CN117813194A - 用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的深度控制 - Google Patents

用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的深度控制 Download PDF

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Publication number
CN117813194A
CN117813194A CN202280055773.2A CN202280055773A CN117813194A CN 117813194 A CN117813194 A CN 117813194A CN 202280055773 A CN202280055773 A CN 202280055773A CN 117813194 A CN117813194 A CN 117813194A
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China
Prior art keywords
anvil
horn
film
raised profile
profile
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CN202280055773.2A
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Inventor
安德鲁·杰曼
帕特里克·肖恩·麦克尼科尔斯
彼得·瓦斯科
罗伯特·爱德华·阿尔达兹
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Duken Ias Ltd
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Duken Ias Ltd
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Publication of CN117813194A publication Critical patent/CN117813194A/zh
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    • 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
    • B29C65/02—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
    • B29C65/087—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 both a rotary sonotrode and a rotary anvil
    • 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
    • B29C65/02—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
    • 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
    • B29C65/7435—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
    • B29C65/7443—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
    • 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
    • B29C66/006—Preventing damaging, e.g. of the parts to be joined
    • B29C66/0062—Preventing damaging, e.g. of the parts to be joined of the joining tool, e.g. avoiding wear of the joining 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
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • 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
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    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/133—Fin-type joints, the parts to be joined being flexible
    • 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
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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
    • 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
    • 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
    • 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
    • B29C66/70—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
    • B29C66/73921—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 characterised by the materials of both parts being thermoplastics
    • 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
    • B29C66/81—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
    • 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
    • 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
    • B29C66/81—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
    • B29C66/816—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 mounting of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8167—Quick change joining tools or surfaces
    • 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
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    • 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
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/841—Machines or tools adaptable for making articles of different dimensions or shapes or for making joints of different dimensions
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/841—Machines or tools adaptable for making articles of different dimensions or shapes or for making joints of different dimensions
    • B29C66/8416—Machines or tools adaptable for making articles of different dimensions or shapes or for making joints of different dimensions of different thickness
    • 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
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    • 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
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
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    • 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
    • B29C66/70—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
    • B29C66/735—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 extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
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    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • 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
    • B29C66/81411—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
    • B29C66/81415—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 bevelled
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    • 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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    • 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
    • B29C66/81411—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
    • B29C66/81421—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 convex or concave
    • B29C66/81422—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 convex or concave being convex
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/851—Bag or container making machines
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/851—Bag or container making machines
    • B29C66/8511—Bag making machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7128—Bags, sacks, sachets

Abstract

一种用于沿着密封线将第一膜部分和第二膜部分接合在一起的设备200。该设备包括焊头208和砧220。砧靠近焊头定位。该焊头或砧具有可绕旋转轴线旋转的表面216、226。该表面具有凸起轮廓，并且凸起轮廓相对于该表面的高度的尺寸对应于第一膜部分或第二膜部分的厚度的50％至150％。另一选项是凸起轮廓具有锥形侧，锥形侧具有相对于凸起轮廓的最上表面在0.5和5度之间的半径，该表面定位成使得凸起轮廓沿着该圆周延伸，使得当围绕旋转轴线旋转时，在凸起轮廓与焊头和砧中的所述一个的另一个之间提供连续的运行接触，从而在没有任何外部结构的情况下形成密封线，以便在提供连续的运行接触时控制焊头/砧之间的距离。还公开了牵引图案、切割和密封特征。

Description

用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的 深度控制
相关申请的交叉引用
本申请要求于2021年8月11日提交的标题为“Depth Control of Seal LinePenetration For Rotary Ultrasonic Horn/Anvil Welding Without Mechanical Stop(用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的深度控制)”的第17/399、429号美国专利申请的优先权，该申请的全部内容通过引用并入本文。
技术领域
本发明大体涉及超声焊接系统，更具体地，涉及用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的深度控制。
背景技术
当结合薄(厚度小于150μm)膜时，难以用空气加载系统实现一致的穿透。对于单层膜和单材料膜尤其如此。在一些超声焊接应用中，使用盘形的焊头和砧是有利的，该盘形的焊头和砧被称为旋转焊头或旋转砧。当应用要求在最终产品(例如，小袋或容器)的待接合的两个衬底或层之间形成密封部或接合部时，一些常规旋转超声技术采用机械止动件器以通过停止前进的超声焊头来控制接合部或密封部的深度，但是机械止动件对于薄膜处理具有非常严格的限制。机械止动件要求旋转元件(旋转焊头和旋转砧)的近似完美的同心度和总的同心度，特别是对于厚度在0.002英寸(50μm)左右的薄膜应用，并且随着时间经历机械磨损和撕裂，这不利地影响接合部或密封部的一致深度控制。机械止动件还要求设计者消除热膨胀和收缩的影响，并且操作者将需要高水平的累积技能，以便能够对这种机械止动件进行微调节，以适应不同的膜厚度。机械止动件由多个部件组成，诸如轴承、轴和其它部件，这些部件的制造公差可引起小但重要的旋转跳动元素。如果发生这种跳动，则由于旋转元件之间所需的非常小的间隙尺寸，将失去最终产品与最终产品之间的结合一致性。
采用超声波能量的其它常规旋转应用具有在旋转角和/或旋转砧的表面上形成的脊的图案，诸如在由本公开的相同受让人拥有的第10889066号美国专利中公开的应用，其特别适于通过以永久张力状态截留弹性线来结合非织造织物。这些应用不是特别适于将塑料熔合在一起，以在两个塑料零件之间形成密闭或气密密封部。另外，脊图案倾向于高度远大于通过超声波能量结合在一起的织物的厚度。图案化的轮廓也不会产生气密密封部，这在一些应用中是需要的，例如将填充液体的小袋或容器。
另外，传统的旋转超声焊接应用在焊头或砧上结合有凸起的轮廓，但与图案轮廓类似，这些凸起的轮廓的总高度大于(通常大许多数量级)接合在一起的零件的厚度，因而不能用于控制密封线的深度，并且不能很好地适于将薄膜密封在一起。由于所施加的大的力/压力，像这样的高凸起轮廓导致粘结部或密封部弱化，因而不希望用于密封(塑料)膜。
图1A是现有技术的砧100的切除部分的横截面，该砧100具有凸起的、图案化的轮廓102。图案化的轮廓102的高度H1比夹在砧100与接收超声波能量的传统焊头之间的部分的层的厚度大几个数量级。由于高度H1的数量级，大量的力或压力施加到夹在焊头与砧100之间的层上，特别是在这些层是诸如塑料膜的膜的情况下，当机械止动件不足以限制由于缺乏同心度、热膨胀或操作者调整不当而导致的焊接力和距离时，这会导致在图案化的轮廓102与焊头之间的界面处形成的密封线或结合部的不希望的弱化(例如过度变薄)。
图1B是另一种现有技术的砧110的切除部分的横截面，该砧110也具有凸起的轮廓112，但是该凸起的轮廓112具有与如图1A所示的图案化表面相反的光滑表面。与砧100类似，图1B所示的砧110的凸起轮廓112具有0.063英寸的高度H2，该高度H2远大于夹在砧112与传统焊头之间的零件的层的厚度(通常大于两倍)。与图1A中所示的常规轮廓类似，图1B的常规轮廓将操作为弱化在膜层之间形成的结合部或密封部。图1B中所示的凸起轮廓112形成连续的密封部，但是凸起轮廓112会不利地使进行焊接的材料过度变薄，因而当机械止动件不足以限制由于缺乏同心度、热膨胀或操作者调整不当而导致的焊接力和距离时，凸起轮廓112弱化进行焊接的材料和进行密封的包装。
因此，需要一种旋转超声焊接技术，该旋转超声焊接技术不使用机械止动件，并且能够将两个薄零件(例如，膜的部分)精确且重复地结合在一起，并适应不同厚度的零件。本公开的各方面旨在满足这种需求和其它需求。
发明内容
本发明的关键特征是轮廓的高度和没有任何机械止动装置来控制利用旋转焊头和砧施加的超声波能量的密封部的深度。轮廓的高度非常小，诸如在所接合的膜或零件的厚度的50％与150％或100％之间。通过用足够的力或压力挤压两层膜以实现机械支承，但不会太硬以致熔化膜层中的塑料，在焊头或砧上的轮廓的极低高度(其可存在于焊头和砧中的一个或两个上)在没有任何实际的外部机械止动件的情况下提供“动态机械止动”效果。轮廓的高度和没有任何机械止动结构来控制密封件穿透深度的组合是针对现有技术的关键差别。
该轮廓可连续地延伸，并围绕旋转焊头或旋转砧的整个圆周外表面。连续的周向轮廓在密封的同时保持膜上的恒定和连续的力/压力，同时轮廓的高度不大于膜的厚度。
轮廓高度取决于被密封的膜的厚度，但是在一些实施方式中，轮廓的高度可开始低至0.00”(英寸)高，然后逐步增加非常小的0.0005”的增量，这证明了从采用与本发明的深度控制砧设计相反的传统机械止动件的替代设计所需的高精度。
根据本公开的一方面，公开了一种使用超声波能量沿着密封线将第一膜部分和第二膜部分接合在一起的设备。该设备包括：配置成接收超声波能量的焊头；以及砧，可定位成紧邻焊头，焊头朝向砧前进，其中焊头和砧中的至少一个具有表面，该表面具有宽度尺寸和圆周，并且可绕旋转轴线旋转。该表面具有凸起轮廓，该凸起轮廓的高度的尺寸对应于第一膜部分或第二膜部分的厚度的50％至150％。该表面定位成使得凸起轮廓沿圆周延伸。当围绕旋转轴线旋转时，在凸起轮廓与焊头和砧中的一个的另一个之间提供连续的运行接触，从而在没有任何外部结构的情况下形成密封线，以便控制焊头与砧之间的距离。第一膜部分和第二膜部分的厚度可在10μm与150μm之间。
凸起轮廓的高度尺寸可对应于第一膜部分或第二膜部分的厚度的100％。凸起轮廓的高度尺寸可对应于第二膜部分或第一膜部分的厚度的50％与125％之间。第一膜部分和/或第二膜部分可由塑料构成。第一膜部分或第二膜部分可为多层膜、可回收膜、可生物降解膜、可分解膜、单层膜、纸基膜或单材料膜。
凸起轮廓还可包括刻痕元件，该刻痕元件配置成当砧围绕旋转轴线旋转时沿密封线刻痕或切割。该表面可具有第二凸起轮廓，该第二凸起轮廓具有对应于第一膜部分或第二膜部分的厚度的50％至150％的高度。第二凸起轮廓可沿着圆周延伸，并且当围绕旋转轴线旋转时，可在第二凸起轮廓与焊头或砧中的该一个中的另一个之间提供连续的运行接触。
第二凸起轮廓的高度尺寸可对应于第一膜部分或第二膜部分的厚度的100％。凸起轮廓可为砧的部分，并且进一步与第二砧结合可具有第二凸起轮廓，该第二凸起轮廓的高度尺寸超过凸起轮廓的高度尺寸0.0005英寸。
本发明公开了一种产品，该产品包括第一膜部分和第二膜部分以及通过本文公开的任何设备形成的密封线。
附图说明
图1A是现有技术的具有凸起的图案化轮廓的砧的切除部分的横截面；
图1B是另一现有技术的砧110的切除部分的剖视图，该砧110具有光滑的凸起轮廓112；
图2是旋转超声焊接设备的立体图，该旋转超声焊接设备适于与砧或焊头上的凸起轮廓一起使用，从而产生动态停止效果；
图3是根据本发明的一方面的具有凸起轮廓的焊头或砧的部分的放大剖视图；
图4是根据本发明另一方面的焊头或砧的等角剖视图，该焊头或砧上具有两个凸起的轮廓，从而产生动态停止效果；
图5是图4所示的具有两个凸起轮廓的焊头或砧的等角剖视图；
图6是图5所示的焊头或砧的部分的剖视图；
图7是焊头和砧的部分以及凸起轮廓的横截面图，其中在施加超声波能量的过程中，两层膜在焊头与砧之间通过；
图8是深度控制配置的功能图，其中焊头和砧每个都具有凸起的轮廓，以从进行结合的膜的两侧实现相等或故意不相等的穿透；
图9A是密封和刻痕配置的功能图，其中凸起轮廓包括刻痕元件，以在密封层结合后对密封层施加刻痕；
图9B是倾斜密封轮廓配置的功能图，其中凸起轮廓倾斜以便于密封待结合的层；
图10A是具有锥形结合轮廓和示例性牵引图案的焊头或砧的部分沿着线10B-10B截取的剖视图；
图10B是图10A所示的示例性牵引图案的部分的顶部剖视图；
图10C是沿着线10C-10C截取的牵引图案的部分的剖视图；
图11A是具有切割和密封特征的焊头或砧的侧视图；以及
图11B是图11A所示的切割和密封特征的放大视图，其中插图示出了切割特征的放大视图。
图12示出了在焊头或砧上的锥形结合轮廓，该锥形结合轮廓可在焊头或砧的任一侧上具有不同的轮廓。
具体实施方式
图2是旋转超声结合设备200的一般图示，旋转超声结合设备200的一般操作和部件对于超声焊接领域的普通技术人员是非常熟悉的，特别是旋转超声焊接技术。设备200具有砧模块202和焊头模块204，砧模块202和焊头模块204协作以执行多个零件的接合或密封操作，该多个零件例如为两个或更多个膜层，如下面更详细描述的。
焊头模块204包括框架206，框架206上安装有盘状旋转焊头208、用于经由合适的传动系212驱动焊头208旋转的马达210、以及壳体214，壳体214容纳振动控制单元(未示出)的至少部分，振动控制单元使焊头208振动。焊头208具有暴露的外表面216，外表面216具有基本上连续的轮廓(即，焊头表面216具有在其整个表面区域上基本上平滑(或不间断)的轮廓)。在其它实施方式中，焊头表面216可具有任何合适的轮廓，该轮廓便于焊头208如本文所述地起作用。
在一些实施方式中，振动控制单元(虽然未示出)包括机械地连接至转换器的常规增压器(例如，驱动增压器和整体增压器)，所述转换器可电连接至发电机。该转换器能够将由发电机提供的高频电能转换为机械能(或振动)，该机械能(或振动)选择性地跨过一个或多个增压器(booster)传输到焊头208。该一个或多个增压器能够改变(即，增加或减少)从转换器传递到焊头208的振动，使得焊头208(特别是焊头208的面216)在结合操作期间旋转的同时振动，如下面更详细地阐述的。可设想的是，焊头模块204可具有以任何合适的方式布置的任何合适的操作部件，以便于使焊头208能够如本文所描述的那样工作。对于熟悉旋转超声结合系统的任何技术人员来说，未示出的细节都是显而易见的。
在所示实施方式中，砧模块202包括框架218，框架218上安装有盘状旋转砧220和用于通过合适的传动系驱动砧220旋转的马达222。砧220具有暴露的外表面226，该暴露的外表面226具有基本上连续的轮廓(即，砧表面226具有在其整个表面区域上基本上平滑或不间断的轮廓)。砧模块202相对于焊头模块204定位，使得砧表面226可围绕旋转轴线R(见图4)旋转，紧邻焊头表面216，反之亦然，以便于当零件被保持张力下穿过设备200时对零件进行超声结合，如下面更详细描述的。如本文所使用的，术语“紧邻”指的是当砧表面226与焊头表面216接触时，或者当焊头208没有超声振动时与焊头表面216最小地间隔开。
在一些实施方式中，设备200可配置成使得砧模块202和焊头模块204中的至少一个可经由合适的位移机构相对于另一个位移，所述位移机构在以下情况下可操作：(A)当系统100离线并且焊头208静止时(即，当焊头208不旋转或不振动时)；以及(B)当系统100在线并且焊头208活动时(即，当焊头208旋转和振动时)。
特别地，参考图2所示的实施方式，设备200可配置成连续夹持设备，其中焊头模块204将：(a)在系统100在线并且焊头208活动时，相对于砧模块202固定在适当位置；以及(B)在系统100离线并且焊头208静止时，相对于砧模块202可位移。通过将框架206、218彼此连接的可选择地致动的气压缸228(或其它合适的线性致动器)来促进这种位移。以这种方式，当系统100离线时，焊头表面216和砧表面226之间的间隔可调节，主要用于维修设备200。
图3示出了焊头208或砧220的部分的剖视图，该焊头或砧具有外表面302和凸起轮廓312，该外表面302具有基本上连续的轮廓(即，外表面302具有在其整个表面区域上基本上平滑或不间断的轮廓)，该凸起轮廓312具有高度H3，该高度H3在焊头208与砧220之间待连接的零件的厚度的50％与150％之间(例如，100％)。应该强调的是，凸起轮廓312可存在于焊头208或砧220或两者上，并且本文讨论的原理同样适用于焊头208和砧220。在大多数应用中，凸起轮廓312存在于砧220上。可存在一个以上的凸起轮廓312，例如，如图4中最佳示出的。像凸起轮廓312那样的多个凸起轮廓可存在于焊头208上，存在于砧220上，或者分布在焊头208与砧220之间(例如，凸起轮廓可存在于焊头208上，以及凸起轮廓可存在于砧220上)，用于将一对零件连接在一起或者将多对零件连接在一起。凸起轮廓312在本文可被称为“深度控制”轮廓，因为凸起轮廓用于控制通过密封或结合将待连接在一起的零件中的焊接穿透深度。
图3中所示的凸起轮廓312具有基本上平坦且连续的凸起表面，该凸起表面的宽度为0.040英寸，并且该凸起表面在两侧上通过半径为R＝0.015英寸的弯曲表面过渡。与现有技术的非图案化轮廓相比，凸起轮廓312的宽度也窄得多，并且例如，跨越焊头208或砧220的整个宽度的小于10％或小于7％或小于5％。半径尺寸是示例性的，但是在不需要在现有技术的旋转超声焊接系统中存在的机械止动件的情况下，起到对旋转系统赋予动态止动功能的作用。该半径尺寸也是凸起轮廓312的高度H3的函数，但是高度H3被限制为不超过在焊头208与砧220之间待连接的诸如膜的零件的厚度，其中在焊头208和砧220围绕旋转轴线R(见图4)彼此相对旋转时，通过向焊头208施加超声波能量而连接该零件。在该示例中，凸起轮廓312具有例如大约0.0035英寸(在典型公差内)的高度H3。然而，高度H3可低至0.002英寸以适应该厚度的膜。
焊头208或砧220可容易地换出以用于具有不同尺寸(例如，高度和/或宽度)的凸起轮廓的另一焊头208或砧220。每个凸起轮廓的高度H3可加工成与轮廓之间仅相差0.0005英寸的增量。例如，如果最小高度的轮廓具有0.0020英寸的高度，则下一个轮廓可具有0.0025英寸的高度，接着是0.0030英寸，以此类推。使用图3所示的示例，在一个砧220上的凸起轮廓312可具有大约0.003英寸的高度，以及另一个砧可具有高度为0.0035英寸的凸起轮廓，接着为0.0040英寸的凸起轮廓，以此类推。根据接合在一起的零件(例如，膜)的厚度，砧220或焊头208可容易地换出，以使凸起轮廓的高度与零件的厚度相匹配。应该强调的是，本文提供的尺寸或公差仅是示例性的，并且用于说明轮廓相对于被焊接或连接在一起的一个或多个零件层的厚度的相对高度。
凸起轮廓312可围绕焊头208或砧220的整个圆周，如图4中所示的局部剖视立体图以及图5和图6中更详细地所示。由于凸起轮廓312a、312b的高度非常低，因而图5和图6示出了凸起轮廓312a、312b(图5中示出了两个)的放大视图。提供用于在轮廓312处进行充分结合的能量。应该注意的是，凸起轮廓312a、312b的高度可不同。这可能有用，例如，当凸起轮廓312a、312b位于焊头208上并且砧220与焊头208相比具有更窄的宽度时。这允许操作者或终端用户通过简单地翻转焊头208以使得适当的凸起轮廓(312a或312b)与砧220接触来使用相同的焊头208焊接不同的零件厚度。例如，如果凸起轮廓312a具有高度X，并且凸起轮廓312b具有高度Y，Y>X，则当需要焊接较厚零件时，可翻转焊头208，使得凸起轮廓312b接触砧208。而当需要焊接较薄的零件时，可翻转焊头208，使得凸起轮廓312a接触砧208。应该强调的是，焊头208和砧220的相应宽度可相同或不同(例如，当凸起轮廓312a、312b存在于焊头220上时，与焊头220相比，砧208可更薄或更窄)。
图7示出了两个零件的示例性横截面，在该示例中两个零件是两层膜，包括下膜400和上膜402。当膜400、膜402在焊头208与砧220之间被拉动时，由于将超声波能量施加到焊头208中，膜400、膜402开始熔化。当膜400、膜402通过力或压力而沿着图7中所示的箭头G的方向移动或移动到空间中时，膜400、膜402由凸起轮廓312挤压，该空间具有与膜400、膜402中的仅一个的厚度相对应的高度(因为凸起轮廓312的高度不超过膜400、膜402中的一个的厚度)。假设膜400、膜402的厚度是相同的，但是膜400、膜402的厚度不一定相同。凸起轮廓的高度H3可确定尺寸以适应两个膜400、膜402中的较厚膜。
凸起轮廓312的高度尺寸的一个重要方面是，凸起轮廓产生了动态停止效果，而不需要外部机械止动件装置。当膜400、膜402进入焊头208与砧220之间的间隙时，在凸起轮廓312处产生的夹持力和超声波能量的幅度提供了足够的能量，以用于沿着凸起轮廓312进行结合。由于在实现轮廓穿透之后焊接力分布在增加的表面区域上，因而在超过凸起轮廓的焊头208和砧220之间的区域中没有足够的能量来结合。在这些区域中，未结合的膜400、膜402防止焊头208与砧220之间的接触。结果，这就消除了对外部物理机械止动件的需要，否则需要该外部物理机械止动件来保持密封线的厚度和一致性。在焊头208与砧220之间的未结合层变成通常由机械止动件提供的物理止动件，但是机械止动件通过本公开的各方面被消除。
在现有技术的系统中，当凸起轮廓的高度远大于存在于焊头与砧之间的膜的厚度时，需要外部机械止动件装置来通知系统何时停止焊头的前进运动。否则，会对膜施加过量或不足量的力或压力，并且在密封界面处形成不足或较差的结合。相比之下，诸如轮廓312的深度控制轮廓具有更浅的轮廓并且也更窄。该连续轮廓(参见图4)可通过在轮廓表面312上引发熔化直到轮廓312穿透到相邻肩部的深度来焊接膜400、402。一旦肩部与膜400、402相遇，大得多的表面积就在肩部上触底，并且熔化和穿透停止(在本文中称为动态停止效应)。
焊头208与砧220之间的间隙和最终的密封线厚度由作为单个材料层的厚度的百分比的轮廓高度来确定。例如，如果材料厚度＝x，则轮廓高度是x的预定百分比，通常为50％至150％，这取决于所结合的材料和所希望的结合结果(例如，气密密封)。
与现有技术的旋转系统相比，通过根据本公开的设备和方法制造的焊接部的益处在于，连续焊接部更坚固并形成气密密封。根据本公开的各方面的凸起轮廓可应用于多层膜、可回收膜、可生物降解膜、可分解膜、单层膜、纸基膜或单材料膜。根据本公开的各方面，对于在10μm至150μm范围内的材料厚度，可实现对密封线厚度的完全控制。
如上所述，在焊头208和砧220两者上都可具有相同高度或不相等高度的凸起轮廓。图8示出了示例性深度控制配置800，其中焊头208和砧220中的一个具有第一凸起轮廓812a，而砧220或焊头208中的另一个具有第二凸起轮廓812b，为了便于说明和讨论，这两个轮廓在尺寸和轮廓上都进行夸大。诸如要填充液体并因而需要气密密封的小袋或容器的产品802具有第一层400和第二层402。当轮廓具有相同高度时，每个凸起轮廓812a、812b均必须具有小于x的100％的高度(其中x是膜400、膜402的厚度)。当轮廓具有不同的高度或需要不相等的穿透时，一个元件可能超过x的100％，但另一个元件必须成比例地减小。虽然在图8中示出的焊头208和砧220二者都具有凸起的轮廓812a、812b，但是在替换实施方式中，焊头208和砧220中的仅一个可具有凸起轮廓，而焊头208和砧220中的另一个没有凸起轮廓。
例如，如果膜400、膜402的厚度为100μm(x＝100)，并且需要在界面830处的密封厚度为25μm，并且密封部830需要偏移，则在一个元件812a(焊头208或砧220)上的x的125％的轮廓高度和在第二元件812b(砧或焊头)上的x的50％的轮廓将获得25μm厚的偏移密封线。如果需要相等的穿透，则焊头208和砧220将具有高度对应于x的87.5％的凸起轮廓812a、812b。密封界面830下游的区域832中的未结合膜400、膜402防止焊头208与砧220之间的接触。结果，消除了对外部物理机械止动件的需要，否则需要外部物理机械止动件来保持密封线的厚度和一致性。在焊头208与砧220之间的区域832中的未结合膜400、膜402变成物理止动件。
图9A示出了“密封和刻痕”配置900，其中在焊头208或砧220上的凸起轮廓912包括刻痕元件916，以刻痕或切割正好在凸起轮廓912的远侧(相对于产品902)肩部之一处的结合膜400、膜402的密封界面930。区域932中的未结合膜400、膜402进行刻痕或从密封界面930切割，使得密封和刻痕操作能够在一个步骤中进行。同样，与图8中所示的配置800类似，为了便于说明和讨论，图9A中所示的凸起轮廓912和刻痕元件916被大大夸大。刻痕元件916可具有楔形形状以刻痕其它材料，诸如在收缩包装应用中。区域932中的未结合膜保持结合和刻痕深度，从而消除砧220损坏焊头208的可能性(假定刻痕元件916是砧220的凸起轮廓912的部分)。
图9B示出了“倾斜的密封轮廓”配置950，其中在焊头208或砧220上的凸起轮廓952包括倾斜的轮廓，以有助于密封或结合结合的膜400、膜402的密封界面930。产品包装或容器902(例如，在密封外壳内容纳诸如液体、粉末、凝胶、食品等的内容物960)具有部分地由凸起轮廓952的倾斜的轮廓形成的密封界面930。如图9B所示，凸起轮廓952的密封线跨过界面930倾斜，其浅边缘邻近或最靠近产品902。随着距产品902的距离沿着界面930增加，该角度增加或逐渐变细远离产品902。凸起轮廓952的倾斜轮廓改善了速度，并增加了密封强度，同时使更多的熔融材料400、402转向产品侧。
将结合图10A至图11B讨论可与本文所公开的任何凸起轮廓结合的附加特征。下面将描述广泛地概括为“牵引”、“锥形结合轮廓”和“切割和密封”的三个特征。这些特征中的一些可结合，诸如牵引特征可与锥形结合轮廓特征结合，诸如如图10A所示。
图10A示出了结合在旋转超声焊接设备1000中的诸如上述的焊头208或砧220，该旋转超声焊接设备1000具有与上述的旋转超声焊接设备200相同的基本结构，不同之处在于，图中示出在凸起轮廓1012的下游的牵引部件1020、以及示出在凸起轮廓1012的上游的锥形焊接轮廓部件1014，并且该锥形焊接轮廓部件1014通向凸起轮廓1012。
图10A所示的特征的示例尺寸在下表中总结。
在图10A所示的示例性凸起结合轮廓1012中，凸起结合轮廓相对于焊头/砧208、220的表面的高度H4为0.0035英寸或约0.1mm。引导至凸起结合轮廓1012的是前导锥形结合轮廓1014，该锥形结合轮廓1014具有跨过焊头/砧108、220的表面的角度α1的锥形角度。角度α1可在0.5度与5度之间，并且在该示例中，示出为具有大约1.15度的角度。在凸起结合轮廓1012之后是尾部锥形结合轮廓1016，之后是牵引或图案特征1020。
牵引特征1020提供了将材料拉过并经过超声辊隙的特征，因而超声辊隙需要提供其自身的驱动。竖直成形填充(Vertical Form Fill)和密封包装系统(FFS，Sealpackaging system)特别适用于牵引特征1020，因为这些系统缺少拉动材料的方式。在图10B中可看到示例图案1020，其中凸起的小块或突起1004的阵列或图案以栅格状图案分布在焊头/砧208、220的表面上。图案1020被设计成避免过度的、局部的热累积，特别是在存在单层膜的情况下，因而图案1020不应该减损材料通过FFS系统所需的驱动。图案1020仅是示例性的，并且尽管已经以平行于焊头208或砧220的边缘延伸的图案示出，但是图案1020可相对于边缘以一定角度倾斜，诸如在1度与15度之间，从而提供期望的驱动特性，而不会产生过多的热积累。同样，可对所示的小块或突起1004的形状和形式进行修改，以提供对通过材料的拉动或抓取摩擦。例如，小块1004可具有齿状形状。在图10C所示的示例中(沿图10B所示的线10C-10C所截取)，可看出的是，小块1004具有如图所示的具有角度α2的锥形轮廓。图10B所示的尺寸的示例值在下表中示出。
尺寸 英寸/度 毫米
W6(相邻小块1004之间的间隙) 0.016 0.4
W7(小块1004的宽度) 0.014 0.3
H6 0.0030 0.1
H7 0.005 0.1
α2 30-50°
水平应用也可受益于牵引特征1020。例如，在要包括拉链的应用中，存在刚好在结合之前预热的材料，并且沿着由膜的激光刻痕引起的边缘存在松弛。由激光刻痕引起的边缘松弛和预热产生控制问题，即，材料难以保持在焊头/砧208、220的辊隙中。牵引图案1020避免了这些问题。
回到图10A，在凸起结合轮廓1012的前侧可看到锥形的结合轮廓或特征1014。角α1所示的锥度可在0.5至5度的范围内，并且在所示的实例中，该角是1.15度。结合的产品侧将在图10A的左侧(例如，在带拉链部的枕形包的情况下，拉链部将在图10A的右侧，并且枕形包内的产品或内容物将在锥形结合轮廓1014的左侧。
锥形结合轮廓1014具有几个优点。首先，将熔体流引向产品侧，这提供了改进的密封。平坦的轮廓(例如，图3)可同等地但以不受控的方式在结合部的两侧上移动材料，而锥形结合轮廓1014将以更受控的方式将熔体导向产品，从而在结合部的该侧上产生更厚的更坚固的密封部。另外，锥形设计对于材料厚度变化是有弹性的，例如，一些材料在材料厚度上具有高达40％的变化)。换言之，如果最大组合厚度(2层)为180μm，但可小至108μm，则具有88μm轮廓的深度控制砧将在其最高点处过度穿透；然而，横向锥形1014将意味着理想的结合点将从焊头/砧208、220的最高点向最低点移动，从而确保即使在材料厚度变化的情况下，理想的结合条件仍将在焊头/砧208、220的轮廓上的一些点处得到满足。锥形设计1014还允许在同一砧或焊头208、220上使用更大范围的膜厚度。
应当注意的是，锥形结合轮廓不会在不使用深度控制的砧/焊头上工作，这是因为会很快发生过度穿透，并且砧会成为切削工具而不是结合工具。本文所公开的锥形结合轮廓1014与深度控制轮廓312、1012一起工作，诸如如图3、图10A-图10C所示，但不适用于不具有例如本文所公开的凸起深度控制轮廓312、1012的常规砧。锥形轮廓设计还提供了速度改进，因为锥形轮廓设计在结合过程中更容易穿透材料。
通常，较薄的材料需要锥形结合轮廓1014中的较小的锥角。与非锥形凸起轮廓相比，可实现更高的速度以及改进的密封。锥形结合轮廓1014的锥度可由半径(例如，曲线)或角度(例如，图10A中所示的斜面或α1)限定。
对于某些包装膜，常规的圆角(非深度控制)轮廓可能是有问题的，因为它们产生“跳跃效应(porpoising effect)”。这是在圆角化的砧开始穿透材料但随着穿透深度增加，砧轮廓和被结合的材料之间的表面接触指数地增加时引起的，这导致幅度和压力不足以保持砧穿透深度的情况，这迫使砧克服材料施加的压力缩回。这样做时，接触面积则指数地减小，从而导致对于减小的结合深度的压力和幅度过量，因而砧穿透增加，从而导致循环的“海豚(porpoise)”效应。
相比之下，使用倾斜轮廓1014(诸如图10A中所示的α1)对这些效果不那么敏感，因为基于膜厚度的范围来确定与平坦凸起轮廓1012的轮廓结合高度(H4)相接合的锥形结合轮廓1014的攻角。
锥形结合轮廓1014的其它优点包括：
·因材料更容易渗透而提高的速度
·改进的密封，具有朝向产品的浅侧的倾斜轮廓1014有助于通过控制熔体流并熔体流引导至密封部的产品侧来改进密封强度。这也提高了真空罐测试性能，并降低了通过结合过程在膜中产生故障线的可能性。
·减小的颗粒铺展，锥形轮廓1014中的锥形的浅角(α1)将颗粒捕获并附着在结合线内，因而将不会在密封线的浅侧处进行结合，而是将施加牢固的接触压力，从而捕获颗粒。
·同时密封/切割可能性，利用角度(例如，α1)允许在深度控制应用和非深度控制应用两者上的可靠切割/密封。切割的深度可通过调节施加压力和/或幅度来精确地控制。该系统将在砧轮廓1012的浅边缘下方利用未结合的材料，以作为与该角度的相对的刀侧(1130，图111B)的穿透相关的可压缩的深度止动件。该结合发生在刀尖1130与轮廓的较浅边缘(例如，图10A中的1014)之间。
接下来，将结合图11A和图11B来描述“切割和密封”特征。在一些应用中，希望同时密封和切割或刻痕收缩包装或其它材料，以提供零翅片密封高度和实际上不可见的密封。图11A-图11B示出了焊头208或砧220，焊头208或砧220利用深度控制，该焊头208或砧220将以例如30μm的组合的两层厚度穿透膜材料，并且留下4μm不切割，然后通过常规真空移除系统(未示出)容易地分离，该真空移除系统是本公开所属领域的技术人员将容易熟悉的步骤。
示例尺寸总结于下表中。
尺寸 毫米
W8 2.55
W9 0.35
W10 2.0
H8 0.4
H9 0.026
R3 0.50
该轮廓的角度(对于获得所需结果是关键的)确保了力的结合条件在狭窄区域内得到满足，从而导致非常狭窄的结合部，但是至少在该膜上是非常强的结合部，这种结合部能够经受结合后收缩包装的活化。如图11A所示，砧208/焊头220具有两个结合轮廓，每个边缘上一个结合轮廓，其可用于超声焊极的宽度小于砧208、220的宽度的应用。在图11A所示的砧208或焊头220中，深度控制轮廓1112是两个轮廓之间的整个中心部分。在图11B中，示出了切割部分的放大视图，其中具有高度H9的切割特征1130向呈现在其表面或界面处的膜(例如，收缩包装)提供切割特征。切割特征1130具有高度H9，高度H9与凸起轮廓1112的高度相比稍微凸起。切割特征1130相对于凸起轮廓1112的表面形成大致尖锐的90度角，并且这种突然的过渡为穿过砧208/焊头220的膜或材料提供切割作用。切割特征1130的高度H9可在凸起轮廓1012、1112的高度H4的1％到20％之间。切割特征1030形成凸起轮廓1112的末端，并因而邻近凸起轮廓1112或位于凸起轮廓1112的端部处。
图12示出了在焊头208/砧220的任一侧上具有两个不同轮廓的锥形结合轮廓。由于轮廓的尺寸相对较小，这里仅示出了焊头208/砧220的一侧，以便于说明。图12中标出的尺寸的示例值在下表中示出。该轮廓包括具有角度α3的倾斜轮廓1214、深度控制轮廓1212，后面跟随尾部轮廓1016，尾部轮廓1016可为成角度的或倾斜的。
尺寸 度数 毫米
W11 2.6-2.7
W12 1.25
H10 0.0635-0.089
H11 0.0635-0.089
α3 1.5°,1.8°,2°
根据本公开的其它方面，增强的深度控制(以及砧几何结构细节)可与发电机输出联接。例如，增加特定的深度控制和砧细节导致更高的超声功率(并因而允许更好的密封和更快的速度)。可围绕这些参数设置限制和功率调节。
本公开产生更一致的功率消耗、通过非深度控制、圆角化砧中看不到的稳定性。实际上，与圆角化砧相比，使用倾斜轮廓1014实现了较低的功率消耗，这导致了较高的速度能力。

Claims (23)

1.一种使用超声波能量沿着密封线将第一膜部分和第二膜部分接合在一起的设备，所述设备包括：
焊头，配置成接收超声波能量；以及
砧，能够定位成紧邻所述焊头，所述焊头朝向所述砧前进，其中，所述焊头或所述砧中的至少一个包括具有宽度尺寸和圆周的表面，并且能够绕旋转轴线旋转，
所述表面具有凸起轮廓，所述凸起轮廓相对于所述表面的高度具有对应于所述第一膜部分或所述第二膜部分的厚度的50％至150％的尺寸，所述表面定位成使得所述凸起轮廓沿着所述圆周延伸，并且当围绕所述旋转轴线旋转时，在所述凸起轮廓与所述焊头或所述砧中的所述一个的另一个之间提供连续的运行接触，从而在没有任何外部结构的情况下形成密封线，以便在提供连续的运行接触时控制所述焊头与所述砧之间的距离。
2.根据权利要求1所述的设备，其中，所述第一膜部分和所述第二膜部分的厚度在10μm与150μm之间。
3.根据权利要求1所述的设备，其中，所述凸起轮廓的高度尺寸对应于所述第一膜部分或所述第二膜部分的厚度的100％。
4.根据权利要求1所述的设备，其中，所述凸起轮廓的高度尺寸对应于所述第二膜部分或所述第一膜部分的厚度的87.5％。
5.根据权利要求1所述的设备，所述凸起轮廓还包括刻痕元件，所述刻痕元件配置成在所述砧围绕所述旋转轴线旋转时沿所述密封线刻痕或切割。
6.根据权利要求1所述的设备，其中，所述表面具有第二凸起轮廓，所述第二凸起轮廓的高度对应于所述第一膜部分或所述第二膜部分的厚度的50％至150％，所述第二凸起轮廓沿着所述圆周延伸，并且当围绕所述旋转轴线旋转时，在所述第二凸起轮廓与所述焊头或所述砧中的所述一个的另一个之间提供连续的运行接触。
7.根据权利要求6所述的设备，其中，所述第二凸起轮廓的高度尺寸对应于所述第一膜部分或所述第二膜部分的厚度的100％。
8.根据权利要求1所述的设备，其中，所述凸起轮廓是所述砧的部分，并且还与具有第二凸起轮廓的第二砧结合，所述第二凸起轮廓的高度尺寸超过所述凸起轮廓的高度尺寸0.0005英寸。
9.一种产品，包括由权利要求1所述的设备形成的密封线、第一膜部分和第二膜部分。
10.根据权利要求1所述的设备，其中，所述第一膜部分和所述第二膜部分由塑料构成。
11.根据权利要求1所述的设备，其中，所述第一膜部分或所述第二膜部分是多层膜、可回收膜、可生物降解膜、可分解膜、单层膜、纸基膜或单材料膜。
12.一种使用超声波能量沿着密封线将第一膜部分和第二膜部分接合在一起的设备，所述设备包括：
焊头，配置成接收超声波能量；以及
砧，能够定位成紧邻所述焊头，所述焊头朝向所述砧前进，其中，所述焊头或所述砧中的至少一个包括具有宽度尺寸和圆周的表面，并且能够绕旋转轴线旋转，
所述表面具有相对于所述表面的凸起轮廓，所述凸起轮廓具有锥形侧，所述锥形侧具有相对于所述凸起轮廓的最上表面在0.5和5度之间的半径，所述表面定位成使得所述凸起轮廓沿着所述圆周延伸，并且当围绕所述旋转轴线旋转时，在所述凸起轮廓与所述焊头和所述砧中的所述一个的另一个之间提供连续的运行接触，从而在没有任何外部结构的情况下形成密封线，以便控制所述焊头与所述砧之间的距离。
13.根据权利要求12所述的设备，其中，所述第一膜部分和所述第二膜部分的厚度在10μm与150μm之间。
14.根据权利要求12所述的设备，其中，所述凸起轮廓的高度尺寸对应于所述第一膜部分或所述第二膜部分的厚度的50％至150％。
15.根据权利要求12所述的设备，其中，所述表面包括牵引特征，所述牵引特征的高度尺寸不超过所述凸起轮廓的高度，所述牵引特征包括布置成栅格或图案的多个突起，所述牵引特征邻近所述凸起轮廓。
16.根据权利要求12所述的设备，其中，所述多个突起布置成与所述表面的边缘不平行的行或列。
17.根据权利要求12所述的设备，其中，所述表面包括切割特征，所述切割特征的高度与所述凸起轮廓的高度相比更高，所述凸起轮廓的高度对应于所述第一膜部分或所述第二膜部分的厚度的50％至150％。
18.根据权利要求17所述的设备，其中，所述切割特征的高度在所述凸起轮廓的高度的1％与20％之间。
19.根据权利要求12所述的设备，其中，包括所述锥形侧的所述凸起轮廓是所述砧的部分。
20.根据权利要求17所述的设备，其中，所述切割特征邻近所述凸起轮廓，并形成所述凸起轮廓的末端。
21.一种产品，包括由权利要求12所述的设备形成的密封线、第一膜部分和第二膜部分。
22.根据权利要求12所述的设备，其中，所述第一膜部分和所述第二膜部分由塑料构成。
23.根据权利要求12所述的设备，其中，所述第一膜部分或所述第二膜部分是多层膜、可回收膜、可生物降解膜、可分解膜、单层膜、纸基膜或单材料膜。
CN202280055773.2A 2021-08-11 2022-08-08 用于无机械止动件的旋转超声焊头/砧焊接的密封线穿透的深度控制 Pending CN117813194A (zh)

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