Profiled Bar Welding Nozzle with Floating Containment
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Solution Overview
Problem
The existing methods for welding profiled bars to form door and window frames result in visible weld beads, which are aesthetically unappealing and can damage special finishes, necessitating additional cleaning processes that complicate production and reduce the quality of the finished product.
Innovation Solution
An apparatus with a welding head that uses containing elements with protuberances to direct softened material inward, creating weld beads that are concealed within the profiled bars, eliminating the need for post-weld cleaning and preserving special finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional welding is used to join profiled bars, then the joining process is simple and direct, but visible weld beads are generated that require additional cleaning operations
Solution Approach 1:
The invention extracts and removes the harmful element (visible weld bead) from the welding process by using a specialized nozzle that directs the weld bead away from the visible surface of the profiled bar, eliminating the need for subsequent cleaning operations
Solution Approach 2:
The invention introduces an intermediary element (specialized welding nozzle with directing mechanism) that mediates between the welding process and the final product appearance, controlling the trajectory and placement of the weld bead to prevent its visibility on the product surface
2Ease of manufacture
If traditional welding is used to join profiled bars, then the welding process is straightforward, but the weld bead damages special finishes on the bars
Solution Approach 1:
The invention extracts the harmful effect (damage to special finishes) by redirecting the weld bead away from the coated surface of the profiled bar, allowing the special finishes to remain intact without requiring additional protective measures or process modifications
Solution Approach 2:
The specialized nozzle acts as an intermediary that protects the special finishes by controlling the weld bead trajectory, preventing direct contact between the hot weld material and the coated surface while maintaining effective welding
3Device complexity
If welding is performed without containing elements, then the welding process is simple, but the weld bead protrudes from the surface requiring cleaning
Solution Approach 1:
The containing elements within the nozzle serve as intermediary structures that guide and confine the molten weld material, ensuring it solidifies in the desired position within or near the joint rather than protruding from the visible surface
Solution Approach 2:
The invention applies local quality control by using containing elements specifically positioned at critical locations within the nozzle to direct the weld bead into the joint area, achieving precise weld placement without requiring complex control systems throughout the entire apparatus
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 solution minimizes the visibility of weld beads, simplifies the production process, and maintains the aesthetic quality of window and door frames by integrating the weld beads within the profiled bars, thus eliminating the need for post-weld cleaning and ensuring high-quality finishes.
Implementation Method 1
the ends of two profiled PVC bars are heated so that the material they consist of is softened locally
Implementation Method 2
they are then pressed against each other in order to join the bars permanently
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An apparatus for joining a profiled bar (2) and a further profiled bar (3) by welding, comprises: - a support device (6) for supporting an end portion (7) of the profiled bar (2); - a further support device (8) for supporting a further end portion (9) of the further profiled bar (3); - a heating device for heating respective terminal sections (18) of the end portion (7) and of the further end portion (9), so as to locally soften the material of the profiled bar (2) and of the further profiled bar (3); - pusher means for pushing at least the profiled bar (2) against the further profiled bar (3), so as to join the profiled bar (2) and the further profiled bar (3) at the respective softened terminal sections (18). At least one device selected from between the support device (6) and the further support device (8) comprises a containing element (21, 22) for containing the softened material during welding, the containing element (21, 22) being floating along a direction parallel to a longitudinal axis (Z) of the corresponding profiled bar (2, 3).