Multi-Component Plastic Welding for Engine Air Ducts
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Solution Overview
Problem
Existing methods for producing complex-shaped plastic hollow bodies with different material properties, such as hard and soft plastics, are limited by the need for complex welding processes and high production costs, especially when trying to combine these materials in intricate designs like air ducting components for internal combustion engines.
Innovation Solution
The method involves producing shaped or hollow body elements separately using multi-component injection molding, melting them at specific temperatures at uniform connection points, and then joining them under pressure to create a continuous, easily accessible weld seam, reducing the complexity and cost of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex-shaped plastic hollow bodies with different material properties are produced using existing methods, then the components can achieve varied material properties (hard and soft plastics), but the welding process becomes complex and production costs increase
Solution Approach 1:
The plastic hollow body is divided into multiple shell sections (first shell section, second shell section, third shell section) that can be produced separately using injection molding with different material properties, then joined together through welding at connection points arranged in a uniform plane
Solution Approach 2:
The connection points are arranged in a uniform plane (welding plane) that extends through the hollow body, transforming the welding problem from three-dimensional complex spatial joining to two-dimensional planar welding, which simplifies the welding process and equipment requirements
2Adaptability or versatility
If complex-shaped plastic hollow bodies are produced using blow molding technique, then hard and soft plastic materials can be combined, but manufacturing effort and complexity increase for complex shapes with undercuts and projections
Solution Approach 1:
Instead of attempting to form the entire complex-shaped hollow body with undercuts and projections in a single blow molding operation, the body is segmented into multiple shell sections that can be independently molded using injection molding, avoiding the limitations of blow molding for complex geometries
Solution Approach 2:
The shell sections are pre-formed using injection molding technology which is better suited for complex shapes, and then these pre-formed sections are joined together through welding, rather than attempting to form the complete complex shape in a single difficult operation
3Adaptability or versatility
If separate hard and soft plastic components are produced and then welded together, then different material properties are achieved, but the welding process requires considerable device technology outlay
Solution Approach 1:
By arranging all connection points in a uniform plane that extends through the hollow body, the welding process is simplified from complex three-dimensional spatial joining to two-dimensional planar welding, reducing equipment requirements and procedural complexity while maintaining the ability to join different material components
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 production of complex-shaped plastic hollow bodies with uniform weld planes, simplifying the welding process and reducing manufacturing effort, enabling the creation of stable and functional components with varied material properties without high production costs.
Implementation Method 1
melted at the same time in the area of the connection points with the melting temperature specified for the respective component
Implementation Method 2
melted at the same time in the area of the connection points with the melting temperature specified for the respective component
Implementation Method 3
joined together under the action of a pressure
Data Source
Figure 1~3
Figure 4~7
AI summary
The present invention relates to a method for manufacturing plastic molded or hollow bodies, preferably for forming components for air ducts in internal combustion engines, in which two or more molded or hollow body elements (1, 2) are produced using injection molding technology, subsequently joined together, and connected by plastic welding technology. The solution to the problem is characterized in that the molded or hollow body elements (1, 2) to be joined are each produced separately from at least two components (3, 4, 5) using a multi-component injection molding process known per se, are simultaneously melted at the connection points at the melting temperature specified for the respective component (3, 4, 5), and subsequently joined together under pressure.