Vibration Welding with Convex Columns and Cooling Flow
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Solution Overview
Problem
Conventional vibration welding of thermoplastic materials in automotive components, such as interior panels and reinforcement members, results in thermal deformation due to excessive heat transmission, leading to reduced welding strength and product quality issues.
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 time is increased to secure sufficient welding strength, then welding strength is improved, but thermal deformation occurs due to heat transmission to adjacent portions
Solution Approach 1:
The patent segments the processed article into multiple convex columns (first convex column surrounding the joining surface, and multiple second convex columns in the surrounded region) that are spatially separated. This segmentation allows localized welding at discrete points while preventing heat accumulation and transmission to adjacent areas, thereby achieving sufficient welding strength without causing surface deformation.
Solution Approach 2:
The patent applies local quality by concentrating the welding action only at the convex column tips that contact the joining surface, while the surrounding regions (including the polypropylene-foam intermediate layer and thermoplastic polyolefin layer) remain unaffected. The cooling fluid is supplied locally to the region surrounded by the first convex column, ensuring that only the necessary welding zones are heated while adjacent portions are actively cooled to prevent thermal deformation.
2Manufacturing precision
If the vibration friction time is shortened to avoid thermal deformation, then surface quality is maintained, but welding strength decreases and welded portions may separate
Solution Approach 1:
The patent uses multiple discrete convex columns (one first convex column and multiple second convex columns) distributed across the joining surface. This segmentation allows the welding process to be completed effectively in a shorter time because the heat is concentrated at multiple discrete points simultaneously, achieving sufficient welding strength without requiring prolonged vibration friction that would cause thermal deformation.
3Manufacturing precision
If cooling fluid is supplied during vibration welding, then thermal deformation is reduced, but device complexity increases due to additional cooling system components
Solution Approach 1:
The patent merges the cooling function directly into the welding apparatus by integrating the cooling fluid supply system with the vibration welding machine. The cooling fluid supply port and discharge port are incorporated into the welding device structure, allowing simultaneous vibration welding and cooling operations without requiring separate standalone cooling equipment, thereby reducing overall device complexity while maintaining effective thermal deformation control.
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 between components, preventing surface deformations like concavities or convexities, while ensuring reliable bonding.
Implementation Method 1
supplying the cooling fluid from the 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.