamp or lock nut) replaces the need for multiple bolts and manual checking, providing both ease of adjustment and precision.
3Productivity
If welding is performed with misaligned horn and anvil, then the process is simpler, but welding is satisfactorily performed only at a portion, forming non-welded and over-welded portions
Solution Approach 1:
The patent implements preliminary alignment of the horn and anvil through rotational adjustment before the welding process begins. The anvil is rotated to achieve parallelism with the horn, and this aligned position is locked before welding starts, ensuring consistent welding quality throughout the entire welding process.
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 rotatable anvil design facilitates precise parallelism, maintaining consistent welding quality, extending horn lifespan, and optimizing production line efficiency by reducing wear and misalignment issues.
Implementation Method 1
The ultrasonic vibrator converts the high-frequency current generated by the ultrasonic oscillator into ultrasonic waves. The converted ultrasonic waves are moved to the booster, and the booster amplifies the received ultrasonic waves and transmits the amplified ultrasonic waves to the horn.
Implementation Method 2
A lubricant or a bearing may be added to contact surfaces of the support portion and the anvil.
Data Source
AI summary
The present invention relates to an ultrasonic welding apparatus including a horn unit including a horn wherein the horn is configured to contact a target to be welded and a vibrator configured to apply vibration to the horn; an anvil unit including an anvil having a first flat surface on which the target to be welded is configured to be placed and a support portion configured to support the anvil in a rotatable state; and a welding main body configured to have the horn unit and the anvil unit fixed thereto, wherein the anvil is rotated in a state of being supported by the support portion such that the first flat surface of the anvil is parallel to a welding surface of the horn, whereby parallelism between the horn and the anvil may be easily achieved, and welding quality may be improved.