Sequential Sonotrodes for Extended Ultrasonic Substrate Exposure
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Solution Overview
Problem
Existing substrate alteration processes using ultrasonic energy in nips between rotating devices and sonotrodes result in significant heat loss, reducing the effective exposure time to ultrasonic energy and limiting the extent of substrate alteration.
Innovation Solution
The implementation of a method involving multiple nips formed between a rotating device with a radial outer surface and multiple sequentially spaced devices with sources of ultrasonic energy, allowing for prolonged exposure of the substrate to ultrasonic energy and enhanced substrate alteration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single nip is used between a rotating device and a sonotrode, then the device complexity is low, but the exposure time to ultrasonic energy is insufficient and heat loss is significant
Solution Approach 1:
The patent divides the ultrasonic energy application process into multiple sequential nips, each formed by a separate sonotrode device. Instead of using a single nip, the system employs multiple nips spaced along the rotating device, allowing the substrate to receive ultrasonic treatment in multiple discrete contact zones as it rotates, thereby extending total exposure time without requiring a single complex prolonged-nip system
Solution Approach 2:
The patent ensures continuous ultrasonic energy application by positioning multiple sonotrode devices along the rotation path of the first device. As the substrate passes through each nip in sequence, ultrasonic energy is continuously imparted, eliminating gaps in treatment. The sequential arrangement of multiple nips creates an uninterrupted treatment process that maintains useful action throughout the substrate's passage
2Loss of energy
If the substrate passes quickly through the nip, then productivity is high, but heat loss occurs rapidly reducing alteration effectiveness
Solution Approach 1:
The patent segments the ultrasonic treatment into multiple discrete nips distributed along the substrate's path. Each nip provides a focused treatment zone, and the cumulative effect of multiple short-duration nips achieves greater total energy transfer than a single long nip would allow, reducing heat loss by concentrating energy delivery in multiple controlled intervals rather than one prolonged contact
Solution Approach 2:
The patent employs periodic ultrasonic energy application through sequentially spaced nips. As the substrate rotates past each sonotrode device, ultrasonic energy is applied in periodic bursts corresponding to each nip passage. This periodic action pattern allows the substrate to receive multiple dosing cycles of ultrasonic treatment, improving heat transfer efficiency while maintaining acceptable processing speeds
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 effectively prolongs the exposure of the substrate to ultrasonic energy, reducing heat loss and improving the extent and uniformity of substrate alteration, leading to more efficient processing.
Implementation Method 1
a second device (200) comprising a source of vibration energy (210)... conveying a substrate (10) on the rotating first device (100) through the first nip (202) to alter the portion (11) of the substrate
Implementation Method 2
imparting thermal energy to a portion (12) of the substrate upstream of the first nip (202) to heat the portion (12) of the substrate to a temperature near or below a melting temperature of the portion (12) of the substrate
Data Source
AI summary
Methods of and devices for altering a portion of a substrate may include providing a first device having a radial outer surface and rotating the first device. Nips may be formed between portions of the radial outer surface and a plurality of additional devices, such as sonotrodes. The substrate may be passed through the nips. The additional devices may have angled or curved working surfaces, allowing the devices to be positioned more closely about the radial outer surface of the rotating first device.