Adjustable Welding Knurls for Uniform Ultrasonic Weld Pressure
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Solution Overview
Problem
Existing ultrasonic welding devices face challenges in maintaining consistent contact and uniform pressure transmission due to wear of welding knurls, leading to non-uniform welds and increased processing costs from frequent replacement or cutting of worn knurls.
Innovation Solution
The ultrasonic welding device features adjustable welding knurls that ascend or descend via screw threads or grooves, allowing independent height adjustment without cutting, ensuring uniform contact with the welding target.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding knurls are used in ultrasonic welding device, then welding function is provided, but wear of welding knurls leads to non-uniform welds and requires frequent replacement or cutting
Solution Approach 1:
The welding knurls are designed to be adjustable in height rather than fixed. The adjustment mechanism allows the knurls to be repositioned vertically to compensate for wear, transforming a static component into a dynamic one that can adapt to changing conditions during its service life
Solution Approach 2:
The invention changes the position parameter of the welding knurls by providing multiple adjustable height positions. This parameter change compensates for wear without requiring replacement, extending the service life while maintaining weld quality consistency
2Manufacturing precision
If welding knurls are worn and need replacement or cutting, then weld uniformity can be maintained, but processing costs increase
Solution Approach 1:
The welding knurls are designed to be self-adjustable through the height adjustment mechanism. Operators can easily reposition worn knurls to their original effective position without requiring cutting or replacement, making the system self-maintaining and reducing external intervention costs
3Adaptability or versatility
If welding knurls are made adjustable with screw threads, then height adjustment is enabled, but device complexity increases
Solution Approach 1:
The head is divided into multiple sections with individual adjustment mechanisms for each welding knurl. This segmentation allows independent adjustment of each knurl's height, providing adaptability while keeping each adjustment mechanism simple and modular
Solution Approach 2:
Screw threads are introduced as an intermediary mechanism between the adjustment operator and the welding knurl position. This simple mechanical intermediary enables precise height adjustment without requiring complex motors or actuators, adding adaptability with minimal complexity increase
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures uniform pressure application and improved weld quality by maintaining consistent contact with the welding target, reducing wear-related issues and processing costs.
Implementation Method 1
Each of the welding knurls may include a screw thread or a screw groove at at least a portion of an outer surface thereof
Implementation Method 2
an ultrasonic welding device includes an anvil configured to support a lower portion of a welding target; and a welding horn disposed above the welding target
Data Source
AI summary
An ultrasonic welding device includes an anvil configured to support a lower portion of a welding target, and a welding horn above the anvil, the welding target being between the welding horn and the anvil, and the welding horn including a body, a head at a first end of the body, and movable welding knurls on a surface of the head.