Aerosol Membrane Unit Weld Layout for Sealing and Oscillation
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Solution Overview
Problem
Existing membrane units for aerosol therapy devices face challenges in achieving appropriate oscillation behavior and sealing due to inadequate connection methods between the membrane and substrate, leading to potential gaps, corrosion, and heat-related issues during manufacturing.
Innovation Solution
A membrane unit design featuring a flange with multiple discontinuous welds and annular welds around the circumference, where the annular welds are arranged radially inward of the discontinuous welds, ensuring a seamless seal and robust connection, preferably achieved through laser welding with specific parameters to prevent deformation and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the membrane is connected to the substrate by adhering or gluing, then the membrane unit can be manufactured, but heat production during connection can lead to distortion or lack of sealing between the membrane and substrate
Solution Approach 1:
The patent replaces thermal connection methods (adhering, gluing, resistance welding, laser welding) with mechanical fastening using a clamp structure. The clamp has arms that extend through openings in the substrate and engage with the membrane flange, providing a mechanical connection that avoids heat-related distortion and sealing issues entirely.
Solution Approach 2:
The patent introduces a clamp as an intermediary component between the membrane and substrate. This clamp structure mediates the connection by providing a mechanical fastening system that eliminates direct thermal contact between the membrane and substrate, thereby preventing heat-induced distortion and sealing failures.
2Strength
If electric resistance welding or laser welding is used to attach the membrane to the substrate, then connection strength is improved, but heat production can cause distortion or lack of sealing
Solution Approach 1:
The patent replaces thermal welding processes (electric resistance welding, laser welding) with a mechanical fastening system using a clamp. The clamp arms engage with the membrane flange and are secured to the substrate, providing strong mechanical connection without generating heat, thus eliminating thermal distortion and sealing issues.
3Device complexity
If a simple connection method is used to reduce manufacturing complexity, then manufacturing is simplified, but gaps between membrane and substrate can form creating weak points for corrosion
Solution Approach 1:
The clamp acts as an intermediary that provides both mechanical strength and sealing functionality. Its arms extend through substrate openings and engage with the membrane flange, creating a secure connection that prevents gaps and eliminates corrosion pathways while maintaining manageable manufacturing complexity.
Solution Approach 2:
The clamp structure is divided into multiple arms that can be independently positioned and secured. This segmentation allows for flexible adaptation to different membrane and substrate configurations while ensuring comprehensive sealing and connection, preventing gaps that would lead to corrosion.
4Reliability
If the membrane is securely connected to ensure appropriate oscillation behavior, then aerosol generation is improved, but heat production during connection can lead to distortion
Solution Approach 1:
The patent replaces thermal connection methods with a mechanical clamp-based fastening system. The clamp arms secure the membrane to the substrate through mechanical engagement, providing the necessary connection strength for appropriate oscillation behavior without generating heat that could cause membrane distortion.
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 design provides a reliable, cost-effective, and efficient method for manufacturing membrane units with optimal oscillation behavior and sealing, minimizing the risk of corrosion and fluid leakage, while ensuring a durable mechanical connection between the membrane and substrate.
Implementation Method 1
the flange of the membrane is welded to the substrate so that the area is located in the opening, wherein the weld comprises at least three discontinuous welds arranged in a distance to each other along a circumference of the opening and first annular weld circumferentially surrounding the opening
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The present invention relates to a membrane unit for generating an aerosol in an aerosol therapy device, the membrane unit comprising a membrane (1) having an area (6) comprising a plurality of through-holes for nebulizing a fluid and a flange (7) circumferentially surrounding the area (6), and a substrate (2) having an opening (8) wherein the flange (7) of the membrane (1) is welded to the substrate (2) so that the area (6) is located in the opening (8) wherein the weld (5) comprises at least three discontinuous welds (5c) arranged at a distance from each other a long a circumference of the opening (8) and a first annular weld (5b) circumferentially surrounding the opening (8).