Liquid Discharge Head Welding with In-Process Chip Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In ultrasonic welding, minute chips generated by frictional heat can stick to the inner walls of the structure, making it difficult and time-consuming to remove them, which affects the performance of the welded product.
Innovation Solution
A method involving the use of a fluid flow, such as air, during the vibration process to remove the chips generated by ultrasonic welding, ensuring they are carried away before sticking to the inner surfaces, thereby facilitating a quicker cleaning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is performed to join members together, then welding speed and cost-effectiveness are improved, but minute chips are generated and stick to inner wall surfaces, making cleaning difficult and time-consuming
Solution Approach 1:
A fluid flow process is performed before the vibration (welding) process to blow away chips generated during welding before they can stick to the inner wall surfaces. This preliminary chip removal action prevents the need for time-consuming post-welding cleaning
Solution Approach 2:
The harmful effect of chip generation during ultrasonic welding is converted into a benefit by using the same vibration process to actively blow away chips through fluid flow. The vibration that creates chips also facilitates their removal when combined with fluid flow, turning a harmful byproduct into a manageable situation
2Manufacturing precision
If cleaning is performed after welding completion, then chips can be removed, but the process takes a long time due to chips sticking to inner wall surfaces
Solution Approach 1:
Instead of performing cleaning action after welding, the patent performs a fluid flow process during the welding process itself to blow away chips before they adhere to surfaces. This preliminary chip removal ensures complete removal without requiring lengthy post-welding cleaning operations
Solution Approach 2:
The chip removal action is made continuous by performing the fluid flow process simultaneously with the welding process rather than sequentially. This continuous action ensures chips are constantly removed throughout welding, maintaining manufacturing precision while reducing total time
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 allows for the efficient removal of chips during the welding process, preventing them from sticking and reducing the time required for cleaning, thus enhancing the productivity and performance of the welded structure.
Implementation Method 1
vibrating the welding horn to weld the first member and the second member together by frictional heat
Implementation Method 2
making a fluid flow through the space... the chips generated by friction are charged with static electricity, and can stick to an inner wall surface of the space
Data Source
AI summary
A method of welding a first member and a second member together includes preparing the first member and the second member, bringing the first member and the second member into contact to form a space between the first member and the second member, and bringing a welding horn into contact with the first member or the second member. The method of welding further includes performing a vibration process to vibrate the welding horn to weld the first member and the second member together by frictional heat, and performing a fluid-flow process to make fluid flow through the space. The fluid-flow process is performed during the vibration process.