# US 4,394,208 A · Ultrasonic bonding > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,394,208 A - Document ID: US4394208A - Status: Granted - Kind: A - Application number: 06/290,714 - Filed: 1981-08-06 - Granted: 1983-07-19 - Earliest claimed: 1981-08-06 - Assignees: Burlington Industries, Inc. - Inventors: Kenneth Y. Wang; Berlie R. Hill - Web page: https://patentgrep.com/patent/US4394208A ## CPC - D04H 1/54: by welding together the fibres, e.g. by partially melting or dissolving (in combination with needling D04H1/485) - D04H 1/555: by ultrasonic heating - B29C 65/086: {using a rotary anvil} - B29C 65/7847: {using vacuum to hold at least one of the parts to be joined (vacuum work holders in general B25B11/005)} - B29C 66/0242: {Heating, or preheating, e.g. drying (B29C66/3464 takes precedence)} - B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)} - B29C 66/3452: {Making complete joints by combining partial joints} - B29C 66/45: {Joining of substantially the whole surface of the articles (methods or apparatus for laminating B32B37/00)} - B29C 66/69: {General aspects of joining filaments (bundling articles B65B13/00; interconnecting successive lengths of material B65H69/00)} - B29C 66/73921: {characterised by the materials of both parts being thermoplastics} - B29C 66/81467: {arranged in an offset pattern} - B29C 66/83411: {Roller, cylinder or drum types (B29C66/83431 takes precedence; rollers, cylinders or drums moving relative to and tangentially to the parts to be joined B29C66/8362)} - B29C 66/83413: {cooperating rollers, cylinders or drums} - B29C 66/83415: {the contact angle between said rollers, cylinders or drums and said parts to be joined being a non-zero angle (B29C66/83433 takes precedence)} - B29K 2105/0854: {in the form of a non-woven mat} - Y10T 156/1737: Discontinuous, spaced area, and/or patterned pressing - Y10T 156/1741: Progressive continuous bonding press [e.g., roll couples] - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An apparatus and method are provided for producing a non-woven fabric ultrasonically without unacceptable streaking. A fibrous batt is continuously fed in a first direction toward and past a plurality of vibration sources and anvil. Energy is supplied to the vibration sources so that bonding of the fibrous batt in a non-woven fabric takes place at the vibration sources and anvil. Significant migration of fibers of the batt is positively prevented just prior to passage of the batt into contact with the vibration sources so that a streakless bonded non-woven fabric is produced. Migration may be positively prevented by disposing a heated roller of hard material just upstream of the vibration sources, and providing a second compression roller upstream of the heated roller. ## Claims ### Claim 1 Apparatus for vibration bonding of material comprising means for transporting in a first direction a batt of primarily ultrasonically fusible fibers to be vibration bonded into a bonded non-woven web; a plurality of ultrasonic vibration sources disposed to act upon substantially the entire width of the web; anvil means cooperating with said vibration sources to effect bonding, said anvil means disposed on the opposite side of the batt as said ultrasonic vibration sources; and means for preventing any significant migration of fibers in the fibrous batt just prior to bonding so that a substantially streakless bonded non-woven web is produced. ### Claim 2 (depends on 1) Apparatus as recited in claim 1 wherein said migration preventing means comprises means for applying a compressive force to said fibrous batt just prior to passage thereof into operative engagement with any of said vibration sources. ### Claim 3 (depends on 2) Apparatus as recited in claim 2 wherein said compressive force applying means comprise a roller of hard material. ### Claim 4 (depends on 3) Apparatus as recited in claim 3 further comprising means for heating said roller to facilitate fiber migration prevention when said roller acts upon said fibrous batt. ### Claim 5 (depends on 3) Apparatus as recited in claim 3 wherein said roller has a diameter of about 1 inch. ### Claim 6 (depends on 3, 5) Apparatus as recited in claims 3 or 5 wherein said roller comprises a stainless steel roller. ### Claim 7 (depends on 3) Apparatus as recited in claim 3 wherein said roller is a first roller, and further comprising a second roller disposed upstream of said first roller, and for applying a compressive force to said batt. ### Claim 8 (depends on 7) Apparatus as recited in claim 7 wherein said transporting means include a vacuum screen conveyor and a conveyor belt, said conveyor belt disposed downstream of said vacuum screen conveyor; and wherein said migration-preventing means comprise means for mounting said second roller between said vacuum screen conveyor and conveyor belt in said first direction. ### Claim 9 (depends on 3) Apparatus as recited in claim 3 wherein said migration-preventing means comprise means for mounting said roller so that is applies compressive forces by its weight alone. ### Claim 10 (depends on 1, 2) Apparatus as recited in claims 1, 2, or 3 wherein said plurality of ultrasonic vibration sources comprise first and second rows of staggered, overlapping ultrasonic horns and wherein said anvil means comprises an anvil roller. ### Claim 11 Apparatus for vibration welding of material comprising means for transporting in a first direction a web of material to be vibration welded; a plurality of ultrasonic vibration sources disposed to act upon substantially the entire width of the web; anvil means cooperating with said vibration sources to effect welding, said anvil means disposed on the opposite side of the web as said ultrasonic vibration sources; a roller of hard material extending substantially the entire width of the web; and means for mounting said roller just before any of said ultrasonic vibration sources so that said roller applies a force to the web. ### Claim 12 (depends on 11) Apparatus as recited in claim 11 wherein said roller mounting means comprise means for mounting said roller so that by its weight alone it applies a compressive force to the web. ### Claim 13 (depends on 11, 12) Apparatus as recited in claims 11 or 12 further comprising means for heating said roller. ### Claim 14 (depends on 13) Apparatus as recited in claim 13 wherein said roller is of electrically conductive material, and wherein said roller heating means comprises a stationary electrically conductive rod electrically interconnected to said roller and a source of electrical energy. ### Claim 15 (depends on 11) Apparatus as recited in claim 11 wherein said roller comprises a first roller, and further comprising: a second roller of hard material; and means for mounting said second roller upstream of said first roller in the web direction of transport, and in operative association with the web for applying a compressive force to the web.