Spin Welding Component Concave Opening Resolves Deformation
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Solution Overview
Problem
Current spin welding techniques face challenges in achieving balanced manufacturing cost and welding strength, often resulting in insufficient strength, appearance issues, and dimensional accuracy due to molten material concentration at the center, leading to deformation and poor bonding.
Innovation Solution
A spin welding component with a concave-shaped opening at its center, allowing the molten resin to flow and solidify within, enhancing bonding strength by distributing pressure evenly and preventing unnecessary deformation, while maintaining dimensional accuracy and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the molten material is concentrated in the center during spin welding, then the welding process is simplified, but the mounting bracket rises from the base member causing insufficient welding strength, poor appearance and low dimensional accuracy
Solution Approach 1:
The bottom surface of the spin welding component is designed with a concave portion that has a specific volume to receive and contain the concentrated molten material. This local structural modification allows the molten material to be contained in a specific region, preventing the mounting bracket from rising while maintaining the simplified spin welding process.
Solution Approach 2:
The invention introduces a vertical dimension solution by creating a concave portion that extends downward from the bottom surface. This vertical space allows the molten material to flow downward and be contained, rather than forcing the material to spread horizontally and cause the bracket to rise, thus solving the dimensional accuracy problem.
2Manufacturing precision
If the volume of the concave opening is increased to accommodate more molten resin, then the pressure is reduced preventing deformation, but the component complexity increases
Solution Approach 1:
The concave portion is designed with a specific volume ratio (0.5-1.5 times the volume of molten resin) to optimally contain the molten material. This localized structural feature with precisely controlled dimensions provides the necessary pressure distribution without requiring complex overall component redesign.
Solution Approach 2:
The invention optimizes the volume parameter of the concave portion relative to the amount of molten resin. By setting the volume ratio between 0.5 and 1.5 times the molten resin volume, the design achieves optimal pressure distribution and deformation prevention through parameter optimization rather than structural complexity.
3Strength
If the spin welding component presses the molten resin downward to improve bonding, then the welding strength increases, but the appearance deteriorates due to deformation
Solution Approach 1:
The invention extracts the molten material from the problematic central concentration area and redirects it into the concave portion at the bottom. This separation of the molten material containment function from the visible surface area prevents deformation and appearance deterioration while maintaining the downward pressing action for strong bonding.
Solution Approach 2:
The concave portion acts as an intermediary structure between the molten resin and the base member. It provides a controlled environment for the molten material to be pressed downward, mediating the interaction between the resin and the welding surface to achieve both strong bonding and good appearance.
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 configuration increases welding strength by 1.4 to 1.6 times, ensuring good appearance and high dimensional accuracy by evenly distributing pressure and solidifying the molten resin within the concave opening, thus preventing deformation and enhancing bonding.
Implementation Method 1
melting the spin welding component by frictional heat between the base member and the spin welding component caused by the rotating
Implementation Method 2
causing molten resin to be concentrated in a center and flow into the opening by the rotating
Data Source
AI summary
An object is to provide a spin welding component that has a simple configuration of a welding surface and provides enhanced welding strength. A spin welding component 1 includes a shaft portion 2 formed in an approximately columnar shape, a flange portion 3 extended outward from below the shaft portion 2 to be formed in a disk-like shape, and an opening 4 formed by opening part of a bottom face of the flange portion 3. A molten resin 9 as molten material is applied on the bottom face. High-speed rotation causes the molten resin 9 to be melted by the frictional heat, and part of the molten resin 9 enters the opening 4 to be welded.