Ultrasonic Lap Sealing in Web Processing Machines

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Solution Overview

Problem

Existing web processing machines that form lap seals using heated seal bars require high energy consumption, large footprints, and complex cooling systems, and often necessitate multiple sealers, leading to inefficiencies and increased maintenance needs.

Innovation Solution

The development of machines that utilize ultrasonic sealers with a horn and anvil configuration to form lap seals, which reduce energy consumption, eliminate the need for cooling devices, and allow for real-time seal adjustments and customizations, while maintaining high seal strength and minimizing machine footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heated seal bars are used to form lap seals, then seal strength is achieved, but energy consumption increases and machine footprint enlarges

Engineering Contradiction:

Improveseal strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent replaces the thermal heating system with an ultrasonic vibration system. The ultrasonic sealer uses high-frequency mechanical vibrations to generate heat locally at the seal interface through friction and molecular friction, eliminating the need for large heated seal bars and their associated energy consumption while maintaining effective seal formation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the sealing mechanism from thermal conduction using heated bars to ultrasonic vibration-induced localized heating. This parameter change allows sealing to occur with significantly lower overall energy consumption and without requiring large heated components, thus reducing both energy use and machine footprint

Inventive Principle:

Principle #35Parameter changes

2Strength

If heated seal bars are used to form lap seals, then seal formation is achieved, but machine footprint and cooling system complexity increase

Engineering Contradiction:

Improveseal formation capabilityVSAvoidcooling system complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The ultrasonic sealing system replaces the complex thermal management infrastructure (heated bars, insulation, cooling systems) with a straightforward ultrasonic vibration mechanism. The localized heating effect occurs only at the seal interface during the sealing cycle, eliminating the need for continuous heating and cooling systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the cooling system entirely from the sealing mechanism. Since ultrasonic sealing generates heat only locally and temporarily at the seal interface, there is no need for continuous cooling infrastructure, thereby simplifying the device and reducing its footprint

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If multiple sealers are used to form lap seals, then sealing coverage is improved, but maintenance needs and device complexity increase

Engineering Contradiction:

Improvesealing coverageVSAvoidnumber of sealers

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The ultrasonic sealer with its horn and anvil configuration is designed to handle multiple sealing functions with a single device. The system can accommodate different sealing patterns and configurations through the geometry of the horn and anvil surfaces, eliminating the need for multiple separate sealers while maintaining comprehensive sealing coverage

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the functions of multiple sealers into a single ultrasonic sealing system. The horn and anvil work together as an integrated unit that can simultaneously or sequentially perform multiple sealing operations, reducing the total number of sealing devices required while maintaining or improving sealing reliability

Inventive Principle:

Principle #5Merging (Combining)

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 ultrasonic sealer system achieves efficient lap seal formation with lower energy costs, reduced maintenance, and improved machine efficiency, enabling a smaller machine footprint and better web handling with minimal scrap.

Implementation Method 1

An ultrasonic sealer with a horn and an anvil defines a nip therebetween through which the first web section passes. The ultrasonic sealer is configured to form the lap seal in the first web section.

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

The ultrasonic sealer is configured to form the lap seal in the first web section through ultrasonic vibration between the horn and anvil, generating localized heat to bond the material

Methodology Applied

Scientific EffectFrictional heating: Viscous Heating

Data Source

PatentUS20260097571A1Web processing machines with ultrasonic sealers

Publication Date: 2026.04.09 CMD CORP

AI summary

A machine that forms a web into bags or pouches includes a folding station configured to fold the web such that opposing sides of the web overlap each other and void is defined therein. A sealing section is located downstream in a machine direction from the folding station and configured to receive the web from the folding station. The sealing section is configured to form a lap seal in the web with an ultrasonic sealer having a horn and an anvil, wherein the anvil is located in the void and is configured to rotate about an axis.