Sonotrode Support Element Layout for Uniform Ultrasonic Welding
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Solution Overview
Problem
Existing ultrasonic processing devices for material webs face issues with sonotrode bending due to uneven force distribution, leading to high wear on radial bearings and inconsistent welding results, especially when processing wide material webs.
Innovation Solution
The introduction of a support element that engages the sonotrode perpendicularly to the axis, relieving the radial bearing and maintaining uniform contact pressure, combined with a second radial bearing and a counter tool, allows for reduced sonotrode bending and improved processing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sealing surface is spaced from the radial bearing in the axial direction, then the sonotrode can be designed for ultrasonic processing, but the sonotrode bends due to force application
Solution Approach 1:
A support element is introduced as an intermediary component between the sonotrode and the processing force. This support element absorbs and distributes the forces applied during ultrasonic processing, preventing direct force transmission that causes sonotrode bending. The support element acts as a mediator that maintains force balance while allowing the sonotrode to maintain its shape and sealing surface uniformity.
2Stability of the object's composition
If two radial bearings are provided to support the sonotrode, then the bending is reduced but not eliminated and bearing wear increases
Solution Approach 1:
The support element serves as a mediator that shares the load between the two radial bearings. By introducing this intermediate support structure, the force distribution is optimized, reducing the individual load on each bearing while maintaining sonotrode stability. This intermediary component prevents the bearings from bearing excessive forces that would accelerate wear.
Solution Approach 2:
The support element provides localized support at specific points on the sonotrode, creating optimal force distribution. Rather than relying solely on the radial bearings to handle all forces, the support element provides targeted local support where needed, reducing the overall stress on the bearing system while maintaining sonotrode stability during processing.
3Shape
If the diameter of the sonotrode is increased in sections, then the bending is reduced for a specific application, but the device loses adaptability to different applications
Solution Approach 1:
The support element system segments the force distribution function from the sonotrode structure itself. Instead of modifying the sonotrode diameter for different applications, the support elements can be adjusted or repositioned to provide appropriate rigidity support for various processing requirements. This segmentation allows the sonotrode to maintain a consistent, adaptable design while the support system handles the rigidity requirements.
Solution Approach 2:
The support element system introduces dynamic adaptability to the sonotrode configuration. Rather than requiring different sonotrode diameters for different applications, the support elements can be dynamically adjusted in position or configuration to provide the necessary structural support for various processing conditions, maintaining both rigidity and versatility.
4Area of stationary object
If the distance between the sealing surface and radial bearing is large for wide material webs, then the processing capability is improved, but the radial bearing experiences high forces and wear
Solution Approach 1:
The support element acts as an intermediary that bridges the gap between the sealing surface and the radial bearing location. For wide material webs where the sealing surface must be spaced far from the bearing, the support element provides intermediate structural support, distributing the forces along the sonotrode length. This reduces the force burden on the radial bearing while maintaining the necessary spacing for wide material processing capability.
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 configuration reduces sonotrode bending, extends radial bearing lifespan, and ensures consistent welding results by distributing forces more evenly and reducing friction, while maintaining high processing quality across various material web widths.
Implementation Method 1
The ultrasonic converter, which usually has respective piezo elements, converts an electrical alternating voltage into a mechanical vibration.
Implementation Method 2
the ultrasonic vibration is transmitted to the material webs and local heating and possibly welding of the material webs occurs in the region of the interface between the material webs
Implementation Method 3
the ultrasonic vibration is transmitted to the material webs and local heating and possibly welding of the material webs occurs
Implementation Method 4
at least one support element which is engageable or in engagement with the sonotrode in such a way that a force acting perpendicular to the axis on an engagement section of the sealing surface is at least partially taken up by the support element
Data Source
AI summary
A device for ultrasonic processing of materials comprising a sonotrode rotatable about a first axis and having a first sealing surface extending in the axial direction, the device having a first radial bearing supporting the sonotrode, at least a portion of the first sealing surface being spaced in the axial direction from the radial bearing, characterised in that at least one support element is engageable or in engagement with the sonotrode such that a force acting perpendicular to the axis on an engagement portion of the sealing surface is at least partially taken up by the support element.