Patent Publication Number: US-11654637-B2

Title: Depth control of seal line penetration for rotary ultrasonic horn/anvil welding without mechanical stop

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of U.S. patent application Ser. No. 17/399,429, titled “Depth Control of Seal Line Penetration For Rotary Ultrasonic Horn/Anvil Welding Without Mechanical Stop,” filed Aug. 11, 2021, the entirety of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates generally to ultrasonic welding systems, and, more particularly, to depth control of seal line penetration for a rotary ultrasonic horn or anvil welding without a mechanical stop. 
     BACKGROUND OF THE INVENTION 
     When bonding thin (thickness less than 150 μm) films, it can be difficult to achieve consistent penetration with an air-loaded system. This is particularly true of monolayer and mono-material films. In some ultrasonic welding applications, it is advantageous to use a horn and anvil that are disc-shaped, which are referred to as rotary horns or rotary anvils. When the application calls for a seal or joint to be formed between two substrates or layers to be joined of an end product (e.g., a pouch or container), some conventional rotary ultrasonic techniques employ a mechanical stop to control the depth of the joint or seal by stopping the advancing ultrasonic horn, but mechanical stops have very severe limitations for thin film processing. A mechanical stop requires near perfect and total concentricity of the rotating elements (rotary horn and rotary anvil), especially for thin film applications around 0.002 inches (50 μm) in thickness, and is subject to mechanical wear and tear over time, which adversely impacts consistent depth control of the joint or seal. Mechanical stops also require the designer to eliminate the effects of thermal expansion and contraction, and the operator would require a high level of accumulated skill to be able to make micro adjustments to such a mechanical stop to accommodate different film thicknesses. Mechanical stops are composed of multiple components, such as bearings, shaft, and other components whose manufacturing tolerances can induce small but significant elements of rotational runout. If such runout were to occur, and due to the very small gap dimension required between the rotating elements, bond consistency from end product to end product would be lost. 
     Other conventional rotary applications employing ultrasonic energy have a pattern of ridges formed on the surface of the rotary horn and/or rotary anvil, such as disclosed in U.S. Pat. No. 10,889,066 owned by the same assignee of the present disclosure, which is particularly well suited for bonding nonwoven fabrics, by entrapping elastic strands in a permanent state of tension. These are not particularly well suited for melting plastics together to create a hermetic or airtight seal between the two plastic parts. Moreover, the ridge pattern tends to have a height far greater than a thickness of the fabric being bonded together by the ultrasonic energy. Patterned profiles also do not create hermetic seals, which are required in some applications, e.g., pouches or containers that will be filled with a liquid. 
     Still further conventional rotary ultrasonic welding applications incorporate a raised profile on the horn or anvil, but like patterned profiles, the overall height of these raised profiles are greater (typically many orders of magnitude greater) than a thickness of the parts being joined together, and thus cannot serve to control the depth of the seal line and are not well suited for sealing thin films together. Tall raised profiles like these lead to weakening of the bond or seal due to the high force/pressure applied, and are thus not desirable for use in sealing (plastic) films. 
       FIG.  1 A  is a cross-section of a cutaway portion of a prior art anvil  100  having a raised, patterned profile  102 . The patterned profile  102  has a height, H 1 , that is orders of magnitude greater than a thickness of a layer of a part sandwiched between the anvil  100  and a conventional horn that receives ultrasonic energy. Due to the magnitude of height, H 1 , a high amount of force or pressure is applied to the layers sandwiched between the horn and anvil  100 , which, particularly in the case where the layers are films, such as plastic films, can lead to an undesirable weakening (e.g., excessive thinning) of the seal line or bond formed at the interface between the patterned profile  102  and the horn when the mechanical stop insufficiently limits the weld force and distance due to lack of concentricity, thermal expansion, or improper operator adjustment. 
       FIG.  1 B  is a cross-section of a cutaway portion of another prior art anvil  110 , also having a raised profile  112 , but the raised profile  112  has a smooth surface as opposed to a patterned surface such as shown in  FIG.  1 A . Like the anvil  100 , the raised profile  112  of the anvil  110  shown in  FIG.  1 B  has a height, H 2  of 0.063 inches, much greater than a thickness (typically more than double) of a layer of a part sandwiched between the anvil  112  and a conventional horn. Like the conventional profile shown in  FIG.  1 A , the conventional profile of  FIG.  1 B  will operate to weakening the bond or seal formed between film layers. The raised profile  112  shown in  FIG.  1 B  forms a continuous seal, but it can adversely thin the material being welded too much, thus weakening it and the package being sealed when the mechanical stop insufficiently limits the weld force and distance due to lack of concentricity, thermal expansion, or improper operator adjustment. 
     A need exists, therefore, for a rotary ultrasonic welding technique that does not use a mechanical stop and can accurately and repeatedly join two thin parts (e.g., portions of film) together and accommodate parts of varying thickness. Aspects of the present disclosure are directed to fulfilling this and other needs. 
     SUMMARY OF THE INVENTION 
     Key features of the present invention are the height of the profile and the absence of any mechanical stop device to control depth of the seal using ultrasonic energy applied by a rotary horn and anvil. The height of the profile is extremely small, such as between 50% and 150% or 100% of a thickness of the film or part being joined. The extremely low height of the profile on the horn or anvil (it can be present on either, or both), provides a “dynamic mechanical stop” effect without any actual external mechanical stop, by squeezing the two layers of film with enough force or pressure to achieve the mechanical support, but not so hard as to melt the plastic in the film layers. The combination of the height of the profile and the absence of any mechanical stop structure to control depth of seal penetration is a key difference over the prior art. 
     The profile can extend continuously and circumscribe an entire circumferential outer surface of a rotary horn or rotary anvil. A continuous, circumferential profile maintains a constant and continuous force/pressure on the film while sealing while the profile&#39;s height is no greater than a thickness of the film. 
     The profile heights depend on a thickness of the film being sealed, but in some embodiments, the height of the profile can begin as low as 0.002″ (inches) high and then step up very tiny, 0.0005″ increments, which demonstrates the high precision needed from an alternative design employing a conventional mechanical stop as opposed to the depth control anvil design of the present disclosure. 
     According to an aspect of the present disclosure, an apparatus for joining a first film portion and a second film portion together along a seal line using ultrasonic energy is disclosed. The apparatus includes: a horn configured to receive ultrasonic energy; and an anvil positionable in close proximity to the horn that is advanced toward the anvil, wherein at least one of the horn or the anvil has a face with a width dimension and a circumference and is rotatable about a rotation axis. The face has a raised profile, a height of the raised profile has a dimension corresponding to 50% to 150% of a thickness of the first film portion or the second film portion. The face is positioned such that the raised profile extends along the circumference. Continuous running contact is provided between the raised profile and the other of the one of the horn or the anvil when rotated about the rotation axis, to form the seal line without any external structure to control a distance between the horn and the anvil. The thickness of the first film portion and the second film portion can be between 10 μm and 150 μm. 
     The height dimension of the raised profile can correspond to 100% of the thickness of the first film portion or the second film portion. The height dimension of the raised profile can correspond to between 50% and 125% of the thickness of the first film portion of the second film portion. The first film portion and/or the second film portion can be composed of a plastic. The first film portion or the second film portion can be a multilayer film, a recyclable film, a biodegradable film, a compostable film, a monolayer film, a paper-based film, or a mono-material film. 
     The raised profile can further include a scoring element configured to score or cut along the seal line as the anvil is rotated about the rotation axis. The face can have a second raised profile having a height corresponding to 50% to 150% of the thickness of the first film portion or the second film portion. The second raised profile can extend along the circumference, and continuous running contact can be provided between the second raised profile and the other of the one of the horn or the anvil when rotated about the rotation axis. 
     The height dimension of the second raised profile can correspond to 100% of the thickness of the first film portion or the second film portion. The raised profile can be part of the anvil, and further in combination with a second anvil can have a second raised profile having a height dimension exceeding the height dimension of the raised profile by 0.0005 inches. 
     A product is disclosed which includes the first film portion and the second film portion and the seal line formed by any apparatus disclosed herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1 A  is a cross-section of a cutaway portion of a prior art anvil having a raised, patterned profile; 
         FIG.  1 B  is cross-section of a cutaway portion of another prior art anvil  110 , having a smooth, raised profile  112 ; 
         FIG.  2    is a perspective illustration of a rotary ultrasonic bonding apparatus suitable for use with the raised profile on either the anvil or horn, creating a dynamic stop effect; 
         FIG.  3    is an enlarged, cross-sectional view of a portion of a horn or anvil having a raised profile according to an aspect of the present disclosure; 
         FIG.  4    is an isometric, cutaway view of a horn or anvil according to another aspect of the present disclosure having two raised profiles thereon, creating a dynamic stop effect thereby; 
         FIG.  5    is an isometric, cutaway view of the horn or anvil having two raised profiles shown in  FIG.  4   ; 
         FIG.  6    is a cross-sectional view of a portion of the horn or anvil shown in  FIG.  5   ; 
         FIG.  7    is a cross-sectional view of a portion of the horn and the anvil together with the raised profile with two layers of film passing between the horn and anvil during application of ultrasonic energy; 
         FIG.  8    is a functional diagram of a depth control configuration in which a horn and anvil each have a raised profile to achieve equal or deliberately non-equal penetration from both sides of film being bonded; 
         FIG.  9 A  is a functional diagram of a seal and score configuration in which the raised profile includes a scoring element to score the sealed layers after they have bonded; 
         FIG.  9 B  is a functional diagram of an angled seal profile configuration in which the raised profile is angled to facilitating in sealing the layers to be bonded; 
         FIG.  10 A  is a cross-sectional view taken along line  10 B- 10 B of a portion of the horn or anvil having a tapered bonding profile and an exemplary traction pattern; 
         FIG.  10 B  is a top cut-away view of a portion of the exemplary traction pattern shown in  FIG.  10 A ; 
         FIG.  10 C  is a cross-sectional view of the portion of the traction pattern taken along line  10 C- 10 C; 
         FIG.  11 A  is a side view of a horn or anvil having a cut and seal feature; 
         FIG.  11 B  is an enlarged view of the cut and seal feature shown in  FIG.  11 A  with a callout showing an enlarged view of the cutting feature; and 
         FIG.  12    illustrates a tapered bond profile on a horn or anvil, which can have a different profile on either side of horn or anvil. 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  2    is a general illustration of a rotary ultrasonic bonding apparatus  200 , the general operation and components of which will be very familiar to a person of ordinary skill in the art of ultrasonic welding, and in particular, rotary ultrasonic welding technology. The apparatus  200  has an anvil module  202  and a horn module  204 , which cooperate to perform a bonding or sealing operation of multiple parts, e.g., two or more layers of film, as set forth in more detail below. 
     The horn module  204  includes a frame  206  on which are mounted a disc-like rotary horn  208 , a motor  210  for driving rotation of the horn  208  via a suitable drive train  212 , and a housing  214  that contains at least part of a vibration control unit (not shown) that causes the horn  208  to vibrate. The horn  208  has an exposed outer face  216  with a substantially continuous contour (i.e., the horn face  216  has a contour that is substantially smooth (or uninterrupted) across its entire surface area). In other embodiments, the horn face  216  may have any suitable contour that facilitates enabling the horn  208  to function as described herein. 
     In some embodiments, the vibration control unit (while not illustrated) includes a conventional booster (e.g., a drive booster and an integral booster) mechanically connected to a converter, which is electrically connectable to a generator. The converter is capable of converting high frequency electrical energy supplied by the generator into mechanical energy (or vibration) that is selectively transmitted to the horn  208  across the booster(s). The booster(s) are capable of modifying (i.e., increasing or decreasing) the vibration transmitted to the horn  208  from the converter, such that the horn  208  (particularly, the face  216  of the horn  208 ) vibrates while it rotates during a bonding operation, as set forth in more detail below. It is contemplated that the horn module  204  may have any suitable operational components arranged in any suitable manner that facilitates enabling the horn  208  to function as described herein. The details not shown would be readily apparent to any person skilled in the art familiar with rotary ultrasonic bonding systems. 
     In the illustrated embodiments, the anvil module  202  includes a frame  218  on which are mounted a disc-like rotary anvil  220  and a motor  222  for driving rotation of the anvil  220  via a suitable drive train. The anvil  220  has an exposed outer face  226  with a substantially continuous contour (i.e., the anvil face  226  has a contour that is substantially smooth or uninterrupted across its entire surface area). The anvil module  202  is positioned relative to the horn module  204  such that the anvil face  226  is rotatable about a rotation axis, R (seen in  FIG.  4   ), in close proximity to the horn face  216 , and vice versa, to facilitate ultrasonically bonding the parts as they are held in tension across apparatus  200 , as set forth in more detail below. As used herein, the term “close proximity” refers to when the anvil face  226  is either in contact with, or is minimally spaced apart from, the horn face  216  when the horn  208  is not ultrasonically vibrating. 
     In some embodiments, the apparatus  200  may be configured such that at least one of the anvil module  202  and the horn module  204  is displaceable relative to the other via a suitable displacement mechanism operable either: (A) when the system  100  is offline and the horn  208  is at rest (i.e., when the horn  208  is not rotating or vibrating); or (B) when the system  100  is online and the horn  208  is active (i.e., when the horn  208  is rotating and vibrating). 
     With particular reference to the embodiment illustrated in  FIG.  2   , the apparatus  200  may be configured as a continuous-nip apparatus in which the horn module  204  is to be: (A) fixed in position relative to the anvil module  202  when the system  100  is online and the horn  208  is active; and (B) displaceable relative to the anvil module  202  when the system  100  is offline and the horn  208  is at rest. Such displacement is facilitated by a selectively actuatable pneumatic cylinder  228  (or other suitable linear actuator) that connects the frames  206 ,  218  to one another. In this manner, the spacing between the horn face  216  and the anvil face  226  is adjustable primarily for servicing the apparatus  200  when the system  100  is offline. 
       FIG.  3    illustrates a cross section of a part of the horn or anvil  208 ,  220  having an outer face  302  having a substantially continuous contour (i.e., the outer face  302  has a contour that is substantially smooth or uninterrupted across its entire surface area), and a raised profile  312  having a height, H 3 , that is between 50% and 150% (e.g., 100%) of a thickness of a part to be joined between the horn and anvil  208 ,  220 . It should be emphasized that the raised profile  312  can be present on the horn  208  or the anvil  220  or both, and the principles discussed herein apply equally to both the horn  208  and the anvil  220 . In most applications, the raised profile  312  is present on the anvil  220 . There can be more than one raised profile  312 , e.g., such as best seen in  FIG.  4   . Multiple raised profiles like the raised profile  312  can be present on the horn  208 , on the anvil  220 , or distributed among the horn  208  and the anvil  220  (e.g., a raised profile can be present on the horn  208 , and a raised profile can be present on the anvil  220 ) for joining one pair of parts together or multiple pairs of parts together. The raised profile  312  can be referred to herein as a “depth control” profile, because it serves to control the depth of weld penetration into parts to be joined together by sealing or bonding. 
     The raised profile  312  shown in  FIG.  3    has a substantially flat and continuous raised surface having a width of 0.040 inches, and which is transitioned on both sides by a curved surface having a radius, R=0.015 inches. The width of the raised profile  312  is also much narrower compared to prior art non-patterned profiles, and e.g., spans less than 10% or less than 7% or less than 5% of the entire width of the horn  208  or the anvil  220 . The radius dimension is exemplary, but plays a role in imparting a dynamic stop functionality to the rotary system without the need for a mechanical stop found in prior art rotary ultrasonic welding systems. The radius dimension is also a function of the height, H 3 , of the raised profile  312 , but the height, H 3 , is constrained not to exceed a thickness of a part, such as a film, to be joined between the horn  208  and the anvil  220  by application of ultrasonic energy to the horn  208  as the horn  208  and anvil  220  rotate relative to one another about a rotation axis, R (seen in  FIG.  4   ). In this example, the raised profile  312  has a height, H 3 , e.g., that is about 0.0035 inches (within a typical tolerance). However, the height, H 3 , can be as low as 0.002 inches to accommodate films of that thickness. 
     The horn  208  or the anvil  220  can be readily swapped out for another horn  208  or anvil  220  having a differently sized (e.g., height and/or width) raised profile. The height, H 3 , of each raised profile can be machined to differ by increments of only 0.0005 inches from profile to profile. For example, if the smallest height profile has a height of 0.0020 inches, the next profile can have a height of 0.0025 inches, followed by 0.0030 inches, and so forth. Using the example shown in  FIG.  3   , the raised profile  312  on one anvil  220  can have a height of approximately 0.003 inches, and another anvil can have a raised profile with a height of 0.0035 inches, followed by 0.0040 inches, and so forth. Depending on the thickness of the parts (e.g., films) being joined together, the anvil  220  or the horn  208  can be easily swapped out to match the raised profile&#39;s height with the part&#39;s thickness. It should be emphasized that the dimensions or tolerances provided herein are exemplary only and are used to illustrate the relative height of the profile relative to the thickness of the part layer(s) being welded or joined together. 
     The raised profile  312  can encircle the entire circumference of the horn  208  or the anvil  220 , such as shown in the partial cutaway perspective view shown in  FIG.  4    and in more detail in  FIGS.  5  and  6   . Due to the extremely narrow height of the raised profiles  312   a ,  312   b ,  FIGS.  5  and  6    illustrate enlarged views of the raised profiles  312   a ,  312   b  (two are shown in  FIG.  5   ). Energy for adequate bonding to occur at the profile  312  is provided. It should be noted that the height of the raised profiles  312   a ,  312   b  can be different. This can be useful, e.g., when the raised profiles  312   a ,  312   b  are on the horn  208 , and the anvil  220  has a narrower width compared to the horn  208 . This allows the operator or end user to use the same horn  208  for welding different part thicknesses by simply flipping the horn  208  around so that the appropriate raised profile ( 312   a  or  312   b ) is in contact with the anvil  220 . For example, if the raised profile  312   a  has height X, and the raised profile  312   b  has height Y&gt;X, when the thicker part is needed to be welded, the horn  208  can be flipped so that the raised profile  312   b  contacts the anvil  208 ; whereas when a thinner part is needed to be welded, the horn  208  can be flipped so that the raised profile  312   a  contacts the anvil  208  instead. It should be emphasized that the respective widths of the horn  208  and the anvil  220  can be the same or different (e.g., the anvil  208  can be thinner or narrower compared to the horn  220  when the raised profiles  312   a ,  312   b  are present on the horn  220 ). 
       FIG.  7    illustrates an example cross-section of two parts, which in this example are two layers of film comprising a lower film  400  and an upper film  402 . As the layers  400 ,  402  are pulled between the horn  208  and the anvil  220 , the layers  400 ,  402  begin to melt due to the application of ultrasonic energy into the horn  208 . The layers  400 ,  402  are squeezed by the raised profile  312  as they move or are moved along a direction of arrow G shown in  FIG.  7    into a space by force or pressure, which has a height corresponding to a thickness of only one of the layers  400 ,  402  (because the height of the raised profile  312  does not exceed the thickness of one of the layers  400 ,  402 ). It is assumed that the thickness of the layers  400 ,  402  are the same, but they do not have to be identical. The height, H 3 , of the raised profile can be dimensioned to accommodate the thicker of the two layers  400 ,  402 . 
     An important aspect of the dimension of the height of the raised profile  312  is that it creates a dynamic stop effect without the need for an external mechanical stop apparatus. When the layers  400 ,  402  enter the gap between the horn  208  and the anvil  220 , the amplitude of the ultrasonic energy and the nip force created at the raised profile  312  provide sufficient energy for bonding to occur along the raised profile  312 . There is insufficient energy to bond in areas between the horn  208  and anvil  220  beyond the raised profile due to the weld force&#39;s being distributed across increased surface area after profile penetration has been achieved. In these areas, the unbonded layers  400 ,  402  prevent contact between the horn  208  and the anvil  220 . As a result, this eliminates the need for an external physical mechanical stop, which otherwise would be required to maintain seal line thickness and consistency. The unbonded layers between the horn  208  and the anvil  220  become the physical stop conventionally provided by a mechanical stop, but which is eliminated by the aspects of the present disclosure herein. 
     In prior art systems, when the raised profile has a height much greater than the thickness of the film being presented between the horn and anvil, an external mechanical stop device is required to inform the system when to stop advancing movement of the horn. Otherwise, an excessive or inadequate amount of force or pressure can be applied to the films, and an inadequate or inferior bond formed at the sealing interface. By contrast, a depth control profile such as the profile  312  has a much shallower profile and is also narrower. This continuous profile (see  FIG.  4   ) can weld the film  400 ,  402  by initiating the melt on the profile surface  312  until the profile  312  penetrates to the depth of the adjacent shoulders. Once the shoulder meets the film  400 ,  402 , the much larger surface area bottoms out on the shoulders and the melts and penetration are halted (referred to herein as a dynamic stop effect). 
     The gap between the horn  208  and anvil  220  and resultant seal line thickness is determined by profile height as a percentage of the thickness of a single material ply. E.g., if material thickness=x, then the profile height is a predetermined percentage of x, typically 50% to 150%, depending upon the material being bonded and desired bonding result (e.g., hermetic seal). 
     The benefit of welds made by the apparatus and methods according to the present disclosure over prior art rotary systems is that the continuous weld is stronger and forms a hermetic seal. The raised profile according to the aspects of the present disclosure can be applied to multilayer, recyclable, biodegradable, compostable, monolayer, paper-based, or mono-material films. Full control of the seal line thickness is achievable according to aspects of the present disclosure, for material thicknesses in a range from 10 μm up to 150 μm. 
     As mentioned above, a raised profile can be present on both the horn  208  and the anvil  220 , with the same or unequal heights.  FIG.  8    illustrates an example depth control configuration  800  in which one of the horn  208  or anvil  220  has a first raised profile  812   a , and the other of the anvil  220  or horn  208  has a second raised profile  812   b , both of which have been exaggerated grossly as shown in size and profile for ease of illustration and discussion. A product  802 , such as a pouch or container to be filled with a liquid, and thereby requiring a hermetic seal, has a first layer  400  and a second layer  402 . Each raised profile  812   a ,  812   b  must have a height of less than 100% of x (where x is the thickness of the layer  400 ,  402 ) when the profiles have the same height. When the profiles have different heights or where unequal penetration is required, one element may exceed 100% of x, but the other must be proportionately less. While both the horn  208  and the anvil  220  are shown in  FIG.  8    as having a raised profile  812   a ,  812   b , in alternate embodiments, only one of the horn  208  or the anvil  220  can have a raised profile while the other of the horn  208  and the anvil  220  lacks a raised profile. 
     For example, if thickness of the layer  400 ,  402  is 100 um (x=100) and a seal thickness at an interface  830  of 25 μm is desired, and the seal  830  needs to be offset, a profile height of 125% of x on one element  812   a  (horn  208  or anvil  220 ) and a profile of 50% x on the second element  812   b  (anvil or horn) will achieve an offset seal line of 25 um thickness. If equal penetration is required, then both horn  208  and anvil  220  would have a raised profile  812   a ,  812   b  having a height corresponding to 87.5% of x. The unbonded layers  400 ,  402  in an area  832  downstream of the seal interface  830  prevent contact between the horn  208  and the anvil  220 . As a result, the need for an external physical mechanical stop is eliminated, which otherwise would be required to maintain seal line thickness and consistency. The unbonded layers  400 ,  402  in the area  832  between the horn  208  and the anvil  220  become the physical stop. 
       FIG.  9 A  illustrates a “seal and score” configuration  900  in which the raised profile  912  on either the horn  208  or the anvil  220  includes a scoring element  916  to score or cut the sealed interface  930  of the bonded layers  400 ,  402  right at one of the distal (relative to the product  902 ) shoulders of the raised profile  912 . The unbonded layers  400 ,  402  in the area  932  are scored or cut from the sealed interface  930 , enabling a sealing and scoring operation to take place in one step. Again, like the configuration  800  shown in  FIG.  8   , the raised profile  912  and scoring element  916  shown in  FIG.  9 A  has been grossly exaggerated for ease of illustration and discussion. The scoring element  916  can have a wedge shape to score other materials, such as in shrink wrap applications. The unbonded film in the area  932  maintains the bond and score depth, eliminating the possibility of the horn  208  being damaged by the anvil  220  (assuming the scoring element  916  is part of the raised profile  912  of the anvil  220 ). 
       FIG.  9 B  illustrates an “angled seal profile” configuration  950  in which the raised profile  952  on either the horn  208  or the anvil  220  includes an angled profile to aid in sealing or bonding the sealed interface  930  of the bonded layers  400 ,  402 . The product package or container  902  (e.g., containing contents  960  such as liquids, powders, gels, food, or the like, within the sealed enclosure) has the sealed interface  930  created in part by the angled profile of the raised profile  952 . As shown in  FIG.  9 B , the seal line of the raised profile  952  is angled across the interface  930  with its shallow edge adjacent or closest to the product  902 . The angle increases or tapers away from the product  902  as the distance from the product  902  increases along the interface  930 . The angled profile of the raised profile  952  improves speed and increases seal strength while diverting more melt material  400 ,  402  toward the product side. 
     Additional features that can be incorporated with any of the raised profiles disclosed herein will be discussed in connection with  FIGS.  10 A through  11 B . Three features broadly summarized as “traction,” “tapered bond profile” and “cut and seal” will be described next. Some of the features can be combined, such as the traction feature can be combined with the tapered bond profile feature, such as shown in  FIG.  10 A . 
       FIG.  10 A  illustrates a horn or anvil  208 ,  220  such as disclosed above incorporated in a rotary ultrasonic bonding apparatus  1000 , which has the same basic structure as the rotary ultrasonic bonding apparatus  200  disclosed above, except that a traction feature  1020  is shown downstream of the raised profile  1012 , and a tapered bond profile feature  1014  is shown upstream from and leading to the raised profile  1012 . 
     Example dimensions of the features shown in  FIG.  10 A  are summarized in the table below. 
     
       
         
           
               
               
               
             
               
                   
               
               
                   
                 Inches/ 
                 Milli- 
               
               
                 Dimension 
                 Degrees 
                 meters 
               
               
                   
               
             
            
               
                 W1 (width of raised bond profile 1012) 
                 0.049- 
                 1.2-13 
               
               
                   
                 0.051 
                   
               
               
                 W2 (width of raised bond profile 1012 including  
                 0.103 
                 2.6 
               
               
                 tapered bond profiles 1014, 1016) 
                   
                   
               
               
                 W3 (gap between trailing tapered profile 1016 and  
                 0.015 
                 0.4 
               
               
                 traction feature 1020) 
                   
                   
               
               
                 W4 (distance between edge of horn/anvil 208, 220  
                 0.080 
                 2.0 
               
               
                 and start of leading tapered profile 1014) 
                   
                   
               
               
                 W5 (offset from center of raised bond profile 1012  
                 0.025 
                 0.6 
               
               
                 and radius of trailing tapered profile 1016) 
                   
                   
               
               
                 α1 (angle of leading tapered bond profile 1014  
                 1.15° 
                   
               
               
                 relative to top flat surface of raised bond profile 1012) 
                   
                   
               
               
                 R1 (radius of taper of the trailing tapered bond profile  
                 0.098 
                 2.5 
               
               
                 1014) 
                   
                   
               
               
                 H4 (height of raised bond profile 1012) 
                  0.0035 
                 0.1 
               
               
                 H5 (maximum height of the traction feature 1020) 
                 0.005 
                 0.1 
               
               
                   
               
            
           
         
       
     
     In the example raised bond profile  1012  shown in  FIG.  10 A , the height, H 4 , of the raised bond profile relative to the surface of the horn/anvil  208 ,  220  is 0.0035 inches or about 0.1 mm. Leading to the raised bond profile  1012  is a leading tapered bond profile  1014  having a taper of angle α1 across the face of the horn/anvil  108 ,  220 . The angle α1 can be between 0.5 and 5 degrees, and in this example, is shown to have an angle of about 1.15 degrees. Following the raised bond profile  1012  is a trailing tapered bond profile  1016  followed by the traction or pattern feature  1020 . 
     The traction feature  1020  offers a feature to pull the material through and past the ultrasonic nip and so the ultrasonic nip needs to provide its own drive. Vertical Form Fill &amp; Seal packaging systems (FFS) are particularly well-suited for the traction feature  1020 , because these systems lack a way of pulling the material. An example pattern  1020  can be seen in  FIG.  10 B , in which an array or pattern of raised nubs or protrusions  1004  are distributed in a grid-like pattern on the surface of the horn/anvil  208 ,  220 . The pattern  1020  is designed to avoid excessive, localized heat build-up, particularly in the presence of monolayer films, so the pattern  1020  should not detract from the required drive of the material through the FFS system. The pattern  1020  is exemplary only, and while it has been shown in a pattern that runs parallel with the edges of the horn or anvil  208 ,  220 , the pattern  1020  can be pitched at an angle relative to the edges, such as between 1 and 15 degrees, to provide a desired drive characteristic without creating excessive heat build-up. Likewise, the shape and form of the nubs or protrusions  1004  can be modified from that shown to provide a pulling or grabbing friction to the passing material. For example, the nubs  1004  can have a tooth-like shape. In the example shown in  FIG.  10 C  (taken along line  10 C- 10 C shown in  FIG.  10 B ), the nubs  1004  can be seen to have a tapered profile as shown with an angle α2 Example values of the dimensions shown in  FIG.  10 B  appear in the table below. 
     
       
         
           
               
               
               
             
               
                   
               
               
                 Dimension 
                 Inches/Degrees 
                 Millimeters 
               
               
                   
               
             
            
               
                 W6 (gap between adjacent nubs 1004) 
                 0.016 
                 0.4 
               
               
                 W7 (width of nub 1004) 
                 0.014 
                 0.3 
               
               
                 H6 
                  0.0030 
                 0.1 
               
               
                 H7 
                 0.005 
                 0.1 
               
               
                 α2 
                 30-50° 
               
               
                   
               
            
           
         
       
     
     Horizontal applications can also benefit from the traction feature  1020 . For example, in applications where a zipper is to be included, there is material that is pre-heated just before the bond, and there is slackness along the edge caused by laser-scoring of the film. The pre-heating and edge slackness caused by the laser scoring creates control problems, namely the material was difficult to keep in the nip of the horn/anvil  208 ,  220 . The traction pattern  1020  avoids these problems. 
     Returning to  FIG.  10 A , a tapered bond profile or feature  1014  can be seen on the leading side of the raised bond profile  1012 . The taper, shown by angle α1, can range from 0.5 to 5 degrees, and in the illustrated example, the angle is 1.15 degrees. The product side of the bond would be to the left of  FIG.  10 A  (e.g., in the case of a zippered pillow pack, the zipper would be to the right of  FIG.  10 A , and the product or contents inside the pillow pack would be to the left of the tapered bond profile  1014 . 
     The tapered bond profile  1014  provides several advantages. First, melt flow is directed towards the product side, which provides an improved seal. A flat profile (e.g.,  FIG.  3   ) could displace material equally but in an uncontrolled way on both sides of the bond, whereas a tapered bond profile  1014  would direct the melt in a more controlled way towards the product, resulting in a thicker stronger seal on this side of the bond. Additionally, the tapered design is resilient to material thickness variation, e.g., some materials have up to a 40% variation in material thickness). Put another way, if the maximum combined thickness (2 layers) were 180 μm, but could be as little as 108 μm, a depth control anvil with a 88 μm profile would over-penetrate at its highest point; however, the lateral taper  1014  would mean that the ideal bonding point would shift from the highest point of the horn/anvil  208 ,  220  across towards the lowest point ensuring that even with a material thickness variation, ideal bonding conditions will still be satisfied at some point across the profile of the horn/anvil  208 ,  220 . The tapered design  1014  also allows a broader range of film thicknesses to be used on the same anvil or horn  208 ,  220 . 
     It should be noted that the tapered bond profile would not work on an anvil/horn that does not use depth control because over-penetration would quickly occur, and the anvil would become a cutting tool rather than a bonding tool. The tapered bond profile  1014  disclosed herein works with the depth control profile  312 ,  1012 , such as shown in  FIGS.  3 ,  10 A- 10 C , but would not be suitable on a conventional anvil that does not have a raised depth control profile  312 ,  1012  such as disclosed herein. The tapered profile design also provides a speed improvement as it more easily penetrates the material during the bond process. 
     In general, thinner materials require a shallower angle of the taper in the tapered bond profile  1014 . Higher speeds can be achieved as well as improved sealing compared to non-tapered raised profiles. The taper of the tapered bond profile  1014  can be defined by a radius (e.g., a curve) or an angle (e.g., a ramp or α1 shown in  FIG.  10 A ). 
     With certain packaging films, conventional radiused (non-depth control) profiles can be problematic as they produce a “porpoising effect.” This is caused when the radiused anvil starts to penetrate the material but as depth of penetration increases, surface contact between the anvil profile and the material being bonded increases exponentially, which results in a situation where amplitude and pressure are insufficient to maintain the depth of anvil penetration, this forces the anvil to retract against the pressure exerted by the material. As it does so, the contact area then decreases exponentially resulting in an excess of pressure and amplitude for the reduced depth of bond, and so the anvil penetration increases, causing the cyclic “porpoise” effect. 
     By contrast, use of an angled profile  1014  (such as α1 shown in  FIG.  10 A ) is not as sensitive to these effects, because the angle of attack of the tapered bond profile  1014 , married to profile bond height (H 4 ) of the flat raised profile  1012 , is determined based on a range of film thicknesses. 
     Additional advantages of the tapered bond profile  1014  include: 
     Improved speed due to easier material penetration 
     Improved sealing—an angled profile  1014  having the shallow side towards the product helps improve seal strength by controlling the melt flow and directing it to the product side of the seal. This also improves vacuum tank testing performance and reduces the possibility of a fault line being created in the film by the bond process. 
     Reduced particulate spread—the shallow angle (α1) of the taper in the tapered profile  1014  traps and attaches particulates within the bond line, so no bond will occur at the shallow side of the seal line but firm contact pressure will be applied, entrapping the particulates. 
     Simultaneous seal/cut possibility—Utilizing an angle (e.g., α1) allows a reliable cut/seal on both depth control and non-depth control applications. Depth of cut can be accurately controlled by adjusting application pressure and/or amplitude. The system would leverage unbonded material under the shallow edge of the anvil profile  1012  to act as a compressible depth stop in relation to penetration of the opposite, knife-side ( 1130 ,  FIG.  111 B ) of the angle. The bond occurs between the knife point  1130  and the shallower edge of the profile (e.g.,  1014  in  FIG.  10 A ). 
     Next, the “cut and seal” feature will be described in connection with  FIGS.  11 A and  11 B . In some applications, it is desirable to simultaneously seal and cut or score shrink wrap or other material to provide a zero fin seal height and a virtually invisible seal.  FIGS.  11 A- 11 B  illustrate a horn or anvil  208 ,  220 , utilizing depth control that would penetrate the film material with a combined two-layer thickness of, e.g., 30 μm and leaving 4 μm uncut, which is then easily parted by a conventional vacuum removal system (not shown), a step that will be readily familiar to those skilled in the art to which the present disclosure pertains. 
     Example dimensions are summarized in the table below. 
     
       
         
           
               
               
               
             
               
                   
                   
               
               
                   
                 Dimension 
                 Millimeters 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 W8 
                 2.55 
               
               
                   
                 W9 
                 0.35 
               
               
                   
                 W10 
                 2.0 
               
               
                   
                 H8 
                 0.4 
               
               
                   
                 H9 
                 0.026 
               
               
                   
                 R3 
                 0.50 
               
               
                   
                   
               
            
           
         
       
     
     The angle of the profile (critical to achieve the desired result) ensured that the bonding conditions of force were met in a narrow area resulting in a very narrow, but on this film at least, very strong bond that withstood post bond shrink wrap activation. As can be seen in  FIG.  11 A , the anvil/horn  208 ,  220  has two bond profiles, one on each edge, which can be used for applications where the sonotrode has a width less than a width of the anvil  208 ,  220 . In the anvil or horn  208 ,  220  shown in  FIG.  11 A , the depth control profile  1112  is the entire center section between the two profiles. In  FIG.  11 B , an enlarged view of the cutting section is shown, where the cutting feature  1130  having a height, H 9 , provides a cutting feature to the film (e.g., shrink wrap) presented at its surface or interface. The cutting feature  1130  has a height, H 9 , that is slightly more raised compared to the height of the raised profile  1112 . The cutting feature  1130  forms a generally sharp 90 degree angle relative to the surface of the raised profile  1112 , and this abrupt transition provides the cutting action to the film or material passing by the anvil/horn  208 ,  220 . The height, H 9 , of the cutting feature  1130  can be between 1% to 20% of the height, H 4 , of the raised profile  1012 ,  1112 . The cutting feature  1030  forms a terminus of the raised profile  1112  and thus is positioned adjacent to or at an end of the raised profile  1112 . 
       FIG.  12    illustrates a tapered bond profile having two different profiles on either side of the horn/anvil  208 ,  220 . Only one side of the horn/anvil  208 ,  220  is shown here for ease of illustration due to the relatively small dimensions of the profile. Example values for the dimensions labeled in  FIG.  12    are illustrated in the table below. The profile includes an angled profile  1214  having an angle α3, a depth control profile  1212 , followed by a trailing edge profile  1016 , which can be angled or sloped. 
     
       
         
           
               
               
               
               
             
               
                   
                   
               
               
                   
                 Dimension 
                 Degrees 
                 Millimeters 
               
               
                   
                   
               
             
            
               
                   
                 W11 
                   
                 2.6-2.7 
               
               
                   
                 W12 
                   
                 1.25 
               
               
                   
                 H10 
                   
                 0.0635- 
               
               
                   
                   
                   
                 0.089 
               
               
                   
                 H11 
                   
                 0.0635- 
               
               
                   
                   
                   
                 0.089 
               
               
                   
                 α3 
                 1.5°, 1.8°, 2° 
               
               
                   
                   
               
            
           
         
       
     
     According to other aspects of the present disclosure, enhanced depth control (and anvil geometry details) can be coupled with generator outputs. For example, adding a specific depth control and anvil detail results in higher ultrasonic power (and thus allows for better seal and faster speed). Limits and power regulation can be set around these parameters. 
     The present disclosure produces a more consistent power draw, a stability not seen with a non-depth control, radiused anvil. In fact, a lower power draw using the angled profile  1014  is achieved compared to a radiused anvil, which leads to higher speed capabilities.