Ultrasonic Welding Housing Rib Volume Optimization
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Solution Overview
Problem
Conventional ultrasonic welding methods often require excessive energy and working time due to uneven welding strength across joined surfaces, particularly in highly rigid portions like corners, where energy and time are wasted melting ribs more than necessary.
Innovation Solution
The method involves optimizing the volume and distribution of ribs on the joining surfaces so that maximum stress values across different regions fall within a predetermined range relative to the yield stress value, ensuring consistent stress distribution and reducing unnecessary energy use by adjusting rib density and shape to match varying rigidity areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniform rib volume is used across all regions, then manufacturing simplicity is maintained, but welding strength becomes uneven and energy is wasted in highly rigid portions
Solution Approach 1:
The patent applies local quality by varying the rib volume according to the local rigidity requirements of different regions. Specifically, the rib volume in each region is set based on the stress distribution characteristics of that region, with smaller rib volumes in highly rigid portions (like corners) and larger rib volumes in less rigid portions. This ensures that each region receives just enough welding strength without excessive energy consumption.
Solution Approach 2:
The patent changes the parameter of rib volume from a uniform value to a region-dependent value. By setting the rib volume in each region according to the maximum stress values and yield stress values of that specific region, the patent optimizes the welding process parameters to match the local structural requirements, thereby reducing overall energy consumption while maintaining welding strength.
2Ease of manufacture
If uniform rib volume is used across all regions, then manufacturing simplicity is maintained, but working time increases due to excessive melting requirements in rigid portions
Solution Approach 1:
The patent implements local quality by differentiating rib volumes across regions based on their structural characteristics. In highly rigid portions where stress concentration occurs, smaller rib volumes are used, which melt faster during ultrasonic welding. This reduces the overall working time required for the welding process while still ensuring adequate welding strength in those regions.
Solution Approach 2:
The patent applies partial action by providing just enough rib volume in each region to achieve the required welding strength, rather than using excessive rib volume uniformly across all regions. This prevents over-melting in highly rigid portions, thereby reducing the total working time without compromising welding quality.
3Use of energy by moving object
If rib volume is optimized for each region, then energy consumption and working time are reduced, but manufacturing complexity increases
Solution Approach 1:
While local quality increases design complexity, the patent manages this by establishing clear criteria for rib volume determination based on stress analysis and material properties. The rib volume in each region is calculated using a systematic approach involving maximum stress values and yield stress values, which provides a structured method for implementation despite the increased complexity.
Solution Approach 2:
The patent manages parameter complexity by defining rib volume as a function of region-specific stress characteristics and material properties. This systematic parameter relationship provides a clear design guideline that reduces the complexity of implementation while still achieving the energy and time benefits of optimized rib distribution.
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 approach reduces energy consumption and working time during ultrasonic welding while maintaining adequate welding strength by optimizing rib volume and distribution, ensuring consistent stress values across the joined surface.
Implementation Method 1
The conventionally proposed ultrasonic welding technology welds and joins a plurality of members by inducing frictional heat on the joining surface using ultrasonic vibrations.
Implementation Method 2
welds and joins a plurality of members by inducing frictional heat on the joining surface using ultrasonic vibrations
Implementation Method 3
joining the first case and the second case together by melting the ribs
Data Source
AI summary
A manufacturing method of a housing that includes a first case having a first surface, a second case having a second surface opposite to the first surface, and ribs provided between the first case and the second case includes disposing the ribs on the first surface, and joining the first case and the second case together by melting the ribs. In the disposing, in a case where a load in a first direction orthogonal to an applied surface including a joined surface between the first case and the second case is applied to the applied surface, a volume of each rib is set so that maximum values of stresses generated in a plurality of regions having the same area of the ribs fall within in a range from a value of 80% of a yield stress value of a material of the ribs to the yield stress value.