Sonotrode Grooves for Thread Handling in Ultrasonic Welding
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Solution Overview
Problem
Existing apparatuses for producing gathered materials with threads are inefficient due to complex tooling requirements, especially when changing thread materials or tensions, leading to high effort and cost in tool replacement and material compatibility issues.
Innovation Solution
The sonotrode features a series of grooves oriented in the feed direction to securely hold and guide the thread during ultrasonic welding, allowing for relative movement between the thread and material web portions without welding, and the grooves can be designed with varying spacings, depths, and cross-sections to accommodate different thread sizes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complexly engraved counter tool roller is used to hold threads during processing, then the thread can be securely positioned, but the device complexity increases and tool replacement becomes necessary when thread specifications change
Solution Approach 1:
The counter tool roller is segmented into multiple independent groove elements arranged in parallel. Each groove can independently receive and position a thread, allowing the same tool to handle different thread configurations without replacement. This segmentation transforms a complex monolithic structure into simple, replaceable modular elements.
Solution Approach 2:
The counter tool roller is designed with multiple grooves of varying dimensions that can accommodate different thread materials, thicknesses, and tensions simultaneously. This multi-functional design eliminates the need for tool replacement when thread specifications change, as the same roller can adapt to various threading requirements through its diverse groove configurations.
2Adaptability or versatility
If the counter tool is frequently replaced to accommodate different thread materials and tensions, then material compatibility is maintained, but productivity decreases due to frequent tool changes
Solution Approach 1:
The counter tool roller incorporates grooves with varying cross-sections, depths, and spacings that can accommodate different thread materials, thicknesses, and tension requirements. This universal design allows a single tool to handle diverse threading specifications without replacement, maintaining adaptability while eliminating productivity losses from frequent tool changes.
Solution Approach 2:
The grooves in the counter tool are designed to dynamically adapt to different thread specifications through their varied geometries. The tool structure allows for flexible accommodation of different thread types without requiring physical replacement, enabling the system to dynamically adjust to various material compatibility requirements while maintaining continuous production.
3Strength
If threads are welded to material web portions, then strong connection is achieved, but relative movability required for gathering is lost
Solution Approach 1:
The ultrasonic welding process applies localized heating and bonding only at specific contact points between the thread and material web portions, rather than creating a continuous weld along the entire thread length. This local quality approach maintains strong connections at bonding points while preserving relative movability in other areas, enabling both connection strength and gathering flexibility.
Solution Approach 2:
Instead of fully welding the entire thread to the material web portions, the process uses partial welding only where necessary for connection strength. This partial action approach provides sufficient bonding strength while leaving portions of the thread unwelded, thereby maintaining the relative movability needed for gathering operations.
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 design simplifies the production process by allowing for easier thread handling and material compatibility, reducing the need for frequent tool replacement and enabling the use of various thread sizes and materials, while maintaining a secure form-locking connection between the thread and material web portions.
Implementation Method 1
The sonotrode is designed to be excited with an ultrasonic vibration such that contact between the first sealing surface vibrating with the ultrasonic vibration and the material webs results in a welding process
Data Source
AI summary
The present invention relates to an apparatus for producing a gathered material, wherein the material consists of two material web portions and a thread positioned between the material web portions and the two material web portions are connected to one another at two connecting surfaces, wherein the thread is disposed between the two connecting surfaces such that the thread is connected to the material web portions, wherein the apparatus comprises a sonotrode having a first sealing surface and a counter tool having a second sealing surface, wherein the counter tool is cylindrical with a lateral surface and a cylinder axis and the second sealing surface is disposed on the lateral surface, wherein the sonotrode and the counter tool are disposed with respect to one another in a processing position such that the material web portions and the thread can be guided through a gap formed by the first and the second sealing surface in a feed direction tangential to the lateral surface of the counter tool. To overcome or at least mitigate the described drawbacks, it is proposed according to the invention that the sonotrode comprise a groove which is oriented in feed direction and extends over the entire first sealing surface for receiving the thread.