Movable Fusion Pin Tip for Gap-Free Heat Bonding
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Solution Overview
Problem
Heat fusion methods often result in gaps between a sub-material and a base material due to insufficient bonding, leading to reduced bonding force, especially in applications with vibrations like automobiles.
Innovation Solution
A fusion tip with a base tip and a movable fusion pin, including auxiliary pins and a moving member, is used to heat and press the sub-material's boss or rib, filling gaps and enhancing bonding by moving the fusion pin up and down separately from the base tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat fusion is performed using a conventional fusion tip, then the bonding process is simple, but gaps form between the boss or rib and insertion hole, reducing bonding force
Solution Approach 1:
The fusion tip is segmented into a base tip and a separate fusion pin that can move independently. The fusion pin is positioned in a pinhole of the base tip and can move up and down separately, allowing focused pressure on the boss or rib to fill gaps while the base tip provides overall support.
Solution Approach 2:
The fusion pin is designed to be movable relative to the base tip, transitioning between retracted and extended positions. This dynamic structure allows the fusion pin to protrude toward the boss or rib during heat fusion to apply concentrated pressure, then retract when not needed, enabling adaptive gap filling.
2Strength
If the fusion pin is made with auxiliary pins for better gap filling, then bonding force increases, but the device complexity increases
Solution Approach 1:
The auxiliary pins are strategically positioned only where needed to fill gaps between the boss or rib and insertion hole. The auxiliary pins have cross-sectional areas smaller than the body portion and are disposed toward the boss or rib, providing localized pressure exactly where gap filling is required without adding unnecessary complexity throughout the entire structure.
3Manufacturing precision
If the fusion pin moves up and down separately from the base tip, then gap filling improves, but the control complexity increases
Solution Approach 1:
An elastic body is introduced as an intermediary between the fusion pin and the base tip. The elastic body is connected to the fusion pin and is configured to be compressed during heat fusion so that the fusion pin is accommodated in the pinhole, providing automatic return force and simplified control of the fusion pin's movement.
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 method effectively fills gaps and increases bonding force between the sub-material and base material, ensuring stable fixation even under vibration.
Implementation Method 1
Heat fusion is also called thermoplastic fusion and refers to a method of joining two different materials. It is a technology of transferring thermal energy to a surface of a product formed 1 of a thermoplastic resin, raising a temperature of the surface of the product to be joined to the melting point thereof
Implementation Method 2
an elastic body connected to the fusion pin, wherein the elastic body is configured to be compressed during heat fusion so that the fusion pin is accommodated in the pinhole
Data Source
AI summary
A fusion tip of a heat fusion machine assembling a sub-material including a boss or rib with a base material and then heat-fusing the boss or rib to fix the sub-material and the base material includes a base tip including a pinhole formed vertically in a center and a tip head contacting the boss or rib during heat fusion and a fusion pin positioned in the pinhole and configured to move up and down separately from the base tip.