Embedded Wire for Ultrasonic Weld Disassembly
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Solution Overview
Problem
Existing methods for disassembling components welded by ultrasound, such as those used in aircraft, are often irreversible and risk damaging the composite material walls due to high heat or mechanical stress, leading to unsatisfactory disassembly outcomes.
Innovation Solution
Incorporating a wire with suitable mechanical characteristics into the energy director during the manufacturing process, allowing it to cut the ultrasonic welding junction without interfering with the assembly process, and using a rotary motion to separate the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to assemble the support to the wall, then the assembly strength and bond quality are improved, but the disassembly becomes difficult or irreversible
Solution Approach 1:
A wire is embedded within the energy director during the manufacturing process, before the ultrasonic welding takes place. This preliminary inclusion of the wire allows it to be positioned exactly where it is needed to cut the junction later, enabling controlled disassembly without compromising the original strong bond.
2Ease of repair
If a cutting tool with heating is used to disassemble the support, then the junction can be destroyed, but the composite material wall is at risk of damage from heat and geometry
Solution Approach 1:
The harmful heating function is extracted from the disassembly process. Instead of using an external heating tool that risks damaging the composite wall, the wire embedded in the energy director performs the cutting mechanically or with minimal heating, significantly reducing the risk of wall damage.
Solution Approach 2:
The embedded wire acts as an intermediary element between the disassembly tool and the junction. It transmits the cutting action directly at the junction point without requiring external heating tools that could damage the surrounding composite material wall.
3Ease of repair
If an ultrasonic knife is used to destroy the junction, then disassembly is enabled, but the composite material wall remains at risk of damage
Solution Approach 1:
The need for external ultrasonic cutting tools is eliminated by extracting the cutting function to the embedded wire. The wire, already positioned within the energy director, performs the cutting action from within, avoiding the need to insert external tools that could damage the composite wall.
4Object-affected harmful factors
If a rotary cutting tool is used to remove the support, then the wall damage risk is reduced, but the surface of the wall may still be scratched
Solution Approach 1:
The embedded wire serves as an intermediary that performs the cutting action precisely at the junction point without contacting the wall surface. This eliminates the scratching problem associated with rotary tools while maintaining low wall damage risk.
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
Facilitates disassembly while minimizing damage to the composite material walls by using a wire to cut the junction formed by the energy director, reducing the risk of heat-induced damage and surface scratching.
Implementation Method 1
the support is in contact with a vibration transmitter and its front face 14 is applied against the wall. Following, by applying vibrations, a heating is generated at the interface between the support and the wall
Implementation Method 2
by applying vibrations, a heating is generated at the interface between the support and the wall up to their melting temperatures
Implementation Method 3
positioning a wire between the two assembled elements, secantly to the energy director... move the wire between the two assembled elements so as to cut said junction
Data Source
Figure 1~3
Figure 4A~6B
Figure 7~8B
AI summary
The method involves positioning a wire (44) between an assembled support (30) and a wall (36) to an energy director in a secant manner, where the wire includes appropriate mechanical properties to cut a junction (42) formed by the energy director and move the wire between the support and the wall to intersect the junction. Force is exerted on the wire to cause a rotary movement of multiple portions (46, 46') of the wire around the junction formed by the energy director, where the rotary movement of the wire separates the support and the wall. An independent claim is also included for an element intended to be assembled with another element by ultrasonic welding.