Ultrasonic Bonding Anvil Pattern for Stability

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Solution Overview

Problem

Ultrasonic bonding systems face issues with bond strength variability and productivity due to interruptions in contact between the ultrasonic horn and anvil, causing structural resonances and generator overloads when using patterns of bars oriented perpendicular to the anvil axis, leading to waste and reduced performance.

Innovation Solution

The implementation of a dual bonding pattern system where a primary bonding pattern of discreet bars extending in the machine direction provides the main bonding energy, while a secondary bonding pattern, such as angled bars or circular elements, supports the ultrasonic horn and maintains continuous contact, reducing power feedback spikes and enhancing bond uniformity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If bars are oriented perpendicular to the anvil axis to achieve high bond strength and elongation, then bond performance is improved, but contact area interruptions cause structural resonances and generator overloads

Engineering Contradiction:

Improvebond strengthVSAvoidsystem stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The bonding pattern is segmented into two distinct components: primary bars oriented perpendicular to the anvil axis for bonding, and secondary bars oriented parallel to the anvil axis for support. This segmentation allows each component to fulfill its specific function without interfering with the other, resolving the contradiction between bond strength and system stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary bonding pattern serves multiple functions: it provides continuous support for the ultrasonic horn, maintains stable contact area, and prevents structural resonances. This multi-functionality allows the system to achieve both high bond strength and operational reliability simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If bars are oriented perpendicular to the anvil axis to achieve high bond strength, then bonding performance is improved, but productivity is reduced due to generator overloads and waste

Engineering Contradiction:

Improvebond strengthVSAvoidproduction efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

By separating the bonding function (primary perpendicular bars) from the support function (secondary parallel bars), the system eliminates generator overloads and associated waste, thereby improving productivity without sacrificing bond strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary bonding pattern, which initially seemed redundant, actually converts the harmful effect of contact interruptions into a beneficial continuous support system, preventing generator overloads and reducing waste, thus improving overall productivity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If a continuous secondary bonding pattern is used to support the ultrasonic horn, then system stability is improved, but material is wasted where discreet bars are spaced apart

Engineering Contradiction:

Improvecontact stabilityVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The secondary bonding pattern uses discreet bars spaced apart rather than a continuous pattern. This segmentation provides sufficient support for the ultrasonic horn while minimizing material waste in the gaps between bars, balancing stability and efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary bonding pattern provides partial support rather than continuous support, which is sufficient to maintain system stability while reducing material usage and waste in the spaces between discreet bars.

Inventive Principle:

Principle #16Partial or excessive action

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 stabilizes the bonding process, increases bond strength and elongation, and reduces waste by minimizing power spikes and variability, resulting in more consistent and efficient ultrasonic bonding.

Implementation Method 1

thermal bonding using ultrasonics to form nonwovens and provide embossing patterns

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

applying thermal energy to work pieces, such as for bonding

Methodology Applied

Scientific EffectThermal energy: Heating

Data Source

PatentEP3845382B1Method of forming a composite web utilizing a rotary bonding system with an anvil pattern

Publication Date: 2024.03.20 KIMBERLY CLARK WORLDWIDE INC

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AI summary

A method of bonding a first web of material to a second web of material to form a composite material is disclosed herein. First, a first web of material and a second web of material moving in a machine direction is provided. The webs of material pass over a first energy application device extending transverse in the cross-machine direction. The first energy application device includes a primary bonding pattern and a secondary bonding pattern. The primary bonding pattern in combination with the secondary bonding pattern extends continuously across the first energy application device in the cross-machine direction. In addition, a second energy application device is provided. The second energy application device is moved in the cross-machine direction, and thereby extending the second energy application device over the first energy application device and operating the first and second energy application devices in combination to bond a composite web.