Ultrasonic Welding Line for Continuous Layered Material Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing manufacturing systems fail to continuously produce finished products by layering materials, attaching layers together, creating apertures, and separating portions with minimal to no manual intervention.

Innovation Solution

An ultrasonic welding system comprising a feeding device, fabrication system, and finalization system, which includes pace feeders, position feeders, retention members, attachment apparatuses, anvils, and an aperture generator to automate the layering, attachment, and separation processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing systems are used, then manual intervention is required for layering, attachment, and separation processes, but this increases production time and reduces productivity

Engineering Contradiction:

Improveproduction speedVSAvoidmanual intervention level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system employs self-regulating mechanisms where pace feeders automatically control material feed rates, position feeders autonomously position materials, and the ultrasonic welding system automatically performs attachment operations without manual intervention, enabling continuous automated production

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system maintains continuous operation through coordinated feeding mechanisms that constantly supply materials to the ultrasonic welding point, ensuring uninterrupted layering, attachment, and separation processes throughout production

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If automated feeding and positioning systems are implemented, then material layering and positioning precision is improved, but device complexity increases

Engineering Contradiction:

Improvematerial positioning accuracyVSAvoidsystem structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The feeding system is divided into distinct pace feeders for material supply and position feeders for precise positioning, with each segment performing a specific function to achieve overall precision while maintaining modularity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Retention members act as intermediary components that temporarily hold and align materials between the feeding mechanism and the ultrasonic welding point, facilitating precise positioning without requiring complex direct control

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If ultrasonic welding is used for attaching layers, then attachment speed and strength is improved, but energy consumption increases

Engineering Contradiction:

Improveattachment strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The ultrasonic welding operates through periodic high-frequency vibrations that generate heat only at the contact interface between materials, concentrating energy where needed for strong attachment while minimizing overall energy consumption

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Ultrasonic vibrations at high frequency create localized friction and heat at the welding interface, enabling rapid and strong bonding of material layers through mechanical energy conversion rather than continuous thermal input

Inventive Principle:

Principle #18Mechanical vibration

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

Enables the efficient assembly of products with minimal manual intervention, creating attachments and apertures in layered materials, resulting in a continuous production process.

Implementation Method 1

attachment apparatuses positioned on a first side of the path of travel... Each of the anvils are positioned adjacent to one of the attachment apparatuses to define a contact point between the anvils and the attachment apparatuses

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

At least one portion of the layering of product materials is pressed to create an attachment point at the contact point to attach layers of the layering of product materials

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS12383991B2Ultrasonic welding system

Publication Date: 2025.08.12 STERN BRANDS INC

AI summary

An ultrasonic welding system for assembling materials is provided. The system may comprise a feeding device, a fabrication system, a product uniformer, and a finalization system. The feeding device may include pace feeders, position feeders, and one or more of a retention member. The pace feeders may carry and supply product materials to be distributed by the position feeders and layered by the retention member. The fabrication system may include a main retention member, attachment apparatuses, anvils, and an aperture generator. The attachment apparatuses and anvils may be utilized to crate one or more of an attachment point on the layered product materials, and the aperture generator may be utilized to create at least one through-hole ending through at least a portion of the layered product materials. The finalization system may comprise a product separator and a motion inducer. The product separator may separate the layered product materials.