Sharp-Corner Sealing Structure for Ultrasonic Welded Housings
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Solution Overview
Problem
Existing sealing technologies face challenges in achieving waterproof and dustproof properties while maintaining sharp corners, as ultrasonic welding is difficult at sharp corners and additional sealing elements like O-rings increase costs.
Innovation Solution
A sealing structure with sharp corners and arc-shaped annular grooves for ultrasonic welding, combined with hollowed-out areas to ensure uniform thickness and reinforcing ribs for structural support, allowing for effective sealing without additional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is applied to join the shell structure, then sealing effect is improved, but it requires arc-shaped corners which conflicts with sharp corner design requirements
Solution Approach 1:
The patent divides the corner structure into two separate components: the outer corner portion that maintains the sharp corner appearance, and the inner welding groove portion that provides the arc-shaped geometry needed for ultrasonic welding. This segmentation allows each part to fulfill its specific function independently.
Solution Approach 2:
The patent applies different geometric qualities to different locations of the corner structure. The outer surface maintains sharp corner geometry for aesthetic and design requirements, while the inner welding groove area has arc-shaped geometry optimized for ultrasonic welding process. This local differentiation resolves the contradiction between appearance and manufacturing requirements.
2Reliability
If O-rings are disposed at the joints to achieve waterproof and dustproof properties, then sealing performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the O-ring sealing element from the design, replacing it with an integrated ultrasonic welding solution. The sealing function is achieved directly through the welded joint between the box body and cover body, removing the need for separate sealing components and reducing manufacturing complexity.
Solution Approach 2:
The patent enables the shell structure to achieve sealing through self-welding of its own components. The ultrasonic welding process directly joins the box body and cover body without requiring external sealing elements, allowing the structure to create its own seal through the welding process.
3Ease of manufacture
If the corner portion has uniform thickness, then manufacturing is simplified, but surface defects occur due to uneven cooling during injection molding
Solution Approach 1:
The patent applies different thickness characteristics to different regions of the corner portion. The outer corner maintains uniform thickness for manufacturing simplicity, while the inner welding groove area has varied thickness to control cooling rates and prevent surface defects. This local differentiation allows both manufacturing ease and surface quality to be optimized in their respective regions.
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 structure achieves excellent waterproof and dustproof performance, meets design requirements for sharp corners, and reduces manufacturing costs by eliminating the need for O-rings while ensuring consistent thickness and quality.
Implementation Method 1
Another design method is to join the shell structure through ultrasonic welding
Data Source
AI summary
A sealing structure includes a box body and a cover body. The box body includes a plurality of side walls respectively including a plurality of outer and inner portions, an annular groove formed on the inner portions, and an annular protrusion portion. Each outer portion has a level difference with the corresponding inner portion. Any two adjacent ones of the side walls form a corner portion. An outer surface of each corner portion forms a sharp corner. The annular groove is arc-shaped at a position corresponding to each corner portion. Each corner portion includes a hollowed-out area. The cover body includes a main body in a polygonal shape with sharp corners, an annular protrusion portion protruding from the main body, and an annular groove. The annular protrusion portions extend into the annular grooves, so that the cover body is sealedly joined to the box body.