Ultrasonic Welding With One-Way Anvil Energy Control
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Solution Overview
Problem
Existing ultrasonic welding devices experience unstable welding strength and deteriorated appearance due to misalignment between weld traces caused by web misalignment during anvil reciprocation.
Innovation Solution
An ultrasonic welding device and method that controls the application of ultrasonic energy to a web only in one direction of the anvil's reciprocating path, using a conveying drum with rotating horns and anvils, and a control unit to manage energy application, ensuring stable weld strength and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic energy is applied in both outward path and return path of anvil reciprocation, then welding process is performed in both directions, but weld trace misalignment occurs due to web misalignment causing unstable welding strength and deteriorated appearance
Solution Approach 1:
The patent extracts the ultrasonic energy application from one of the reciprocating paths (either outward or return path). By applying ultrasonic energy only in one direction during anvil reciprocation, the invention eliminates weld trace misalignment while maintaining welding productivity, thus resolving the contradiction between productivity and manufacturing precision.
2Strength
If web is held between horn and anvil during reciprocation, then welding can be performed, but web misalignment occurs causing unstable welding strength
Solution Approach 1:
The patent removes ultrasonic energy application from one reciprocating path, ensuring that welding occurs only when the web is properly aligned between horn and anvil in a single direction. This extraction approach stabilizes welding strength by preventing misalignment-related defects.
3Productivity
If anvil reciprocates to perform welding in both paths, then welding coverage is increased, but appearance deteriorates due to weld trace misalignment
Solution Approach 1:
The patent extracts ultrasonic energy application from one reciprocating path, allowing the anvil to reciprocate for positioning and coverage while ensuring welding occurs in only one direction. This maintains excellent weld trace appearance without compromising welding coverage 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
This approach prevents misalignment of weld traces, stabilizes welding strength, and maintains excellent appearance by controlling ultrasonic energy application in one path, enhancing the quality of the welding process.
Implementation Method 1
an ultrasonic wave generator 16 that vibrates the horn 14 to apply ultrasonic energy to the web W sandwiched between the anvil 15 and the horn 14
Data Source
AI summary
A control is performed to drive a horn via an ultrasonic wave generator so as to apply ultrasonic energy to a web in one of an outward path and a return path of an anvil and not to apply ultrasonic energy to the web in the other one of the outward path and the return path.