The invention relates to a device and a method for ultrasonic treatment according to the preamble of the independent claims. With a device of this type it is possible, for example, for two films of plastic one lying flat on the other to be joined to each other at the borders (ultrasonic welding). For example, tubular bags for packaging a product or item to be packaged can be produced in this way. With the device according to the invention it is also possible to apply notches in films (for example as an aid for tearing open), in which case only one film could be processed in the device for this purpose. Finally, separation sealing methods are also covered by the invention.
Devices for so-called torsional ultrasonic welding have been known and customary for some time. Such a welding device is disclosed, for example, by EP 930 148 A1. The device includes a sonotrode, which can be induced to undergo ultrasonic vibrations by means of exciters. Opposite the sonotrode there is a so-called anvil, which has a moulding receptacle for receiving a plastic housing. For example, with this device, a cover can be firmly welded onto the plastic housing. The parts to be joined to each other are not moved during the welding process, at least with respect to the longitudinal axis of the sonotrode. The device is consequently suitable for stationary welding; however, the device is not suitable for continuous welding, for example of endless films. Moreover, with this device, two films cannot be joined to each other in a suitable way, and in particular not at the borders.
It is therefore an object of the present invention to avoid the disadvantages of the known art and, in particular, to provide a device and a method of the type stated at the beginning with which two sheet-like articles can be joined to each other in a simple and advantageous manner. In particular, the device and the method are intended to be suitable for joining two or more film parts to each other at the borders. The device is, however, also intended to make it possible to create notches or ultrasonically separate and seal at least one article. Furthermore, the method is intended to be distinguished by an efficient and reliable mode of operation.
These other objects are achieved according to the invention by a device and a method according to the independent patent claims.
The device according to the invention has a sonotrode which can be induced to undergo torsional ultrasonic vibrations by means of exciters. Sonotrodes of this type are also known to a person skilled in the art by the term “torsion sonotrode”. Torsional is understood as meaning a vibration of the sonotrode about its longitudinal axis, i.e. the sonotrode performs a torsional movement about a torsion axis (longitudinal axis). The device also has an anvil lying opposite the sonotrode. At least one article can be guided through between the sonotrode and the anvil to achieve notching (scoring) or separating (separating and sealing) or at least two articles can be guided through between the sonotrode and the anvil to achieve a welded joint. In this case, the anvil has an engaging portion, along which the at least one article or the at least two articles can be guided. The sonotrode has a working area for subjecting the at least one article to ultrasonic vibrations, the engaging portion and/or the working area extending at least in certain portions approximately parallel to the longitudinal axis of the sonotrode, at least in a neutral position. The articles can be guided through continuously between the engaging portion and the working area. The working area undergoes vibrations, which extend approximately perpendicularly to it.
In an advantageous embodiment, the sonotrode may have at least one slit, into which an engaging element of the anvil can be inserted, or is inserted, so that a gap for the at least one article is formed. For the aforementioned case in which two articles are guided through between the sonotrode and the anvil to achieve a welded joint, the term “welding gap” is used for the gap. Two films (parts thereof), one lying flat on the other, for example, may be guided by their borders through the welding gap between the sonotrode and the anvil and welded in this way. With this device, continuous longitudinal weld seams can be produced in a simple manner. It goes without saying, however, that a discontinuous operating mode, in which the individual weld seams are interrupted by unwelded portions, is also possible with this device. With the device, films of plastic or else metal foils (for example aluminium foils) as well as coated films can be advantageously processed. The films may be drawn through the welding gap by conveying means or be moved in some other way. This guiding of the borders of the film through the welding gap formed between the engaging element and the working area ensures reliable and efficient operation during a welding process. In principle, the device is suitable for joining different types of articles. For example, with the device, a film-like cover could also be welded onto a container provided with a collar.
In the latter application, the collar would have to be guided through the arrangement with the welding gap along the collar. Apart from the advantages already mentioned, the device may also be favourably inserted and used in an automatic production line. If the beginning of the actual welding gap (for example formed by a rocking edge) extends approximately centrally, i.e. through or alongside the sonotrode axis, the amplitude in a central region is zero, or in any event very small. Towards the periphery of the sonotrode, the amplitude increases. In this way, a continuous increase can be achieved.
The working area may be created by a corresponding configuration at least of the end face of the sonotrode that is facing the anvil. For example, a tongue extending in the axial direction (for example a flattened profile extending in the axial direction) may be formed onto the end face of the sonotrode or be attached in some other manner. The working area may also be provided by a step-like cutout being made in the region of the end face of the sonotrode. It would even also be conceivable that—instead of the sonotrode—the anvil could have at least one slit. The engaging element would in this case consequently be assigned to the sonotrode. In this case, the engaging element assigned to the sonotrode could be configured as, for example, a pin-shaped tongue extending in the direction of the longitudinal axis. The provision of one or more slits in the sonotrode is therefore not absolutely necessary for certain applications.
Theoretically, it is then even conceivable that the device could be provided with a number of parallel extending or even crossing slits. Preferably, however, the sonotrode has only one slit.
In a first embodiment, the slit may be a groove extending in a groove direction, it being possible for the groove direction to extend transversely, preferably at right angles, to the longitudinal axis of the sonotrode and/or have side walls which extend parallel to the longitudinal axis and form the working area. The groove direction also defines moreover the direction of advancement of the articles during welding operation. The slit is advantageously configured as a continuous groove, it being possible for the groove cross section preferably to be rectangular. Consequently, two films of plastic placed one on the other can be drawn by the borders particularly easily in the groove direction through the slit or through the welding gap.
It may be particularly advantageous if the slit is a groove which is recessed with respect to an end face in the direction of the longitudinal axis of the sonotrode. This recess establishes the groove depth. For the first-mentioned variant, in which the slit is assigned to the sonotrode and the engaging element is assigned to the anvil, the side of the sonotrode that is facing the anvil may form the said end face.
The groove depth of the slit establishes the upper limit for the weld seam width. The width of the weld seam may be approximately the depth of penetration of the engaging element into the slit. The slit may have a groove depth which lies between 5 and 30 mm and preferably between 10 and 15 mm. The groove width may lie between 5 and 15 mm and, with a sonotrode diameter of 40-50 mm, preferably be approximately 10 mm. The engaging element corresponding to the slit may have an undersize with respect to the extent of the width. The welding gap width depends on the film material and the film thickness. The width of the welding gap (gap size) varies for commonly used film thicknesses (for example 20-150 μm).
In a further embodiment, the slit may have two side walls lying opposite each other, it being possible for one of the side walls to form a working area for subjecting the at least one article to ultrasonic vibrations. In this case, the anvil or the sonotrode may have an engaging portion facing the working area, the welding gap lying between the working area and the engaging portion. The engaging portion may form a guiding area for a film part. During a welding process, the articles can slide along on one side on this guiding area with surface-area contact and the articles can be subjected to ultrasonic vibrations on the other side by the working area.
The engaging element or the sonotrode may be supportable or supported by spring means for producing a prestressed pressure for pressing against a working area of the slit. With the spring arrangement, an advantageous gap compensation is obtained. This makes it possible, for example, to compensate for suddenly occurring thick locations (for example a film splice, folds, etc.) when the at least one article is being guided through. In particular, in this way it is possible, for example, for films of plastic or other film parts and very thin articles, such as membranes for instance, to be protected in a simple manner from being damaged. This arrangement also allows the joining of successive overlapping film webs (known as splicing).
To set the width of the welding gap or to set the pressing pressure produced by the spring means, the engaging element or a part of the anvil that is assigned to the gap may be movably secured to an anvil holder by means of an adjusting mechanism. This allows the device to be adapted in a simple manner to different thicknesses of articles to be welded. In addition or alternatively, the device may have an adjusting mechanism, with the aid of which the angular position of the engaging element with respect to the gap is adjustable. With the angular position adjustment it is possible as far as the neutral position is concerned to set an exact plane parallelism of the working area and the engaging portion or an opening or narrowing welding gap, whichever is desired.
The engaging element of the anvil or a part of the anvil that is assigned to the gap may be mounted on an anvil holder pivotably (or tiltably) about a pivot axis. The pivot axis may in this case extend axially parallel to the longitudinal axis of the sonotrode. The pivot axis may, for example, be defined by an axial journal and a complementary pivot bearing. It goes without saying, however, that it is also conceivable that the device could have an imaginary pivot axis. For example, the engaging element may be supported on the anvil holder only by two laterally arranged springs, whereby a pivoting or tilting movement of the engaging element would likewise be possible.
Advantages may be obtained if the engaging element is of an approximately U-shaped or bow-shaped configuration. In this case, to form the U or bow shape, the engaging element may have two securing arms and a web portion connecting them. The web portion may in this case be received, or able to be received, in the slit. The engaging element may be positioned or aligned in such a way that the U lies on a plane of which the normal to its surface extends parallel to the longitudinal axis.
It may be particularly advantageous if a spring element, for example a helical compression spring, is respectively provided for resilient support in the connecting region between an anvil holder and the securing arms.
Advantageous welding can be achieved if the engaging element is longer than the gap with respect to the groove direction and preferably protrudes beyond the gap on both sides. If, for example, the engaging element is of a U-shaped or bow-shaped configuration, the securing arms may be respectively formed on the part of the web portion that protrudes beyond the gap.
The engaging element including the two securing arms and the web portion may be configured as a one-piece body of metal (for example steel). One-piece components of this type can be produced in a simple manner by milling operations.
The engaging element may have an edge in the region of the engaging portion. The edge may, for example, be a rocking edge which is adjoined by a tapering area. The edge may be located in the centre of the engaging element. The edge may furthermore be positioned in the device in such a way that it lies approximately in the centre of the slit with respect to the groove direction.
Theoretically, it is conceivable that the engaging portion is convexly curved in a plan view.
For certain applications, it may be advantageous if the working area formed by a side wall is planar.
However, it may also be advantageous if the working area formed by a side wall is contoured. For example, the side wall could be provided with a plurality of projections, for example approximately punctiform projections, whereby the two articles can be subjected to ultrasonic vibrations at discrete points.
However, it may be particularly advantageous if the contour is formed by at least one rib-like projection. The contour in this case preferably has a number of rib-like projections. The contour may have longitudinal ribs extending in the groove direction.
In a further embodiment, the engaging element or the slit may have a supporting segment for the axial support of the sonotrode. The supporting segment may extend in the direction of the longitudinal axis. The supporting segment may in this case be positioned, at least in a working position, in such a way that the supporting segment defines a point of engagement which preferably lies in the longitudinal axis of the sonotrode. Such a central point of engagement produces a fixed stop or zero-point contact, which is not involved in the vibration occurring in the ultrasonic welding process. The supporting segment may, for example, be a cone-shaped projection formed at the base of the slit or secured in some other way. An advantageous stop in the form of a point is ensured by the tip of the cone. It goes without saying that, apart from the cone shape, other shapings for the projection are also conceivable.
A further aspect of the invention concerns a method for the ultrasonic welding of at least two preferably sheet-like articles. The method may be performed in an advantageous manner on the device described above. The method is distinguished by the fact that, for example, to produce a longitudinal seam, the at least two articles are guided through a welding gap formed between a working area of a torsion sonotrode and an engaging portion.
The working area extends approximately parallel to the axis of the torsion sonotrode. In the case of the present ultrasonic welding method, the articles are subjected to ultrasonic vibrations approximately perpendicularly to them by means of a torsionally vibrating sonotrode which has at least one slit.
Further individual features and advantages of the invention emerge from the following description of the exemplary embodiments and from the drawings, in which:
With the device 1, two films of plastic 11 and 12 lying one on the other can be welded to each other at the borders. For this purpose, the films 11, 12 are guided through a welding gap, which is formed by a lateral delimitation of the slit 4 and the engaging element 5 inserted therein, and welded under the effect of torsional vibrations. In this way, a longitudinal seam is produced at the borders. The device is suitable for welding two films, and in particular films of plastic, at the borders. It goes without saying that, if required, three or more films could be joined to one another. Furthermore, the continuous notching of films (scoring, for example as an aid for tearing open) or the complete continuous separation or cutting and sealing of films is also possible with the device. Instead of plastics, the processing of other materials is also conceivable, foils of metal coming into consideration in particular. Sheet-like formations of paper coated with plastic or other laminates are then also suitable for welding with the device that is described in more detail below.
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Sectional representations of the device are shown in
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As a difference from the previous exemplary embodiment, in
To set the width of the welding gap and/or set the pressing pressure, the engaging element 5 is secured to an anvil holder movably in the y direction by means of an adjusting mechanism (not represented here).
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A further alternative configuration of a sonotrode is shown in
It can be seen from the plan view according to
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From the edge 20, the welding amplitude increases continuously.
Number | Date | Country | Kind |
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09162197.9 | Jun 2009 | EP | regional |