Torsion Sonotrode Pyramidal Elevations for Ultrasonic Welding

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Solution Overview

Problem

Existing torsion sonotrodes often result in energy loss during ultrasonic welding, leading to inconsistent weld strength and potential surface melting or improper bonding.

Innovation Solution

A torsion sonotrode with island-like pyramidal elevations spaced by flat sections, allowing for a form-fitting connection that ensures consistent energy transmission and penetration depth, thereby achieving reproducible weld strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If radial ribs with V-shaped notches are used on the contact surface, then energy transmission is improved, but penetration depth consistency deteriorates due to varying material hardness

Engineering Contradiction:

Improveultrasonic vibration energy transmissionVSAvoidpenetration depth consistency

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The invention changes the geometric parameters of the contact surface features from V-shaped notches to pyramidal elevations with flat bases. This parameter change ensures that the elevations can penetrate to a consistent depth regardless of material hardness variations, as the flat base provides a defined stop surface that limits penetration depth uniformly across different materials.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The pyramidal elevations are pre-formed on the contact surface with specific dimensions and angles. This preliminary action ensures that when ultrasonic welding begins, the elevations are already positioned to penetrate to the correct depth, eliminating the need for real-time adjustment during the welding process and ensuring consistent penetration depth from the start.

Inventive Principle:

Principle #10Preliminary action

2Use of energy by moving object

If higher welding pressure is applied to improve penetration, then energy transmission is improved, but surface melting and damage increase

Engineering Contradiction:

Improveenergy transmission to componentVSAvoidsurface melting and damage

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The invention changes the contact surface geometry from flat or V-shaped to pyramidal elevations. This geometric parameter change allows the elevations to concentrate the welding pressure at their tips, achieving effective penetration and energy transmission at lower overall welding pressures, thereby preventing surface melting and damage.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The contact surface is segmented into multiple pyramidal elevations distributed across the surface. This segmentation allows the welding pressure to be distributed across multiple contact points, with each elevation concentrating force locally for effective penetration while the overall pressure remains controlled to prevent surface damage.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the contact surface area is increased to improve welding stability, then reliability is improved, but energy density decreases leading to inconsistent weld strength

Engineering Contradiction:

Improvewelding stabilityVSAvoidenergy density at contact surface

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The contact surface is divided into multiple discrete pyramidal elevations rather than a continuous flat surface. This segmentation maintains a large overall contact area for stability while concentrating the ultrasonic energy at the tips of individual elevations, preserving high energy density at each contact point for consistent weld strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact surface features local pyramidal elevations with specific geometric properties (apex angle, base area, height) that are optimized for energy concentration. These local features have different properties than the overall contact surface, allowing high energy density at the elevation tips while maintaining adequate overall contact area for stability.

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

The solution enables ultrasonic welds with consistent strength by ensuring complete penetration of elevations into the component, minimizing energy loss and preventing surface melting, resulting in reliable and reproducible welds.

Implementation Method 1

a contact surface for transmitting a torsional vibration directed about a torsional axis to a component to be welded

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

The island-like and pointed elevations are pressed into the component by the welding pressure used in ultrasonic welding, so that a form-fitting connection is achieved between the contact surface and the component

Methodology Applied

Scientific EffectMechanical penetration and form-fitting connection: Mechanical Force

Data Source

PatentEP2593291B1Torsion sonotrode and ultrasonic welding process using a torsion sonotrode

Publication Date: 2014.10.22 TELSONIC HLDG AG

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AI summary

The invention relates to a torsion sonotrode (S) having a contact surface (1, 1') for transferring a torsional oscillation directed about a torsion axis (T) onto a component (4) to be welded. To ensure that the welded joint has a uniform strength, it is proposed according to the invention that the contact surface (1, 1') has a flat stop surface (2, 2') which runs substantially perpendicular to the torsion axis (T) and from which elevations (3, 3') of insular design extend with a pointed form.