Web Welding System with Multiple Anvils and Horns
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Solution Overview
Problem
Conventional web welding systems for wearing articles are inefficient in terms of time and speed, as they typically use a pair of ultrasonic horns that operate simultaneously, leading to increased load on anvil rolls and reduced accuracy in welding position.
Innovation Solution
The system employs multiple anvil rolls with pairs of ultrasonic horns arranged to apply vibration energy simultaneously, allowing webs to pass through multiple gaps for sequential welding, reducing the time required for welding and increasing speed by skipping certain parts until others are welded, while maintaining accuracy through balanced forces on the anvil rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pair of ultrasonic horns operates simultaneously in a conventional web welding system, then the load on the anvil roll is reduced and welding position accuracy is enhanced, but the welding time is increased and welding speed is reduced
Solution Approach 1:
The patent divides the welding system into multiple independent welding units, each with its own ultrasonic horn and anvil arrangement. Instead of using a single pair of horns that process the web sequentially, the system employs multiple horn pairs that can weld different sections of the web simultaneously or in rapid succession, thereby increasing overall welding speed while maintaining precision through each individual unit's focused operation
Solution Approach 2:
The patent combines multiple welding operations into a single integrated system where multiple ultrasonic horns and anvil rolls work together on the same web material. This merging allows parallel processing of different web sections, reducing total welding time while maintaining the precision benefits of controlled, focused welding at each location
2Productivity
If multiple anvil rolls are provided in the web welding system, then the welding speed is increased and welding time is reduced, but the device complexity is increased
Solution Approach 1:
The patent designs the multiple anvil rolls and ultrasonic horn assemblies to be functionally similar and interchangeable, where each unit performs the same welding function. This standardization allows the system to increase capacity through replication rather than through fundamentally different mechanisms, thereby increasing welding speed while limiting complexity growth through modular, uniform components
Solution Approach 2:
The patent transitions from a single-line sequential welding approach to a multi-line parallel welding arrangement by adding anvil rolls in the vertical or lateral dimension. This dimensional expansion allows multiple welding operations to occur simultaneously at different positions along the web, increasing throughput without requiring excessive complexity in any single welding path
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 reduces the time needed for welding, enhances welding speed, and improves the accuracy of the welding process by distributing the load and ensuring precise positioning of the anvil rolls, even under high vibration energy application.
Implementation Method 1
first and second ultrasonic horns that work together with the pair of anvils to apply vibration energy (energies) to the webs; third and fourth ultrasonic horns that work together with the pair of anvils in the second anvil roll to apply vibration energy (energies) to the webs
Data Source
AI summary
First and second anvil rolls (10A, 10B) are arranged so that in the welding of webs, the webs are transported to pass through a first gap (Δ1) between the first anvil roll (10A) and a first horn (21), a third gap (Δ3) between the second anvil roll (10B) and a third horn (23), a fourth gap (Δ4between the second anvil roll (10B) and the fourth horn (24) and a second gap (Δ2) between the first anvil roll (10A) and the second horn (22) in this order.