Ultrasonic Welding Biasing Members to Prevent Workpiece Breakage
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Solution Overview
Problem
In ultrasonic welding, increasing pressure or ultrasonic vibration amplitude to generate large frictional thermal energy for diffusion welding can lead to breakage of metal plates.
Innovation Solution
The ultrasonic welding method involves applying ultrasonic vibration to workpieces while vibrating them at an amplitude smaller than the ultrasonic vibration amplitude, using a holding member, a biasing member, and a horn to control the vibration and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure applying force by horn or amplitude of ultrasonic vibration is increased to generate large frictional thermal energy, then welding quality is improved, but metal plates may be broken
Solution Approach 1:
A holding member is introduced as an intermediary between the horn and the workpiece. The holding member receives ultrasonic vibration from the horn and transmits it to the workpiece, while also providing mechanical support and positioning. This mediator allows the system to achieve effective welding without directly applying excessive force that would damage the workpiece.
Solution Approach 2:
The system separates the amplitude parameters: the horn operates at a larger amplitude to generate sufficient ultrasonic vibration energy, while the workpiece is constrained to vibrate at a smaller amplitude to prevent breakage. This parameter differentiation resolves the contradiction between needing high energy for welding and low amplitude for workpiece safety.
2Temperature
If pressure applying force by horn is increased to attain large frictional thermal energy, then thermal energy at welding interface is increased, but workpiece breakage risk increases
Solution Approach 1:
The holding member serves as a mediator that decouples the high-pressure application from the workpiece. It receives the force from the horn and translates it into controlled vibrations at the workpiece interface, generating thermal energy without directly transmitting damaging impact forces to the workpiece.
Solution Approach 2:
The system transitions from static high-pressure application to dynamic vibration-based heating. The holding member enables the workpiece to vibrate dynamically at controlled amplitudes, generating frictional thermal energy through motion rather than through static pressure, thereby reducing the risk of breakage while maintaining effective welding temperature.
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 increases thermal energy at the welding interface while preventing breakage of the workpieces, thereby improving productivity.
Implementation Method 1
a horn that applies ultrasonic vibration to the workpiece held by the holding member
Implementation Method 2
applying ultrasonic vibration to the plurality of metal foils... to generate large frictional thermal energy
Implementation Method 3
a biasing member that biases the holding member toward the workpiece... so as to vibrate the workpiece at an amplitude smaller than an amplitude of the ultrasonic vibration
Data Source
AI summary
An ultrasonic welding method includes welding workpieces by applying ultrasonic vibration to the workpieces, wherein in the welding, the workpieces are vibrated at an amplitude smaller than an amplitude of the ultrasonic vibration.