Ultrasonic Joining of Metal and Ceramic Members via Vertical Vibration
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Solution Overview
Problem
Existing methods for joining metal and inorganic materials, such as ceramics, stacked vertically using ultrasonic wave vibration fail to achieve ingot-like, diffusion-like, or alloy-like states due to the vertical load and transverse vibration configuration.
Innovation Solution
A joining method where one member is received into an inside space with a slope in the other member, allowing vertical load and ultrasonic wave vibration to cooperate, enabling the outer peripheral portions to be joined in an ingot-like, diffusion-like, or alloy-like state by vertical vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultrasonic wave vibration with vertical load and transverse vibration is used to join metal members, then the joining process can be completed, but the members cannot be joined in an ingot-like state, diffusion-like state, or alloy-like state
Solution Approach 1:
The patent inverts the conventional ultrasonic joining approach by changing the vibration direction from transverse to vertical, and by introducing a sloped receiving space instead of a flat interface. This inversion allows the members to be joined in ingot-like, diffusion-like, or alloy-like states, achieving higher quality joints.
Solution Approach 2:
The patent changes key parameters of the joining process: (1) changes vibration direction from transverse to vertical, (2) introduces a sloped receiving space geometry, (3) applies vertical load combined with vertical vibration. These parameter changes enable the achievement of ingot-like, diffusion-like, or alloy-like joining states that were not possible with conventional methods.
2Productivity
If conventional ultrasonic joining method is used, then the joining process is simple, but the joining time is long and the members cannot achieve desired joining states
Solution Approach 1:
By changing the vibration direction to vertical and introducing the sloped receiving space, the patent achieves both rapid joining and high-quality joining states (ingot-like, diffusion-like, or alloy-like). The vertical vibration combined with vertical load on the sloped surface accelerates material flow and bonding, simultaneously improving productivity and manufacturing precision.
3Reliability
If vertical load and transverse ultrasonic vibration are applied, then the joining process can proceed, but voids form at the interface and structural integrity is compromised
Solution Approach 1:
The patent inverts the conventional approach by using vertical vibration instead of transverse vibration, and by employing a sloped receiving space instead of a flat interface. This inversion eliminates interface voids and achieves void-free joining, significantly improving structural integrity and reliability.
Solution Approach 2:
The patent utilizes vertical ultrasonic vibration combined with vertical load on a sloped surface to generate intense material flow and bonding. This mechanical vibration mechanism ensures complete contact between joining surfaces, eliminating voids and achieving high structural integrity.
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 successfully joins metals and ceramics in ingot-like, diffusion-like, or alloy-like states without voids, allowing for rapid normal temperature joining within seconds, with no interface voids and maintaining structural integrity under heat cycles.
Implementation Method 1
an outer peripheral portion of the one member to be joined and the slope of the other member to be joined are joined to each other while a vertical load and vibration in a vertical direction due to acoustic wave vibration or ultrasonic wave vibration are cooperating with each other
Implementation Method 2
an outer peripheral portion of the one member to be joined and the slope of the other member to be joined are joined to each other while a vertical load and vibration in a vertical direction due to acoustic wave vibration or ultrasonic wave vibration are cooperating with each other
Implementation Method 3
an inside space portion having a slope is provided in the other member to be joined so as to be opened upward or downward, and in a state where one member to be joined of the plurality of members to be joined is received into the inside space portion from the opening of the other member to be joined to be supported by the slope
Data Source
AI summary
[Solving Means]A method for joining a plurality of members to be joined composed of metals or materials different in kind from each other which are metal and such an inorganic substance as ceramics to each other, the members being put in a state stacked up and down by having a configuration that a member to be joined 1 is received from an opening of an inside space portion 3 provided in a member to be joined 2 into the inside space portion 3 to be supported by a slope 7 of the inside space portion 3 and the members to be joined 1 and 2 are subjected to a vertical load shown by arrow 14 from a joining tool portion 12 and an anvil 13, while the joining tool portion 12 resonates with acoustic wave vibration or ultrasonic wave vibration transmitted from an acoustic wave vibrator or an ultrasonic wave vibrator to be subjected to vibration in a longitudinal direction shown by arrow 15, so that the members are joined in an ingot-like state, in a diffusion-like state, or in an alloy-like state.