Guide Jig Structure for Ultrasonic Welding of Flexible Busbars
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Solution Overview
Problem
Ultrasonic welding of flexible materials, such as aluminium busbar members, often results in deformation, lifting, interface cracks, and thickness imbalances, leading to quality defects and product failure due to excessive material deformation and uneven structure during the welding process.
Innovation Solution
An ultrasonic welding device featuring an anvil, a horn, and a guide jig with a specific design that includes an opening and plane corresponding portions to guide and cover the welding area, preventing deformation and lifting by ensuring proper alignment and support during the welding process, using materials with greater strength and stiffness than the busbar members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is performed on flexible busbar members, then welding speed and environmental friendliness are improved, but material deformation and lifting occur around the welding portion
Solution Approach 1:
A guide jig is introduced as an intermediary device between the horn and the busbar members. The guide jig includes a guide portion with an opening that guides the horn's elevation and ultrasonic vibration, and a plane corresponding portion that covers the external plane around the welding portion. This intermediary structure prevents direct uncontrolled deformation while allowing the ultrasonic welding process to proceed efficiently.
Solution Approach 2:
The guide jig changes the physical constraints and boundary conditions of the welding process. By providing a structured opening and covering portions, it modifies how the ultrasonic vibration and pressure are distributed, controlling the deformation parameters and preventing lifting while maintaining welding effectiveness.
2Reliability
If horn design is optimized for welding ductile materials, then welding quality is improved, but excessive deformation occurs leading to cracks and product failure
Solution Approach 1:
The guide jig serves as a mediator that distributes and controls the mechanical stress and ultrasonic vibration during welding. The guide portion with its specific opening dimensions and the plane corresponding portion work together to prevent stress concentration that would cause cracks in ductile materials.
Solution Approach 2:
The guide jig applies different functional characteristics to different regions: the guide portion with the opening provides controlled guidance and vibration transmission where needed, while the plane corresponding portion provides covering and support in surrounding areas. This local differentiation prevents excessive deformation in critical regions.
3Manufacturing precision
If guide jig covers the entire external plane, then deformation control is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The guide jig is segmented into distinct functional portions: the guide portion with the opening that guides the horn, and the plane corresponding portion that covers the external plane. This segmentation allows each portion to be optimized for its specific function while keeping the overall structure manageable and manufacturable.
Solution Approach 2:
The guide jig combines multiple functions in a single device: guiding the horn's elevation and ultrasonic vibration through the opening, covering the external plane to prevent deformation, and providing structural support. This multi-functionality reduces the need for separate components, simplifying the overall device.
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
The solution effectively controls deformation, prevents interface cracks and thickness imbalances, and enhances the strength and reliability of the welding portion, thereby improving the overall quality of the ultrasonic welding process.
Implementation Method 1
a horn for ultrasonically welding the first member and the second member by elevation and ultrasonic vibration
Data Source
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AI summary
An ultrasonic welding device is provided. The ultrasonic welding device includes: an anvil for supporting a flexible first member on a lower side from among the first member and a flexible second member overlapping in a top to bottom direction and sequentially disposed from bottom to top; a horn for ultrasonically welding the first member and the second member by elevation and ultrasonic vibration at an upper portion of the second member; and a guide jig including an opening corresponding to a welding portion of the flexible first member and the flexible second member for guiding elevation and ultrasonic vibration of the horn, and covering an external plane around the welding portion with a plane corresponding portion so as to ultrasonically weld the first member and the second member.