Rotating Sonotrode Ultrasonic Welding Device for Wear-Free Packaging Cutting
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Solution Overview
Problem
Existing packaging machines face issues with wear and maintenance due to mechanical contact between sonotrodes and knives during ultrasonic welding and cutting, leading to increased costs and reduced efficiency.
Innovation Solution
A device with a rotatable sonotrode and anvil, where the knife is positioned to maintain a minimum distance from the sonotrode, allowing contactless cutting and welding, eliminating the need for hard metal inserts and reducing wear, with a simple sonotrode design and adjustable knife for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a knife is positioned to contact the sonotrode for cutting packaging material, then cutting function is achieved, but wear occurs on both the knife and sonotrode requiring frequent replacement
Solution Approach 1:
The patent introduces an intermediary air gap between the sonotrode and knife, allowing ultrasonic vibrations to transmit through the air to sever the packaging material without direct mechanical contact. This mediator approach eliminates wear on both components while maintaining cutting effectiveness.
Solution Approach 2:
The patent replaces the traditional mechanical contact-based cutting system with an ultrasonic vibration-based cutting system. The sonotrode generates high-frequency vibrations that cut the material through air coupling to the knife edge, substituting mechanical friction-based cutting with vibration-based severing.
2Reliability
If hard metal inserts are used in ultrasonic tools to protect against wear, then service life is extended, but device complexity and manufacturing costs increase
Solution Approach 1:
By introducing air as an intermediary medium between the sonotrode and knife, the patent eliminates the need for hard metal inserts or other protective wear components. The ultrasonic vibrations transmit through air without requiring complex protective structures.
Solution Approach 2:
The patent extracts and removes the hard metal inserts and protective wear components from the ultrasonic welding device. By eliminating these additional components through the contactless cutting approach, device complexity is reduced while maintaining wear resistance.
3Productivity
If the sonotrode and anvil are positioned close together for welding, then sealing efficiency is improved, but contact between sonotrode and knife causes wear
Solution Approach 1:
The patent uses air as an intermediary medium that allows the sonotrode to maintain close proximity to the anvil for efficient welding while preventing direct contact with the knife. The ultrasonic vibrations pass through air to cut the material without mechanical contact.
Solution Approach 2:
The patent applies different local qualities to different regions: the sonotrode surface maintains close contact with the anvil for welding efficiency, while the knife edge remains slightly separated by an air gap for contactless cutting, optimizing both functions simultaneously.
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 solution enables a longer service life, reduced manufacturing costs, improved sealing seam quality, and accelerated production with minimal rotational movements and reduced cutting forces, achieving contact-free and wear-free separation of packaging materials.
Implementation Method 1
an ultrasonic welding device with a sonotrode (3) and an anvil (5), by means of which a preceding pack (14) and a following pack (15) are sealed
Implementation Method 2
The sonotrode (3) vibrates with high frequency, so that the packaging material (4) is severed on the cutting edge (8) of the knife (7)
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a device for welding and separating a packaging material (4) for a package, comprising an ultrasonic welding device (2) with a sonotrode (3) and an anvil (5) for sealing the packaging material (4), wherein the sonotrode (3) is rotatable about a first axis of rotation (X) and the anvil (5) is rotatable about a second axis of rotation (Y), and a cutting device (6) with at least one blade (7) for separating the packaging material (4), which device is arranged in the anvil (5), wherein the at least one blade (7) is arranged on the anvil (5) in such a way that a minimum distance (S) between the sonotrode (3) and a cutting edge (8) of the blade (7) is maintained, and so the packaging material (4) can be severed without any contact between the sonotrode (3) and the blade (7).