Resin Manifold Rib Structure for Deformation-Tolerant Welding
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Solution Overview
Problem
Existing manifolds made of thermoplastic resin suffer from reduced weld strength due to deformation of housing components during manufacturing, leading to potential cracks and inadequate joint contact, which compromises the integrity of the weld.
Innovation Solution
The manifold design incorporates ribs on the outer periphery of housing openings to ensure proper close contact during heat welding, applying pressure perpendicular to the joint surfaces to maintain a sufficient welded area and prevent weld strength reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two members are joined by heat welding to form a housing, then the housing is integrated with sufficient weld strength, but when the members are deformed during molding, the joint surfaces cannot achieve proper close contact and weld strength decreases
Solution Approach 1:
The rib structures are pre-formed on the joint surfaces of both housing members before welding. These ribs extend toward each other and make contact during the welding process, automatically compensating for deformations and ensuring proper close contact between joint surfaces before the weld is applied, thus maintaining sufficient weld strength despite manufacturing variations
Solution Approach 2:
The rib structures modify the geometric parameters of the joint surfaces by adding protruding elements that extend toward each other. This geometric modification allows the ribs to bridge gaps caused by deformation, ensuring that the joint surfaces achieve adequate contact pressure and close contact during welding, thereby maintaining weld strength despite variations in manufacturing precision
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 rib structure ensures reliable welding despite housing deformation, securing a strong weld and preventing cracks, even when precision is compromised.
Implementation Method 1
heating the joint surface of the first opening portion in the first housing and the joint surface of the second opening portion in the second housing in such a way that a temperature of each of the joint surfaces becomes a melting temperature
Implementation Method 2
Each joint surface of the first opening portion and the second opening portion is welded to each other
Implementation Method 3
The pressure-bonding step includes pressure-bonding the joint surface of the first opening portion and the joint surface of the second opening portion to each other after the heating step
Data Source
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AI summary
A manifold (M) includes a first housing (10) forming a first opening portion (S1) and a second housing (20) forming a second opening portion (S2). Each joint surface (SW) of the first opening portion (S1) and the second opening portion (S2) is welded to each other, thereby integrating the first housing (10) and the second housing (20) with each other and forming a housing (MN) including a fluid space (LS) inside. The housing (MH) includes a rib (R) formed on at least one of an outer peripheral side of an opening edge of the first opening portion (S1) and an outer peripheral side of an opening edge of the second opening portion (S2). The rib (R) protrudes outward along a surface parallel to the joint surface (SW).