Ultrasonic Web Bonding Control for Consistent High-Speed Seals

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Solution Overview

Problem

Existing technologies for producing ultrasonically bonded cross seals in disposable undergarments fail to maintain consistent bond quality at high production speeds, leading to weak, uneven bonds, low yield, and premature component wear due to slow sample rates and inconsistent force control.

Innovation Solution

A system and method for bonding nonwoven materials using a controller that adjusts force applied to workpieces based on real-time force measurements, enabling closed-loop control and automated cycle detection to ensure consistent bond strength and reduce variability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If production speed is increased above 175-200 units per minute, then productivity improves, but bond quality deteriorates with weak, uneven, or inconsistent bonds

Engineering Contradiction:

Improveproduction speedVSAvoidbond quality consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system employs real-time feedback control by measuring the actual bond force during each bonding operation and using this information to adjust subsequent bonding parameters. This closed-loop feedback mechanism enables the system to maintain consistent bond quality even at high production speeds by continuously adapting to variations in material properties and process conditions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The bonding system dynamically adjusts bonding parameters such as force, duration, and amplitude based on real-time measurements and process conditions. This dynamic adaptation allows the system to optimize each bonding operation individually, ensuring consistent bond quality across varying production speeds without requiring manual intervention.

Inventive Principle:

Principle #15Dynamics

2Strength

If bond force control parameter is increased to compensate for weak leading bonds, then leading bond strength improves, but trailing bonds become overwelded and machine stress increases

Engineering Contradiction:

Improveleading bond strengthVSAvoidoverwelding and machine stress

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The system applies different bonding parameters to different locations (leading vs. trailing bonds) based on their specific requirements. By measuring and analyzing the characteristics of each bond location, the system tailors the bonding force and duration to achieve optimal results for each position, preventing both weak leading bonds and overwelded trailing bonds.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system dynamically changes bonding parameters such as force amplitude, duration, and timing based on real-time measurements of bond characteristics. This parameter adaptation allows the system to optimize each bonding operation individually, ensuring consistent bond strength across all positions without excessive force that would cause overwelding or increased machine stress.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If traditional PLC-based control systems are used with sample rates of a few to 20 milliseconds, then device complexity remains manageable, but response time is too slow for high-speed production

Engineering Contradiction:

Improvecontrol system complexityVSAvoidresponse time

Core Design Contradiction:

Device complexityVSSpeed

Solution Approach 1:

The system replaces traditional PLC-based mechanical control with a computer vision-guided control system that processes images and calculates bonding parameters in real-time. This substitution enables much faster response times by using automated image processing and algorithmic control, allowing the system to keep up with high-speed production lines while maintaining manageable complexity through software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Achieves consistent bond strength variability of less than 10% and eliminates the need for operator adjustments, resulting in higher product quality, yield, and reduced wear and tear.

Implementation Method 1

apparatus for bonding a workpiece... a welding device arranged to apply energy to the workpiece

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

bonding operation... ultrasonically bonded cross seals

Methodology Applied

Scientific EffectUltrasonic heating: Ultrasonic Vibration

Data Source

PatentUS20250289191A1Apparatus and a method for bonding webs of non-woven plastic material

Publication Date: 2025.09.18 DUKANE IAS LLC

AI summary

An apparatus having a first treatment module and a second treatment module, at least one of which includes a welding device for treating one or more workpieces. The apparatus has a controller arranged to: receive a real-time amplitude signal of ultrasonic vibration of at least one of the first treatment module and the second treatment module during a treatment cycle; segment the amplitude signal into a plurality of amplitude segments for the treatment cycle; monitor an amplitude value of each of the plurality of amplitude segments during the treatment cycle; operate a plurality of closed-loop control algorithms to determine a plurality of amplitude adjustment values, each of the plurality of amplitude adjustment values corresponding to a respective one of the plurality of amplitude segments; and apply each amplitude adjustment value to the corresponding respective one of the plurality of amplitude segments during the subsequent treatment cycle in real-time.