Vibration Welded Tailgate Spoiler Protrusion Deflection
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Solution Overview
Problem
The strength of the slope portion in vibration welded articles, such as tailgate spoilers, is reduced when an opening is formed for components like brake lamps, leading to potential insufficient welding of the inner member to the outer member due to deflection during the welding process.
Innovation Solution
Incorporating protrusions on the second joint surface portion of the inner member that protrude towards the base surface portion, which helps in suppressing deflection and ensuring strong vibration welding by providing additional support during the process, and using a vibration welding apparatus with specific molds to effectively weld the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an opening is formed in the slope portion to attach another component (e.g., brake lamp), then the adaptability or versatility is improved, but the strength of the slope portion is reduced
Solution Approach 1:
The inner member is segmented with protrusions extending from its second joint surface portion toward the base surface portion. These protrusions divide the joint surface into multiple contact areas, distributing the welding force and preventing deflection while maintaining structural integrity despite the opening in the slope portion.
2Manufacturing precision
If the slope portion is pressed with a jig during vibration welding, then the manufacturing precision is improved, but the deflection of the slope portion increases due to reduced strength
Solution Approach 1:
The protrusions on the inner member are designed in advance to provide preliminary support during the welding process. When the pressing jig applies force to the slope portion, the protrusions engage with the outer member first, preventing excessive deflection before the main welding pressure is applied.
3Device complexity
If the inner member is vibration welded to the outer member without additional support, then the device complexity is reduced, but the welding strength is insufficient due to deflection
Solution Approach 1:
The inner member is designed with self-supporting protrusions that automatically engage with the outer member during the welding process. This self-service mechanism provides the necessary support and stability without requiring additional external fixtures or complex positioning devices, achieving both simplicity and welding strength.
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 configuration allows for the inner member to be welded to the outer member with high strength, preventing large deflections and ensuring a robust bond without the need for additional adhesives, while maintaining design flexibility and ease of assembly.
Implementation Method 1
vibrations are applied while pressing the first joint surface portion toward the base surface portion
Implementation Method 2
the inner member and the outer member are vibration welded
Data Source
AI summary
A vibration welded article includes an outer member having a substantially V-shaped portion, and an inner member that is vibration welded to the outer member. The outer member includes a substantially plate-shaped base surface portion, and a slope portion formed obliquely relative to the base surface portion. The slope portion has an outer member opening which is opened to attach another component. The inner member includes a first joint surface portion that is vibration welded to the base surface portion, a second joint surface portion that is vibration welded to the slope portion, and at least one protruding portion that protrudes from the second joint surface portion toward the base surface portion.