Ultrasonic Welding Filter Material to Fluidic Components

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Solution Overview

Problem

The existing methods for connecting filter materials to fluidic components in vehicles are costly and inefficient, requiring additional components like clips, screws, or adhesives, and involving complex assembly processes.

Innovation Solution

A method and system that utilize a material bonding process, specifically ultrasonic welding, to connect filter materials directly to fluidic components, eliminating the need for additional connecting materials and simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If filters are clipped or screwed into components, then filtering function is achieved, but additional components and assembly complexity are required

Engineering Contradiction:

Improvefiltering functionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filter material is integrated directly into the functional element or housing part through material bonding, merging the filtering function with the structural component. This eliminates the need for separate filter clips, screws, or adhesive connections, thereby reducing assembly complexity while maintaining the filtering function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The functional element or housing part serves multiple functions: it provides structural support and simultaneously integrates the filtering function through the bonded filter material. This multi-functionality reduces the number of separate components needed in the pneumatic system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If filters are injection molded as insert parts, then filtering is integrated, but cost-intensive tooling and additional component numbers are required

Engineering Contradiction:

Improveintegrated filteringVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The filter material is bonded to the functional element or housing part using material bonding processes, integrating the filtering function without requiring separate injection molding tooling. This approach maintains integrated filtering while avoiding the high costs of dedicated insert molding tools and multiple component numbers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The method allows flexible adjustment of filtering parameters (filter material type, position, area) by changing the bonding process parameters rather than requiring different injection molding tools. This enables cost-effective customization of filtering characteristics.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If additional connecting materials like adhesives are used, then filter connection is achieved, but long waiting times for hardening are required

Engineering Contradiction:

Improvefilter connectionVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The material bonding process replaces chemical bonding (adhesives) with a mechanical/thermal bonding mechanism that does not require hardening time. The ultrasonic or friction-based material bonding process achieves immediate connection strength, eliminating long waiting times and enabling continuous production processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If separate components with and without filtering are produced, then flexibility is achieved, but storage and procurement complexity increase

Engineering Contradiction:

Improvefiltering flexibilityVSAvoidcomponent management complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single functional element or housing part design can be produced with or without integrated filter material through the material bonding process. This universal component design reduces the number of component numbers to be managed while maintaining the flexibility to provide filtering when needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables flexible and cost-effective filtering by allowing the filter material to be connected during the production process without requiring additional components, thereby reducing assembly time and costs.

Implementation Method 1

the material bonding process is an ultrasonic welding process

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

connecting the filter material to the fluidic component by a material bonding process

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Data Source

PatentUS12220655B2Method for joining a filter and a component, and filter-component system

Publication Date: 2025.02.11 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

AI summary

A method for connecting a filter material to a fluidic component, the method including: connecting the filter material to the fluidic component by a material bonding process. A system, including: a fluidic component; and a filter material that can be connected to the fluidic component; in which the filter material is configured to be connected to the fluidic component by a material bond.