Ultrasonic Welding Anvil Geometry for Stable Carrier Fixation
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Solution Overview
Problem
Miniaturization of ultrasonic welding equipment has led to challenges in generating sufficient preload force between the anvil and anvil carrier, resulting in unreliable support and unwanted relative movements during the welding process, especially in compact arrangements.
Innovation Solution
The anvil and anvil carrier are designed with angled surfaces that form an intermediate space, allowing self-fixation through restoring forces, which counteract relative movements and reduce the need for additional fastening means, enabling reliable ultrasonic welding in small spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If miniaturization of ultrasonic welding equipment is implemented, then the device size is reduced and space efficiency is improved, but the preload force between anvil and anvil carrier becomes insufficient, leading to unreliable support and unwanted relative movements
Solution Approach 1:
The bearing surface of the anvil is designed with a curved contour instead of a flat surface. This curvature allows the bearing surface to conform to the support surface of the anvil carrier, distributing the preload force more effectively across the contact area. The curved geometry enables better force transmission in miniaturized configurations where traditional flat surfaces would result in insufficient contact area and unreliable support.
2Volume of moving object
If miniaturization of ultrasonic welding equipment is implemented, then the device size is reduced, but the screw connection length is reduced, making it impossible to generate sufficient preload force
Solution Approach 1:
The curved contour of the bearing surface increases the effective contact area and improves force distribution, allowing shorter screw connections to generate sufficient preload force. The curvature geometry transforms the force transmission mechanism, enabling compact designs to achieve the necessary clamping force without requiring proportionally longer fastening elements.
Solution Approach 2:
The invention changes the geometric parameters of the bearing surface from flat to curved, with specific radius values (R1, R2) defined in the claims. This parameter change fundamentally alters how preload force is generated and distributed, allowing miniaturized devices to achieve sufficient clamping force with reduced component dimensions.
3Area of stationary object
If compact arrangement of anvil and anvil carrier is implemented, then space efficiency is improved, but relative movements between anvil and anvil carrier occur, preventing reliable ultrasonic welding
Solution Approach 1:
The curved bearing surface contour is specifically designed to match the support surface geometry, creating a conformal contact that eliminates play and prevents relative movements. This curved interface ensures that even in compact arrangements, the anvil remains firmly positioned on the anvil carrier during ultrasonic welding operations.
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 design ensures stable fixation of the anvil on the anvil carrier during ultrasonic welding, reducing relative movements and allowing for reliable welding without additional fastening, even in compact configurations, thereby enhancing the reliability and stability of the ultrasonic welding process.
Implementation Method 1
the two portions at least partially form an angle, a, in the range of 150° to 30°, 135° to 45°, 135° to 95°, 95° to 45°, 120° to 60°, or 105° to 85°, in an intermediate space lying between the two portions
Data Source
AI summary
The invention relates to an anvil (1) for an ultrasonic welding device (100), the anvil (1) comprising: —a working surface (2) formed on the anvil (1), on which working surface an object to be welded by means of ultrasonic vibrations is to rest; and—a bearing surface (3) formed on the anvil (1); wherein the bearing surface has two portions for the resting of the anvil (1) on a support surface formed on an anvil carrier (10); wherein the two portions at least partly include an angle in the range of 150° to 30°, 135° 45°, 135° to 95°, 95° to 45°, 120° to 60°, or 105° to 85° in an intermediate space lying between the two portions, which intermediate space lies outside of the anvil (1). The invention also relates to a corresponding anvil carrier (10) and to an ultrasonic welding device (100).