Vibration Welding Cooling Channels for Thermoplastic Deformation
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Solution Overview
Problem
Conventional vibration welding of thermoplastic materials in automotive components, such as interior panels and reinforcement members, leads to thermal deformation and reduced welding strength due to excessive heat transmission, causing surface deformities and potential separation of welded portions.
Innovation Solution
The method involves using first and second processed articles with convex columns and a cooling fluid supply system to prevent non-joining portions from reaching melting temperature during vibration welding, ensuring effective cooling and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the vibration friction period is increased to secure sufficient welding strength, then welding strength between articles is improved, but thermal deformation of the product deteriorates
Solution Approach 1:
The invention segments the heating and cooling processes by introducing separate cooling channels (first cooling channel in the substrate, second cooling channel in the foam layer) that operate independently during vibration friction welding. This allows localized cooling of specific regions to prevent thermal deformation while maintaining the welding process at the joining surfaces.
Solution Approach 2:
The invention applies local quality by providing different cooling configurations for different layers: the substrate layer has a first cooling channel with specific flow rate control, while the foam layer has a second cooling channel. This enables differential thermal management - cooling critical regions to prevent deformation while allowing welding heat to act on joining surfaces.
2Manufacturing precision
If cooling fluid flow rate is increased to prevent thermal deformation, then manufacturing precision is improved, but welding strength deteriorates
Solution Approach 1:
The invention changes thermal parameters by controlling cooling fluid flow rates at different stages: during vibration friction welding, the first cooling channel maintains a first flow rate to prevent substrate deformation, while the second cooling channel maintains a second flow rate to prevent foam layer deformation. This parameter control ensures both welding strength and manufacturing precision are achieved.
3Device complexity
If conventional vibration welding is used to join thermoplastic materials, then welding process simplicity is maintained, but product quality deteriorates due to thermal deformation
Solution Approach 1:
The invention introduces cooling fluid as an intermediary substance that mediates between the welding heat and the thermoplastic materials. The cooling fluid absorbs excess heat through the cooling channels, preventing thermal deformation of the substrate and foam layer while allowing the welding process to proceed effectively.
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 significantly reduces thermal deformation and enhances welding strength, preventing surface deformities and ensuring reliable bonding between thermoplastic components.
Implementation Method 1
supplying the cooling fluid from a cooling fluid source to the region surrounded by the first convex column via the supply port and discharging the cooling fluid via the discharge port so as to effect cooling in the region
Implementation Method 2
the articles are vibrated in relation to each other along the extending direction (surface direction) of the joining surfaces, while pressure is applied to the articles. Thus, contacting portions of the articles are melted and joined together by means of friction heat
Data Source
AI summary
Provided is a welded processed product which is reduced in the hear deformation thereof and can exhibit improved the welding strength between component processed articles. A welded processed products, wherein a first convex column (13) and second convex columns (14A and 14B) to be subjected to the vibration-welding with a joining surface (11a) of a first processed article (11) with each other are provided on a joining surface (12a) of a second processed article (12). When or after the above first and second convex columns (13) and the second convex columns (14A and 14B) and the joining surface 11a of the first processed article 11 are vibration-welded together by use of a vibration welding machine, a cooling fluid from a cooling fluid source 26 is supplied to a region surrounded by the first convex column 13 via a supply port 15 and discharged therefrom via a discharge port 16 so as to effect cooling in the region.