Membrane Welding for Nebulizer Carrier Sealing
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Solution Overview
Problem
The existing methods for connecting a membrane to a carrier in membrane nebulizers, such as gluing with adhesives, are time-consuming, costly, and difficult to handle, and can affect the oscillation behavior and sealing of the nebulizer, leading to potential leaks and reduced aerosol generation efficiency.
Innovation Solution
The use of resistance welding, specifically medium frequency and capacitor discharge welding, to securely attach the membrane to the carrier, ensuring a sealed and stable connection without distorting the thin metal components, thus maintaining the oscillation behavior and aerosol generation quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive connection is used to attach the membrane to the carrier, then the connection is simple to implement, but the processing time increases due to adhesive hardening time and the complexity increases due to special pressing tools and pre-treatment requirements
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical resistance welding system. The welding device applies electrical current through electrodes to generate heat at the contact interface between membrane and carrier, melting and fusing the materials together. This substitution eliminates the need for adhesives, pre-treatment processes, and pressing tools, thereby reducing process complexity while maintaining ease of connection.
Solution Approach 2:
The patent changes the fundamental connection parameter from chemical bonding (adhesive) to thermal-mechanical bonding (welding). By controlling welding parameters such as current intensity, duration, and electrode pressure, the connection process becomes faster and simpler. The welding parameters can be precisely adjusted to achieve optimal bonding without requiring additional processing steps.
2Ease of manufacture
If adhesive connection is used to attach the membrane to the carrier, then the connection method is simple, but the production time increases due to adhesive hardening time
Solution Approach 1:
The patent replaces the time-consuming chemical adhesive hardening process with an instantaneous thermal welding process. The resistance welding generates heat quickly at the contact interface, melting the membrane and carrier materials within seconds. This eliminates the prolonged hardening time required for adhesives, dramatically increasing production speed while maintaining the simplicity of the connection method.
Solution Approach 2:
The welding process uses periodic electrical current pulses to generate heat in controlled intervals. This allows for precise control of the welding duration, ensuring complete bonding in the shortest possible time. The periodic action of the welding current enables rapid cycling through multiple connection points, thereby increasing overall production throughput.
3Strength
If high heat production connection methods are used to attach the membrane to the carrier, then the connection strength increases, but the thin metal components become distorted or leak due to heat production
Solution Approach 1:
The resistance welding method concentrates thermal energy locally at the precise contact interface between the membrane and carrier where bonding is required. The heat is generated only at this specific location through electrical resistance, while the surrounding thin metal components remain relatively cool. This localized heating achieves strong bonding without causing distortion or leakage in the thin-walled components.
Solution Approach 2:
The patent optimizes welding parameters including current intensity, pulse duration, and electrode pressure to achieve the right balance between connection strength and heat input. By carefully controlling these parameters, sufficient heat is generated to create strong welds at the interface, while the total heat input remains low enough to prevent distortion of the thin metal components. The welding parameters can be adjusted based on material thickness and properties.
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 reduces production time and costs, provides a stable and reproducible connection, minimizes energy consumption, and ensures a leak-proof seal, maintaining the oscillation behavior and aerosol generation efficiency while eliminating the need for adhesives and pre-treatment processes.
Implementation Method 1
welding of the membrane to the carrier using a resistance welding method
Implementation Method 2
resistance welding method is preferably used for this purpose
Implementation Method 3
Medium frequency welding and capacitor discharge welding may, for example, be used here
Implementation Method 4
Medium frequency welding and capacitor discharge welding may, for example, be used here
Data Source
AI summary
A membrane nebulizer for producing aerosol in an aerosol therapy device includes a membrane having several through-holes for nebulizing a fluid; and a laminar carrier having an opening, the membrane being arranged in the opening and fastened to the carrier in such a way that the nebulizing occurs on a first side of the carrier and the fluid is present at the membrane on the opposite second side of the carrier, wherein the membrane is welded to the carrier by means of a resistance welding method.