Ultrasonic Joining Interface With Soft Buffer for Horn Protection
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Solution Overview
Problem
High-energy joining processes using sound vibration or ultrasound often result in damage to the horn part and poor energy transmission efficiency between the horn and joining member group.
Innovation Solution
A joining method and machine that employs a buffer member softer than the horn to apply sound vibration or ultrasound, where the buffer member's temperature exceeds its melting point, and at least one joining member's temperature exceeds that of the buffer member, with protrusions or recessed grooves on contact faces for enhanced energy concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a horn part directly applies sound vibration or ultrasound vibration to the joining member group, then joining efficiency is improved, but the horn part suffers from damage and durability decreases
Solution Approach 1:
The patent introduces a buffer member as an intermediary component positioned between the horn part and the joining member group. This buffer member transmits the sound vibration or ultrasound vibration from the horn to the joining members while protecting the horn from direct contact damage. The buffer member acts as a mediator that enables energy transmission while preventing harmful interactions between the horn and joining members.
2Use of energy by moving object
If a horn part directly applies sound vibration or ultrasound vibration to the joining member group, then energy transmission is more direct, but energy transmission efficiency becomes poor due to damage and interference
Solution Approach 1:
The buffer member serves as an intermediary that improves energy transmission efficiency by providing a stable, damage-resistant interface between the horn and joining members. It ensures consistent acoustic coupling while protecting the horn from damage that would otherwise degrade energy transmission over time.
Solution Approach 2:
The patent changes the physical parameters of the interface between the horn and joining members by introducing the buffer member with specific material properties. This alters the acoustic impedance matching and vibration transmission characteristics, optimizing energy transfer while preventing horn damage.
3Stability of the object's composition
If the horn part is supported at multiple portions, then structural stability is improved, but the contact area with joining members is reduced
Solution Approach 1:
The patent segments the contact interface by introducing the buffer member as a separate component. This allows the horn to be supported at multiple portions for stability while the buffer member provides the actual contact area with the joining members, effectively separating the support function from the contact function.
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 protects the horn and joining members from damage, improves energy transmission efficiency, and allows for effective joining of various materials by preventing horn damage and optimizing energy transfer, thereby enhancing the durability and cost-effectiveness of the joining process.
Implementation Method 1
a horn part provided in the joining machine applies sound vibration and/or ultrasound vibration to the joining member group
Implementation Method 2
a horn part provided in the joining machine applies sound vibration and/or ultrasound vibration to the joining member group
Implementation Method 3
the temperature of the buffer member becomes higher than the melting temperature
Implementation Method 4
the temperature of the buffer member becomes higher than the melting temperature
Data Source
AI summary
A joining method, etc., is provided, suitable for providing improved joining giving attention to the relation between a horn part and a joining member group. A joining machine performs joining of the joining member group (a first joining member and a second joining member). A horn part of a joining processing part applies sound vibration and/or ultrasound vibration to the joining member group via a buffer member. The horn part and the first joining member are each formed of metal. The buffer member has a greater softness than that of the metal that forms the horn part.