Vibratable Tool for Mark-Free Ultrasonic Welding of Thermoplastics
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Solution Overview
Problem
Ultrasonic welding of thermoplastics generates undesirable waste due to the use of disposable welding films and can result in visible marks on the workpiece due to the flexible nature of these films, which fold over and create unwanted marks.
Innovation Solution
A vibratable tool is positioned between the ultrasonic horn and the thermoplastic workpiece to transfer energy without direct contact, reducing waste and preventing marking, and can be reused for extended periods or used simultaneously on multiple workpieces, with contoured surfaces to match varying workpiece geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If welding films are used between the ultrasonic horn and the thermoplastic workpiece to prevent marking, then the workpiece surface quality is improved, but material waste increases due to the disposable nature of the films
Solution Approach 1:
The patent introduces a reusable anvil as an intermediary component between the ultrasonic horn and the thermoplastic workpiece. This anvil serves as a mediator that prevents direct contact between the horn and workpiece, thereby preventing surface marking without requiring disposable welding films. The anvil can be reused multiple times, eliminating the material waste associated with single-use films.
Solution Approach 2:
The patent replaces the disposable welding films with a durable, reusable anvil. Instead of using cheap short-living objects that need continuous replacement, the system employs a long-lasting anvil that can serve multiple workpieces, thereby reducing material consumption and waste generation while maintaining the protective function.
2Manufacturing precision
If custom three-dimensional contoured horns are machined or cast to match workpiece contours, then the welding precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the system into two separate functional components: a simple, flat-faced ultrasonic horn and a contoured anvil. The contouring function is segmented from the horn and transferred to the anvil, which remains stationary. This segmentation allows the horn to remain simple and easy to manufacture, while the anvil absorbs the complexity of matching workpiece contours.
Solution Approach 2:
Instead of making the moving horn contoured to match the workpiece, the patent inverts the approach by making the stationary anvil contoured. This inversion allows the simple horn to vibrate freely while the contoured anvil provides the necessary geometric matching, reducing horn complexity and manufacturing difficulty.
3Object-affected harmful factors
If welding films are used to buffer between the horn and workpiece, then surface marking is prevented, but the flexibility of the films causes folding and creates unwanted visible marks
Solution Approach 1:
The patent replaces the flexible welding film intermediary with a rigid or semi-rigid anvil intermediary. The anvil maintains its structural integrity and contour shape without folding or creasing, thereby preventing surface marking without generating the folding marks that plague flexible films. The anvil provides stable, consistent contact with the workpiece throughout the welding process.
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 vibratable tool effectively welds, stakes, swages, or degates thermoplastics without generating waste and minimizing surface marks, while being adaptable to different workpiece contours, enhancing process efficiency and reducing material costs.
Implementation Method 1
Ultrasonic welding is a process for joining two or more parts together using high-frequency ultrasonic vibrations. The horn 16 emits ultrasonic energy that causes melting at the interface of the two plastic parts 10, 12
Implementation Method 2
a vibratable tool may be positioned between a vibratable horn and a thermoplastic workpiece for transferring energy from the horn, through the vibratable tool, to the workpiece
Data Source
AI summary
A system for ultrasonic or vibration welding, staking, swaging, forming or degating of a thermoplastic workpiece includes a vibratable horn having a face, a thermoplastic workpiece, and a vibratable tool positioned between the vibratable horn and the thermoplastic workpiece. The system is configured to energize the vibratable horn to transfer energy from the vibratable horn through the vibratable tool to the thermoplastic workpiece to induce welding, staking, swaging, forming or degating of the thermoplastic workpiece. Optionally, the upper and/or lower surfaces of the vibratable tool may have three-dimensional contour(s) that are complementary to three-dimensional contour(s) of the vibratable horn and/or the thermoplastic workpiece. Additional systems and methods for ultrasonic or vibration welding, staking, swaging, forming or degating of a thermoplastic workpiece are also disclosed.