Ultrasonic perforator and a method for performing an ultrasonic perforation
First Claim
1. A method of performing an ultrasonic perforation, comprising:
- providing a material web;
tensioning the web;
unwinding the web onto a pin roll;
passing the web on the pin roll under an ultrasonic emitter;
forcing the ultrasonic emitter into contact with the web using an actuator, wherein the force is imparted to the ultrasonic emitter and transferred only to the web, thereby forcing the web against the pin roll;
applying ultrasonic energy to the web from the ultrasonic emitter winding the web from the pin roll to an exit nip roll in tangential contact with the pin roll;
spooling the web off the exit nip roll.
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Accused Products
Abstract
The invention includes of a system and method of ultrasonically perforating adhesive bandage backings. The invention eliminates the gap between the ultrasonic horn and the pin roll, and provides for a wear resistant release coating on the pin roll. Further, the method and system disclose cooling the ultrasonic horn with a forced air stream, and provide for a pre- or post-nip roll to control the tension of the continuous web of backing. The web of backing is kept under tension with a nip roll, and passes between an ultrasonic horn and an immediately adjacent pin roll for perforation by the ultrasonic horn. The resulting material of the web backing is smoother, and has better hole quality than that seen in the prior art.
39 Citations
67 Claims
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1. A method of performing an ultrasonic perforation, comprising:
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providing a material web;
tensioning the web;
unwinding the web onto a pin roll;
passing the web on the pin roll under an ultrasonic emitter;
forcing the ultrasonic emitter into contact with the web using an actuator, wherein the force is imparted to the ultrasonic emitter and transferred only to the web, thereby forcing the web against the pin roll;
applying ultrasonic energy to the web from the ultrasonic emitter winding the web from the pin roll to an exit nip roll in tangential contact with the pin roll;
spooling the web off the exit nip roll. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
sensing tension in the web using a tension sensing roller; and
controlling tension in the web at said nipping based on said tension sensing.
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8. The method of claim 1, further comprising rewinding the web after said spooling.
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9. The method of claim 1, further comprising cooling the ultrasonic emitter.
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10. The method of claim 9, further comprising controlling said cooling using a feedback controller to maintain a constant temperature of the ultrasonic emitter.
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11. The method of claim 10, wherein said cooling comprises forcing air onto the ultrasonic emitter.
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12. The method of claim 1, further comprising placing the nip roll between 15 and 345 degrees around the circumference of the pin roll from the ultrasonic emitter before said providing.
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13. The method of claim 1, further comprising hardening the pin roll by applying a wear resistant release coating before said providing.
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14. A method of performing an ultrasonic perforation, comprising:
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(a) unwinding a material web and a carrier entwined with the web under controlled tension;
(b) defining two web paths, the first web path including a nip roll followed sequentially by a pin roll which tangentially contacts the nip roll, the second web path including the pin roll sequentially followed by the nip roll;
(c) passing the material web and the carrier along one of the web paths;
(d) contacting the material web with a plurality of pins on the pin roll;
(e) contacting the carrier with an ultrasonic emitter;
(f) forcing the ultrasonic emitter into contact the carrier using an actuator, which actuator exerts a force on the ultrasonic emitter that is transferred only to the material web, thereby forcing the material web into contact with the pins;
(g) applying to the carrier ultrasonic energy from the ultrasonic emitter;
(h) cooling the ultrasonic emitter;
(i) passing the material web through an exit nip station after steps (a) through (g); and
(j) rewinding the material web. - View Dependent Claims (15)
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16. An ultrasonic system for perforating a tensioned web having a top surface and a bottom surface, comprising:
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a pin roll, having a plurality of perforators thereon, which pinroll receives said tensioned web;
at least one ultrasonic emitter having an outlet that contacts said tensioned web and exerts a pressure on said tensioned web;
at least one actuator that forces said ultrasonic emitter toward said tensioned web and maintains contact between the outlet and said tensioned web, wherein the outlet exerts the pressure only on said tensioned web, thereby forcing said tensioned web against the perforators; and
a nip roll that tangentially contacts said pin roll, which nip roll receives said web. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47)
a driven exit nip;
a variable speed exit nip drive transmission connected to said driven exit nip;
a non-driven exit nip which tangentially contacts said driven exit nip;
at least one air cylinder proximate to said non-driven exit nip, which exerts air pressure on said non-driven exit nip, thereby urging said non-driven exit nip toward said driven exit nip.
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38. The ultrasonic perforatore of claim 37, wherein one of either said driven exit nip or said non-driven exit nip comprises steel.
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39. The ultrasonic perforator of claim 38, wherein said driven exit nip is formed of steel, and wherein said driven exit nip is release coated.
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40. The ultrasonic perforator of claim 37, wherein at least one of said driven exit nip and said non-driven exit nip comprises rubber.
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41. The ultrasonic perforator of claim 37, wherein said driven exit nip is driven by a pin roll drive motor.
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42. The ultrasonic perforator of claim 37, further comprising a rewind station which receives said tensioned web from said exit nip station.
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43. The ultrasonic perforator of claim 37, further comprising a tension sensing roller that senses and controls tension in said tensioned web at said exit nip station.
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44. The ultrasonic perforator of claim 16, wherein said tensioned web is continuous along one length, and up to 6″
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45. The ultrasonic perforator of claim 16, further comprising a forced air source that directs forced air onto the outlet.
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46. The ultrasonic perforator of claim 16, wherein the outlet is variably displaced from said pin roll, and wherein the variable displacement forms a variable gap between the outlet and said pin roll.
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47. The ultrasonic perforator of claim 16, wherein said actuator is selected from the group consisting of an air actuator, a hydraulic actuator, and a spring actuator.
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48. An ultrasonic system for perforating a tensioned web, comprising:
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a pin roll, having a plurality of perforators thereon, which pinroll receives said tensioned web;
at least one ultrasonic emitter having an outlet that contacts said tensioned web and exerts a pressure on said tensioned web;
a forced air source that directs forced air onto the outlet; and
a feedback controller that allows the outlet to reach a predetermined temperature, and then maintains that temperature by alternately activating and deactivating said forced air source. - View Dependent Claims (49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64)
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65. An ultrasonic system for perforating a tensioned web having a top surface and a bottom surface, comprising:
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a pin roll, having a plurality of perforators thereon, which pinroll receives said tensioned web;
at least one means for providing ultrasonic energy to the tensioned web, wherein said means for providing contacts said tensioned web and exerts a pressure on said tensioned web;
at least one means for forcing said means for providing ultrasonic energy toward said tensioned web, which means for forcing maintains contact between said means for providing and said tensioned web, wherein said means for providing exerts the pressure only on said tensioned web, thereby forcing said tensioned web against the perforators; and
means for nipping that tangentially contacts said pin roll, which means for nipping receives said web.
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66. An ultrasonic system for perforating a tensioned web, comprising:
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a pin roll, having a plurality of perforators thereon, which pinroll receives said tensioned web;
at least one means for providing ultrasonic energy that contacts said tensioned web and exerts a pressure on said tensioned web;
means for directing forced air onto said means for providing; and
means for controlling said means for directing, wherein said means for controlling allows said means for providing to reach a predetermined temperature, and then maintains that temperature by alternately activating and deactivating said means for directing, the activating and deactivating being based on feedback of that temperature. - View Dependent Claims (67)
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Specification