Sheet Joining Line With Overlap Fusion and Inline Tape Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing joining techniques for sheet-like materials using ultrasonic waves struggle with insufficient joining strength and gaps due to lack of overlap at the boundary, requiring separate fusing and tape sticking processes that cannot be continuously performed.
Innovation Solution
A joining apparatus with a fusing mechanism and a sticking mechanism that allows continuous conveyance of sheet-like materials, using a guide to align and overlap end portions for ultrasonic fusion and subsequent tape application without unfolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If two sheet-like materials are joined by fusing with ultrasonic waves, then a flat finish is achieved without protrusions, but joining strength is insufficient and gaps occur due to lack of overlap
Solution Approach 1:
The patent combines the fusing mechanism and sticking mechanism into a single integrated apparatus that processes materials continuously in one linear path. The fusing unit creates the flat bonded joint while the subsequent sticking unit applies tape reinforcement, merging two previously separate operations into a unified system that maintains continuous material flow and achieves both flat finish and strength.
Solution Approach 2:
The fusing operation is performed first to create a flat bonded joint between the sheet-like materials before any tape application. This preliminary fusing action establishes the base joint with flat finish, and then the sticking mechanism applies tape reinforcement to the already-fused area, ensuring the reinforcement adheres properly to a stable surface.
2Strength
If separate fusing and tape sticking processes are used, then joining strength is improved, but continuous conveyance becomes difficult and work efficiency decreases
Solution Approach 1:
The patent integrates the fusing mechanism and sticking mechanism into a single continuous processing line where materials pass through both stations without interruption. The fusing unit and sticking unit are positioned sequentially along the material conveyance path, allowing both operations to be performed in one continuous pass rather than requiring separate processing steps.
Solution Approach 2:
The apparatus maintains continuous material conveyance through both the fusing and sticking operations. The guide structure keeps materials aligned and moving continuously, and both mechanisms operate in sequence without requiring the materials to be stopped, removed, or repositioned between operations, thereby maintaining uninterrupted productive action throughout the entire process.
3Ease of operation
If materials are unfolded between fusing and sticking, then tape application is enabled, but continuous conveyance is interrupted and productivity decreases
Solution Approach 1:
The guide structure serves multiple functions simultaneously: it aligns the sheet-like materials during conveyance, maintains their folded state throughout processing, and positions them correctly for both fusing and sticking operations. This multi-functional guide eliminates the need to unfold materials for tape application while still enabling proper tape placement on the bonded joint area.
Solution Approach 2:
The tape application is performed on the folded materials without requiring unfolding to a different dimensional state. The sticking mechanism applies tape along the length of the folded materials in their compact configuration, utilizing the longitudinal dimension rather than requiring the materials to be spread out in a different spatial arrangement.
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
Enables continuous and efficient joining and tape sticking of sheet-like materials, improving work efficiency and maintaining a flat finish without protrusions.
Implementation Method 1
a fusing mechanism part configured to join two thermoplastic sheet-like materials by fusing
Implementation Method 2
the end portions to be joined are fed to the fusing mechanism part while overlapping each other along a plane and are fused by ultrasonic waves
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A joining apparatus (10) includes a fusing mechanism part (20) that joins two thermoplastic sheet-like materials (C1, C2) by fusing, a sticking mechanism part (30) that sticks an adhesive tape (T) along a joined portion (C12) of the sheet-like materials (C1, C2), a workbench (11) having a placement surface (110) on which the fusing mechanism part (20) and the sticking mechanism part (30) are disposed side by side, the placement surface (110) allowing the sheet-like materials (C1, C2) in an unfolded state to be placed thereon, and a guide (40) that allows an end portion to be joined (C11) of one of the sheet-like materials (C1) and an end portion to be joined (C12) of the other sheet-like material (C2) to overlap each other while aligned along a plane intersecting the placement surface (110), each of the end portions to be joined (C11, C21) of the sheet-like materials (C1, C2) being placed on the placement surface (110), and to feed the overlapping end portions to be joined (C11, C21). The fusing mechanism part (20) fuses and joins the end portions to be joined of the sheet-like materials (C1, C2) fed from the guide (40) in an overlapping state to sandwich the end portions to be joined (C11, C21) from opposite sides thereof.