L-Shaped Valve Flow Channel Structure for Stable Ultrasonic Welding
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Solution Overview
Problem
The efficiency of ultrasonic welding for L-shaped flow channels in valve devices is compromised due to the long distance between the supported and welded portions, leading to potential deformation and reduced rigidity of the connection between the channel portions.
Innovation Solution
Incorporating a pair of projecting portions that interpose the first and second portions radially and extend from the outer surface of the first portion to the second portion, allowing for more effective ultrasonic welding and increased rigidity by reducing the distance between supported and welded areas, and including a connecting portion to further enhance rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the L-shaped flow channel is manufactured by injection molding with a lid member covering the tip end, then the flow channel can be formed with the required shape, but the distance between the supported portion and welded portion becomes long, decreasing ultrasonic welding efficiency
Solution Approach 1:
The flow channel is divided into a first portion (linear) and a second portion (L-shaped with hose joint), allowing the lid member to be positioned closer to the welding area while maintaining the required flow channel geometry. This segmentation enables the supporting jig to support the first portion near the welding location, reducing the distance between supported and welded portions.
Solution Approach 2:
The lid member acts as an intermediary structure that bridges the first portion and the second portion. By positioning the lid member at the tip end of the first portion and supporting the first portion near the welding location, the intermediary structure allows ultrasonic welding to occur at a shorter distance from the support point, improving welding efficiency while maintaining the L-shaped configuration.
2Reliability
If the lid member is joined by ultrasonic welding at the tip end of the first portion, then the flow channel can be sealed, but the long distance from the supported portion reduces welding efficiency and may cause deformation
Solution Approach 1:
The flow channel structure is segmented into portions that allow the lid member to be positioned optimally for welding. The first portion provides a support location near the welding area, while the second portion maintains the L-shaped configuration, enabling both effective sealing and high-quality welding.
Solution Approach 2:
The first portion is designed to be supportable by a jig at a location close to where the lid member will be welded. This preliminary structural arrangement ensures that during assembly, the support point is optimally positioned to minimize welding distance and maximize welding quality before the actual welding process occurs.
3Adaptability or versatility
If the hose is mounted on the second portion, then the flow channel can be connected to the hose, but the connection may damage and deform due to applied force
Solution Approach 1:
The flow channel is segmented into a first portion for structural support and a second portion for hose connection. This segmentation allows the L-shaped second portion to be optimized for hose mounting while the first portion maintains rigidity and provides support, preventing deformation during hose installation.
Solution Approach 2:
The L-shaped configuration of the second portion, extending perpendicular to the first portion, creates a spatial arrangement where the hose connection point is positioned in a different dimension. This dimensional change allows force application during hose mounting to be directed away from the critical connection between the first and second portions, reducing the risk of deformation.
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 configuration stabilizes the welding process, enhances the rigidity of the flow channel connections, and prevents deformation during hose mounting by acting as a positioning stopper.
Implementation Method 1
an ultrasonic vibration is applied to the lid member for welding
Data Source
AI summary
A first flow channel of a flow channel switching valve includes a first portion that is connected to a valve body and that is linear, a second portion that is connected such that the second portion is perpendicular to the first portion and that is linear, and a lid member that is joined such that the lid member covers an opening of a tip end of the first portion. The first flow channel also includes a pair of projecting portions that is disposed such that the projecting portions interpose the first portion therebetween in a radial direction and face each other, and a connecting portion that couples the pair of projecting portions with each other. The pair of projecting portions includes a planar surface portion that faces the valve body direction.