Static Ultrasonic Welding Device for Continuous Packaging Seals
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Solution Overview
Problem
Existing longitudinal welding devices in packaging machines require intermittent movement of material or complex mechanisms for continuous operation, limiting production capacity and causing issues with sealing liquids or granulated products, especially during longitudinal welding.
Innovation Solution
A longitudinal continuous welding device with a static setup using an ultrasonic welder and an elastic pusher, allowing continuous welding without material movement, and featuring positioning elements and longitudinal reliefs on the sonotrode and supporting piece for efficient welding and particle removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heated soldering irons are attached to actuating clamps that carry out alternate opening and closing movements, then welding can be performed on superimposed layers of material, but the device complexity increases and production capacity is limited
Solution Approach 1:
The patent replaces the mechanical heated clamp system with an ultrasonic welding system. Instead of using heated soldering irons attached to actuating clamps, the invention uses ultrasonic vibrations generated by a sonotrode to weld the layers of material. This substitution eliminates the need for complex heating mechanisms and actuating clamps, significantly reducing device complexity while maintaining welding quality.
Solution Approach 2:
The patent employs ultrasonic vibration as the core welding mechanism. The ultrasonic welder generates high-frequency mechanical vibrations through the sonotrode, which is pressed against the layers of material to be welded. This vibrational energy generates friction and heat at the interface of the material layers, causing them to bond together. This approach replaces the thermal conduction method with a vibration-based method, simplifying the overall device structure.
2Productivity
If welding devices can be displaced longitudinally to accompany material movement, then continuous welding is enabled, but the production capacity is limited due to mechanism complexity and inertia
Solution Approach 1:
The patent inverts the traditional approach by making the welding device static rather than mobile. Instead of moving the welding device longitudinally to follow the material, the material is fed continuously through the stationary welding zone. The ultrasonic welder remains fixed in position, and the continuous feed of material layers through the welding area enables continuous welding operation without requiring complex movement mechanisms or dealing with inertia.
Solution Approach 2:
The patent replaces the mechanical displacement system with a continuous material feed system. Rather than moving the welding device back and forth along the material, the invention uses a static welding zone through which material is continuously fed. This substitution eliminates the need for complex displacement mechanisms, reduces inertia effects, and enables continuous welding operation.
3Adaptability or versatility
If heated clamps are used for welding, then welding can be performed on container perimeters and lateral sides, but sealing effectiveness is reduced when material particles or waste are present in the welding area
Solution Approach 1:
The patent uses ultrasonic vibration to weld the material layers, which generates intense friction and heat at the welding interface. This vibrational energy effectively melts and bonds the materials together, creating a tight seal. The mechanical vibration also helps to expel any trapped particles or waste from the welding zone, ensuring that particles do not interfere with the sealing quality. This is particularly effective for welding containers with liquids, doughy, or granulated products where particle removal is critical.
Solution Approach 2:
The patent changes the welding parameter from thermal conduction (heated clamps) to ultrasonic vibration. This parameter change fundamentally alters the welding mechanism, allowing for more effective particle removal and tighter sealing. The ultrasonic vibration creates a dynamic welding process that can accommodate the presence of particles while maintaining seal integrity, unlike the static thermal conduction method of heated clamps.
4Reliability
If longitudinal welding is performed in the direction of container movement, then complete container sealing is achieved, but the welding time increases due to the longer welding length
Solution Approach 1:
The patent replaces the slow thermal conduction welding method with rapid ultrasonic vibration welding. The ultrasonic welder generates high-frequency vibrations that quickly generate heat and bond the material layers together, dramatically reducing the welding cycle time. This allows the longer longitudinal welding path to be completed in a fraction of the time required by traditional heated clamp methods, making the process suitable for high-speed continuous production.
Solution Approach 2:
The patent enables continuous welding action by using a static ultrasonic welding device through which material is continuously fed. The ultrasonic vibration operates continuously as material passes through the welding zone, eliminating the start-stop cycles inherent in traditional welding methods. This continuous action maintains high welding speed throughout the entire longitudinal welding process, reducing the time penalty associated with the longer welding length.
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, efficient welding of thermoplastic materials without material movement, ensuring tight seals and increased production capacity, even with liquids or granulated products, by using ultrasonic vibrations to remove particles and adjust pressure dynamically.
Implementation Method 1
at least one ultrasonic welder with a sonotrode... by using ultrasonic vibrations to remove particles and adjust pressure dynamically
Implementation Method 2
an elastic pusher... adjust pressure dynamically
Implementation Method 3
heated soldering irons act on the superimposed layers of material to be welded, causing them to be welded together
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
Longitudinal continuous welding device for packaging machines; wherein it comprises at least: - one supporting piece (1) for the layers of material to be welded continuously, - one ultrasonic welder (2) equipped with a sonotrode (21); this sonotrode (21) and the aforementioned supporting piece (1) face each other horizontally, arranged on opposite sides of the longitudinal path of the layers of material (M) to be welded, and unable to move in the direction of longitudinal movement of the layers of material (M); - at least one positioning element (3) of the welding device in a non-operating position or in an operating position; and - at least one elastic pusher (4), which acts on the welding iron (2) and/or the supporting piece (1) to push them against the opposite sides of the layers of material (M) to be welded continuously.