Roller Shutter Box Ultrasonic Welding for Homogeneous Seams
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Solution Overview
Problem
Existing roller shutter box manufacturing methods are inefficient, relying on time-consuming screwing processes and lacking in strength and stability, with prior methods such as ultrasonic welding not fully addressing the need for a homogeneous weld seam and adaptable production of different lengths.
Innovation Solution
The method involves providing oversized projections on head parts that melt during an ultrasonic welding process, creating a homogeneous weld seam and allowing for the production of roller shutter boxes of varying lengths using a device with movable welding jaws, eliminating the need for screwing and ensuring high strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screwing processes are used to fix roller shutter box components, then the connection strength is sufficient, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The patent replaces the mechanical screwing system with an ultrasonic welding system. The welding device uses ultrasonic vibration to melt and fuse thermoplastic materials at the connection interfaces, eliminating the need for separate fastening elements like screws. This substitution of mechanical assembly with thermal welding directly resolves the contradiction by improving productivity while reducing process complexity.
Solution Approach 2:
The invention utilizes the phase transition of thermoplastic materials from solid to molten state during ultrasonic welding. The ultrasonic vibration generates localized heating that melts the thermoplastic components at the joint surfaces, allowing them to fuse together. After cooling, the material solidifies to form a strong weld. This phase transition mechanism enables direct welding of box components without mechanical fasteners, thereby increasing manufacturing efficiency and simplifying the assembly process.
2Strength
If ultrasonic welding is used to join parts, then the connection strength is high, but achieving a homogeneous weld seam is difficult without proper surface features
Solution Approach 1:
The patent applies local quality by providing protrusions specifically at the connection surfaces of box components. These protrusions are strategically positioned to concentrate ultrasonic energy and material flow at critical joint areas during welding. By modifying only the local surface geometry at connection points rather than the entire component, the invention achieves homogeneous weld seams with high strength while maintaining manufacturing feasibility.
Solution Approach 2:
The protrusions on the box components are pre-formed during the molding process before welding occurs. This preliminary action ensures that when ultrasonic welding takes place, the material distribution and contact surfaces are already optimized for homogeneous fusion. The pre-existing protrusions guide the welding process to produce consistent, high-quality weld seams across all joints, resolving the challenge of achieving uniform weld quality.
3Adaptability or versatility
If fixed-length box components are manufactured, then the production process is simple, but the product cannot adapt to different installation requirements
Solution Approach 1:
The invention implements dynamics by making the box component lengths adjustable rather than fixed. The modular design with standardized welding interfaces allows components to be connected in series to achieve various total lengths. The ultrasonic welding process maintains consistent joint strength regardless of the number of segments, enabling the system to adapt to different installation requirements while preserving manufacturing simplicity through standardized components and processes.
Solution Approach 2:
The patent applies segmentation by dividing the roller shutter box into multiple standardized segments that can be individually manufactured and then connected through ultrasonic welding. Each segment has uniform connection interfaces with protrusions designed for welding. This segmentation allows flexible assembly of different length configurations while maintaining ease of manufacture through standardized production of individual modules, thereby resolving the contradiction between adaptability and manufacturing simplicity.
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 simplifies the manufacturing process, eliminates the need for screwing, and provides high-strength, stable connections with a direct seal, enabling efficient production of roller shutter boxes of different lengths using thermoplastic materials and rigid foam components.
Implementation Method 1
the head part is welded to an associated end face of the ceiling part, and the front wall part, and preferably one or more bottom parts and/or the rear wall part, in that excess projections formed on an end face of both head parts melt during the welding process
Implementation Method 2
excess projections formed on an end face of both head parts melt during the welding process
Implementation Method 3
a support part with welding jaws for contact with one of the head parts is provided, which is movable in the longitudinal direction with respect to an inserted roller shutter box
Data Source
Figure 1
Figure 2~3b
Figure 4~5
AI summary
The invention relates to a method for manufacturing a roller shutter box (1), wherein the roller shutter box (1) comprises two end pieces (2), a top piece (3), one or more bottom pieces (4, 5), a front panel (6), and a back panel (7). The invention further relates to a composite roller shutter box (1) comprising two end pieces (2), a top piece (3), one or more bottom pieces (4, 5), a front panel (6), and a back panel (7). The invention also relates to a device (8) for manufacturing a roller shutter box (1) comprising two end pieces (2), a top piece (3), one or more bottom pieces (4, 5), a front panel (6), and a back panel (7).In order to advantageously improve a method as well as a roller shutter box of the type in question, it is proposed that the ceiling part (3), the front wall part (6) and preferably one or more bottom parts (4, 5) and/or the rear wall part (7) be welded together with the head parts (2), with the exception of an inspection part (R), optionally the rear wall part (7) or bottom part (5) designed as an inspection part (R).