CN107684490A - 一种超声波熔接装置 - Google Patents

一种超声波熔接装置 Download PDF

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CN107684490A
CN107684490A CN201610632744.4A CN201610632744A CN107684490A CN 107684490 A CN107684490 A CN 107684490A CN 201610632744 A CN201610632744 A CN 201610632744A CN 107684490 A CN107684490 A CN 107684490A
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weld portion
ultrasonic wave
bead mount
fused
wave welding
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龚志龙
李大柱
丁胜
朱钱军
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Huangshan Futian Precision Manufacturing Co Ltd
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Huangshan Futian Precision Manufacturing Co Ltd
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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Abstract

本发明公开了一种超声波熔接装置，用于对被熔接物上若干个等间距配置的预设区域进行间歇性熔接，该预设区域包括第一熔接部和第二熔接部。上述熔接装置包括分别与任意一个第一熔接部和第二熔接部相对应的熔接组件，该熔接组件包括用于对沿着被熔接物流程方向运动的第一熔接部或第二熔接部进行熔接的超声波焊头和砧台，以及用于向超声波焊头提供能量的超声波振子，超声波焊头的输出侧端部具有能够熔接第一熔接部和第二熔接部的尺寸。本发明通过在被熔接物流程方向上至少布置两个熔接组件，每一个熔接组件分别作用于预设区域上相应熔接部，因而增加了相应熔接部的能量分布，增大了输出振幅，使得被熔接物连接更加可靠，同时提高生产效率。

Description

一种超声波熔接装置
技术领域
本发明属于卫生用品制造设备领域，尤其涉及一种超声波熔接装置。
背景技术
以往，已知具备穿着时配置在穿着者的腹部的前腹部、配置在穿着者的臀部的后背部以及从前腹部通过穿着者的两腿部间而延伸至后背部的裆部的一次性尿布。在该一次性尿布中，前腹部的两侧缘和后背部的两侧缘被互相熔接，以使前腹部和后背部被连接成环状。
在制造此种一次性尿布时，首先准备构成要素在横向上连续的连续体，其中，该构成要素是前腹部和后背部通过裆部在纵向连接而成。然后，在纵向上对折连续体，并且，在该状态下对前腹部和后背部的重叠部分进行超声波熔接，并以该熔接部分存在于裆部的两侧的方式在横向上切断连续体。
由于连续体包含无纺布片体、防水性片体以及弹性体，连续体的重叠部分的厚度尺寸大且不均匀，因此，为了在此种被熔接物有效地产生利用超声波振动的热能，要求增大从超声波焊头输出的超声波振动的振幅(以下称为输出振幅)。
一般来讲，在超声波焊头中，已知以被输入的超声波振动的节点部为基准，输出面侧的质量与靠近超声波振子一侧的输入面侧的质量之比越小，输出振幅就越大。然而为了在被熔接物的预设区域范围内熔接规定的尺寸，现有的超声波焊头普遍在与被熔接物流程方向相垂直的宽度方向上具有与前腹部和后背部的重叠部分的纵长大致相当的尺寸，由于超声波焊头的能量有限，有时并不能够保证连接的可靠性。
再者，为进一步提高腰围部分的弹性性能，或者被熔接物的上部设有折边，此时被熔接物在预设区域的上部第一熔接部的厚度会超过下部第二熔接部的厚度，如果采用同一超声波焊头同时对第一熔接部、第二熔接部进行熔接，往往会造成第一熔接部连接不可靠或者第二熔接部手感变硬，外观差等问题。
发明内容
鉴于此，本发明的目的在于提供一种能够增大输出振幅的超声波熔接装置，解决现有装置输出振幅有限、以及连接不可靠的问题。
本发明解决上述技术问题所采用的技术方案为：一种超声波熔接装置，用于对被熔接物上若干个等间距配置的预设区域进行间歇性熔接，该预设区域包括第一熔接部和第二熔接部。上述超声波熔接装置，包括分别与任意一个第一熔接部和任意一个第二熔接部相对应的熔接组件，该熔接组件包括用于对沿着被熔接物流程方向运动的第一熔接部或第二熔接部进行熔接的超声波焊头和砧台，以及用于向超声波焊头提供能量的超声波振子。其中，超声波焊头的输出侧端部具有能够熔接第一熔接部和第二熔接部的尺寸。
作为本发明的进一步改进，上述预设区域由上部的第一熔接部和下部的第二熔接部组成，并且第一熔接部和第二熔接部根据被熔接物在对应位置上具有的不同厚度将预设区域分割成上下两部分，如在第一熔接部具有六层织物，第二熔接部具有四层织物，因此可能出现第一熔接部和第二熔接部面积相同或不同的情形。更进一步的，预设区域还包括设置在第一熔接部和第二熔接部之间的空隙部，此空隙部的产生是由于两熔接组件的超声波焊头的安装误差而形成的，安装时应尽量保证两超声波焊头在第一熔接部和第二熔接部沿流程方向延伸的假想分界线相切。
此外，熔接组件包括与任意一个第一熔接部相对应的第一熔接组件，以及与任意一个第二熔接部相对应的第二熔接组件。作为本发明的一种具体实施方式，第一熔接组件、第二熔接组件同时作用于同一预设区域上的第一熔接部或第二熔接部。作为本发明的另一种具体实施方式，第一熔接组件、第二熔接组件沿着被熔接物的流程方向错位配置且分别作用于不同预设区域上的第一熔接部或第二熔接部，此时两熔接组件熔接的时机可能是同时也可能不是同时的，是否同步主要取决于两熔接组件的初始相位是否存在偏差。当两熔接组件熔接时机是同时的，第一熔接组件和第二熔接组件在流程方向上的间隔距离与对应预设区域的间距相适配。当两熔接组件熔接时机是非同步时，可分别通过伺服电机驱动对应熔接组件中砧台的旋转，从而实现在不同时间焊接，还可通过相位调整改码。
更进一步的，第一熔接组件中超声波焊头的输出侧端部和第二熔接组件中超声波焊头的输出侧端部，相对于被熔接物上第一熔接部和第二熔接部沿流程方向延伸的假想分界线的位置关系是相离、相切或者部分重叠中的任意一种。需要说明的是，此处的“相切”并非指的是两输出侧端部与上述假想分界线只有一个交点，可以理解成恰恰与假想分界线相搭接的情形。优选采用相切或相离的方式。
上述第一熔接组件、第二熔接组件还包括振荡出高频电能且与超声波振子相连的超声波振荡器。当第一熔接部的厚度大于或等于第二熔接部的厚度时，如第一熔接部具有六层织物，第二熔接部具有四层织物，第一熔接组件中超声波焊头的输出振幅大于或等于第二熔接组件中超声波焊头的输出振幅。
优选的，熔接组件的砧台具有工作部和非工作部，在工作部的中央沿与被熔接物流程方向相垂直的宽度方向上开设有凹槽。此时第一熔接部和第二熔接部在沿宽度方向的中间位置设有供下一流程切断连续体的缝隙，将凹槽设置在砧台上，与对超声波焊头进行改进方案相比，更易于加工，且大大降低了装置的制造成本。
本发明与现有技术相比，具有如下优点：本发明通过在被熔接物流程方向上至少布置两个熔接组件，每一个熔接组件分别作用于预设区域上相应熔接部，因而较之现有技术增加了相应熔接部的能量分布，增大了输出振幅，使得被熔接物的连接更加可靠，与此同时提高了生产效率。
附图说明
图1是实施例1中被熔接物的产品流程图。
图2是图1状态下，第一熔接组件和第二熔接组件的错位关系示意图。
图3是实施例1的侧视图。
图4是第一熔接组件的输出侧端部和第二熔接组件的输出侧端部于宽度方向中心线相切、相离、部分重叠三种状态下的俯视图。
图5是图4相离情况下，预设区域的结构示意图。
图6是实施例2中第一熔接组件和第二熔接组件对齐状态下的位置关系示意图。
图7是实施例3中被熔接物的产品流程图。
图8是实施例3中超声波焊头与砧台的结构示意图。
具体实施方式
以下参照说明书附图和具体实施方式，对本发明进行说明。
实施例1，
请参阅图1，被熔接物101是一种一次性吸收物品，其具备穿着时配置在穿着者的腹部的前腹部20a、配置在穿着者的臀部的后背部20b以及从前腹部20a通过穿着者的两腿部间而延伸至后背部20b的裆部20c。
前腹部20a的两侧缘部以及后背部20b的两侧缘部被两处的熔接部互相被熔接，以将前腹部20a和后背部20b连接成环状。
下面，说明一次性吸收物品的制造方法。
＜搬送工序P1＞
在搬送工序P1，将在特定方向上延伸的片体W沿其长度方向搬送。下面，设片体W的运动方向为流程方向MD、与流程方向MD相垂直的方向为宽度方向CD进行说明。
片体W具有：穿着时面向穿着者的体表侧的内侧片体；穿着时面向穿着者的外侧的外侧片体；以及夹在内侧片体与外侧片体之间的弹性部件。
内侧片体采用具有透液性的无纺布片体及/或网状片体而形成。外侧片体采用与内侧片体相同的材质、聚乙烯膜、聚丙烯膜、或具有防水性以及通气性的无纺布而形成。
弹性部件使用聚氨酯、天然橡胶、由热塑性树脂形成的片体或丝而形成。
＜腿口形成工序P2＞
在腿口形成工序P2，在片体W的纵向的中央位置形成腿口L。
片材W中两个腿口L之间的区域是相当于裆部20c的部分。此外，片材W中相当于裆部20c的部分的纵向的两侧位置是分别相当于前腹部20a以及后背部20b的部分。
也就是说，搬送工序P1以及腿口形成工序P2相当于准备构成要素在横向上连续的连续体(被熔接物)的准备工序，其中，该构成要素是前腹部20a和后背部20b通过裆部20c在纵向上连接而形成。
＜吸收体接合工序P3＞
在吸收体接合工序P3，将吸收体A接合于片体W中的两个腿口L之间的位置。
吸收体A包括：具有透液性的透过性片体；具有防水性以及通气性的防水片体；以及夹在透过性片体与防水片体之间的吸收性芯。
透过性片体采用具有透液性的无纺布片体及/或网状片体而形成。防水片体采用聚乙烯膜、聚丙烯膜或具有防水性以及通气性的无纺布而形成。
吸收性芯是将粉碎的纸浆或在纸浆中混合高吸水性聚合物的材料层叠而成型。
此外，虽然说明了在片体W上接合吸收体A的方法，但也可以在片体W的内侧片体与外侧片体之间夹住吸收性芯而接合。此时，内侧片体采用具有透液性的无纺布片体及/或网状片体而形成。外侧片体采用聚乙烯膜、聚丙烯膜或具有防水性以及通气性的无纺布而形成。
＜对折工序P4＞
在对折工序P4，将载置了吸收体A的片体W(连续体)在纵向上对折。据此，片体W中相当于前腹部20a的部分和相当于后背部20b的部分重叠。
＜熔接工序P5＞
在熔接工序P5，对于被对折的片体W中相当于前腹部20a的侧缘部的部分和相当于后背部20b的侧缘部的部分进行超声波熔接。
具体而言，在熔接工序P5对预设区域的第一熔接部1和第二熔接部2进行超声波熔接，其中，预设区域102由上部的第一熔接部1和下部的第二熔接部2组成，并且第一熔接部1和第二熔接部2根据所含织物的层数将预设区域102分割成面积大致相等的上下两部分。作为下一工序中的切断线与第一熔接部1和第二熔接部2沿流程方向MD的中心线T2重合。
此外，两个熔接部1、2分别形成于相当前腹部20a的侧缘部的部分和相当后背部20b的侧缘部的部分的纵向的1/2个范围D1。
＜切断工序P6＞
在切断工序P6，沿着在熔接工序P5中提到的中心线T2切断片体W。据此，片体W(连续体)按每个一次性吸收物品而被切开。
如图2至5所示，进行熔接工序P5使用的超声波熔接装置，用于对被熔接物101上若干个等间距配置的预设区域102进行间歇性熔接，其具有与前一个预设区域的第一熔接部1相对应的第一熔接组件103，以及与后一个预设区域的第二熔接部2相对应的第二熔接组件103’。前一个预设区域与后一个预设区域沿流程方向相隔一个吸收性物品的长度D3，即第一熔接组件103与第二熔接组件103’间隔一个吸收性物品的长度D3。
每一个熔接组件103、103’均具备：振荡出高频电能的超声波振荡器5、5’，将从超声波振荡器输出的电能转换为机械性振动而输出的超声波振子4、4’，连接于超声波振子4、4’的超声波焊头3、3’，以及与超声波焊头3、3’相对应的砧台6、6’。当然，还可以视具体情况在超声波振子与超声波焊头之间设置增幅器，以进一步增大输出振幅。此外，上述熔接组件还可以包括一转鼓，超声波焊头或砧台对应安装在转鼓的鼓体上，工作时被熔接物绕在鼓体上依次被熔接、切断。
其中，超声波焊头3、3’靠近被熔接物101的一侧为输出侧端部7、7’，靠近超声波振子的一侧为输入侧端部9、9’。第一熔接组件103中超声波焊头的输出侧端部7具有能够熔接被熔接物101中相当于前腹部的侧缘部以及相当于后背部的侧缘部的宽度方向CD的1/2个范围D1的尺寸D2。D1＝2*D2。
优选的，第一熔接组件103中超声波焊头3的输出侧端部7和第二熔接组件103’中超声波焊头3’的输出侧端部7’，于被熔接物101流程方向相垂直的宽度方向CD的中心线T1相切，此时可实现第一熔接部1和第二熔接部2的无缝对接，这时对于装配的精度有极高的要求。此外，将两输出侧端部7、7’设置成与中心线T1相离或者部分重叠亦可。若两者相离，在第一熔接部1和第二熔接部2之间会形成一空隙部8，该空隙部8沿宽度方向的尺寸优选不超过2mm可保证熔接部柔软的手感。若两者部分重叠，其手感欠佳，重叠部分的手感较硬，外观不佳。如上所述，优选两输出侧端部7、7’设置成与中心线T1相离或者相切。
当第一熔接部1的厚度大于第二熔接部2的厚度时，第一熔接组件103中超声波焊头3的输出振幅大于第二熔接组件103’中超声波焊头3’的输出振幅，如此可以保证上下两熔接部手感的一致性。
实施例2，
请参阅图6，第一熔接组件103、第二熔接组件103’同时作用于同一预设区域102上的第一熔接部1或第二熔接部2。换句话说，第一熔接组件103、第二熔接组件103’在流程方向MD上位于被熔接物的同上、同下或一上一下对齐布置。
其余同实施例1。
实施例3，
请参阅图7至8，为在第一熔接部1和第二熔接部2的切断线(中心线T2)处预留缝隙，熔接组件中可旋转的砧台6、6’具有工作部61和非工作部62，在工作部61的中央沿与被熔接物101流程方向相垂直的宽度方向CD上开设有凹槽63，该凹槽63与上述预留缝隙的宽度相适配。
其余同实施例1。
以上所述及图中所示的仅是本发明的优选实施方式，但本发明的保护范围不限于此，任何熟悉本技术领域的普通技术人员来说，在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。

Claims (10)

1.一种超声波熔接装置，用于对被熔接物(101)上若干个等间距配置的预设区域(102)进行间歇性熔接，其特征在于：
所述预设区域(102)包括第一熔接部(1)和第二熔接部(2)；
所述熔接装置具有分别与任意一个第一熔接部(1)和任意一个第二熔接部(2)相对应的熔接组件(103、103’)；所述熔接组件(103、103’)包括用于对沿着被熔接物(101)流程方向运动的第一熔接部(1)或第二熔接部(2)进行熔接的超声波焊头(3、3’)和砧台(6、6’)，以及用于向超声波焊头(3、3’)提供能量的超声波振子(4、4’)；
其中，超声波焊头(3、3’)的输出侧端部(7、7’)具有能够熔接第一熔接部(1)和第二熔接部(2)的尺寸。
2.如权利要求1所述超声波熔接装置，其特征在于：所述预设区域(102)由上部的第一熔接部(1)和下部的第二熔接部(2)组成，并且第一熔接部(1)和第二熔接部(2)根据被熔接物(101)在对应位置上具有的不同厚度将预设区域(102)分割成上下两部分。
3.如权利要求1或2所述超声波熔接装置，其特征在于：所述熔接组件包括与任意一个第一熔接部(1)相对应的第一熔接组件(103)，以及与任意一个第二熔接部(1)相对应的第二熔接组件(103’)。
4.如权利要求3所述超声波熔接装置，其特征在于：所述第一熔接组件(103)、第二熔接组件(103’)同时作用于同一预设区域上的第一熔接部(1)或第二熔接部(2)。
5.如权利要求3所述超声波熔接装置，其特征在于：所述第一熔接组件(103)、第二熔接组件(103’)沿着被熔接物(101)的流程方向错位配置且分别作用于不同预设区域上的第一熔接部(1)或第二熔接部(2)。
6.如权利要求3所述超声波熔接装置，其特征在于：所述第一熔接组件(103)中超声波焊头(3)的输出侧端部(7)和第二熔接组件(103’)中超声波焊头(3’)的输出侧端部(7’)，相对于被熔接物(101)上第一熔接部(1)和第二熔接部(2)沿流程方向延伸的假想分界线的位置关系是相离、相切或者部分重叠中的任意一种。
7.如权利要求1所述超声波熔接装置，其特征在于：所述预设区域(102)还包括设置在第一熔接部(1)和第二熔接部(2)之间的空隙部(8)。
8.如权利要求1所述超声波熔接装置，其特征在于：所述熔接组件(103、103’)还包括振荡出高频电能且与超声波振子(4、4’)相连的超声波振荡器(5、5’)。
9.如权利要求3所述超声波熔接装置，其特征在于：所述第一熔接组件(103)中超声波焊头(3)的输出振幅大于或等于所述第二熔接组件(103’)中超声波焊头(3’)的输出振幅。
10.如权利要求1所述超声波熔接装置，其特征在于：所述砧台(6、6’)具有工作部(61)和非工作部(62)，在工作部(61)的中央沿与被熔接物(101)流程方向相垂直的宽度方向上开设有凹槽(63)。
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EP3870426A4 (en) * 2018-10-26 2022-08-17 Curt G. Joa, Inc. DUAL BONDER

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