Herrmann Ultraschalltechnik @ Index20: New th...
Herrmann Ultraschalltechnik @ Index20

New thread fixation: ultrasonic anchoring of diaper elastics

(Source: Herrmann Ultraschall)
(Source: Herrmann Ultraschall)

The insertion of elastic threads can be complex and costly in the manufacture of hygiene products. Herrmann Ultraschalltechnik GmbH & Co.KG, Karlsbad/Germany, has developed a novel patented method for fixing elastic threads that simplifies handling, reduces the risk of breakage, enlarges the process window and lowers production costs.
The innovative process creates a tunnel between the 2 layers of nonwovens in which the stretched elastic thread is guided. By using ultrasonics specific bonding areas are created in which the thread is partially anchored, and after cutting the product the thread relaxes and is clamped by the weld spots. A wide range of material combinations, thread counts, diameters, elongations and production speeds have been successfully tested. Easy positioning of multiple threads is another advantage of this development.
This new anchoring process, which will be presented at the Index in Geneva/Switzerland from October 19-22, 2021, can be executed intermittently or continuously. Further innovations in controlling the signal of the ultrasonic generator Ultrabond allow for “triggering” the ultrasonic energy extremely fast in the right places. Thus format-dependent tools are no longer needed, as the areas to be bonded can be configured freely while rendering a format anvil drum unnecessary. With less costs for tools and less time for format changes, the Overall Equipment Efficiency (OEE) is increased.

The standardized ultrasonic tools (sonotrodes) in the Microbond CSI system offer the proven Microgap technology. Multi-dimensional process monitoring is possible by combining the generator signal feature with the Microgap technology, which controls the gap in the bonding area and ensures a constant bonding quality with direct system feedback.
The new fixation process called Anchoring, enable the manufacture of softer and more sustainable products.
Elastic threads are widely used in the hygiene market to reach better body comfort for the waist area or leg cuffs. Using ultrasonic technology offers multiple advantages over gluing:
- softer touch which is what consumers want
- controlled and repeatable process with high production speeds and wide web widths
- outstanding creep performance and splice processing
- better stretch performance of threads as they are not exposed to any heat during the process.

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