Ultrasonic Double Ball Welding for Versatile Component Connections
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Solution Overview
Problem
Existing component connections using balls as connecting elements are limited in their applications and do not offer sufficient versatility for advanced configurations like double or multiple ball connections.
Innovation Solution
A method involving ultrasonic welding of thermoplastic or fiber-reinforced thermoplastic components to create double or multiple ball connections, where balls can be made entirely of thermoplastic material or have a core coated with thermoplastic, allowing for enhanced properties and precise positioning using a sonotrode and positioning aids for high-quality welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single ball is welded onto a component, then the connection is simple and straightforward, but the application areas are limited and versatility is insufficient
Solution Approach 1:
The connecting element is divided into multiple balls (double ball or multiple ball) instead of using a single ball. This segmentation allows the connection to engage with multiple recesses simultaneously, thereby increasing versatility and application areas while maintaining a relatively simple overall structure.
Solution Approach 2:
The multiple ball connecting element is designed to be universally applicable across different component configurations. By having multiple balls that can engage with different recesses, the same connecting element type can be used in various application scenarios, enhancing versatility without requiring multiple specialized connection types.
2Ease of manufacture
If ultrasonic welding is used to weld balls onto components, then the welding process is efficient and clean, but the balls must be made of thermoplastic material or coated with thermoplastic material
Solution Approach 1:
The ball is constructed as a composite structure with a core made of a different material (such as metal) coated or covered with thermoplastic material. This allows the ball to have the desired mechanical properties from the core material while the thermoplastic coating enables ultrasonic welding with thermoplastic components, thus resolving the material selection limitation.
Solution Approach 2:
The surface properties of the ball are changed by applying a thermoplastic coating to a non-thermoplastic core. This parameter change in surface material properties allows the ball to be compatible with ultrasonic welding processes while maintaining the beneficial properties of alternative core materials.
3Manufacturing precision
If the ball is pressed against the component by a sonotrode and set into vibration, then material melts locally and welding occurs, but the process requires precise positioning and control
Solution Approach 1:
Positioning aids are provided on the component or ball before the welding process begins. These positioning aids ensure that the ball is correctly positioned relative to the component recesses prior to ultrasonic welding, thereby achieving high welding precision without requiring complex real-time positioning control during the welding operation.
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 method enables the creation of high-quality, versatile ball connections with increased strength and application possibilities, particularly in vehicle body construction, by achieving clean, localized melting and precise alignment, resulting in robust and reliable joints.
Implementation Method 1
The sonotrode sets the first ball, pressed against the first component, into vibration, causing material of the first ball and/or material of the first component to melt locally
Implementation Method 2
causing material of the first ball and/or material of the first component to melt locally, i.e. around the point of contact
Data Source
Figure 1~4
Figure 5~7
AI summary
The invention relates to a method for producing a component connection, said method being characterized by the following steps: - providing a first component (1), - providing a first ball (5), - pressing the first ball (5) against the first component (1) by means of a sonotrode (4), - vibrating the first ball (5) by means of the sonotrode (4) such that material of the first ball (5) and/or material of the first component (1) melts, and the first ball (5) is welded to the first component (1), - providing a second ball (6), - pressing the second ball (6) against the first ball (5) by means of the same sonotrode (4) or another sonotrode, and - vibrating the second ball (6) by means of the same sonotrode (4) or the other sonotrode such that material of the second ball (6) and/or material of the first ball (5) melts, and the second ball (6) is welded to the first ball (5).