Segmented Die Head for Precision Adhesive Application
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Solution Overview
Problem
Existing die heads used for applying materials in joined member manufacturing are hindered by their larger width, which prevents the application of materials when projections are present near the outer edge of the application area, leading to incomplete coverage.
Innovation Solution
A die head design with a narrow, elongated ejection port and a reservoir system, allowing for precise application of materials even near projections, combined with a suction stage and ultraviolet irradiation to adjust viscosity, ensuring uniform application and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the die head covers the shim plate from three directions to prevent displacement, then the shim plate is securely held, but the width of the die head becomes larger than the application width of the applied material
Solution Approach 1:
The die head is divided into two separate heads (first head and second head) that hold the shim plate between them. This segmentation allows the shim plate to be securely held from opposite directions while keeping each individual head narrow enough to fit within the application width of the applied material.
2Manufacturing precision
If the die head width is reduced to avoid projections, then the applied material can be applied with predetermined width, but the shim plate may displace or come off
Solution Approach 1:
The die head is divided into two separate heads (first head and second head) that hold the shim plate between them. This segmentation allows the shim plate to be securely held from opposite directions while keeping each individual head narrow enough to fit within the application width of the applied material.
Solution Approach 2:
Instead of expanding the die head width in the horizontal direction to secure the shim plate, the solution moves to the vertical dimension by having the first and second heads approach the shim plate from opposite sides, securing it through thickness rather than width.
3Manufacturing precision
If a narrow, elongated ejection port is used, then the applied material can be applied precisely without interference from projections, but the ejection port structure becomes more complex
Solution Approach 1:
The ejection port is formed by grooves in both the first head and second head that together create the narrow, elongated ejection opening. This segmentation of the ejection port formation across two heads allows for precise material application while distributing the structural complexity across multiple 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
Enables the application of materials with a predetermined width without interference from projections, ensuring uniform coverage and adherence between members, while maintaining a controlled thickness and preventing voids.
Implementation Method 1
an ultraviolet irradiator 45 configured to radiate an ultraviolet ray; and a chamber 51 configured such that a degree of vacuum inside the chamber 51 is adjustable... wherein the applied material G is configured such that viscosity of the applied material G changes when the applied material G is irradiated with an ultraviolet ray
Implementation Method 2
a chamber 51 formed to have a size enabling the chamber 51 to accommodate the first and second suction stages 20A and 20B at the same time, the chamber 51 being configured such that a degree of vacuum inside the chamber 51 is adjustable by an operation of a vacuum pump 53
Implementation Method 3
a first suction stage 20A configured to suction-hold the first application target member D... a second suction stage 20B configured to suction-hold the second application target member E
Data Source
AI summary
To provide a joined member manufacturing apparatus, a method for manufacturing a joined member, and a method for manufacturing a member on which an applied material has been applied, with which it is possible to apply an applied material even in cases where a projection is present in the vicinity of an outer side of an application width of an applied material to be applied on an application target surface. A joined member manufacturing apparatus includes an application device including die head 10 having a distance between the ejection port forming groove and an outer edge of the first opposing face at a portion where an ejection port is formed being 0.1 mm to 1.0 mm, a first suction stage 20A, a second suction stage 20B, an ultraviolet irradiator 45 configured to radiate an ultraviolet ray, a chamber 51 formed to have a size enabling the chamber 51 to accommodate the first and second suction stages 20A and 20B at the same time, the chamber 51 being configured such that a degree of vacuum inside the chamber 51 is adjustable by an operation of a vacuum pump 53, where the applied material G is configured such that viscosity of the applied material G changes when the applied material G is irradiated with an ultraviolet ray.