CN113453857A - 向层压材料中引入穿孔的装置和方法 - Google Patents

向层压材料中引入穿孔的装置和方法 Download PDF

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Publication number
CN113453857A
CN113453857A CN202080015195.0A CN202080015195A CN113453857A CN 113453857 A CN113453857 A CN 113453857A CN 202080015195 A CN202080015195 A CN 202080015195A CN 113453857 A CN113453857 A CN 113453857A
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optionally
perforating
groove
laminate
array
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CN113453857B (zh
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乌尔夫·约翰尼森
斯蒂恩·乔根森
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Molnycke Health Care AB
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Molnycke Health Care AB
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/24—Perforating by needles or pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7443—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc by means of ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B23K20/106—Features related to sonotrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/086—Means for treating work or cutting member to facilitate cutting by vibrating, e.g. ultrasonically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
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    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/384—Cutting-out; Stamping-out using rotating drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
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    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/3846—Cutting-out; Stamping-out cutting out discs or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7435—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a roller
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7437—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a perforating tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/749—Removing scrap
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
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    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81413—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being non-symmetrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/82—Testing the joint
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83511—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9513—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools characterised by specific vibration frequency values or ranges

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)

Abstract

本发明涉及层压材料的超声波焊接，更具体地，涉及使用超声波能量在层压材料中，特别是包含硅凝胶的层压材料中产生稳定的穿孔。具体地，提供了穿孔元件，其任选地是穿孔元件阵列的一部分，该穿孔元件或穿孔元件阵列有利地用于超声波焊接装置中和向层压材料中连续引入穿孔的工艺中。该穿孔元件的特征在于特征最大宽度和/或外周长以及凹槽，两者一起限定了外侧表面和内侧表面，该外侧表面和内侧表面任选地相对于表面法线(纵轴)倾斜，但方向相反。外缘可以具有锋利边缘，而内侧表面具有朝向外缘的圆形(凸起的，即向外凸出的)部分。

Description

向层压材料中引入穿孔的装置和方法
技术领域
本发明涉及层压材料的超声波焊接，更具体地，涉及使用超声波能量在层压材料中，特别是包含硅凝胶的层压材料中产生稳定的穿孔。具体地，提供了穿孔元件，其任选地是穿孔元件阵列的一部分，该穿孔元件或穿孔元件阵列有利地用于超声波焊接装置和用于向层压材料连续引入穿孔的工艺。
该穿孔元件的特征在于特征最大宽度和/或外周长以及凹槽，两者(即凹槽和最大宽度和/或外周长)一起限定了外侧表面和内侧表面，该外侧表面和内侧表面任选地相对于表面法线(纵轴)倾斜，但是方向相反。外侧表面外缘可以具有，任选地是，锋利边缘，优选切割边缘，该内侧表面可以具有朝向所述外缘的圆形(凸起的，即向外凸出的)部分。
这种几何形状与超声波焊接结合，允许向层压材料中可再现地引入穿孔、减少穿孔边缘周围材料的“堆积”和/或从层压材料去除“穿孔外”部分，例如通过将穿孔外部分转移至牺牲基底。
背景技术
已知超声波焊接是一种连接或改变复杂零件或结构的合适技术，其包括通常包含至少一个热塑性层的材料(1)的层压材料。待连接或改变的零件或层通常夹在固定形状的套[穿孔元件40]和连接至换能器(31)的超声波焊极(焊头)(30)之间(这种超声波焊接装置的示意图见图1)。通常发出20～kHz的低振幅声振动(热塑性塑料超声波焊接中使用的其他常见频率为15kHz、20kHz、30kHz、35kHz、40kHz和70kHz)。当焊接塑料时，穿孔元件(40)和超声波焊极(30)之间的界面被特别设计成“集中”用于局部熔化的能量输入。超声波能量(局部)在零件之间的点接触处熔化层压材料，产生接头，或者根据能量输入和接触时间，产生孔。
原则上，专门用于在层压材料中产生穿孔的超声波焊接是已知的，例如从US 4747 895中已知，其公开了连续移动的材料带(例如背胶塑料带)的超声波穿孔。根据US 4747 895，连续移动的带通过由超声波焊头限定的间隙，并与具有用作穿孔元件阵列的穿孔突起的旋转鼓接触。
该基本原理在EP 2 382 069中应用于包含硅凝胶的层压材料。根据EP 2 382 069的穿孔元件被实现为旋转鼓上的销状平顶突起(见图2)，其用作穿孔元件(40)的阵列(41)。类似地，EP 1 112 823公开了一种在超声波装置中使用具有针状穿孔元件的旋转鼓(“销辊”)的幅材穿孔方法。根据EP 1 112 823的图4，销具有平顶。
用简单的(平顶)销进行超声波穿孔的过程的一个潜在缺点是，层压材料中存在的任何非热塑性材料(即加热时不(完全)熔化的材料)，例如US 4 747 895中所述的粘合剂或EP 2 382 069中所述的硅凝胶，被挤压到孔的边缘。然后，多余的材料位于穿孔周围，并可能(部分)堵塞穿孔。
在这种情况下，见图3，显示了通过不同的技术/穿孔元件穿孔的包含硅凝胶的层压材料的表面扫描。如图3(b)所示，本领域已知的方法(使用平顶销作为穿孔元件)导致穿孔边缘周围存在有机硅“环”(聚集的有机硅)。
此外，如果使用简单的“冲孔”来产生穿孔，冲孔过程的“悬挂”残余物(残留在冲孔工具上和/或层压材料上的“碎屑(confetti)”)可能导致工具故障和/或干扰穿孔层压材料的预期用途，特别是在伤口处理中的任何用途。
即使当使用超声波穿孔时，即当潜在地避免冲孔的缺点时，层压材料的被切掉部分(“碎屑”)可能在使用点产生问题，并且需要从产物中去除，例如通过穿孔吹气，这增加了另一个工艺步骤。
当用于对包含硅凝胶的层压材料穿孔时，使用平顶销的常规超声波穿孔的另一个缺点是难以产生较大直径的穿孔，例如直径大于2mm的穿孔。这个基本问题被认为与这样的事实有关，即平顶越大，在可以向层压材料中引入穿孔之前需要移位(从待穿孔的横截面去除)的硅凝胶越多。增加的硅凝胶移位/置换与所需的更高能量输入有关，也与穿孔边缘周围更多的硅凝胶堆积有关。因为当半径(和/或克重)增加时，需要移位/替换的有机硅的体积不仅是线性增加，所以当涉及向包含硅凝胶的层压材料中引入穿孔时，常规的超声波焊接具有显著的局限性。
发明内容
鉴于现有技术的上述或其他缺点或未满足的需求，本发明的一个目的是提供一种用于超声波能量输入，特别是用于向包含硅凝胶层的层压材料中引入穿孔的工具和方法，该方法改善了过程控制、能量消耗和产品层压材料质量中的至少一个，任选地改善了所有这些，其中所得层压材料应特别适合用于伤口处理。
在下文中，示例性地参考附图，特别是图4至7，其示出了根据本发明的一些或所有方面的示例性实施方案。所提供的任何附图标记旨在提供所要求保护的功能或结构元件的说明，但绝不旨在将所要求保护的主题限于附图中示例性示出的实施方案。
例如，图4示出了本发明的第一方面。
在第一方面，该目的或这些目的通过用于超声波能量输入的穿孔元件来实现，其中所述穿孔元件(40)包括：
(A)外侧表面(10)，其具有外缘(11)和纵轴(12)；和
(B)凹槽(2)，其具有内侧表面(20)；
其中
(A1a)所述外缘(11)的最大宽度MW在0.5mm至20mm的范围内；和/或
(A1b)所述外缘(11)的外周长在分别1.6mm或π·0.5mm至分别63mm或π·20mm的范围内；
并且其中
(B1a)所述凹槽(2)的至少一个最大内宽度IW，特别地所述凹槽分别在沿纵轴的至少一个位置或高度处的最大内宽度，分别在所述外缘(11)最大宽度MW的30％至95％的范围内；和/或
(B1b)所述凹槽(2)的至少一个内周长，特别地所述凹槽分别在沿纵轴的至少一个位置或高度处的内周长，分别在所述外缘(11)外周长的30％至95％的范围内；
进一步地，其中
(B2)内侧表面(20)向外缘(11)发散；
(B2.1)内侧表面(20)的至少一部分相对于纵轴(12)倾斜，使得在至少一个横截面中，优选地在包括纵轴(12)的至少一个横截面中，内侧表面的至少一条切线与所述纵轴相交，任选地以大于0度、任选地至少5度、特别地至少7度的角度β相交；
并且其中
(B3)内侧表面的至少一部分(21)是圆形的。
因此，在第一方面，特征(A)、(B)、(B2)、(B2.1)和(B3)以及特征(A1a)、(A1b)中的至少一个和特征(B1a)、(B1b)中的至少一个分别存在或实现。
其中，本发明基于这样的认识，即如上定义的穿孔元件在用于超声波穿孔过程中时，可以对层压材料穿孔，同时便于管理、特别是去除“穿孔外”或切掉的(残余)材料。
特别地，穿孔元件(40)包括可以在层压材料中产生切口的外缘(11)(例如锋利边缘)，此外，还包括在内侧表面上的圆形部分(21)，该圆形部分不一定产生切口，而是提供焊接点(当施加超声波能量时)，使得切掉的(“穿孔外”)材料可以焊接到例如层压材料的牺牲层上。由此，切割材料的管理受到控制，因为切割材料可以收集在例如牺牲层上，并且可以减少过程中产生的松散的切掉的材料的量。此外，穿孔元件的凹槽有助于有利结果，即切掉的材料的残余材料(例如硅凝胶)的量被最小化，否则该残余材料可能被推到穿孔边缘周围(从而产生不平的表面)。当平顶销用作穿孔元件时，已知穿孔边缘周围的硅凝胶聚集是一个问题。
据信内侧表面(20)的至少一部分的倾斜(以角度β)有利于帮助层压材料的“穿孔外”部分“转移”到“牺牲”层，如图4中示例性示出。
术语“轴向”优选地表示分别平行于或沿着纵轴的方向。因此，圆周方向优选地表示绕所述纵轴的旋转方向，而术语“径向”优选地表示垂直于纵轴和这样的圆周方向的方向。换句话说，术语“轴向”、“圆周方向”和“径向”分别优选地以它们相对于本文的纵轴的通常或常见的含义来使用或理解。
术语“周长”优选地表示周长长度。
在本发明的实施方案中，外侧表面至少部分地包围或围绕纵轴和/或凹槽，和/或术语“外侧表面”表示(侧)表面，该表面的表面法线(矢量)分别指向远离纵轴，和/或术语“内”分别指凹槽或其((内)侧)表面。在本发明的实施方案中，术语“外”、“外侧表面”和/或“内”优选地分别作为“径向外/内”和/或其通常或常见的含义使用或理解。
在本发明的实施方案中，外侧表面(10)(轴向)终止于外缘(11)或外缘(11)(轴向)终止或界定外侧表面(10)。因此，在本发明的实施方案中，外缘(11)包括外侧表面(10)的边缘、边界或边线，特别是分别相对于纵轴和/或切割边缘的轴向方向的(轴向)边缘/边界/边线，和/或连接外侧表面(10)与凹槽(2)(的内侧表面(20))或连接至凹槽(2)(的内侧表面(20))的(轴向的，任选地平面的)端面。
或许如图4中最佳示出的，根据本发明的外“缘”是指穿孔元件的实际外边缘，即限定穿孔元件的最外延伸部。据此，本发明的外缘(11)不同于图7的下图所示的平顶表面或“环”。
在优选实施方案中，外缘11是锋利的(“刀刃”)，内“缘”是圆形部分(21)，见图7的上图。
在本发明的实施方案中，如图7的上图所示，所述外缘(11)是或形成这样的(轴向)边缘/边界/边线，和/或外侧表面(10)与凹槽(2)(的内侧表面(20))、或外侧表面(10)与连接至凹槽(2)(的内侧表面(20))的(轴向的，任选地平面的)端面在所述外缘(11)中彼此连接。
在本发明的其它实施方案中，如图7的下图所示，所述外缘(11)是或形成分别连接至凹槽(2)(的内侧表面(20))的(轴向的，任选地平面的)端面或环(如图所示的上平顶)，所述端面或环的(径向外)边缘(轴向地)限制外侧表面。在该实施方案中，从外边缘/外缘计算最大宽度MW，本发明的所有实施方案都如此(见下一部分)。
在本发明的实施方案中，所述外缘(11)的所述最大宽度MW在外缘(11)，特别是其(径向外)边缘的两个点之间测量，这两个点特别是在径向上彼此最大程度地间隔开。因此，如果外缘(11)具有，特别地是，圆形(径向外)边缘，那么所述最大宽度MW等于该圆形边缘的直径。例如，如果外缘(11)具有，特别地是，方形(径向外)边缘，那么所述最大宽度MW等于该方形边缘的对角线。
因此，在本发明的实施方案中，所述条件(A1a)和(A1b)彼此相当，特别是对于具有，特别地是，直径Da＝MW且外周长(长度)为π·MW的圆形(径向外)边缘的外缘。
在本发明的实施方案中，所述凹槽(2)的所述最大内宽度IW在凹槽(2)的两个点之间测量，这两个点分别沿着纵轴具有相同的(轴向)位置或高度，并且特别是在径向上彼此最大程度地间隔开。因此，如果凹槽(2)(的内侧表面(20))(分别在沿纵轴的该(轴向)位置或高度)分别具有垂直于纵轴的圆形形状或横截面，则所述最大内宽度IW等于所述圆的直径。例如，如果凹槽(2)(的内侧表面(20))(分别在沿纵轴的该(轴向)位置或高度)分别具有垂直于纵轴的方形形状或横截面，则所述最大内宽度IW等于所述方形区的对角线。
因此，在本发明的实施方案中，所述条件(B1a)和(B1b)彼此相当，特别是对于在沿纵轴的(轴向)位置或高度处具有垂直于纵轴的圆形横截面的凹槽(2)(的内侧表面(20))，该圆形横截面分别具有直径di＝IW和内周长π·IW：
Figure BDA0003217642200000061
k∈[0,3；0,95]。
在本发明的实施方案中，内侧表面的所述圆形部分(21)是凸起的。
用于本申请的术语“凸起”如图4所示，并且通常用于描述光学透镜，即凸起是指表面连续地向外弯曲。
在本发明的实施方案中，朝向外缘(11)的内侧表面的所述圆形部分(21)具有至多10mm-1的曲率(ρ＝1/R)。例如，曲率可以是1至10mm-1。
这些特征，特别是结合起来，可以改善“穿孔外”或切掉的(残余)材料的焊接和/或管理，特别是去除。
在本发明的实施方案中，外侧缘(11)是圆形的。
在实施方案中，外侧表面(10)是锥形的。
这些特征，特别是结合起来，可以改善层压材料的切掉的部分。
在本发明的实施方案中，所述外缘的最大宽度MW是直径，并且所述外缘是圆形的。
在本发明的实施方案中，所述外缘的最大宽度MW为0.75mm至5mm，任选地为0.75mm至3mm。在本发明的实施方案中，所述外缘的外周长为分别2.36mm或π·0.75mm至分别16mm或π·5mm，任选地为分别2.36mm或π·0.75mm至分别9mm或π·3mm。
本发明可以特别有利地用于获得这些尺寸的穿孔。
在本发明的实施方案中，(A2)外侧表面(10)朝向外缘(11)会聚，并且外侧表面(10)相对于纵轴(12)倾斜，使得外侧表面的至少一条切线在至少一个横截面中，优选地在包括纵轴(12)的至少一个横截面中，以大于0度，任选地至少5度的角度α与纵轴相交。
据信，外侧表面的这种倾斜(也可从图4中看出)有利于使粘附到穿孔元件外侧的材料量最小化。
在本发明的实施方案中，角度α在5度至30度，任选地7度至25度，进一步任选地10度至20度的范围内。
在本发明的实施方案中，角度β在7度至30度，任选地9度至25度，进一步任选地11度至20度的范围内。
在本发明的实施方案中，凹槽(2)的内侧表面(20)相对于纵轴(12)旋转对称；任选地与所述外缘(11)同心。
在本发明的实施方案中，所述凹槽的(最大)内宽度(IW，IW’)是直径，并且所述凹槽是圆形的。
这些特征，特别是结合起来，可以改善“穿孔外”或切掉的(残余)材料的切割、焊接和/或管理，特别是去除。
在本发明的实施方案中，所述凹槽(2)的最大内宽度IW在所述外缘(11)最大宽度MW的40％至90％的范围内，任选地在所述外缘最大宽度MW的50％至80％的范围内。在本发明的实施方案中，所述凹槽(2)的内周长在所述外缘(11)的外周长的40％至90％的范围内，任选地在所述外缘的外周长的50％至80％的范围内。
据信，如果分别由外侧表面和/或凹槽限定或连接至外侧表面和/或凹槽的缘或(轴向的，任选地平面的)端面变得太宽(从而基本上接近平顶销的形态(behavior))，则平顶销的上述缺点将再次出现。
在本发明的实施方案中，内侧表面(20)是锥形的。
在本发明的实施方案中，角度β大于角度α，任选地，β比α大至少3度。
在本发明的实施方案中，外缘分别是尖头或切割刃或锐边。在本发明的实施方案中，外缘或其(径向外)边缘具有至少20mm-1的曲率，优选地没有可辨别的曲率。
这些特征，特别是结合起来，可以支持“穿孔外”或切掉的(残余)材料的切割、焊接和/或管理，特别是去除。
根据一个实施方案，凹槽在其与外缘相对的端部处封闭。在本发明的实施方案中，凹槽的深度D，即从外缘(11)到凹槽的内底表面的距离，比所述凹槽或外侧表面分别位于其上的外下表面或外底表面上方的同一凹槽的高度H，即分别从外缘到所述外下表面或外底表面的距离，大至少10％，任选地大至少20％。
如图4所示，如果凹槽的深度D增加，则凹槽内的体积会变大。不希望受理论束缚，据信如果体积太小并且在穿孔和能量输入点处有太多的材料聚集在凹槽内，则可能形成过压，该过压可能阻碍穿孔过程和/或向牺牲层转移“穿孔外”的过程。
在本发明的实施方案中，如图7下图的优选实施方案所示，外缘(11)是或包括锋利边缘，并且分别连接到或为平面端面，该端面然后连接到朝向外缘的内侧表面的圆形/凹面部分(21)。
在优选的实施方案中，外侧表面的切线与以外缘连接至外侧表面的所述平面端面的切线之间的角度γ(如图4和图6的中间图所示)在60°至120°的范围内。
如图6所示的工艺步骤序列所示，与“锋利边缘”(11)和圆形部分(21)的这种组合(其中一个连续地会聚到另一个中)相关联的一个优点是，穿孔元件(40)的外“锋利边缘”切出穿孔，而基本上同步地，圆形部分(21)不切割层压材料，而是产生“焊接点”。其中，所述焊接点用于基本上封闭由至少一个热塑性层和至少一个另外的层(例如层压材料的另一层和/或牺牲层)形成的袋或囊中的穿孔残余物(最终将被切除)中的层中存在的至少一部分硅凝胶。因此，如本领域已知的方法(使用平顶销)中的情况，较少的硅凝胶聚集在穿孔周围，但是大部分硅凝胶或至少其重要部分被有效地从穿孔外层压材料中去除。特别地，通过将硅凝胶转移到牺牲层(18)的方式有效地去除了硅凝胶。
根据本发明，特别是在权利要求中，术语“包含(comprisisng)”和“包含(comprise(s))”不排除其他元件或步骤。不定冠词“一(a)”或“一(an)”的使用不排除多个元件或步骤。
仅在相互不同的从属实施方案或权利要求中列举某些措施的事实并不表示不能有利地使用这些措施的组合。
在第二方面，如图5所示，通过用于超声波能量输入的穿孔元件阵列(41)来实现上文公开的一个或多个目的，其中所述阵列(41)包括：
如以上任一实施方案中所述的穿孔元件的多个行(60)，其中至少一行包括至少五个，任选地至少八个穿孔元件，进一步任选地其中所述阵列总共包括5-70个穿孔元件，进一步任选地包括10-60个穿孔元件。
在本发明的实施方案中，穿孔元件行相对于垂直于阵列移动方向(“加工方向”)的轴线以不同的角度定向。
据信，相对于阵列的移动(“加工方向”)以不同的角度定向/间隔穿孔元件行减少了超声焊头表面上的磨损和摩擦(即确保穿孔元件和焊头表面之间的接触点更均匀地分布)，并且还确保了超声波装置在穿孔过程期间更均匀的功耗。
在本发明的实施方案中，穿孔元件相对于彼此布置成“六边形”图案、“菱形”图案或“正方形”图案。
在本发明的实施方案中，所述阵列中的两个穿孔元件之间的平均距离d、d’为1mm至10mm，任选地为2mm至5mm。
在本发明的实施方案中，所述阵列是旋转鼓的一部分。
根据本发明的第三方面，上述目的和其他目的通过一种用于超声波能量输入的装置、特别是一种用于向层压材料中引入穿孔的装置来实现，所述装置包括：
·如以上任一实施方案所述的至少一个穿孔元件(40)，或如以上任一实施方案所述的至少一个穿孔元件阵列(41)；
·至少一个超声波焊极(30)，其与如上所述的所述穿孔元件或所述穿孔元件阵列相对设置；
·至少一个装置，用于任选地至少部分地连续地将层压材料(1)输送通过所述穿孔元件或所述穿孔元件阵列与所述超声波焊极之间的间隙。
根据本发明的第四方面，上述目的和其他目的通过一种用于向层压材料至少部分地引入穿孔的方法来实现，所述层压材料包括至少一个热塑性材料层和至少一个硅凝胶层，其中所述方法包括以下步骤：
·使以上任一实施方案所述的至少一个穿孔元件、或以上任一实施方案所述的至少一个穿孔元件阵列的一部分、或上述至少一个装置的一部分与所述层压材料接触
·施加超声波能量以向所述层压材料中引入至少一个穿孔
·将前一步骤中引入的所述穿孔的至少一个剩余部分转移到牺牲基底上。
根据本发明的第五方面，上述目的和其他目的通过使用上述任一实施方案中所述的穿孔元件或上述任一实施方案中所述的至少一个穿孔元件阵列，或上述任一实施方案中所述的用于向层压材料引入穿孔的装置来实现，其中所述层压材料包括至少一个硅凝胶(任选地热塑性基底上的硅凝胶)层。
硅凝胶
在本发明的层压材料和方法中使用的硅凝胶(参见如上所述的第四和第五方面，以及权利要求17和19)是本领域已知的(参见例如WO2009/031948)，特别是在伤口护理中用作粘合剂和/或伤口接触表面。
具体地，与例如丙烯酸粘合剂的较硬粘合剂相比，硅凝胶被理解为对皮肤温和。这是因为软的硅凝胶可以很好地遵循皮肤的轮廓，从而提供大的接触表面积。因此，尽管硅凝胶粘合剂的每个接触点的实际粘合力通常小于典型的丙烯酸粘合剂的粘合力，但是用硅凝胶实现的大接触表面积提供了对皮肤的高整体粘附力，同时，硅凝胶是对皮肤友好的，即当硅凝胶从皮肤上去除时，由于每个接触点的粘合力相对较低，很少的皮肤细胞被共同去除。因此，可以避免或最小化皮肤剥离的问题。
在优选的实施方案中，硅凝胶包括或为双组分加成硬化硅凝胶。这种双组分硅凝胶可以是化学交联的硅凝胶，例如聚二甲基硅氧烷凝胶，例如铂催化的双组分加成硬化RTV-有机硅。可以使用的凝胶的示例是来自德国布格豪森的Wacker-Chemie GmbH的SilGel612和来自美国卡平特里亚的NuSil Technology的MED-6340。GB-A-2 192 142、GB-A-2 226780和EP-A1-0 300 620中也描述了在此上下文中有用的硅凝胶的示例。
在本发明的实施方案中，“克重”(每平方米硅凝胶的量)为10g/m2至500g/m2，优选15g/m2至200g/m2。发明人已经发现，如果克重太高，例如高于500g/m2，则堵塞更难防止或最小化。
具体实施方式
本发明由以下附图说明，其中：
图1：示出了超声波能量输入/“超声波焊接”装置的元件示意图。
图2：示出了根据现有技术的使用平顶销对层压材料进行超声波穿孔的装置。
图3：示出了与(a)根据本发明实施方案的穿孔元件和(b)平顶销穿孔元件(根据现有技术)结合使用超声波能量输入通过穿孔产生的穿孔层压材料的表面扫描。
图4：示出了四个穿孔元件的阵列(如图5所示)，这些穿孔元件是示例性的，但是说明了本发明的基本原理(截面图)。
图5：示出了穿孔元件的阵列(俯视图)。
图6：示出了示意性说明用于向层压材料至少部分地引入穿孔的方法的实施方案的流程图。
图7：示出了根据本发明的穿孔元件的圆形“内”边缘的多种示例性实现。
本发明的优点在以下对附图的更详细讨论中进行说明。
图1示出了超声波穿孔装置的可能设置。层压材料(1)位于超声波焊极的焊头(30)和穿孔元件(40)之间。换能器(31)和电源(50)等用于控制输入到层压材料中的超声波能量。
图2描述了本领域已知的超声波穿孔过程。在穿孔元件(40)的阵列(41)和超声波焊极的焊头(30)之间连续地供给层压材料(1)，其中该阵列实现为旋转鼓，并且穿孔元件实现为平顶销。
图3示出了与(a)根据本发明实施方案的穿孔元件和(b)平顶销穿孔元件(根据现有技术)结合使用超声波能量输入通过穿孔产生的穿孔层压材料的示例性表面扫描。从图(b)中所示的现有技术/平顶穿孔与根据本发明的方法的结果[图(a)]的比较中明显看出，在用根据本发明的穿孔元件产生的穿孔边缘周围有少得多或几乎没有硅凝胶聚集。在根据本领域的使用平顶销或其他简单穿孔元件的工艺中，沉积在边缘周围的大量硅凝胶通常极力“移回”至其原始位置，因此至少部分地堵塞如此产生的穿孔。通过使用根据本发明的穿孔元件和方法，这种负面结果被避免或最小化。
图4示出了如图5所示的穿孔元件(40)的阵列(41)的截面图(A-A)，其中该截面包括穿孔元件(40)的纵轴(12)。所示的每个穿孔元件(40)包括外缘(11)，特别是可以在层压材料中产生切口的锋利边缘，以及在内侧表面上进一步向内朝向凹槽(2)的圆形部分(21)，该圆形部分不一定产生切口，而是提供焊接点(当施加足够的超声波能量时)。根据这些功能，切掉的(“穿孔外”)材料可以焊接在一起和/或焊接至另一层，例如层压材料的牺牲层(18)(参见图6)。因此，由于可以将切掉的材料收集在牺牲层上并且可以减少在该过程中产生的松散的切掉的材料的量，所以改善了切割材料的管理。作为额外的优点，穿孔元件的凹槽(2)有助于减少切掉的材料的残余材料(例如硅凝胶)的量，所述残余材料在没有凹槽或没有大的凹槽体积的情况下，可以沉积在穿孔的边缘周围(从而产生不平的表面)。
图5示出了穿孔元件(40)的阵列(41)的俯视图。第一穿孔元件行相对于垂直于阵列移动方向(“加工方向”)的轴线以角度δ定向，其中第二穿孔元件行相对于垂直于阵列移动方向(“加工方向”)的轴线以角度η定向。在图5所示的实施方案中，穿孔元件以“六边形”图案布置，其中角度δ和角度η之和为60度。在其他示例性实施方案(未示出)中，穿孔元件可以以“正方形”图案布置，其中角度δ和角度η之和为90度。据信，相对于垂直于阵列移动方向(“加工方向”)的轴线，以不同角度定向的穿孔元件行减少了超声焊头表面上的磨损和摩擦(即确保接触点的更均匀分布)，并且还确保了穿孔过程期间超声波装置的更均匀的功耗。
如图6所示，与根据本发明的穿孔元件相关联的一个优点是，穿孔元件(40)的外“锋利边缘”(11)切出穿孔，而基本上同时圆形部分(21)不切割层压材料，而是产生“焊接点”。其中，所述焊接点用于基本上封闭由至少一个热塑性层和至少一个另外的层(例如层压材料的另一层和/或牺牲层)形成的袋或囊中的(最终将被切除的)穿孔残余物中的层之间存在的硅凝胶的至少一部分。因此，穿孔周围聚集的硅凝胶较少，如本领域已知的方法(使用平顶销，见图3)中的情况，但是大部分硅凝胶或至少其重要部分被有效且永久地从穿孔外的层压材料中去除。特别地，可以通过将硅凝胶转移至牺牲层(18)的方式有效地从穿孔层压材料中去除硅凝胶。
图7示出了穿孔元件(40)的更详细视图，该穿孔元件(40)具有作为外缘(11)的“锋利边缘”和凹槽(2)(的内侧表面)的圆形部分(21)，其中外缘(11)连接外侧表面(10)和圆形部分(图7的上图)或连接至所述外缘(11)的端面(图7的下图)。后一种设计的穿孔元件可能比图7的上图所示的实施方式更容易尖锐化。

Claims (19)

1.一种用于超声波能量输入的穿孔元件(40)，其中所述穿孔元件(40)包括：
外侧表面(10)，其具有外缘(11)和纵轴(12)；和
凹槽(2)，其具有内侧表面(20)；其中
所述外缘(11)的最大宽度MW在0.5mm至20mm的范围内，和/或所述外缘(11)的外周长在1.6mm至63mm的范围内；并且其中
所述凹槽(2)的至少一个最大内宽度IW，特别是所述凹槽分别在沿纵轴的至少一个位置或高度处的最大内宽度，分别在所述外缘(11)最大宽度MW的30％至95％的范围内，和/或
所述凹槽(2)的至少一个内周长，特别是所述凹槽分别在沿纵轴的至少一个位置或高度处的内周长，在所述外缘(11)外周长的30％至95％的范围内；进一步地，其中
所述内侧表面(20)向外缘(11)发散；
所述内侧表面(20)的至少一部分相对于纵轴(12)倾斜，使得在至少一个横截面中，内侧表面的至少一条切线与纵轴相交，任选地以大于0度的角度β相交，并且其中
内侧表面的至少一部分(21)是圆形的。
2.根据权利要求1所述的穿孔元件，其中内侧表面的朝向外缘的所述圆形部分(21)是凸起的。
3.根据权利要求1或2所述的穿孔元件，其中内侧表面的朝向外缘的所述圆形部分(21)的曲率(1/R)为至多10mm-1。
4.根据前述权利要求中任一项所述的穿孔元件，其中所述外缘是圆形外缘(11)，任选地，其中所述外侧表面(10)是锥形的。
5.根据前述权利要求中任一项所述的穿孔元件，其中所述外缘的最大宽度MW为0.75mm至5mm，任选地为0.75mm至3mm；和/或其中所述外缘的外周长为2.36mm至16mm，任选地为2.36mm至9mm。
6.根据前述权利要求中任一项所述的穿孔元件，其中所述外侧表面(10)向所述外缘(11)会聚，并且所述外侧表面(10)相对于所述纵轴(12)倾斜，使得在至少一个横截面中，所述外侧表面的至少一条切线以大于0度的角度α与所述纵轴相交。
7.根据权利要求6所述的穿孔元件，其中所述角度α为至少5度，任选地在5度至30度，任选地7度至25度，进一步任选地10度至20度的范围内。
8.根据前述权利要求中任一项所述的穿孔元件，其中所述角度β在5度至30度，任选地9度至25度，进一步任选地11度至20度的范围内。
9.根据前述权利要求中任一项所述的穿孔元件，其中所述凹槽(2)的内侧表面(20)相对于所述纵轴(12)旋转对称；任选地与所述外缘(11)同心。
10.根据前述权利要求中任一项所述的穿孔元件，其中所述凹槽的内宽度(IW，IW’)是直径和/或所述凹槽是圆形的。
11.根据前述权利要求中任一项所述的穿孔元件，其中所述凹槽(2)的最大内宽度IW在所述外缘(11)的最大宽度MW的40％至90％的范围内，任选地在所述外缘(11)的最大宽度MW的50％至80％的范围内；和/或其中凹槽(2)的所述内周长在所述外缘(11)的外周长的40％至90％的范围内，任选地在所述外缘(11)的外周长的50％至80％的范围内。
12.根据前述权利要求中任一项所述的穿孔元件，其中所述内侧表面(20)是锥形的。
13.根据前述权利要求中任一项所述的穿孔元件，其中所述凹槽的深度D，即从外缘到凹槽的内底表面的距离，比所述凹槽或外侧表面分别位于其上的外下表面或外底表面上方的同一凹槽的高度H，即从外缘到所述外下表面或外底表面的距离，大至少10％，任选地大至少20％。
14.根据前述权利要求中任一项所述的穿孔元件，其中所述外侧表面的切线与以外缘连接至所述外侧表面的端面的切线之间的角度γ在60°至120°的范围内，所述端面任选地为平面端面。
15.一种用于超声波能量输入的穿孔元件(40)的阵列(41)，其中所述阵列(41)包括：
根据前述权利要求中任一项所述的穿孔元件的多个行(60)，其中至少一行包括至少五个，任选地至少八个穿孔元件，进一步任选地其中所述阵列总共包括5-70个穿孔元件，进一步任选地10-60个穿孔元件。
16.根据权利要求15所述的阵列，其中所述阵列(41)是旋转鼓的一部分。
17.根据权利要求1-14中任一项所述的至少一个穿孔元件或根据权利要求15或16所述的至少一个穿孔元件阵列用于向层压材料，特别是向包含硅凝胶的层压材料中超声引入穿孔的用途。
18.一种用于超声波能量输入，特别是用于向包含硅凝胶的层压材料中引入穿孔的装置，所述装置包括：
·根据权利要求1-14中任一项所述的至少一个穿孔元件(40)或根据权利要求15或16所述的至少一个穿孔元件阵列(41)；
·至少一个超声波焊极(30)，其与所述穿孔元件或所述穿孔元件阵列相对设置；
·至少一个装置，用于任选地至少部分地连续地将层压材料输送通过所述穿孔元件或所述穿孔元件阵列与所述超声波焊极之间的间隙。
19.一种用于向层压材料中至少部分引入穿孔的方法，所述层压材料包括至少一个热塑性材料层和一个硅凝胶层，其中所述方法包括以下步骤：
·使权利要求1-14中任一项所述的至少一个穿孔元件、或权利要求15或16所述的至少一个穿孔元件阵列的一部分、或权利要求18所述的至少一个装置的一部分与所述层压材料接触
·施加超声波能量以向所述层压材料中引入至少一个穿孔
·将前一步骤中引入的所述穿孔的至少一个剩余部分转移到牺牲基底上。
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