Sonotrode Machining Passages Reduce Notch Effect
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Solution Overview
Problem
Ultrasonic sonotrodes with large sealing surfaces experience reduced service life and vibration amplitude due to the notch effect caused by intersecting slits, leading to local stress concentrations and irregular deformation, which complicates the machining process to remove sharp edges.
Innovation Solution
Incorporating machining passages in the sonotrode main body allows for easy access and removal of sharp edges at intersection points, reducing the notch effect without significantly affecting vibration characteristics, thereby increasing service life or vibration amplitude.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If slits are provided in the sonotrode main body to achieve uniform vibration amplitude, then vibration uniformity is improved, but service life is reduced due to notch effect
Solution Approach 1:
The patent applies local quality by providing reinforcement elements specifically at the slit intersections where stress concentrations occur, rather than reinforcing the entire sonotrode. This localized reinforcement addresses the notch effect at critical points while maintaining the overall vibration characteristics and uniform amplitude distribution across the sealing surface.
2Weight of moving object
If slits are provided in the sonotrode main body to reduce mass, then weight is reduced, but manufacturing complexity increases due to edge removal requirements
Solution Approach 1:
The patent applies preliminary action by providing reinforcement elements at the slit intersections during the manufacturing process. This preliminary reinforcement prevents the formation of problematic sharp edges and stress concentrations, simplifying subsequent machining operations and reducing the complexity of edge removal while maintaining the weight reduction benefits of the slitted design.
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 additional machining passages minimize the notch effect, allowing for increased sonotrode service life or vibration amplitude with minimal impact on resonance frequency and amplitude transformation.
Implementation Method 1
The frequency range of ultrasonic vibrations is approximately between 20 kHz and one GHz. Mechanical vibrations in the ultrasonic frequency range are frequently produced from electric energy by means of piezoelectric sound transducers (converters).
Implementation Method 2
To be able to ensure effective transmission of the ultrasonic vibrations to a material to be processed by means of an ultrasonic vibration unit it is necessary for the ultrasonic vibration unit be caused to resonate.
Implementation Method 3
The ultrasonic energy is transmitted by way of the sealing surface from the sonotrode to the material to be processed. This involves conversion of ultrasonic vibrations into frictional energy whereby heat is produced, which leads to plasticization of the processed material.
Data Source
AI summary
The present invention relates to an ultrasonic sonotrode with a main sonotrode body and a sealing area arranged on one side of the main sonotrode body. The main sonotrode body has two through-slits extending in or through the main sonotrode body respectively along a slit axis. These through-slits intersect in such a way that a through-channel through the main sonotrode body is formed from the one through-slit into the other through-slit. This creates a slit portion that is formed both by the one through-slit and the other through-slit. Provided in this main sonotrode body is a processing channel, which extends along a processing channel axis from a side area of the main sonotrode body up to the through-channel and is arranged substantially symmetrically about the processing channel axis.