Rotating Ultrasonic Energy Transfer for Longer Bonding Dwell
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Solution Overview
Problem
Current ultrasonic bonding equipment often fails to provide sufficient dwell time for effective energy transfer, leading to less than desirable bond strength, especially with increased manufacturing speeds or complex absorbent article configurations, and existing solutions involve complicated systems with multiple moving components.
Innovation Solution
An energy apparatus featuring a first energy mechanism fixedly coupled to a rotatable drum and a second energy mechanism that rotates around its circumference, with a translation system allowing the second energy mechanism to move to an end position for precise energy transfer without relative motion, enhancing dwell time and bond strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manufacturing speed is increased, then productivity is improved, but bond strength deteriorates due to insufficient dwell time
Solution Approach 1:
The ultrasonic anvil is made movable relative to the ultrasonic horn through a translation system, allowing dynamic adjustment of the gap distance. This enables the system to maintain optimal energy transfer conditions at higher manufacturing speeds by dynamically positioning the anvil closer to the horn, thereby preserving bond strength while increasing productivity.
Solution Approach 2:
The system changes the physical parameter of gap distance between the ultrasonic horn and anvil. By translating the anvil to reduce this gap, the energy transfer efficiency is improved, allowing sufficient dwell time and bond strength even at increased manufacturing speeds.
2Strength
If dwell time is increased to improve bond strength, then manufacturing speed must be reduced, but productivity deteriorates
Solution Approach 1:
Rather than increasing dwell time by reducing speed, the system dynamically translates the anvil closer to the horn during the bonding process. This increases energy transfer efficiency, allowing sufficient bond strength to be achieved at high manufacturing speeds without compromising productivity.
Solution Approach 2:
The system replaces the traditional approach of extending dwell time (which would require slower production) with a mechanical translation system that adjusts the physical positioning of the anvil. This substitution allows maintaining high speed while achieving adequate bonding through improved energy coupling.
3Strength
If a complicated system with multiple moving components is used to increase dwell time, then bond strength is improved, but device complexity increases
Solution Approach 1:
The translation system is integrated as a focused subsystem rather than multiple separate moving components. By segmenting the complexity into a dedicated translation mechanism with controlled degrees of freedom, the system achieves improved dwell time and bond strength without overwhelming overall system complexity.
Solution Approach 2:
The translation system serves multiple functions: it adjusts the gap distance for optimal energy transfer, maintains consistent positioning during operation, and can be controlled to adapt to different bonding requirements. This multi-functionality reduces the need for additional separate components, managing device complexity while improving bond strength.
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 provides improved bond strength and handling characteristics by ensuring consistent energy transfer over the entire dwell time, reducing the risk of manufacturing disruptions and improving product quality.
Implementation Method 1
ultrasonic bonding apparatus and methods of providing ultrasonic energy to an item
Data Source
AI summary
An energy apparatus can be configured for providing energy to an item being transferred over a rotatable drum. The energy apparatus can include a first energy mechanism configured to be fixedly coupled to the rotatable drum and rotate with the rotatable drum. The energy apparatus can also include a second energy mechanism configured to rotate around a circumference of the rotatable drum. The energy apparatus can additionally include a translation system coupled to the second energy mechanism and configured to move the second energy mechanism to an end position that allows the second energy mechanism and the first energy mechanism to provide energy to the item while there is no relative motion between the first energy mechanism and the second energy mechanism. Methods of providing energy to an item utilizing an energy apparatus are also disclosed.