How Emerson is responding to the Covid-19 outbreak

Web content editor Ian Bolland, caught up with William Vaughan, vice president of Business Development and Global Marketing for Assembly Technologies at Emerson, about its response to the coronavirus outbreak, including the use of ultrasonics for manufacturing Personal Protection Equipment (PPE).

What are the benefits of using ultrasonics when manufacturing PPE?

Similar to ultrasonic welding technology used in welding rigid plastic parts, ultrasonic welders like the Branson 2000Xc from Emerson transmit high-frequency mechanical vibration by way of tooling through thermoplastic material to create frictional heat. Depending on the selection of weld parameters and tooling, the frictional heat generated by ultrasonics can be focused and utilised to:

• Cut or slit a large roll of nonwoven fabric into narrower strips (cut edges are simultaneously seamed/sealed by the friction).
• Bond two pieces of nonwoven fabric into the finished seam of a garment, such as a surgical gown, or a piece of protective gear, such as a surgical mask or cap.
• “Quilt” multiple layers of nonwoven material into laminated absorbent products, alone for use in some sanitary pads, or together with other absorbents such as the superabsorbent wood/paper fibers that are sometimes used in disposable diapers.

The greater energy efficiency of ultrasonics occurs because the ultrasonic welder only consumes power when it is actually slitting or bonding. Since it generates its heat instantly through vibration, there’s no additional energy consumption due to preheating a heat knife and no need to maintain it at the proper operating temperature. 

There are a couple of examples of what ultrasonics are used for in manufacturing - can you provide as comprehensive a list as possible?

Ultrasonic welding is a versatile solution with assembly applications across many industries from packaging and consumer electronics to medical, automotive, and appliance.

Ultrasonic applied technologies have also played a critical role in enabling the rapid growth of nonwovens. Ultrasonics for nonwovens is used in such healthcare applications as packaged sterile surgical drape kits, PPE, including surgical caps and N95 masks, gowns, and scrubs, or even foot covers.  

In addition to the medical space making headlines today because of the Covid-19 pandemic, ultrasonic welding for nonwovens is used in the manufacture of consumer and personal care products, baby diapers and training pants, mattress pads, seat cushions and covers, household mops and cleaning products, and disposable vacuum and filter bags.

Is there a benefit to using ultrasonics when scaling up production vastly and quickly?

Because ultrasonics use friction and pressure to bond materials directly to each other, it eliminates the added cost of glue and solvents, as well as the cost for added fixturing and the time for glue to “set up.” It also bypasses the added step of “sewing” all of the components together. In addition, it removes glues and solvents as potential sources of contamination, as well as the need to clean and maintain glue and solvent application equipment.

Is it particularly beneficial when it comes to infection control?

Bonding with adhesives and glues has the potential for introducing new contaminants into the process. And traditional sewing creates tiny holes that can allow microscopic contaminants to travel through the fabric, causing possible health risks for workers and potentially compromising product quality. Eliminating the thread holes also eliminates contamination potential.

Ultrasonic technology produces strong, repeatable seams and joints, withstands sterilisation processes, and eliminates the need for solvents or glue. It not only solves medical nonwoven and device manufacturing problems, but does so while reducing the risks and sources of potential contamination.

As the number of older citizens in the U.S. and many Western countries continues to grow as a share of total population, the demand for medical, sanitary, consumer care, bedding, seating, cleaning, and filtration products will continue to grow. So, too, will the need to produce these products efficiently, with maximum cleanliness and minimum risk of contamination.

The unique ability of ultrasonics equipment to handle a broad scope of nonwoven product manufacturing—slitting, cutting, embossing, quilting, and bonding—offers the perfect solution to this growing need. In addition, Branson ultrasonics technology can meet cleanroom manufacturing requirements, where required, and provide the data monitoring and storage capabilities needed to meet the highest regulatory requirements. These and other ultrasonics capabilities will only continue to evolve and expand in the future.

Can you give us an insight as to what it's been like in terms of demand lately compared to an average time period?

Medtech manufacturers are stepping up production to accommodate an unprecedented need for face masks, gowns, boots, and other nonwoven PPE used to protect frontline healthcare workers from Covid-19.

Emerson, with facilities in North America, Europe, and Asia, is rapidly responding to support these manufacturers using Emerson’s Branson ultrasonic technology to manufacture this equipment quickly, safely, and cleanly.

Because of increased demand beginning in Asia, where the virus originated, followed by Europe, Emerson has been ramping up production, and making some standard assemblies to increase production and get the products to customers as quickly as possible.

While many of its current customer base use proprietary processes that require custom Branson designs, Emerson has developed a standard assembly that is being sold to new customers to prepare them to ramp up production as quickly as possible.

Some of these are existing customers, others are in adjacent spaces, and others are manufacturers in different industries that understand they have the capacity right now to assist in this particular challenge to make additional products.