Semispherical Resonator Protrusions for Ultrasonic Foil Joining
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Solution Overview
Problem
The existing methods for joining metal foils using ultrasonic vibration often result in breaking of the foils due to the sharp edges of the distal end portions of the resonator and anvil, especially when the foils are thin and the number of foils to be joined is increased, necessitating the use of protection members that complicate the joining process.
Innovation Solution
A resonator and reception jig with distal end portions designed as protrusions having smooth, convex or concave arc-shaped surfaces without angular sharp edges, allowing for ultrasonic or acoustic vibration joining of metal foils without protection members, preventing foil breakage and ensuring a clean joining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pyramidal or truncated pyramidal protrusions are used as distal end portions for pressing down metal members, then the object to be joined can be gripped effectively, but the sharp edges of the protrusions can pierce and break thin metal foils during joining
Solution Approach 1:
The patent applies spheroidality by replacing the pyramidal or truncated pyramidal protrusions with semispherical protrusions at the distal ends of both the resonator and anvil. This curvature eliminates the sharp edges that cause foil breakage while maintaining the gripping and pressing function needed for effective joining of metal foils through ultrasonic vibration.
2Object-affected harmful factors
If protection members are added to prevent metal foil breakage during joining, then foil integrity is maintained, but the joining process becomes more complex and requires additional steps
Solution Approach 1:
The patent extracts and eliminates the need for protection members by modifying the distal end portions of the resonator and anvil to have semispherical shapes. This design change inherently prevents foil breakage through its geometry, removing the requirement for additional protection members and simplifying the joining process to its essential elements only.
3Adaptability or versatility
If the number of metal foils to be joined is increased and their thickness is reduced, then more complex assemblies can be created, but the risk of foil breakage during joining increases significantly
Solution Approach 1:
The semispherical protrusion design provides a distributed contact surface that reduces stress concentration on thin foils, enabling reliable joining of multiple thin metal foils without breakage.
Solution Approach 2:
The patent utilizes ultrasonic vibration applied through the semispherical protrusions to join multiple thin metal foils. The vibration mechanism, combined with the curved geometry, allows for precise joining of complex multi-foil assemblies while maintaining foil integrity through controlled energy application.
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 successful joining of multiple thin metal foils without breaking them, eliminating the need for protection members and ensuring a beautiful finish by using semispherical or hog-backed protrusions that distribute pressure and vibration effectively.
Implementation Method 1
lateral ultrasonic vibration is applied to an object to be joined 52 composed of a plurality of metal members 51 stacked on one another by a resonator 53
Implementation Method 2
friction occurs at an interface between the plurality of metal members 51 stacked together, motions of metal atoms are activated from heating due to frictional heat
Implementation Method 3
joining of metal foils can be performed by ultrasonic vibration or acoustic vibration
Implementation Method 4
migration of the metal atoms due to diffusion occurs, the metal atoms is bonded together by attraction force generated between the metal atoms
Data Source
AI summary
A distal end portion for pressing an object to be joined of one of a resonator and a reception jig is constituted as a protrusion having an outer face not including an angular sharp edge, such as a hog-backed shape or a semispherical shape, and during joining, while metal foils stacked are being laterally thinly stretched with lateral vibration from the resonator and atoms of the metal foils are being moved laterally without the protrusions forcibly holding down the metal foils, a metal amount corresponding to a volume stretched is smoothly discharged along a curved face without breaking the metal foils, and even when the stacked metal foils are used as the object to be joined, breaking of the metal foils is not generated during joining, so that a step of protecting the metal foils with a protection member is unnecessary.