Vibration Decoupling Zones for Asymmetrical Welding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for connecting structural elements using ultrasonic or vibration welding risk damaging vibration-sensitive components and result in insufficient weld strength due to vibration energy diversion, particularly with large and asymmetrical structural elements.

Innovation Solution

The use of spatially separated weld portions with vibration decoupling zones, where each weld portion is isolated from the rest of the structural element, preventing vibration energy transfer and ensuring that only a minimal amount of vibration energy is diverted, allowing for reliable connection of large and asymmetrical structural elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If vibratory welding is applied to connect structural elements, then welding strength is improved, but vibration-sensitive components may be damaged and vibration energy is diverted from the weld portion

Engineering Contradiction:

Improveweld strengthVSAvoiddamage to vibration-sensitive components

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The structural element is divided into multiple separate weld portions (first weld portion, second weld portion, etc.) that are spatially separated from each other. Each weld portion can be welded independently without affecting other weld areas, allowing sequential welding operations that prevent damage to already-welded components while maintaining overall weld strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Vibration decoupling zones are introduced as intermediary regions between weld portions and the rest of the structural element. These zones act as buffers that absorb and isolate vibration energy, preventing it from propagating to vibration-sensitive components or other weld portions during the welding process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If vibratory welding is applied to large and heavy structural elements, then connection capability is improved, but vibration energy is diverted away from the weld portion reducing weld quality

Engineering Contradiction:

Improveconnection capability for large elementsVSAvoidvibration energy diversion

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The structural element is segmented into distinct weld portions separated by vibration decoupling zones. This segmentation confines vibration energy to specific localized areas during welding, preventing energy from dispersing throughout the entire large structure. Each weld portion receives sufficient vibration energy independently, maintaining weld quality even in large and heavy elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Vibration decoupling zones are strategically positioned to create localized vibration isolation at critical interfaces. The structural element has different vibration characteristics in different regions - weld portions are designed to concentrate and maintain vibration energy locally, while decoupling zones are designed to absorb and dissipate vibration energy, preventing its spread to other areas.

Inventive Principle:

Principle #3Local quality

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 reduces the risk of damage to structural elements during welding, enhances weld strength by maximizing available vibration energy for the actual welding process, and expands the application spectrum to include larger and heavier structural elements.

Implementation Method 1

Each weld portion is spatially separated from each other weld portion and from the rest of the structural element by at least one vibration decoupling zone. The vibration decoupling zone has the effect that it is only to the least possible extent that vibration energy that is introduced into one of the weld portions is transferred to the other weld portions

Methodology Applied

Scientific EffectVibration decoupling: Damping

Implementation Method 2

The vibratory welding may be an ultrasonic welding such as, for example, a linear ultrasonic welding or a torsional ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 3

Alternatively, the vibratory welding may also be vibration welding

Methodology Applied

Scientific EffectVibration welding: Vibration

Data Source

PatentUS11618220B2Part for connection to at least one further part, method for connecting a part to at least one further part, and composite part

Publication Date: 2023.04.04 TELSONIC HLDG AG

AI summary

Parts (10) for connection to at least one further part (30, 30′). The part (10) has at least two weld sections (11, 11′) to be welded individually to at least one of the further parts (30, 30′) by vibration welding. Each weld section (11, 11′) has at least one weld surface (13, 13′), for connection to the corresponding further part (30, 30′), and is spatially separated from each other weld section (11, 11′) by at least one vibration decoupling zone (14, 14′,23, 26). The part (10) has a particular arrangement of the weld section (11, 11′) with respect to the center of gravity (S) or has a particular mass distribution with respect to the weld section (11, 11′). Methods for connecting a part to at least one further part (30, 30′) and a composite part (90) containing a part (10) and a further part (30, 30′) are also disclosed.