Ultrasonic Label Welding Unit for Multi-Label Alignment
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Solution Overview
Problem
Sewing operators face difficulties in aligning and handling multiple labels simultaneously during the sewing process, leading to decreased production efficiency due to continuous adjustments and rearrangements, which hampers the speed of garment production.
Innovation Solution
A sonic label welding unit that aligns and bonds multiple labels together into a single packet using ultrasonic welding, allowing for easier handling and maintaining alignment during the sewing operation, with adjustable weld strength for easy removal of top and bottom labels without damaging the others.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple labels are handled individually during sewing, then each label can be sewn separately, but the sewing operator has to continuously align and adjust the labels, decreasing production speed
Solution Approach 1:
Multiple individual labels are merged into a single multi-layered label assembly through ultrasonic welding. The labels are stacked in a predetermined arrangement and bonded together at peripheral portions, creating one integrated unit that is easier to handle and position during sewing operations, thereby eliminating continuous alignment adjustments and increasing sewing speed
Solution Approach 2:
The labels are pre-aligned and pre-bonded together in the desired configuration before the sewing operation. This preliminary arrangement and bonding of multiple labels into an assembly eliminates the need for continuous alignment and adjustment during the sewing process, directly improving productivity
2Stability of the object's composition
If multiple labels are bonded together strongly, then they stay aligned during sewing, but the labels cannot be easily removed or separated
Solution Approach 1:
The bonding is applied selectively only at the peripheral portions of the labels rather than across the entire surface. This localized welding approach provides sufficient alignment stability during sewing while leaving the central portions of the labels unbonded, enabling easy removal or separation of individual labels after the sewing operation
3Productivity
If labels are aligned and bonded into a packet, then handling and sewing speed improve, but the device complexity increases
Solution Approach 1:
The mechanical alignment and bonding operations are replaced with an ultrasonic welding system. The ultrasonic horn, when actuated, automatically aligns and bonds multiple labels together through high-frequency vibration, eliminating the need for complex mechanical alignment mechanisms and simplifying the overall device while maintaining high productivity
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 increases sewing speed and garment production efficiency by keeping labels aligned and secure, allowing for seamless installation into garments without constant adjustments, while maintaining the integrity of the remaining labels.
Implementation Method 1
the ultrasonic horn emits ultrasonic waves such that the blade cuts the fabric
Implementation Method 2
The present invention utilizes a sonic label welding unit that welds multiple labels together into one packet or stack with the individual labels aligned in the stack prior to bonding
Data Source
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AI summary
A sonic label welding device (500) for welding multiple labels together using ultrasonic welding is disclosed. The sonic label welding device (500) comprises a digital controls main menu screen (100) which includes touch screen buttons that are utilized to go to specific screens to program the device to perform in a certain manner. For example, a user can press the cut to length button (104) if wanting to cut a label to a specific length, or the label weld count button to specify the number of labels being sonically welded. Further, the sonic label welding device (500) comprises a head (504) for allowing multiple labels to be assembled under pressure and an anvil (502) for directing the high frequency vibrations. A method of manufacturing a multi-layer care label is also disclosed.