Ultrasonic Counter-Tool Segmentation for Seal and Cosmetic Welds
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Solution Overview
Problem
Ultrasonic welding machines struggle to reliably produce both seal and cosmetic welds in a single station for recyclable stand-up pouches made from polypropylene monomaterials, due to the high risk of the cosmetic weld reopening if insufficient force is applied, and potential damage if excessive force is used for the seal weld.
Innovation Solution
A counter-tool with two separate sealing surfaces, allowing independent adjustment of force for each weld type, enabling separate process control and evaluation of each weld quality, and optionally incorporating a deflection element for packaging fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the force with which the sonotrode and counter-tool are pressed together is increased to prevent cosmetic weld reopening, then the reliability of the cosmetic weld is improved, but the seal weld may be damaged
Solution Approach 1:
The counter-tool is divided into two separate parts: a first part with a first sealing surface for the seal weld, and a second part with a second sealing surface for the cosmetic weld. This segmentation allows each part to be independently controlled, enabling different force levels to be applied to each weld type simultaneously, thus resolving the contradiction between preventing cosmetic weld reopening and avoiding seal weld damage
Solution Approach 2:
The counter-tool parts are designed with movable joints that allow dynamic adjustment of the force applied to each sealing surface. The movable connection enables the first and second parts to move independently relative to each other, allowing real-time optimization of force distribution during the welding process to maintain both cosmetic weld reliability and seal weld integrity
2Manufacturing precision
If the force with which the sonotrode and counter-tool are pressed together is reduced for optimal seal weld, then the seal weld quality is improved, but the cosmetic weld will reopen
Solution Approach 1:
By segmenting the counter-tool into two independently controllable parts, each with its own sealing surface, the system can apply different force levels to each weld type. The first part applies lower force optimized for seal weld quality, while the second part applies higher force to prevent cosmetic weld reopening, thus resolving the contradiction between seal weld precision and cosmetic weld reliability
Solution Approach 2:
Each part of the counter-tool is optimized with specific local properties: the first sealing surface has characteristics optimized for high-quality seal welding with lower force, while the second sealing surface has characteristics optimized for cosmetic welding with higher force. This local optimization allows each welding zone to have its own force requirements met without compromising the other
3Reliability
If separate welding stations are used for seal weld and cosmetic weld, then each weld can be optimized independently, but the production time increases
Solution Approach 1:
The invention merges the functions of two separate welding stations into a single counter-tool assembly. Both the first part (for seal weld) and the second part (for cosmetic weld) are integrated into one tool that can be actuated simultaneously by the ultrasonic welding machine, enabling both welds to be produced in a single operation while maintaining independent force control, thus resolving the contradiction between process control reliability and production efficiency
Solution Approach 2:
The counter-tool is designed as a multi-functional device that performs both seal welding and cosmetic welding functions within a single tool assembly. The universal design allows the same ultrasonic welding machine to execute both welding operations simultaneously through the integrated counter-tool, eliminating the need for separate welding stations and improving productivity while maintaining reliable process 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 solution ensures reliable and reproducible production of both seal and cosmetic welds in a single station by allowing precise control of force and vibration parameters for each weld, reducing the risk of weld reopening and thermal damage.
Implementation Method 1
the sonotrode is placed in a state of ultrasonic vibration and pressed against the layers of material
Implementation Method 2
heat is only generated where it is actually needed for the welding process
Data Source
AI summary
The present invention relates to a counter-tool for an ultrasonic welding machine, wherein the counter-tool comprises two separate sealing surfaces which are intended to come into contact with a material to be processed, characterized in that the counter-tool is formed in two parts, wherein the two parts of the counter-tool are movable relative to one another, and each of the two parts comprises one of the two sealing surfaces.