Ultrasonic Laminate Perforation Geometry to Prevent Silicone Gel Buildup

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Solution Overview

Problem

Conventional ultrasonic perforation methods using flat top pins for laminates with silicone gel result in material buildup around perforations, difficulty in producing larger diameters, and inefficiencies in energy consumption and material management, particularly in wound treatment applications.

Innovation Solution

A perforation element with a sharp outer rim and a recessed inner surface, inclined and rounded to facilitate controlled material removal and welding, reducing material aggregation and enabling efficient transfer of cut-out material to a sacrificial layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional ultrasonic perforation methods using flat top pins are used, then perforations can be created in laminates, but material buildup occurs around the edges of the perforations

Engineering Contradiction:

Improveperforation creationVSAvoidmaterial buildup around perforation edges

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention replaces the conventional flat top pin with a perforation element that has a rounded top surface. This curvature allows the ultrasonic energy to be distributed more evenly across the perforation area, preventing material from being pushed to the edges and building up around the perforation. The rounded surface geometry directly addresses the material buildup issue by changing the contact distribution between the perforation element and the laminate material.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If larger diameter perforations are required, then patient comfort may be improved, but the process becomes less efficient and energy consumption increases

Engineering Contradiction:

Improveperforation diameterVSAvoidprocess efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The invention changes the geometric parameters of the perforation element, specifically the ratio between the diameter of the perforation element and the diameter of its rounded top surface. By optimizing this ratio, the process can efficiently create larger diameter perforations while maintaining process efficiency and controlling energy consumption. The parameter optimization allows scalable perforation sizes without proportionally increasing energy requirements.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional flat top pins are used, then perforations can be created, but silicone gel is squeezed to the edges and may occlude the perforation

Engineering Contradiction:

Improveperforation creationVSAvoidsilicone gel occlusion of perforation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The rounded top surface of the perforation element prevents the silicone gel from being laterally displaced to the edges during the perforation process. The curved geometry distributes the ultrasonic energy and mechanical pressure more uniformly, allowing the gel to be removed through the perforation rather than pushed to the sides where it would occlude the opening.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Power

If ultrasonic energy is concentrated for localized melting, then joining or perforation can be achieved, but material buildup occurs around the perforation edges

Engineering Contradiction:

Improveenergy concentrationVSAvoidmaterial buildup around perforation edges

Core Design Contradiction:

PowerVSManufacturing precision

Solution Approach 1:

The rounded top surface geometry redistributes the concentrated ultrasonic energy more evenly across the perforation area. Instead of creating a sharp concentration point that pushes material to the edges, the curved surface creates a distributed energy field that melts and removes material uniformly, preventing edge buildup while maintaining effective perforation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 improves process control, energy consumption, and product quality by minimizing material buildup and efficiently removing silicone gel from the laminate, making it suitable for wound treatment applications.

Implementation Method 1

ultrasonic welding is known as a suitable technique of joining or modifying complex parts or structures

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

The perforation element is characterized by a characteristic maximum width and/or outer perimeter and a recess... in conjunction with ultrasonic welding, allows for a reproducible introduction of perforations

Methodology Applied

Scientific EffectUltrasonic energy input: Ultrasonic Vibration

Implementation Method 3

the inner lateral surface may have a rounded (convex, i.e. bulged towards the outside) portion directed towards said outer rim

Methodology Applied

Scientific EffectMaterial flow control through geometry: Geometry

Data Source

PatentUS11673345B2Device and process for introducing perforations into laminates

Publication Date: 2023.06.13 MOLNLYCKE HEALTH CARE AB

AI summary

Described is a ultrasonic welding of laminates, more particular to the use of ultrasonic energy to create stable perforations in a laminate, in particular a laminate that includes a silicone gel. Specifically, a perforation element is provided, that is optionally part of array of perforation elements, which perforation element or array of perforation elements is advantageously used in an ultrasonic welding device and in a process for continuously introducing perforations into a laminate.