Ultrasonic Tab Welding Offset Joining Zone
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Solution Overview
Problem
Existing methods for producing data pages with attached tabs in book-like documents, such as security documents, face challenges in maintaining the contour of the data carrier's front side, creating undesirable burrs, and requiring lengthy process times due to the formation of squeezing zones during ultrasonic welding.
Innovation Solution
A method that introduces a joining zone offset from the data carrier's end face, allowing the tab to be connected without forming a squeezing edge, using a sonotrode with a narrower working surface to apply higher pressure and reduce process time, ensuring the data carrier's contour is preserved and enabling a secure, flexible connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to connect the tab to the data carrier in an overlap area, then the tab is securely joined to the data carrier, but a squeezing zone forms on the end face causing burrs and compromising aesthetic appearance
Solution Approach 1:
The overlap area is segmented into two distinct zones: a joining zone where ultrasonic welding occurs to secure the tab, and a coverage zone where no joining occurs to preserve the original contour. This segmentation allows the welding process to be localized away from the end face, preventing burr formation while maintaining connection strength.
Solution Approach 2:
Different properties are applied to different regions of the overlap area. The joining zone receives ultrasonic energy and compression for strong bonding, while the coverage zone remains untouched to maintain the aesthetic contour. This local differentiation resolves the conflict between joining strength and surface quality.
2Shape
If a template is positioned adjacent to the end face to avoid squeezing zones, then burr formation is reduced, but process time increases and additional fixing is required
Solution Approach 1:
The harmful squeezing zone is extracted from the overlap area by positioning the joining zone at a distance from the end face. This eliminates the need for templates and additional fixing measures, as the welding process naturally occurs away from the critical contour region, reducing process complexity and time.
3Productivity
If the sonotrode working surface is narrower to apply higher pressure, then process time is reduced, but the joining zone must be precisely positioned away from the end face
Solution Approach 1:
The tab is preliminarily positioned in the overlap area such that the joining zone is already offset from the end face before welding begins. This preliminary positioning, combined with the narrower sonotrode, allows higher pressure application and faster processing while maintaining precise positioning through pre-alignment rather than complex real-time control.
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 approach significantly reduces process time by approximately 80% while maintaining the aesthetic integrity of the data carrier's contour, enhancing tear resistance and flexural fatigue strength, and ensuring a smooth transition between the data carrier and tab.
Implementation Method 1
The energy contained in the ultrasonic vibrations is introduced into the overlap area 30 via the sonotrode 36, which is subjected to ultrasonic vibrations, whereby the plastic is melted in the data carrier 20 in the overlap area 30
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to a method for producing a data page (17) for a book-like document (11), in particular a value and/or security document, which comprises a data carrier (20) with a tab (23) which is secured to the data carrier and which is made of a strip material. The strip material for forming the tab (23), said strip material differing from the data carrier (20), is positioned along a longitudinal side (32) of the data carrier (20), thereby forming an overlap region (30), and a region (31) is formed which protrudes beyond the data carrier (20). The strip material and the data carrier (20) are at least partly connected together in the overlap region (30). Ultrasonic vibrations are introduced into the overlap region (31) by means of a sonotrode (36), wherein a joint zone (37) is introduced into the overlap region (30), said joint zone being provided at a distance from the end face (34) of the data carrier (20) such that a covering zone (54) in which the data carrier (20) and the tab (23) are not joined together is formed between the joint zone (37) and the end face (34) of the data carrier (20).