Plastic Fluid Delivery System Weld Flash Containment
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Solution Overview
Problem
The existing oil shower delivery systems for internal combustion engines, formed from metallic components, have a complex and costly production process, leading to increased weight and the risk of weld flash clogging spray holes during vibration welding, rendering plastic systems defective.
Innovation Solution
A fluid delivery system comprising two injection molded plastic components with a double wall configuration, where primary and secondary weld joints are used to prevent weld flash from entering the fluid passage, ensuring a leak-proof seal and reducing the likelihood of clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If plastic components are used for the fluid delivery system, then weight and production cost are reduced, but weld flash from vibration welding can enter the fluid passage and clog the outlets
Solution Approach 1:
The fluid delivery system is divided into two separate injection-molded plastic components (first component and second component) that are vibration-welded together. This segmentation allows the use of plastic materials for weight reduction while managing the welding process separately from the fluid passage formation.
Solution Approach 2:
A weld flash barrier is introduced as an intermediary structure within the fluid passage. This barrier prevents weld flash generated during vibration welding from entering the fluid passage and clogging the outlets, thus resolving the reliability issue while maintaining the benefits of plastic construction.
2Ease of manufacture
If vibration welding is used to join plastic components, then manufacturing complexity is reduced, but weld flash is generated that can render the system defective
Solution Approach 1:
The weld flash, which is normally a harmful byproduct of vibration welding, is redirected into a dedicated flash receptacle cavity rather than allowing it to contaminate the fluid passage. The barrier structure guides the weld flash away from critical areas, converting a harmful effect into a contained byproduct that does not affect system functionality.
3Strength
If steel components are used for the fluid delivery system, then durability is improved, but production time and expense increase
Solution Approach 1:
The material parameter is changed from steel to injection-molded plastic, which significantly reduces production time and expense. The durability requirement is maintained through proper design of the plastic components and the vibration welding process with flash barriers, demonstrating that parameter changes can achieve both cost reduction and adequate performance.
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 system effectively prevents weld flash from entering the fluid passage, reducing the probability of clogging and improving the reliability of the oil shower delivery system while simplifying production and reducing weight and costs.
Implementation Method 1
The distal ends of the pair of second walls are vibrationally welded to each of the corresponding distal ends of the pair of first walls to form the primary weld joints
Data Source
AI summary
A fluid delivery system formed of a first component and a second component. The first component includes a first surface and a pair of first walls extending outwardly from the first surface. The second component includes a second surface facing the first surface. The second component includes a pair of second walls and a pair of inner walls which both extend outwardly from the second surface. Each of the pair of second walls and each of the pair of first walls are vibrationally welded at a primary weld joint. The pair of inner walls extends outwardly from the second surface and sealingly contacts the first surface to define a fluid passage and a pair of cavities on either side of the fluid passage. Weld flash formed during the vibrational welding of the primary joints is contained within the pair of cavities and prevented from entering the fluid passage.