Flow Path Member Welding Pressure Control
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Solution Overview
Problem
The existing manufacturing methods of flow path members in liquid discharging apparatuses face issues with sink marks leading to non-bonding portions, resulting in insufficient bonding and potential liquid or gas leakage due to inadequate pressure distribution during the welding process.
Innovation Solution
A manufacturing method that involves applying greater pressure at specific welding portions to ensure reliable bonding, with a two-step welding process where the pressure at the second welding portion is increased compared to the first, to compensate for sink marks and enhance bonding reliability, thereby reducing liquid and gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform pressure is applied during welding of stacked resin members, then the welding process is simple, but sink marks cause non-bonding portions and insufficient bonding at thicker portions
Solution Approach 1:
The patent applies different pressure levels to different regions of the bonding surface. Specifically, greater pressure is applied to thicker portions (where sink marks occur) compared to thinner portions during the welding process. This localized pressure adjustment ensures adequate bonding at critical thick portions without compromising the overall welding quality, directly resolving the contradiction between manufacturing simplicity and bonding reliability.
Solution Approach 2:
The patent changes the pressure parameter during the welding process by applying multiple pressure levels. The welding is performed in stages: first with a baseline pressure, then with increased pressure at thicker portions. This parameter variation allows the welding process to accommodate thickness variations and sink marks, improving bonding reliability while maintaining manufacturing feasibility.
2Reliability
If pressure is increased at thicker portions to compensate for sink marks, then bonding reliability improves, but the welding process becomes more complex
Solution Approach 1:
The patent segments the welding process into distinct stages with different pressure levels. The bonding surface is divided into regions (thinner portions and thicker portions), and each region receives appropriate pressure treatment. This segmentation allows complex pressure control to be managed through systematic stages, reducing the perceived complexity while maintaining high bonding reliability.
Solution Approach 2:
The patent performs preliminary welding at a baseline pressure level before applying increased pressure to thicker portions. This preliminary action creates an initial bond that stabilizes the structure, making subsequent localized pressure application more effective and easier to control, thereby reducing the overall process complexity.
3Productivity
If conventional welding is used without pressure adjustment, then manufacturing is efficient, but liquid leakage occurs due to non-bonding portions
Solution Approach 1:
The patent applies localized quality control by targeting pressure application specifically at thicker portions where sink marks and non-bonding portions are most likely to occur. This focused approach prevents leakage at critical areas without requiring uniform pressure increase across the entire bonding surface, thus maintaining manufacturing efficiency while improving leakage prevention.
Solution Approach 2:
The patent modifies the pressure parameter during welding to prevent leakage. By increasing pressure at thicker portions during the welding process, the method ensures adequate bonding strength to prevent liquid leakage, while the staged approach maintains reasonable manufacturing efficiency.
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 method effectively seals the flow paths, reducing leakage and improving the reliability of the liquid discharging apparatus by ensuring more consistent and robust bonding between the first and second members, even in areas prone to sink marks.
Implementation Method 1
a first step of welding the first member and the second member to each other at a first welding portion
Data Source
AI summary
A manufacturing method of a flow path member which includes a flow path between first and second members which are stacked together includes a first step of welding the first and second members to each other at a first welding portion in a state in which a pressure is applied in a stacking direction to the first and second members which are stacked to be in contact with each other, and a second step of welding the first and second members to each other in a state in which a greater pressure is applied in the stacking direction to the first and second members at a second welding portion of a different position from the first welding portion.