An apparatus includes a drum that rotates about an axis and rotating an anvil roll that rotates about an axis of rotation. The drum includes a fluid nozzle and a press member, the press member having an outer surface. The anvil roll includes a compliant outer circumferential surface. First and second substrates are advanced in a machine direction onto the drum. The fluid nozzle moves radially outward and a jet of heated fluid may be directed onto the substrates. The fluid nozzle retracts radially inward and the press member may be shifted radially outward. The substrates may be compressed between the press member and the anvil roll such that the press member deforms the compliant outer circumferential surface of the anvil roll.

A method includes rotating a drum about an axis and an anvil roll about an axis of rotation. The drum includes a fluid nozzle and a press member, the press member having an outer surface. The anvil roll includes a compliant outer circumferential surface. One or more substrates are advanced in a machine direction onto the drum. The fluid nozzle moves radially outward and a jet of heated fluid may be directed onto the substrates. The fluid nozzle retracts radially inward and the press member may be shifted radially outward. The substrates may be compressed between the press member and the anvil roll such that the press member deforms the compliant outer circumferential surface of the anvil roll.

An energy system for applying energy to a workpiece includes a first energy application device, mounted such that the first energy application device has a fixed position relative to the workpiece during energy application; a second energy application device, mounted such that the second energy application device has a moveable position relative to the workpiece to apply energy to the workpiece at a point moving progressively across the workpiece, wherein one of the first and second energy application devices is an anvil and the other of the first and second energy application devices is an ultrasonic bonder; and a controller for regulating the application of energy to the workpiece, wherein the controller is configured to adjust progressively across the workpiece one or more of bonder vibration amplitude versus position on the workpiece, bonder pressure versus position on the workpiece, and horn travel velocity versus position on the workpiece.

A machine and method for making bags is described and includes a web, traveling from an input section to a rotary drum, to an output section. The rotary drum includes at least one seal bar, having a first sealing zone, and an adjacent weakening zone. The weakening zone may be a heated perforator, includes a heating wire, or be disposed to create an auxiliary sealed area. The heating wire can have, connected thereto, a source of power that is at an adjustable voltage or magnitude, and/or pulsed, and/or a feedback loop. The heating wire may be an NiCr wire and make intermittent contact with the web and be disposed in an insert. The weakening zone may create a line of weakness that is uniform or varies in intensity, is a separating zone, or includes a heat film, a toothed blade, a row of pins, a source of air, or a source of vacuum. The sealing zones may include temperature zones, cartridge heaters, cooling air, or heated air, or a source of ultrasonic, microwave or radiative energy.

A microchannel heat exchanger (800) is manufactured by bonding a first sheet (802a) of material and a second sheet (802b) of material in a first connection pattern for integral formation of a core portion (801) and a manifold portion (808) for the first and second sheets (802a, 802b) of material. A third sheet (802c) of material is then superposed on to the second sheet (802b) of material and bonded in a second connection pattern to the second sheet of material for integral formation of the core portion (801) and the manifold portion (808) for the second and third sheets (802b, 802c) of material. The second and third sheets (802b, 802c) of material are bonded without bonding the second sheet (802b) of the material to the first sheet (802a) of material. The core portion (801) and the manifold portion (808) of the heat exchanger (800) are thus integrally created. The interstices between the first, second, and third sheets (802a, 802b, 802c) of material are then expanded to create fluid flow channels (806). This method can also be used to create a heat sink. The bonding method may be a form of laser welding where an opaque sheet absorbs the laser energy and the heat conducts through the top sheet to the sheet immediately below, but does not cause bonding with subsequent sheets below.

The present invention is directed to a heat-sealing apparatus of a flow wrapper machine which facilitates efficient, reliable and versatile operation. Notably, the apparatus includes multiple ring gears driven by multiple servo motors in a desirably compact configuration, with the arrangement including quickly removable heat-sealing die heads for efficient operation and service. The improved drive mechanism facilitates more accurate heat-sealing head placement, smoother operation, controlled stops, independent temperature control, and continuous running through die jams. Also included is a four-bar link on the heat-sealing head for opening and closing the heat-sealing dies.