Ultrasonic Bonding Device for Sheet Members and Cylindrical Bodies
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Solution Overview
Problem
Existing bonding devices for sheet-shaped members and cylindrical bodies require large and costly ultrasonic wave application mechanisms, leading to increased device size and complexity.
Innovation Solution
A bonding method and device that uses a horn part to apply ultrasonic waves to one sheet-shaped member and an anvil part to apply heat to the other, with a pair of heaters for direct bonding of the members, reducing the need for large ultrasonic wave units and minimizing device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two units of ultrasonic wave application mechanisms are provided for bonding both outer surfaces of sheet-shaped members, then bonding reliability is improved, but device cost and overall size increase significantly
Solution Approach 1:
The patent merges the ultrasonic wave application and heating functions into a single integrated horn part. The horn part applies ultrasonic waves to one outer surface while the heating unit simultaneously heats the other outer surface, combining what would traditionally require two separate ultrasonic mechanisms into one unified component, thereby reducing device complexity and cost while maintaining bonding reliability
Solution Approach 2:
The heating unit acts as an intermediary that complements the ultrasonic wave application. By heating the second outer surface while ultrasonic waves treat the first surface, the system achieves balanced bonding of both sheet-shaped members without requiring two ultrasonic mechanisms, thus resolving the contradiction between reliability and device complexity
2Reliability
If large-sized ultrasonic wave application mechanisms are installed at both sides of sheet-shaped members, then bonding effectiveness is improved, but the overall size of the bonding device increases
Solution Approach 1:
The patent combines the ultrasonic wave application mechanism and heating unit into a single integrated horn part that processes both outer surfaces of the sheet-shaped members. This merging eliminates the need for two separate large-sized mechanisms, thereby maintaining bonding effectiveness while significantly reducing the device's overall size and installation area
Solution Approach 2:
The horn part serves multiple functions simultaneously: it applies ultrasonic waves to one surface while the integrated heating unit heats the other surface. This multi-functionality allows the device to achieve effective bonding of both surfaces without requiring separate large-sized mechanisms for each surface, thus reducing the overall device footprint
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
This approach allows for cost-effective bonding operations without increasing the device's overall size, simplifying the process and reducing processing time while maintaining stable bonding properties.
Implementation Method 1
applying an ultrasonic wave to an outer surface of a first one of the sheet-shaped members using a horn part
Implementation Method 2
applying heat to an outer surface of a second one of the sheet-shaped members using an anvil part
Implementation Method 3
directly bonding the two sheet-shaped members by a pair of heaters with holding the two sheet-shaped members between a pair of heaters
Data Source
AI summary
Provided is a bonding method capable of bonding with an inexpensive structure while avoiding an increase in the overall size of the device. The bonding method comprises: an arrangement step for locating a cylindrical body between two sheet-shaped members; a cylindrical body bonding step for applying an ultrasonic wave from the outer surface of a first sheet-shaped member through a horn part and applying heat from the outer surface of a second sheet-shaped member through an anvil part, in a state in which the cylindrical body is arranged between the two sheet-shaped members; and a shoulder part bonding step for directly bonding, through a pair of heating parts, the two sheet-shaped members to each other while the two sheet-shaped members are interposed between the pair of heating parts.