Ultrasonic Sonotrode Surface Patterning for Intermittent Touch Fasteners

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Solution Overview

Problem

Ultrasonic formation technologies for touch fasteners face limitations in rotary and blade sonotrodes, including limited contact area, excessive heat, substrate adhesion, artifacts, and uneven material processing, particularly when forming intermittent patches of fasteners.

Innovation Solution

Implementing rotary sonotrodes with intermittent raised features and varying surface speeds, along with molding rollers having diverse cavity patterns, to control energy application and substrate processing, and using cooling methods to manage heat and friction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ultrasonic vibrations are applied to form touch fasteners, then bonding and formation are improved, but excessive heat is generated causing substrate adhesion and artifacts

Engineering Contradiction:

Improvebonding qualityVSAvoidexcessive heat

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The sonotrode features intermittent raised and recessed areas that create localized bonding zones. The raised areas concentrate ultrasonic energy for effective bonding while the recessed areas provide heat dissipation pathways, preventing excessive heat accumulation and substrate adhesion across the entire bonding surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The intermittent pattern of raised and recessed areas on the sonotrode creates periodic bonding zones along the substrate. This periodic structure allows heat to dissipate in the recessed areas between bonding zones, preventing continuous heat buildup that causes adhesion and artifacts while maintaining reliable bonding at the raised areas.

Inventive Principle:

Principle #19Periodic action

2Manufacturing precision

If continuous ultrasonic energy is applied to ensure uniform processing, then formation consistency is improved, but energy consumption increases and heat accumulation occurs

Engineering Contradiction:

Improveformation consistencyVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The continuous bonding surface is segmented into multiple intermittent raised areas spaced along the sonotrode. Each raised area acts as an independent bonding unit that applies ultrasonic energy only where needed, reducing total energy consumption while maintaining consistent formation quality across the substrate through uniform spacing and standardized raised area geometry.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Ultrasonic energy is concentrated locally at the raised areas where bonding is required, rather than applying energy uniformly across the entire sonotrode surface. This localized energy application reduces overall energy consumption while the standardized geometry of raised areas ensures consistent formation quality at each bonding point.

Inventive Principle:

Principle #3Local quality

3Reliability

If sonotrode contact area with substrate is increased to improve bonding, then bonding reliability is improved, but heat generation increases causing substrate adhesion

Engineering Contradiction:

Improvebonding reliabilityVSAvoidcontact area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The sonotrode employs raised areas that concentrate contact and ultrasonic energy at specific localized points rather than distributing contact over a large continuous area. This localized contact approach achieves reliable bonding at the raised areas while the recessed areas between them provide heat dissipation pathways, preventing the heat accumulation that occurs with large continuous contact areas.

Inventive Principle:

Principle #3Local quality

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

Enhances the formation of touch fasteners by reducing energy requirements, minimizing artifacts, and ensuring uniform substrate processing, allowing for varied and efficient production of intermittent fastener patches.

Implementation Method 1

The functional surface of the sonotrode may be configured to apply ultrasonic vibrations to a substrate that is disposed between the functional surface of the sonotrode and the molding roller to form touch fasteners from the substrate

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

ultrasonic formation technologies employ energy from ultrasonic vibrations to create friction-like motions, thereby producing heat to allow for forming of a substrate material

Methodology Applied

Scientific EffectFriction heating: Friction

Implementation Method 3

using cooling methods to manage heat and friction

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20260054431A1Method and apparatus for improved ultrasonic formation

Publication Date: 2026.02.26 SONI FORM LLC

AI summary

Aspects disclosed herein relate to improvements regarding the formation of touch fasteners on nonwoven materials or other thermoplastic and non-thermoplastic materials employing ultrasonic formation technologies. Such improvements may be applied to rotary sonotrodes or blade sonotrodes. These improvements may include raised or recessed features in the functional surface of the sonotrode, methods and arrangements of pre-heating and/or cooling the functional surface of the sonotrode, varying or fixing the surface speed of the rotary sonotrode relative to a molding roller to form touch fasteners at desired spacing intervals, and the inclusion of supplementary material with the substrate. Various molding rollers are also disclosed.