TW201628749A - Ultrasonic welding method and product obtained with the method - Google Patents

Abstract

An ultrasonic welding method that includes the steps of: preparing at least two members made of thermoplastic material, arranging them with respective connecting regions mutually adjacent in a substantially mated manner; transmitting an ultrasonic beam to at least one of the members at the connecting regions; simultaneously with the ultrasonic transmission, applying a pressure to the members, pressing them one against the other in order to keep the connecting regions in mutual contact. The particularity of the present invention resides in that the connecting regions include curvilinear portions that mutually mate and in that, prior to the preparation of the members, respective mutually mating welding surfaces are defined on the members; such mutually mating welding surfaces make the curvilinear portions at least partially discrete. The invention also relates to a product manufactured with the method.

Description

Ultrasonic welding method and product obtained by the method

The present invention relates to an ultrasonic welding method and a product produced by the method.

As is known, ultrasonic welding is a common technique for assembling plastic parts.

In practice, ultrasonic welding occurs in a load-bearing part that can be used for several welds and a vibrating part that is used to vibrate several weldable objects. The vibrating parts can vibrate by matching the ultrasonic frequency. The adjustment device vibrates.

This strong vibration transmitted by the so-called welding head generates heat, which melts the material and thus welds the two parts.

However, the reliability and correct application of this technology requires the following series of measurements, starting with the applied force and the direction of vibration that must be perpendicular to the weld.

Therefore, if the splice point is between a plurality of curved or contoured surface extensions, the ultrasonic technique has its difficulties if it must be used.

Therefore, in this case, other methods such as, for example, friction welding are required.

Friction welding is a technique of welding a part by relative movement between parts to be welded, such as rotation, friction generated, and combined with application of pressure.

However, friction welding is less precise and can result in fusion flashes that are unacceptable for many applications.

Alternatively, the material can be melted with a laser beam and a weld joint can be established, for example by means of laser welding.

However, this laser beam fusion technique is quite complex and can usually only be performed by robot arms that require high investment costs.

In addition to this, it must also be considered that the time and cost of performing the welding with the laser is quite expensive.

With the following ultrasonic welding method, this goal can be achieved for these purposes. And for a better understanding of other purposes, the method comprises the steps of: preparing at least two members made of a thermoplastic material, positioning in a substantially paired manner with individual connection regions; transmitting a supersonic beam to the At least one of the members on the connection region; and at the same time as the step of transmitting the ultrasonic beam, applying a pressure to the members to press together to maintain the connection regions in contact with each other; characterized in that: The joining regions comprise mutually matching curved portions; prior to the step of preparing the members, the method includes the step of forming matching weld surfaces on the members, leaving at least a portion of the curved portions separated.

According to a further aspect, the present invention provides a product comprising at least two members splicable by transmitting a supersonic beam onto an individual connection region, the connection regions having curved portions; characterized in that the members comprise mutually matched welds The surface is such that the portions of the curves are at least partially separated.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above problems and to provide an ultrasonic welding method capable of accommodating two or more components even when the connecting region includes a curved portion.

Within the scope of this aim, a particular object of the invention is to provide a method of solderable connection at a connection area substantially parallel to the direction of the ultrasonic beam transmitted by the horn.

Another particular object of the present invention is to provide a method that allows the manufacture of a fluid-operated pumped diffuser, or any other product made from two or more components that include a curved portion of the joint region.

Another object of the present invention is to provide a welding method that ensures very reliable and extremely repeatable.

Another object of the present invention is to provide a method for fully exploiting the production potential of an ultrasonic fusion splicer.

1‧‧‧ first component

2‧‧‧Second component

3‧‧‧First connection area

4‧‧‧Second connection area

5 ‧ ‧ steps

5a‧‧‧welding surface

5b‧‧‧ connection surface

6‧‧ steps

6a‧‧‧welding surface

6b‧‧‧ connection surface

50‧‧‧Supersonic beam

100‧‧‧Diffuser

101‧‧‧ first component

102‧‧‧ second component

105‧‧‧First step

105a‧‧‧welding surface

105b‧‧‧ connection surface

106‧‧‧Second step

106a‧‧‧welding surface

106b‧‧‧Connection surface

110‧‧‧First Ontology

111‧‧‧through holes

112‧‧‧ first wall

113‧‧‧ blades

114‧‧‧ edge

115‧‧ ‧ protrusions

116‧‧ ‧ protrusions

120‧‧‧Second ontology

121‧‧‧ recesses

122‧‧‧ seats

Further features and advantages will be gained from the non-limiting examples of the preferred but non-proprietary ultrasonic welding method according to the present invention and the products obtained by the method, wherein: Figure 1 is a schematic cross-sectional view of a general product obtained by the method according to the present invention; the second figure is a top view of a fluid-operated pump diffuser obtained by the method according to the present invention; a sectional view of the plane III-III in the second figure; The fourth view is a perspective view of the diffuser assembly; the fifth view is a top view of the assembly in the previous figure; the sixth view is a cross-sectional view along the VI-VI plane in the fifth figure; and the seventh view is the diffuser. A top view of another component in the middle; the eighth figure is a cross-sectional view along the plane VIII-VIII in the seventh figure.

DETAILED DESCRIPTION OF THE INVENTION Referring to the drawings, the present invention is directed to a method of ultrasonically fusing a plurality of mutually assembled thermoplastic materials. In particular, the method is conceived to perform ultrasonic welding between at least one first member 1 and at least one second member 2, both of which have connection regions, including mutually matching curved portions, designated as reference number 3, respectively. And 4.

According to the invention, the method comprises defining mutually matching weld surfaces on the first member 1 and the second member 2 and at least partially separating the curved portions of the welded surfaces.

Conveniently, the welding surfaces are defined on the first connection zone 3 and on the second connection zone 4, respectively, prior to performing the welding operation.

According to preferred but not exclusive embodiments, the fused surfaces are substantially perpendicular to the ultrasonic beam used to perform the splicing and are contemplated to be curved continuity interrupting portions of the curves.

In the illustrated example, the fused surfaces are defined by a first plurality of steps 5 and by a second plurality of steps 6, respectively.

In a particular case, steps 5 are adjacent to each other, as are steps 6; however, according to further embodiments, the steps may be separated.

In practice, each step 5 consists of a welded surface 5a and a connecting surface 5b. The welded surface 5a is substantially perpendicular to the ultrasonic beam 50 for welding.

Similarly, each step 6 is formed by a substantially welded surface 6a and a connecting surface 6b substantially perpendicular to the ultrasonic beam 50 for welding.

In the illustrated example, the attachment surfaces 5b and 6b are substantially parallel to the ultrasonic beam 50 for fusion, but other shapes may be used without departing from the inventive concept.

Conveniently, the weld surface 5a substantially matches the corresponding weld surface 6a, while the joint surface 5b substantially matches the corresponding joint surface 6b.

Please note that when making steps 5 and 6, please be careful that the thickness of the first member 1 and the second member 2 is sufficient to obtain a reliable splice point.

Preferably, steps 5 and 6 are provided during the forming of members 1 and 2.

In addition, steps 5 and 6 can be provided by removing the material in the connection regions 3 and 4.

Once the steps 5 and 6 have been formed, the actual welding operation can be performed, first configuring the first member 1 and the second member 2 adjacent to the steps 5 and 6; in particular, the welding surface 5a is disposed adjacent to the corresponding welding surface 6a.

At this point, a supersonic beam is substantially transmitted to at least one of the two members 1 and 2 on steps 5 and 6 by means of a horn, i.e., a tool that produces ultrasonic vibration.

The other member is conveniently inserted into a mold, which is the anvil.

At the same time, pressure is applied to the two members 1 and 2, so that the two are pressed against each other, so that the steps 5 and 6 are kept in contact with each other.

Most importantly, it is pointed out that by performing the method according to the invention, the ultrasonic beam and the applied pressure are substantially perpendicular to the fused surfaces 5a and 6a.

Therefore, the presence of the fused surfaces 5a and 6a allows efficient transmission of the ultrasonic beam and Thrust to ensure good results of this welding operation.

Still further, this configuration prevents the two members 1 and 2 from sliding and/or deforming each other.

The invention also relates to products obtained by the methods described and illustrated above.

This product consists of two or more components that are fused by ultrasonic beams transmitted to individual connection zones.

In accordance with the present invention, the members include weld surfaces that are respectively matched to each other on the joint regions, with the assumption that the curved portions of the joint regions are at least partially separated.

The second to eighth figures illustrate a practical embodiment of a product constructed from a fluidly operated pumped diffuser 100.

Those skilled in the art will recognize that many different products may have substantially equivalent features without departing from the field of the invention.

The diffuser 100 includes a first member 101 and a second member 102, both of which are joined together by the ultrasonic welding method according to the present invention.

The first member 101 includes a first body 110 that provides a consistent perforation 111 in the center and is laterally separated by a first wall 112 having a substantially quadric partial shape.

The vanes 113 extend from the first wall 112 and are obliquely symmetrically distributed about the axis of the first body 110.

Conveniently, the blades 113 are curved so as to form a radially disposed conduit with the second member 102.

The second member 102 includes a substantially cylindrical second body 120 having a recess 121 centrally received for receiving at least a portion of the first member 101.

Conveniently, the pocket 121 has a shape substantially complementary to the envelope of the blade 113. shape.

In fact, the two members 101 and 102 are to be joined to each other in such a manner that the edge 114 of the blade 113 matches the surface of the pocket 121, thus defining the above-mentioned duct.

In accordance with the present invention, both the first member 101 and the second member 102 include individual weld surfaces that match each other and at least partially separate the curved portions of the joint regions of the two members 101 and 102.

Such a spliced surface is defined by a first plurality of adjacent steps 105 and by a second plurality of adjacent steps 106, respectively.

The first step 105 is formed substantially on the edge 114 of the blade 113, while the second step 106 is provided on the surface of the pocket 121 with a pattern that matches the pattern of the first step 105.

In practice, each step 105 consists of a splicing surface 105a that is substantially parallel to a pedestal of the first body 110 and a connecting surface 105b.

Similarly, each step 106 is formed by a splicing surface 106a that is substantially parallel to a pedestal of the second body 120 and a connecting surface 106b.

Conveniently, on the splicing surface 105a of each step 105, there is a protrusion 115 which has the task of concentrating the energy provided by the horn during welding.

Additionally, the protrusions may be formed on the weld surface 106a of each step 106.

As mentioned earlier, the diffuser 100 is fabricated by separately manufacturing the two members 101 and 102 and joining the two later, such that the welded surface 105a is welded to the corresponding welded surface 106a.

In effect, the matching of the weld surface 105a to the corresponding weld surface 106a, the attachment surface 105b to the corresponding joint surface 106b, and the transmission of a supersonic beam to the base or second member of the first member 101 The base of 102; simultaneously applying pressure to join the two Components 101 and 102.

It is understood that the fused surface 105a of each step 105 is substantially perpendicular to the ultrasonic beam for fusion.

Similarly, the fused surface 106a of each step 106 is substantially perpendicular to the ultrasonic beam for fusion.

According to a further aspect of the invention, the phase control problem of the two members 101 and 102 during welding is also addressed. This problem can be solved by forming the adjusted protrusion 116 on one of the members and forming the corresponding seat 122 on the other member. The protrusion 116 is adjusted to interlock with a number of corresponding seats 122 provided on another member.

At this time, it is apparent that the present invention achieves the desired object and purpose.

In other words, the present invention can perform ultrasonic welding on the joint region including the curved portion.

This method can also be applied to the connection region substantially parallel to the direction of the used ultrasonic beam.

A practical application of the method is, for example, to fabricate a fluid-operated pumped diffuser by ultrasonic welding a two component on a junction region comprising a curved portion.

This method and the products it provides are also particularly advantageous from a purely economic standpoint.

In fact, it has been found that, according to the present invention, the ultrasonic welding method and the products obtained by using the method completely achieve the desired goals and objectives.

The present application claims priority to the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the benefit of the present disclosure.

1‧‧‧ first component

2‧‧‧Second component

3‧‧‧First connection area

4‧‧‧Second connection area

5 ‧ ‧ steps

5a‧‧‧welding surface

5b‧‧‧ connection surface

6‧‧ steps

6a‧‧‧welding surface

6b‧‧‧ connection surface

50‧‧‧Supersonic beam

Claims (11)

An ultrasonic welding method comprising the steps of: preparing at least two members made of a thermoplastic material, placed adjacent to each other in a substantially paired manner; and transmitting a supersonic beam to the connecting regions At least one of the members; at the same time as the step of transmitting the ultrasonic beam, applying a pressure to the members, pressing each other together to maintain the connection regions in contact with each other; characterized in that the connection regions comprise each other Matching curve portions; prior to the step of preparing the members, the method includes the step of forming matching weld surfaces on the members, leaving at least a portion of the curved portions separated. The method of claim 1, wherein the fused surfaces are substantially perpendicular to the supersonic beam and are coupled to the curved portions, such that the continuity of the curves of the portions of the curves is interrupted. A method of one or more of the preceding claims, wherein the welded surfaces are adjacent to each other. A method according to one or more of the preceding claims, wherein the welded surfaces are provided when the members are molded. A method according to one or more of the preceding claims, wherein the materials are removed from the members to provide the welded surfaces. A method of one or more of the preceding claims, wherein at least a portion of the fused surfaces comprise protrusions that are adjusted to concentrate the energy delivered by the ultrasonic beam. A method according to one or more of the preceding claims, wherein the components comprise a phase controlled device The phase control device includes at least one pair of protrusions formed on one of the members and adapted to interlock with a plurality of corresponding seats formed on the other member. A product comprising at least two members splicable by transmitting a supersonic beam onto an individual connection region, the connection regions having curved portions; characterized in that the members comprise mutually matching weld surfaces, such that at least the curved portions Partial separation. The product of claim 8 is characterized in that the fused surfaces are substantially perpendicular to the supersonic beam and are connected to the curved portions, thus interrupting the continuity of the curve. The product of claim 8 is characterized in that the welded surfaces are adjacent to each other. A product according to claim 8 characterized in that the member is a fluid-operated pumped assembly of a diffuser; the first member comprises a first body, the center providing a consistent perforation and consisting of a first curved wall Laterally separating; the blade extends from the first wall and is obliquely symmetrically distributed about the axis of the first body; the second member includes a second substantially cylindrical body having a recess in the center thereof for accommodating at least a portion of the first a body having a shape substantially complementary to an envelope of the blades; the members comprising weld surfaces that are mated to each other and formed substantially on the edges of the blades, and the pockets On the surface, this is at least partially separated.