Ultrasonic Welding Structure With Gel Overflow Containment
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Solution Overview
Problem
Conventional welding structures in electronic devices often result in gel overflow during ultrasonic welding, leading to appearance issues and increased manpower costs for cleanup, while also compromising the strength of the connection between components.
Innovation Solution
A welding structure featuring anti-overflow microstructures and a detention groove design that prevents gel overflow by accommodating excess gel within the gap between connected objects, enhancing connection strength through increased contact area and preventing gel overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional welding structure is used, then welding speed is fast, but gel overflow occurs affecting appearance and requiring cleanup
Solution Approach 1:
The bonding surface is divided into a welding area and a non-welding area, with the welding area having a smaller area than the bonding surface. This segmentation allows the welding material to be concentrated in a controlled region, preventing gel overflow to the non-welding area while maintaining fast welding speed.
Solution Approach 2:
Different areas of the bonding surface have different properties: the welding area is designed with specific acoustic impedance characteristics to concentrate welding energy and material, while the non-welding area maintains original properties. This local differentiation prevents gel overflow by confining the welding material to the designated welding area.
2Device complexity
If conventional welding structure is used, then assembly is simple, but connection strength is insufficient
Solution Approach 1:
The acoustic impedance parameters of the welding area are specifically adjusted to be different from the non-welding area. This parameter change concentrates the welding energy and material in the welding area, creating stronger bonds without complicating the overall assembly structure.
Solution Approach 2:
The solution introduces a new dimension of control by creating an area difference between welding and non-welding regions. This dimensional differentiation (welding area < bonding surface area) enables enhanced connection strength through concentrated welding while maintaining assembly simplicity.
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
The proposed welding structure effectively prevents gel overflow, saving manpower and resources, while improving production efficiency and maintaining a clean appearance, and enhances the connection strength between components by increasing the bonding stability.
Implementation Method 1
the welding structure is capable of avoiding overflow and enhancing welding strength
Implementation Method 2
When performing an ultrasonic welding process, the welding portion is melted to form a gel for bonding the second bonding surface to the fourth bonding surface
Implementation Method 3
A welding structure featuring anti-overflow microstructures and a detention groove design that prevents gel overflow by accommodating excess gel within the gap between connected objects
Data Source
AI summary
A welding structure includes a first object and a second object connected to each other. The first object includes a first surface, a second surface, a first bonding surface, a welding portion and a second bonding surface. The first bonding surface is connected to one side of the second surface away from the first surface. The welding portion is disposed on a surface perpendicular and connected to the first bonding surface. One side of the second bonding surface is connected to the welding portion. The second object includes a third surface, a fourth surface, a third bonding surface and a fourth bonding surface. The third bonding surface is corresponding to the first bonding surface and connected to one side of the fourth surface away from the third surface. The fourth bonding surface is corresponding to the welding portion and the second bonding surface.