Ramped ultrasonic bonding anvil and method for intermittent bonding

• Main Authors: Couillard, Jack Lee, Coenen, Joseph Daniel, Abel, Kent William
• Format: Patent
• Language: English
• Published: 11.02.2003

The present invention relates to apparatus and methods for effecting ultrasonic bonding on at least one continuously moving web or work piece. The invention more particularly concerns apparatus and methods for ultrasonically bonding at least one continuously moving web using a rotary anvil roll in combination with a rotary ultrasonic horn. Method and apparatus comprising a novel ramped anvil roll for cooperating with a rotary ultrasonic horn and creating ultrasonic bonds in a work piece passing between the anvil roll and ultrasonic horn. A relatively smaller radius portion of the anvil roll extends about a first portion of the circumference, and a relatively larger-radius raised bonding element extends about a second portion of the circumference. An outer surface at at least one of a front and rear end portion of the raised bonding element defines a transition gradient between the raised operating surface and the relatively smaller radius portion. The transition gradient defines a modified sinusoidally-shaped curved loading surface including an inflection locus, the curved loading surface representing a relatively constantly changing angle as measured against respective radii of the anvil roll in combination with advancing along the corresponding portion of the circumference.