Vibration-Welded Structure With Guide Portions For Rib Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vibration-welded structures face reduced welding strength and increased failure risk due to insufficient friction when the angle between the welded surface and vibration direction is large, making it difficult to weld parts effectively.
Innovation Solution
The implementation of welding ribs with guide portions on each part to guide the movement of the other rib in the vibration direction, allowing for adjustment of the welded surface direction to be parallel or near-parallel to the vibration direction, thereby enhancing friction and minimizing rib height and potential misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welded surface is positioned at an angle to the vibration direction, then the welding structure can accommodate part geometry requirements, but the friction between welded surfaces becomes insufficient leading to reduced welding strength
Solution Approach 1:
The patent introduces a new spatial dimension by adding guide portions that extend in a direction different from the vibration direction. This allows the welded surface to be positioned at an angle to accommodate part geometry while the guide portions ensure proper alignment and contact during vibration welding, effectively resolving the conflict between welding structure adaptability and welding strength
Solution Approach 2:
The guide portions act as intermediary elements between the welded surfaces. They provide a guiding function that ensures proper alignment and contact during the vibration welding process, allowing the welded surfaces to maintain both the required angular orientation for part geometry and sufficient friction contact for strong welding
2Adaptability or versatility
If the angle between the welded surface and vibration direction is large, then the welding structure can accommodate complex part geometries, but welding failure becomes more likely
Solution Approach 1:
By adding guide portions that extend in a direction different from the vibration direction, the patent enables the welded surface to be positioned at larger angles to accommodate complex part geometries while maintaining welding reliability through the guiding function of the additional structural dimension
Solution Approach 2:
The welding structure combines the welded surface and guide portions as an integrated composite structure. The guide portions provide alignment and contact functionality while the welded surface provides the joining function, creating a composite structure that maintains both adaptability for complex geometries and reliability for successful welding
3Strength
If the welding rib height is increased to improve welding strength, then the friction and welding strength increase, but rib deflection and sinking occur
Solution Approach 1:
The patent adds guide portions that extend in a direction different from the vibration direction, creating a new structural dimension that provides alignment and support. This allows the welding rib height to be optimized for welding strength without excessive height that would cause deflection and sinking, as the guide portions provide additional structural support in the perpendicular dimension
Solution Approach 2:
The guide portions are positioned specifically at the ends of the welding ribs to provide localized guidance and support. This localized structural enhancement allows the welding rib to maintain optimal height for welding strength while preventing deflection and sinking at critical locations
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 ensures sufficient friction for strong welding, prevents rib deflection and sinking, and maintains reliable vibration-welding performance by adjusting the welded surface direction and minimizing rib height, while avoiding misalignment and detachment.
Implementation Method 1
a welded surface 2 of the welding rib 3 is attached to a general surface 5 of another part 4 and vibrated (in a vibration direction 6) so that a vicinity of the welded surface 2 is frictionally melted to weld the two parts
Implementation Method 2
a welded surface 2 of the welding rib 3 is attached to a general surface 5 of another part 4 and vibrated (in a vibration direction 6)
Data Source
Figure 1~2
Figure 3~4
AI summary
A vibration-welded structure includes a welding rib (15, 16) having a welded surface (13, 14), which is provided on each of two parts (11, 12) to be welded with each other and at least one guide portion (18, 19) provided on one of the two parts, which is capable of guiding a movement of the welding rib of the other of the two parts in a vibration direction (17).