Ribbed Manifold Housing Welding for Deformation-Tolerant Joints
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Solution Overview
Problem
Existing manifolds made of thermoplastic resin are prone to deformation during molding, leading to inadequate contact between joined surfaces and reduced weld strength, which can result in cracks when used in applications like vehicle coolant systems.
Innovation Solution
A method involving the formation of ribs on the outer periphery of the opening edges of the housing components, followed by a heating and pressure-bonding process to ensure proper alignment and contact of the joint surfaces during welding, thereby securing a sufficient welded area and maintaining weld strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If two members are joined by heat welding technique, then the housing is formed as an integrated structure, but the weld strength between joint surfaces is decreased due to deformation during molding
Solution Approach 1:
The rib structure is formed in advance on the joint surfaces of both housing members during the molding process. This preliminary structural preparation ensures that when heat welding is performed, the rib protrusions make contact first and guide the pressing force, compensating for any deformation and ensuring proper alignment of the joint surfaces for strong welding.
2Stability of the object's composition
If two members are joined by heat welding technique, then the housing is formed as an integrated structure, but the joint surfaces cannot be in proper close contact due to deformation
Solution Approach 1:
The rib structure is formed in advance on the joint surfaces of both housing members during the molding process. This preliminary structural preparation ensures that when heat welding is performed, the rib protrusions make contact first and guide the pressing force, compensating for any deformation and ensuring proper alignment of the joint surfaces for strong welding.
Solution Approach 2:
The rib protrusions act as intermediary elements between the two housing members during welding. These ribs make contact first and serve as mediators to transmit and distribute the pressing force uniformly across the joint surfaces, ensuring proper contact and alignment even when the main body surfaces have slight deformations.
3Ease of manufacture
If molding is performed without rib structure, then the manufacturing process is simpler, but the welded area is insufficient and weld strength is reduced
Solution Approach 1:
Instead of making the entire housing structure more complex, the rib structure is applied locally only at the critical joint surfaces where welding occurs. This localized addition provides the necessary welding area and strength enhancement without significantly complicating the overall molding process or adding excessive material.
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 ensures reliable welding by maintaining proper contact and alignment of joint surfaces, preventing weld strength reduction and ensuring the integrity of the manifold, even when deformation occurs during manufacturing.
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
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
AI summary
A manifold includes a first housing forming a first opening portion and a second housing forming a second opening portion. Each joint surface of the first opening portion and the second opening portion is welded to each other, thereby integrating the first housing and the second housing with each other and forming a housing including a fluid space inside. The housing includes a rib formed on at least one of an outer peripheral side of an opening edge of the first opening portion and an outer peripheral side of an opening edge of the second opening portion. The rib protrudes outward along a surface parallel to the joint surface.