Ultrasonic Welding Apparatus Using Curable Liquid Droplets
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Solution Overview
Problem
Existing ultrasonic welding apparatuses are limited in their ability to weld materials of varying shapes, as they require specific welding horns for different shapes, restricting versatility and efficiency.
Innovation Solution
An ultrasonic welding apparatus that uses a liquid droplet discharge head to form curable liquid droplets on the surface of the welding workpieces, allowing for ultrasonic vibration to be applied only to specific areas through a contact member, enabling welding of diverse shapes with a single contact member and enhancing versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a welding horn is designed for a specific shape, then welding precision for that shape is improved, but adaptability to different shapes deteriorates
Solution Approach 1:
The welding surface is segmented into multiple discrete welding portions, each corresponding to a specific welding target shape. Each welding portion has a contact member configured to abut against a respective welding target, allowing selective welding of different shapes using the same welding horn through localized contact zones.
Solution Approach 2:
Different portions of the welding horn surface are designed with different contact member configurations tailored to specific welding target shapes. This local differentiation allows each area of the welding horn to optimize welding precision for its designated shape while maintaining overall versatility across multiple shapes.
2Adaptability or versatility
If multiple welding horns are prepared for different shapes, then adaptability to different shapes is improved, but device complexity deteriorates
Solution Approach 1:
A single welding horn is designed with multiple welding portions, each capable of welding different target shapes. The welding horn serves multiple functions by incorporating various contact member configurations on its surface, eliminating the need for multiple separate welding horns and reducing device complexity.
Solution Approach 2:
Multiple welding functions for different shapes are merged into a single welding horn structure. The contact members for various welding targets are integrated onto one welding horn, combining what would traditionally require multiple separate tools into a single multi-functional device.
3Area of stationary object
If the contact member abuts against the entire surface, then welding coverage is improved, but control over specific welding positions deteriorates
Solution Approach 1:
The contact member is segmented into multiple discrete contact portions, each corresponding to a specific welding target position. This segmentation allows the contact member to maintain broad coverage while providing precise control over each individual welding position through localized contact zones.
Solution Approach 2:
Different portions of the contact member have different abutment characteristics tailored to specific welding targets. This local differentiation enables precise control over welding positions while maintaining overall coverage, as each local area is optimized for its specific welding 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
Enables welding of materials at desired positions with the same contact member, regardless of shape, simplifying the apparatus structure and improving versatility by applying ultrasonic vibration only to areas with cured liquid droplets, thus allowing for flexible and efficient welding of various shapes.
Implementation Method 1
a first liquid droplet discharge head which discharges a curable liquid droplet toward a surface of the welding-objective member
Implementation Method 2
an ultrasonic vibration-applying mechanism which includes a contact member which is brought into contact with the liquid droplets cured on the surface of the welding-objective member and a vibrator which vibrates the contact member and which applies an ultrasonic vibration to the welding-objective member via the cured liquid droplets
Implementation Method 3
when the contact member is pressed against the surface of the welding-objective member, it is possible to provide such a state that the contact member is allowed to abut against the cured liquid droplets converted into the bumps on the surface of the welding-objective member
Data Source
AI summary
In an ultrasonic welding apparatus, ultraviolet-curable ink droplets are discharged to an upper surface of stacked sheets by means of an ink-jet head to land the ink droplets in a predetermined area on the upper surface of the sheets. The sheets, on which the ink droplets have been landed, are interposed and pressed between a welding horn and a receiving stand, while the welding horn is ultrasonically vibrated. Accordingly, the stacked sheets are welded to one another at portions opposed to the predetermined area in which the ink droplets are landed. In this way, the ultrasonic welding apparatus is provided, which makes it possible to perform the ultrasonic welding irrelevant to the shape of the area to be subjected to the welding.