Ultrasonic Welding Device Compression Space Structure

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Solution Overview

Problem

Stranded wires in ultrasonic welding often move longitudinally during the welding process, leading to reduced energy input and pressure application, which compromises the strength of the weld, especially when welding poorly weldable conductors.

Innovation Solution

The compression space in the ultrasonic welding apparatus is structured with side-delimiting areas that run across the longitudinal axis of the conductors, featuring geometric profiles such as saw tooth-shaped elevations and depressions, creating a labyrinth-like seal to prevent longitudinal movement and allow for increased energy input without compromising the weld quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high energy input and pressure application are used to weld poorly weldable conductors, then weld strength is improved, but longitudinal movement of conductors occurs causing quality degradation

Engineering Contradiction:

Improveweld strengthVSAvoidconductor position stability

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The compression space is segmented into multiple functional zones using transverse delimitations that divide the space into welding area and compression area. This segmentation allows independent optimization of each zone - the welding area provides controlled compression for stable conductor positioning while the compression area delivers the necessary pressure for welding, resolving the contradiction between position stability and weld strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a transverse dimension (perpendicular to the longitudinal axis of conductors) by adding side-delimiting areas and transverse delimitations. This dimensional addition creates a three-dimensional compression space structure that constrains conductors in multiple directions, preventing longitudinal movement while maintaining compression force for strong welding

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If reduced energy input and pressure application are used to prevent conductor movement, then position stability is improved, but weld strength deteriorates

Engineering Contradiction:

Improveconductor position stabilityVSAvoidweld strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the compression space are given different functional qualities - the welding area between sonotrode and counter-electrode provides localized compression for position stability, while the compression area with adjustable side slides provides localized high pressure for weld strength. This local differentiation allows both requirements to be satisfied simultaneously

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If adjustable compression space is used to adapt to different conductor cross sections, then versatility is improved, but device complexity increases

Engineering Contradiction:

Improveconductor cross section adaptabilityVSAvoidcompression space adjustment mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The side slides serving as counter-electrodes perform multiple functions: they delimit the compression space laterally, provide adjustable compression force, and create transverse delimitations for space segmentation. This multi-functionality achieves versatility for different conductor types while minimizing additional device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The compression space is designed with dynamic adjustability through movable side slides that can be positioned along the sonotrode. This dynamic structure allows the compression space dimensions to be adapted to different conductor cross sections and welding requirements, providing versatility without requiring completely different tooling for each application

Inventive Principle:

Principle #15Dynamics

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 solution ensures high-quality welding of poorly weldable stranded wires by eliminating longitudinal movement and enabling increased energy levels and pressure application, resulting in stronger welds without negatively affecting the joint quality.

Implementation Method 1

one work area is a section of a sonotrode of the ultrasonic welding apparatus, which can be placed in ultrasonic oscillation

Methodology Applied

Scientific EffectUltrasonic oscillation: Ultrasonic Vibration

Implementation Method 2

at least one of the side-delimiting areas, preferably both side-delimiting areas, are structured at least areally. In this connection, the structures are selected in such manner that they run essentially across the longitudinal axis of the compression space

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS7878384B2Ultrasonic welding device with opposite welding and lateral surfaces that delimit a compression space, and compression space

Publication Date: 2011.02.01 SCHUNK ULTRASCHALLTECHN

AI summary

An ultrasound welding device for welding metallic conductors for producing a junction point includes two welding surfaces, which are located on opposite sides, and two lateral delimiting surfaces, which extend transverse to the working surfaces and which, together, define a compression space. In order to eliminate longitudinal movement of the conductors during welding, at least one of the lateral delimitation surfaces is additionally structured next to the structured welding surfaces.