Two-Material Holding Plate for Vacuum Filter Bag Welding
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Solution Overview
Problem
The connection of known retaining plates with injection-molded sealing lips to the vacuum cleaner filter bag wall via ultrasonic welding is problematic, as it can damage the sealing lip and result in a loose attachment, leading to the risk of dust leakage when the filter bag is removed.
Innovation Solution
A holding plate with a base plate made of a first plastic material and a connecting element made of a second plastic material, specifically a thermoplastic elastomer, which allows for a secure connection to the bag wall using ultrasonic welding with reduced energy, even with short welding times, by selecting materials with a higher melt flow index and lower melting temperature for the connecting element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to connect the holding plate to the bag wall, then the connection strength is improved, but the sealing lip may be damaged and the connection becomes loose
Solution Approach 1:
The holding plate is divided into two distinct parts: a base plate made of first plastic material and a connecting element made of second plastic material with different properties (higher melt flow index and lower melting temperature). This segmentation allows each part to serve its specific function - the base plate provides structural support while the connecting element optimizes the welding connection to the bag wall without damaging the sealing lip.
Solution Approach 2:
Different regions of the holding plate are made from different plastic materials with different properties. The connecting element specifically uses a second plastic material with higher melt flow index and lower melting temperature than the base plate material. This local quality differentiation enables the welding area to have optimal bonding characteristics while the sealing lip area maintains its integrity and sealing function.
2Strength
If high ultrasonic energy is introduced for welding, then the connection between holding plate and bag wall is strengthened, but the sealing lip is damaged
Solution Approach 1:
The patent changes the material parameters of the connecting element by selecting a second plastic material with higher melt flow index and lower melting temperature compared to the base plate material. This parameter change allows the welding process to achieve strong bonding at lower ultrasonic energy levels and shorter welding times, preventing damage to the sealing lip while maintaining connection strength.
Solution Approach 2:
The holding plate is constructed as a composite structure combining two different plastic materials - a first plastic material for the base plate and a second plastic material with superior welding characteristics for the connecting element. This composite material approach enables optimized welding performance and connection reliability without compromising the sealing lip.
3Strength
If welding time is extended to improve connection strength, then the bond between holding plate and bag wall is strengthened, but the sealing lip undergoes thermal damage
Solution Approach 1:
By changing the material parameters of the connecting element to a second plastic material with lower melting temperature and higher melt flow index, the welding process can achieve adequate bond strength in shorter time periods. This parameter optimization prevents thermal damage to the sealing lip while ensuring sufficient connection strength between the holding plate and bag wall.
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 provides a stronger and more secure connection between the holding plate and the bag wall, reducing the risk of unintentional detachment and dust leakage, while minimizing the energy required for welding and enhancing the durability of the connection.
Implementation Method 1
a connecting element made of a second plastic material which is materially connected to the base plate for materially connecting the base plate to the bag wall, in particular by means of ultrasonic welding
Data Source
Figure 1~2
Figure 3~4
AI summary
The plate has a base plate (402) made of plastic material and including a through opening (403). The base plate firmly connects a connecting element (407) made of another plastic material with bag wall using ultrasonic welding. The connecting element is arranged on the bag wall to a side of the base plate to be connected, where the plastic materials are selected from thermoplastic. The former plastic material is different from the latter plastic material, and the connecting element is partially or fully arranged in a recess. Independent claims are also included for the following: (1) a method for connecting a holding plate with bag wall (2) a method for manufacturing a holding plate.