Ultrasonic Paper Sheet Bonding Without Adhesive or Through Holes
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Solution Overview
Problem
Existing methods for bonding paper sheets without thermally fusible components face challenges such as weak bonding strength, texture deterioration, and increased material costs, particularly when using no adhesive or heat embossing, and the formation of through holes when creating fine holes.
Innovation Solution
The method involves pressing a second paper sheet with pulp fibers against a first paper sheet and applying ultrasonic waves to accelerate fiber crystallization at the bonding area, achieving mechanical interlocking without thermal fusion, while maintaining a high degree of gloss and suppressing texture deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the method of forming fine holes is used to bond paper sheets, then bonding is achieved, but liquid permeation increases and texture deteriorates
Solution Approach 1:
The patent replaces thermal fusion (heat-based mechanical system) with ultrasonic vibration (acoustic field) to achieve bonding. The ultrasonic waves cause fibers to vibrate and interlock mechanically without melting or forming holes, thus maintaining texture while achieving strong bonding between paper sheets.
Solution Approach 2:
The patent applies ultrasonic vibration to the pressed portion of overlaid paper sheets. This mechanical vibration accelerates fiber crystallization and enables fibers to entangle and bond together without thermal fusion, achieving strong bonding while preserving the original texture and avoiding hole formation.
2Loss of substance
If the method of overlaying sheets through no adhesive agent and performing embossing is used, then material cost is reduced, but bonding strength becomes weak
Solution Approach 1:
The patent uses ultrasonic vibration applied to pressed portions of overlaid paper sheets to achieve strong bonding without adhesive agents. The vibration accelerates fiber crystallization and creates mechanical interlocking between fibers, providing sufficient bonding strength while eliminating adhesive material costs.
Solution Approach 2:
The patent replaces adhesive-based bonding with ultrasonic vibration-induced fiber entanglement. This substitution eliminates the need for adhesive agents (reducing material cost) while achieving comparable or superior bonding strength through mechanical fiber interlocking.
3Strength
If the method of overlaying papers through adhesive agent and performing embossing is used, then bonding strength is improved, but material cost increases
Solution Approach 1:
The patent replaces adhesive agent-based bonding with ultrasonic vibration-induced fiber entanglement. This substitution eliminates adhesive material costs while maintaining or improving bonding strength through mechanical interlocking of fibers at the pressed portions.
Solution Approach 2:
The patent enables paper fibers to bond with each other through self-entanglement induced by ultrasonic vibration. The fibers themselves perform the bonding function without requiring external adhesive agents, achieving cost reduction while maintaining bonding strength.
4Strength
If heat embossing is used to bond paper sheets, then bonding is achieved, but texture deteriorates due to heating
Solution Approach 1:
The patent uses ultrasonic vibration instead of heat embossing to achieve bonding. The mechanical vibration accelerates fiber crystallization and creates strong bonds without thermal exposure, thereby avoiding texture deterioration while maintaining bonding strength.
Solution Approach 2:
The patent replaces thermal fusion (heat-based system) with ultrasonic vibration (acoustic field) for bonding paper sheets. This substitution eliminates thermal damage to the paper texture while achieving equivalent or superior bonding strength through fiber entanglement.
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 enables strong bonding of paper sheets without through holes or adhesive use, maintaining texture quality and reducing material costs, with a bonding area gloss that enhances appearance and functionality.
Implementation Method 1
applying ultrasonic wave to a pressed portion so as to accelerate crystallization of the fibers at the pressed portion
Implementation Method 2
accelerate crystallization of the fibers at the pressed portion where the first and second paper sheets are bonded together
Implementation Method 3
pressing the second paper sheet against the first paper sheet
Data Source
Figure 1
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AI summary
[PROBLEMS] To bond a paper sheet containing no thermally fusible component with sufficient strength without forming a through hole, deteriorating texture and increasing the material cost. [MEANS FOR SOLVING PROBLEMS] While pressing a second paper sheet (11) containing no thermally fusible component against a first paper sheet (10) containing no thermally fusible component, an ultrasonic wave is applied to the press contact portion so that fibers of the second paper sheet (11) enter mechanically between fibers of the first paper sheet (10) thus forming a bonding portion without requiring thermal fusion.