Device, method and movable joining apparatus for thermal joining respectively two adjacent material sheets over a connecting piece
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Solution Overview
Problem
The existing methods for thermal joining of material sheets over connecting pieces are inefficient, particularly when aiming for a smooth, aesthetically pleasing butt-welded joint, as they often require manual handling and multiple steps, leading to reduced working speed and suboptimal seam quality.
Innovation Solution
A device and method for thermal joining that guides material sheets over a connecting piece, allowing simultaneous heating of the sheets' bottom sides and the connecting piece's top side, producing parallel weld seams in a single operation, thereby increasing efficiency and improving seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual handling and multiple steps are used for thermal joining, then seam quality can be improved, but working speed decreases
Solution Approach 1:
The device combines multiple heating zones (first heating zone for the first material sheet, second heating zone for the second material sheet, and third heating zone for the connecting piece) into a single integrated unit that performs thermal joining in one operation, merging what would traditionally require multiple separate steps into one synchronized process that maintains high seam quality while increasing working speed
Solution Approach 2:
The device enables continuous thermal joining by simultaneously heating and joining both material sheets and the connecting piece in one uninterrupted operation, eliminating the idle time and manual handling between steps that would otherwise be required to achieve comparable seam quality
2Reliability
If multiple steps and manual handling are employed, then joining can be achieved, but efficiency is reduced
Solution Approach 1:
The device merges the heating of multiple components (first material sheet, second material sheet, and connecting piece) into a single integrated operation with coordinated heating zones, ensuring reliable joining is achieved while eliminating the inefficiencies of multiple separate steps and manual handling
3Productivity
If simultaneous heating is applied to produce parallel weld seams, then productivity increases, but device complexity increases
Solution Approach 1:
The device divides the heating function into distinct segmented zones (first heating zone, second heating zone, and third heating zone) that can be independently controlled and positioned, allowing simultaneous heating of multiple components without requiring a monolithic complex system, thereby achieving high productivity while managing device complexity through functional segmentation
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 solution enables faster and more efficient thermal joining with improved seam quality, reducing the need for multiple steps and manual handling, and produces a seamless connection without additional adhesives, enhancing the product's market appeal.
Implementation Method 1
simultaneous heating in sections in the connecting region
Implementation Method 2
the material sheets can be at least partially plasticized by simultaneous and successive heating
Data Source
AI summary
A device, a method and a movable welding apparatus for thermal joining of respective two material sheets over a connecting piece arranged areally on a bottom side, wherein the material sheets are arranged with a respective side surface facing one another abutting against each other at least partially with a respective bottom side lying areally on a top side of the connecting piece are provided. In particular, the two material sheets and the connecting piece can be joined together in one pass.