Friction Welding Plastic Air Intake with Radially Spaced Surfaces
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Solution Overview
Problem
Existing air intake devices for internal combustion engines face challenges in achieving a secure, permanent, and economical joint between plastic component parts while ensuring optimal force transmission and sealing, which is not adequately addressed by current friction welding methods.
Innovation Solution
The air intake device employs plastic component parts with radially spaced-apart weld surfaces that form angles with the flow channel axis, providing multiple weld surfaces for enhanced force transmission and sealing, with the option of different radial distances and orientations to ensure reliability and stability, and the use of connecting ribs for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple spaced-apart weld surfaces are provided on plastic component parts, then force transmission and sealing reliability are improved, but device complexity increases
Solution Approach 1:
The weld surface is segmented into multiple separate areas (first weld surface and second weld surface) positioned at different radial distances from the flow channel. This segmentation allows each weld surface to independently provide sealing and force transmission functions, improving overall reliability while maintaining a manageable configuration through modular design
Solution Approach 2:
The weld surfaces are arranged in different radial dimensions from the flow channel axis, creating a multi-dimensional welding configuration. This dimensional arrangement allows forces to be distributed across multiple planes and improves sealing reliability by providing redundant sealing paths at different radial positions
2Reliability
If weld surfaces are arranged at different radial distances from the flow channel, then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The welding process is segmented into separate welding operations for the first and second weld surfaces at different radial distances. This allows the friction welding process to be applied systematically to each surface independently, maintaining manufacturing simplicity while achieving multi-level sealing
Solution Approach 2:
The weld surfaces are positioned at different radial distances from the flow channel axis, creating parameter variation in the welding configuration. This parameter change allows the same friction welding process to be applied at multiple radial positions, achieving sealing reliability without requiring fundamentally different manufacturing procedures
3Duration of action of stationary object
If multiple weld surfaces are used to distribute forces, then stability and longevity are improved, but the number of component features increases
Solution Approach 1:
The load-bearing function is segmented across multiple weld surfaces positioned at different radial distances. This segmentation distributes forces more evenly across the joint, reducing stress concentration and improving device longevity while maintaining a relatively simple overall structure
Solution Approach 2:
Different regions of the plastic component parts are designed with different welding configurations based on local force requirements. The first and second weld surfaces are positioned to address specific local stress patterns, optimizing both longevity and structural simplicity
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 enhances the stability and longevity of the air intake device by distributing forces and ensuring tightness, even if one weld surface leaks, while maintaining optimal sealing and force transmission, thereby improving the overall performance and durability.
Implementation Method 1
the plastic component parts are joined by friction welding... A bonding force is then applied to the weld surfaces and a relative movement imparted to the housing parts until the parts are friction welded together
Data Source
AI summary
An air intake device for an internal combustion engine formed of at least two plastic component parts assembled to form a combustion air flow channel. The plastic component parts have communicating weld surfaces lying radially outside the flow channel, along which the plastic component parts are joined to each other by friction welding, and at least two communicating weld surfaces with different radial distances from the flow channel are provided on both the first and the second plastic component parts.