Medical Design Briefs - February 2021 - 6

Manufacturing Challenges
ing it to complete all eight machines in
just 18 weeks, start to finish. Pressed for
time, their project managers requested
Branson ultrasonic welding technology
to equip the four welding stations needed in each mask-making machine.
Through Consonic Pty., the regional
representative, Foodmach request expedited deliveries from Emerson.
Emerson responded quickly, shipping
the first group of welders in just 14 days,
with two more shipments to follow. In
all, Emerson's North American-based
manufacturing facility delivered 34 welding units, enough to outfit all eight
mask-making machines and allow for
two welding units as spares. Each unit
included a 20 Hz Branson DCX power
supply, a matched converter and booster, plus application-specific weld tooling
and training, locally produced and supplied by Consonic.
With the help of Emerson's global
supply chain and local customer support, Foodmach completed and delivered all mask-making machines to
MedCon on schedule. This effort helped
put MedCon on track not only to meet
its 29-fold production goal in November
but also to continue meeting Australia's
PPE requirements amid the worsening
global COVID-19 situation.
Ultrasonics: A Natural for
Manufacturing Nonwoven PPE
Ultrasonics are a natural fit for production of nonwoven products. Basically, ultrasonic welders convert electrical energy to high-frequency mechanical vibration, which is transmitted
through tooling into thermoplastic nonwoven material. The vibration creates
frictional heat that melts the material,
an operation that can be focused and
utilized to:
* Cut or slit a large roll of nonwoven fabric into narrower strips (cut edges are
simultaneously seamed/sealed ultrasonically).
* Bond two pieces of nonwoven fabric
into finished seams of surgical garments, or attach loops or ties to caps,
surgical masks, or other types of PPE.
* " Quilt " multiple layers of different
nonwoven material into masks and respirators or other medical absorbent or
infection-control products. For example, in N95 and high-grade surgical
masks, the quilt typically includes an
inner and outer spunbond layer of
meltblown polypropylene, which together provide structure and protec-

Ultrasonic welds strongly bond even small items like the ties on a disposable surgical mask at a fraction of the cost of stitchery or glue and can be used immediately. (Credit: Emerson)

tion for a middle layer of meltblown
polypropylene fibers. The middle fiber
layer is electrically charged to capture
and hold extremely small particles,
such as those of the COVID-19 virus.
Ultrasonic welding is remarkably energy efficient because the welder consumes
power only when it is cutting, slitting/
sealing, or bonding the nonwoven fabric.
Because the welder generates heat
instantly through vibration, there's no
need for constant energy consumption,
such as that required for preheating a
heat knife, for example, or maintaining
it at the proper operating temperature.
Compared with other methods for cutting and bonding nonwovens, ultrasonic
technology offers significant advantages.
By producing strong, repeatable seams
and joints without the need for or glues
or adhesives, it eliminates the risk of contamination and the need for setup time
and space for drying. It replaces the time
and effort of sewing as well, along with
the tiny thread holes that can harbor possible microbial contaminants. Ultrasonic
seams are ready for use as soon as they
are produced and are capable of withstanding repeated sterilization processes.
The ultrasonic welding process can even
be used in cleanrooms.
Conclusion
In times of crisis, every organization
is challenged to balance great urgency

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- the need to adapt to sudden and
unexpected circumstances - with the
need for continued focus on key values, vital personal and business relationships, and the long-term planning
and effort needed to ensure a bright
future.
To adapt to the COVID-19 crisis while
continuing its operations, the Automation Solutions business of Emerson,
for example, is responding with urgent
attention to employee and customer
safety in every interaction, with an
emphasis on making distance training,
learning, and equipment support tools
available in key languages, and with
increasingly rapid response to the vital,
fast-changing supply-chain needs of its
global customers.
The company is staying focused on
the long term by developing new products, improving the applicability and
performance of technologies, and leveraging the vast resources of the company's global organization and supply
chain to give customers and partners
competitive advantage.
This article was written by Vernon Murray,
President of Branson Welding and Assembly
at Emerson. He has global responsibility for
sales, operations, finance, quality, human
resources, engineering, product marketing,
and management for the Branson business.
For more information, visit http://info.
hotims.com/79410-340.
Medical Design Briefs, February 2021

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Medical Design Briefs - February 2021

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