Segmented Pressure Plate for Contour Following in Transmission Welding
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Solution Overview
Problem
Existing transmission welding technologies are limited in their ability to effectively join large thermoplastic resin material parts, particularly those with complex contours or thickness variations, and often require adjustments for tolerances and deformations during the welding process.
Innovation Solution
A transmission welding apparatus with a segmented pressure plate and pressure device that allows for individual movement of plate segments to follow the local contour of the material parts, using thermal radiation and pressure to create joints, and includes features like segmented pressure plates, movable plate segments, and flexible pressure generators to accommodate deformations and thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large pressure plate is used for welding large material parts, then the welding area is covered, but the plate cannot follow local contours and thickness variations
Solution Approach 1:
The pressure plate is divided into multiple segmented pressure plates that can move independently relative to each other. Each segmented plate can follow local contours and thickness variations of the material parts while collectively covering the entire welding area, thus resolving the contradiction between area coverage and contour adaptability
2Adaptability or versatility
If the pressure plate is segmented into multiple movable plates, then contour following is improved, but the device complexity increases
Solution Approach 1:
Multiple segmented pressure plates are combined within a single pressure plate assembly that moves collectively. The segmented plates are interconnected through guiding means and can move relative to each other while maintaining coordinated motion, reducing the overall system complexity compared to completely independent plates
3Temperature
If thermal radiation is applied to large material parts, then welding heat is provided, but thermal extension and deformations occur during the welding process
Solution Approach 1:
The segmented pressure plates are designed to move dynamically during the welding process to compensate for thermal extension and deformations. The plates can adjust their positions in real-time to maintain contact with the material surfaces despite dimensional changes caused by heating, thus preserving welding precision
4Device complexity
If a single pressure generator is used, then the device is simple, but it cannot accommodate thickness variations and tolerances
Solution Approach 1:
The pressure generation system is segmented into multiple pressure generators, each associated with specific segmented pressure plates. This allows independent pressure adjustment for different regions of the workpiece, enabling compensation for thickness variations and tolerances while maintaining reasonable system complexity
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 efficient welding of large and complex thermoplastic resin parts with precise alignment and compensation for deformations, allowing for seamless joints in complex geometries without the need for apparatus adjustments, including convex and concave surfaces.
Implementation Method 1
The heat is generated by laser radiation or infrared radiation
Implementation Method 2
The pressure is applied via a transparent pressure plate driven by a pneumatic or hydraulic pressure generator
Data Source
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AI summary
Disclosed are a transmission welding apparatus for welding thermoplastic resin material parts, wherein a pressure plate is segmented into a plurality of plate segments which are arranged movable relative to one another, and a welding method.