Abstract:
Disclosed is an anti-spillage structure arranged on two components which are connected together by vibration friction welding. The two components comprise a base plate, the anti-spillage structure is provided with a main welding rib and a material-blocking plate, the main welding rib and the material-blocking plate are arranged on the same component or the main welding rib and the material-blocking plate are respectively arranged on the two components. An auxiliary welding rib is arranged at the top end of the material-blocking plate, when the two components are welded to each other, the base plate, the main welding rib, the material-blocking plate and the auxiliary welding rib enclose a spillage cavity, such that the spillage of the main welding rib generated in the welding process is fully accommodated in the spillage cavity. The anti-spillage structure of the present invention effectively improves spillage in the case of the manufacturing difficulty not being increased, and at the same time, solving the problem of dirt being contained that is generated at a conventional welding material-blocking edge.

Description:
FIELD 
       [0001]    The present invention relates to a field of welding, in particularly to an anti-spillage structure. 
       BACKGROUND 
       [0002]    It is well-known that plastic parts cannot be manufactured though molding by one time due to its construction, and welding process may be used subsequently for fusion manufacturing. Commonly used welding processes include conventional hot plate welding, infrared welding, ultrasonic welding and vibration friction welding and so on, wherein ultrasonic welding and vibration friction welding are increasingly used for their excellent properties such as low consumption, self-orthopedic and smoke-free. Both ultrasonic welding and vibration friction welding are based on the basic principles of the generation of heat by friction, but vibration friction welding can be applied to larger area and larger volume (weight) of the plastic parts of the welding. No matter which kinds of the welding technology are used, the spillage after welding is inevitable. The spillage volume is directly proportional to the amount of welding. When the quantities of welding is large, it&#39;s necessary to deal with the spillage by means of either the design of spillage in the non-use area, or the subsequent processing removal, or the design of the material-blocking edge, spillage slot to improve the appearance of the spillage. For the parts whose welding structure cannot be designed in the non-use of the visible areas, spillage slot or subsequent processing removal are generally used to deal with the spillage when hit hot plate welding and infrared welding, and the material-blocking edge would be used to improve the appearance of the spillage when vibration friction welding is used. The amount of the welding is very limited when ultrasonic welding is used, so welding spillage is not discussed. 
         [0003]    According to the welding result of our company actual products and other products on the site, the welding spillage of the vibration friction welding for the welding construction parallel to vibration direction differs from that perpendicular to vibration direction, and the difference is quite large. The welding spillage of welding ribs parallel to the vibration direction extends toward outside in the form of the sheet and has a wool-like outer end, and the degree of the spillage overflowing is larger, while the welding spillage of welding ribs perpendicular to the vibration direction is mostly in the form of extrusion paste and stick to welding ribs, and the degree of the spillage overflowing is small. 
         [0004]      FIG. 1  is a schematic view of the welding design according to the general design guide of the welding block. As shown in  FIG. 1 , a component  100  and a component  200  are welded together by vibration friction welding and form a melt glue zone  202 , wherein the component  200  is provided with a material-blocking edge  201 . As illustrated in  FIG. 1 , the material-blocking edge  201  fails to completely seal a spillage zone  203 , and therefore the material-blocking edge is generally able to confine the welding rib spillage perpendicular to the vibration direction but is unable to completely shield the welding rib spillage parallel to the vibration direction. In addition, the thickness of the material-blocking edge  201  is generally smaller. 
         [0005]    In addition, for welding productions whose applicable environment is required to be hygienic, if material-blocking edge cannot be well aligned with the opposite side due to difference of molding size or failure for vibration welding mold to adjust in place, the cavity between the material-blocking edge and welding ribs will instead become a filthy place and hard to clean. 
       SUMMARY 
       [0006]    Object of the present invention is to effectively improve the spillage in the case of the manufacturing difficulty not being increased, and at the same time, solving the problem of dirt being contained that is generated at conventional welding material-blocking edge. 
         [0007]    In order to achieve the above object, the present invention provides an anti-spillage structure arranged on two components which are connected together by vibration friction welding, and the two components comprising a base plate, wherein the anti-spillage structure is provided with a main welding rib and a material-blocking plate, the main welding rib and the material-blocking plate are arranged on the same component or the main welding rib and the material-blocking plate are respectively arranged on the two components, and an auxiliary welding rib is arranged at the top end of the material-blocking plate, when the two components are welded to each other, the base plate, the main welding rib, the material-blocking plate and the auxiliary welding rib enclose a spillage cavity, such that the spillage of the main welding rib generated in the welding process is fully accommodated in the spillage cavity. 
         [0008]    Preferably, during the welding process, the main welding rib is welded and then the auxiliary welding rib is welded. 
         [0009]    Preferably, the welding area of the auxiliary welding rib is 0.05˜0.5 times that of the main welding rib. 
         [0010]    Preferably, the auxiliary welding rib has a width larger than or equivalent to 0.3 mm. 
         [0011]    Preferably, the auxiliary welding rib has a width being 0.3 mm˜1.5 mm. 
         [0012]    Preferably, the auxiliary welding rib has a slop, which is located on one side of the spillage cavity facing away from the auxiliary welding rib. 
         [0013]    Preferably, the slop has a angle being 45°˜60°. 
         [0014]    Preferably, the width of the top surface of the auxiliary welding rib is larger than or equivalent to 0.3 mm. 
         [0015]    Preferably, the top end of the main welding rib is a main melted zone having a thickness Ha and a width Wa meeting the following relationship: 1 mm≦Ha≦2.5 mm or 2 mm≦Wa≦4 mm. 
         [0016]    Preferably, the material-blocking plate is further provided an art trench which is used for concealing the relative misalignment of the two components when the relative dimension deviation of the two components is large. 
         [0017]    Preferably, the top end of the main welding rib is a main melted zone, which has a thickness Ha and a width Wa meeting the following relationship: 1 mm≦Ha≦2.5 mm, and 2 mm≦Wa≦4 mm 
         [0018]    Preferably, the top end of the main welding rib is a main melted zone, and the top end of the auxiliary welding rib is an auxiliary melted zone, and a thickness Ha of the main melted zone of the main welded rib and a thickness Hb of the auxiliary melted zone of the auxiliary melted rib meet the following relationship: 0.25 Ha≦Hb≦0.5 Ha. 
         [0019]    Preferably, the width of the material-blocking plate is larger than or equivalent to that of the main welding rib. 
         [0020]    The anti-spillage structure of the present invention is provided with an auxiliary welding rib, which is welded to the opposite side when the main welding rib approaches to the end of welding, so that influence on the power of welding equipment is small, and meanwhile the appearance is affected hardly due few welding spillage of the auxiliary welding itself. In the condition of the large relative dimension deviation of the components, the optional art trench can conceal the relative misalignment of two welding components, so as to improve the appearance of the products. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0021]      FIG. 1  is a schematic view of a prior art weld design. 
           [0022]      FIG. 2  is a partial schematic view of a member  1  according to the first embodiment of the present invention. 
           [0023]      FIG. 3  is a partial schematic view of a member  2  according to the first embodiment of the present invention. 
           [0024]      FIG. 4  is a schematic view of the member  1  and member  2  according to the first embodiment of the present invention welded together. 
           [0025]      FIG. 5  shows sizes of various part of the member  1  and member  2  according to the first embodiment of the present invention. 
           [0026]      FIG. 6  is a partial schematic view of a member  1 A according to the second embodiment of the present invention. 
           [0027]      FIG. 7  is a partial schematic view of a member  2 A according to the second embodiment of the present invention. 
           [0028]      FIG. 8  is a schematic view of the member  1 A and member  2 A according to the second embodiment of the present invention welded together. 
           [0029]      FIG. 9  shows sizes of various parts according to the member  1  and member  2  according to the second embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0030]    Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawing in order to provide a clearer understanding of the objects, features and advantages of the present invention. It is to be understood that the embodiments shown in the drawings are not intended to limit the scope of the invention, but merely to illustrate the spirit of the invention. 
         [0031]    As shown in  FIGS. 2-9 , an anti-spillage structure is provided on a component  1  and a component  2  welded together by vibration friction welding, and the component  1  and component  2  comprise a base plate  10  and a base plate  20 . The anti-spillage structure is provided with a main welding rib  11  and a material-blocking plate  12 . Both the main welding rib  11  and the material-blocking plate  12  are arranged on the component  1  or the component  2 , or the main welding rib  11  and the material-blocking  12  are respectively arranged on the component  1  and component  2 , wherein an auxiliary welding rib  13  is provided on the top of the material-blocking plate  12 . When the component  1  and the component  2  are welded to each other, the base plate  10 , the base plate  20 , the main welding rib  11 , the material-blocking plate  12  and the auxiliary wedding rib  13  enclose a spillage cavity  16 , so that the spillage of the main welding rib generated during the welding process is completely accommodated in the spillage cavity  16 . 
       Embodiment-1 
       [0032]      FIG. 2  is a partial schematic view of the component  1  of the present embodiment. As shown in  FIG. 2 , the component  1  comprises a base plate  10 , a main welding rib  11 , a material-blocking plate  12  and an auxiliary welding rib  13 , wherein the auxiliary welding rib  13  is provided on the material-blocking plate  12 , and the auxiliary welding rib  13  and the main welding rib  11  extends from the base plate  10  towards the same direction. Preferably, the width of the material-blocking plate  12  is larger than or equivalent to that of the main welding rib  11 , and the welding area of the auxiliary welding rib  13  is 0.05˜0.5 times the welding area of the main welding rib  11 . 
         [0033]    As shown in  FIG. 2 , in the present embodiment, the auxiliary welding rib  13  has a slope  131  which is located one side of the auxiliary welding rib  13  facing away from the main welding rib  11 . The angle formed by the slope  131  and the horizontal plane (the drawing direction) is 45° to 60° and the width of the top surface  130  of the auxiliary welding rib  13  is no less than 0.3 mm. However, it will be understood for the skilled in the art that the auxiliary welding rib  13  may also have not slope. In this case, the width of the auxiliary welding rib is larger than or equivalent to 0.3 mm. Preferably, the width of the auxiliary welding rib is 0.3 mm˜1.5 mm. 
         [0034]    In the present embodiment, the material-blocking plate  12  is further provided with an art trench  15  used for concealing the relative misalignment between the component  1  and the component  2  when the relative size deviation of the component  1  and the component  2  is large, so as to improve the appearance of the production. 
         [0035]      FIG. 3  is a partial schematic view of the component  2  of the present embodiment. As shown in  FIG. 3 , the component  2  comprises a base plate  20 , an outer side plate  21 , a main welding base surface  22  and auxiliary welding base surface  24 . Wherein the main welding base surface  22  is provided on the base plate  20 , and the auxiliary welding base surface  24  is provided on the outer side plate  21 . Preferably, the component  1  further comprises a saving material slot  23  which is located on either or both sides of the welding base surface  22 . 
         [0036]      FIG. 4  is a schematic view of the component  1  and component  2  welded together by vibration friction welding. As shown in  FIG. 4 , the top end of the main welding rib  11  of the component  1  is a main melt zone  14 , and the top end of the auxiliary welding rib  13  of the component  1  is an auxiliary melted zone  17 . The main welding rib  11 , the base plate  10 , the base plate  20 , the material-blocking plate  12  and the auxiliary welding rib  13  enclose a spillage cavity  16 . Preferably, the thickness Ha and width Wa of the main melted zone  14  meet the following relationship: 1 mm≦Ha≦2.5 mm or 2 mm≦Wa≦4 mm. And the thickness Ha of the main melted zone  14  and the thickness Hb of the auxiliary melted zone  17  meet the following relationship: 0.25 Ha≦Hb≦0.5 Ha. 
         [0037]    During the welding process, the main welding rib  11  is first in contact with the main welding base surface  22  and majority of the welding is completed. Then the auxiliary welding rib  13  is brought into contact with the outer side plate  21  when the main welding rib  11  approaches to the end of welding. And in the subsequent welding process, the auxiliary welding rib  13  is welded on the auxiliary welding base surface  24 , so as to enclose the spillage cavity  16  with material-blocking plate  12 , and main welding rib  11 . During the welding process, the spillage of the main welding rib  11  is accumulated in the spillage cavity  16  and the welding spillage of the main welding rib would not overflow from the spillage cavity  16  due to the auxiliary welding rib  13  welded to the outer side plate  21 . Therefore, after the welding is completed, it is not necessary to perform the removal of the spillage for the main welding rib  11 . 
         [0038]    For the spillage generated by the auxiliary welding rib  13 , only small amount of work should be implemented to remove spillage for the reason that the auxiliary welding rib  13  is far smaller than the main welding rib  11 , thus greatly saving the labor and solving the filth problem caused by the conventional welding material-blocking edge. 
         [0039]    According to the parameters of existing machinery and equipment in market, the work waveforms used in the vibration friction welding are mostly two specifications with amplitude 1 mm, frequency 200 Hz and amplitude 2 mm, frequency 100 Hz. The latter is suitable for the application requirements with relative larger volume and relative deeper welding depth and can provide better welding strength but its spillage is also more. The size requirements of the main welding rib and the auxiliary rib will be specifically described below regarding to the waveform with the specification of amplitude 2 mm, frequency 100 Hz. 
         [0040]    The following description will be made with reference to  FIG. 5 . 
         [0041]    Assuming: the maximum weld dimension of the component  1  is d1, and the corresponding maximum weld dimension of the component  2  is d2, the relative dimensional deviation between the component  1  and component  2  is: K=|d1−d2|. 
         [0042]      FIG. 5  shows sizes of various parts of the component  1  and component  2  according to the first embodiment of the present invention. As shown in  FIG. 5 , the width of the main welding rib  11  is Wa, and the depth of the main melted zone  14  is Ha, and the width of the welding base surface  22  of the component  2  is Wd, and the distance between the edge of the main melted zone  14  and the edge of the saving material slot  23  is Wb. The distance between the edge of the saving material slot  23  and the edge of the auxiliary melted zone  17  is Wc, and the dimension which the length of the main welding ridge  11  minus the depth of the main melted zone  14  is Hd, and the depth of the auxiliary melted zone  17  is Hb. The distance between the main welding surface  22  and the auxiliary welding surface  24  is Hc. The width of the top surface of the auxiliary welding rib  13  is H3. The height of auxiliary welding rib  13  minus the thickness of auxiliary melted zone  17  is Hf, and the inclination angle of the slope  131  of the auxiliary welding is A. 
         [0043]    Preferably, for the welding structure parallel to the vibration direction, the above dimensions meet the following relationship: 
         [0044]    Hc≧0.8 Ha: 
         [0045]    Hd≧Ha; 
         [0046]    Wd≧Wa+K: 
         [0047]    Wb≧0.5(Wa+K); 
         [0048]    Wc=0.5K; 
         [0049]    He≧0.3 mm; 
         [0050]    Hb≈0.3 Ha: That is, the welding cross-sectional area of the auxiliary welding rib is required to be as small as possible meanwhile to ensure sealing inside of the spillage cavity. 
         [0051]    Hc≧0.8 Ha; 
         [0052]    Hd≧Ha. 
         [0053]    Preferably, for the welding structure perpendicular to the vibration direction, the above dimensions meet the following relationship: 
         [0054]    He≧0.8 Ha; 
         [0055]    Hd≧Ha; 
         [0056]    Wd≧Wa+K+2×2, that is, Wd is equal to or greater than the width of the welding rib plus the relative dimension deviation and plus double amplitudes; 
         [0057]    Wb≧0.5×Wa+2, the reason why the cross-sectional width Wb at this time requires contact with relative dimensional deviation is that the space with an amplitude of 2 mm is returned to the vibration origin after the vibration friction welding is completed. 
         [0058]    Wc=2. 
       Embodiment-2 
       [0059]    The main difference between the present embodiment and the embodiment 1 is that the main welding rib and the auxiliary welding rib are respectively provided on different components. A second embodiment of the present invention will be described with reference to  FIGS. 5-8 . 
         [0060]      FIG. 6  is a partial schematic view of the component  1 A of the present embodiments. As shown in  FIG. 6 , the component  1 A comprises a base plate  1 A 0 , a main welding rib  1 A 1 , an outer side plate  1 A 2 , and an auxiliary welding base surface  1 A 3 . Wherein, the main welding rib  1 A 1  extends from the base plate  1 A 0 . 
         [0061]      FIG. 7  is a partial schematic view of the component  2 A of the present embodiment. As shown in  FIG. 7 , the component  2 A comprises a base plate  2 A 0 , a material-blocking plate  2 A 1 , a main welding surface  2 A 2 , and an auxiliary welding rib  2 A 4 . The auxiliary welding rib  2 A 4  extends from the material-blocking plate  2 A 1 . 
         [0062]    In the present embodiment, the auxiliary welding rib  2 A 4  has a slope  2 A 40 , which is located on one side of the auxiliary welding  2 A 4  facing away from the main welding rib  1 A 1 . The angle formed by the slope  2 A 41  and the horizontal plane (shown in figures) is 45˜60°, and the width of the top surface  2 A 41  of the auxiliary welding rib is no less than 0.3 mm. However, it should be understood for the skilled in the art that the auxiliary welding rib may also have not slope. In this case, the width of the auxiliary welding rib is larger than or equivalent to 0.3 mm. Preferably, the width of the auxiliary welding rib is 0.3 mm˜1.5 mm. 
         [0063]    Preferably, the width of the material-blocking plate  2 A is larger than or equivalent to the width of the main welding rib  1 A 1 , and welding area of the auxiliary welding rib  2 A 4  is 0.05˜0.5 times the welding area of the main welding rib  1 A 1 . 
         [0064]    In the present embodiment, the base plate  2 A 0  is further provided with a saving material slot  2 A 3 , and the material-blocking plate  2 A 1  has an art trench  2 A 5  used for concealing the relative misalignment between the component  1 A and the component  2 A when the relative size deviation of the component  1 A and the component  2 A is large, so as to improve the appearance of the production. 
         [0065]      FIG. 8  is a schematic view of the component  1 A and the component  2 A welded together by vibration friction welding. As shown in  FIG. 8 , the top end of the main welding rib  1 A 1  of the component  1 A is a main melted zone  1 A 3 , and the top end of the component  2 A is an auxiliary melted zone  2 A 5 . The main welding rib  1 A 1 , the material-blocking plate  2 A 1  and the auxiliary welding rib  2 A 4  enclose a spillage cavity  17 . Preferably, the thickness Ha and the width Wa of the main melted zone  14  meet the following relationship: 0.25 Ha≦Hb≦0.5 Ha. 
         [0066]    During the welding process, the main welding rib  1 A 1  is first in contact with the main welding base surface  2 A 2  and welded. Then the auxiliary welding rib  2 A 4  is brought into contact with the auxiliary welding base surface  1 A 3  of the outer side plate  1 A 2  when the main welding rib  1 A 1  approaches to the end of welding, and auxiliary welding rib  2 A 4  is welded to the auxiliary welding base surface  1 A 3  of the outer side plate  1 A 2  and enclose a spillage cavity  17  with the main welding rib  1 A 1 , material-blocking plate  2 A 1  and auxiliary welding rib  2 A 4 . During the process, the spillage of the main welding rib  1 A 1  is accumulated in the spillage cavity  17  and t will not overflow from the spillage cavity  17  as the auxiliary welding rib  2 A 4  is welded to the outer side plate  1  A 2 . Therefore, after the welding is completed, it is not necessary to perform the additional removal of the spillage for the main welding rib  1 A 1 . 
         [0067]    For the spillage generated by the auxiliary welding rib  2 A 4 , only small amount of work should be implemented to remove the spillage for the reason that the auxiliary welding rib  2 A 4  is far smaller than the main welding rib  1 A 1 , thus greatly saving the labor and solving the filth problem caused by the conventional welding material-blocking edge. 
         [0068]    According to the parameters of existing machinery and equipment in market, the work waveforms used in the vibration friction welding are mostly two specifications with amplitude 1 mm, frequency 200 Hz and amplitude 2 mm, frequency 100 Hz. The latter is suitable for the application requirements with relative larger volume and relative deeper welding depth and can provide better welding strength, but its spillage is also more. The size requirements of the main welding rib and the auxiliary rib will be described below regarding to the waveform with specification of amplitude 2 mm, frequency 100 Hz. 
         [0069]    The following description will be made with reference to  FIG. 9 . 
         [0070]    Assuming: the maximum weld dimension of the component  1 A is d1, and the corresponding maximum weld dimension of the component  2 A is d2, and the relative dimensional deviation between the component  1 A and component  2 A is: K=|d1−d2|. 
         [0071]    As shown in  FIG. 9 , the width of the main welding rib  1 A 1  is Wa, and the depth of the main melted zone  1 A 3  is Ha, and the width of the welding base surface  2 A 2  of the component  2 A is Wd, and the distance between the edge of the main melted zone  1 A 3  and the edge of the saving material slot  23  is Wb, and the distance between the edge of the auxiliary melted zone  2 A 5  and the edge of the auxiliary welding base surface  1 A 3  is Wc, and the dimension which the length of the main welding ridge  1 A 1  minus the depth of the main melted zone  1 A 3  is Hd, and the distance between the top end of the material-blocking plate  2 A and the main welding base surface  2 A 2  is Hc, and the width of the top surface of the auxiliary welding rib  2 A 4  is He, and the height of the auxiliary welding rib  2 A 4  minis the thickness of the auxiliary melted zone  2 A 5  is Hf, and the thickness of the art trench is Hk. 
         [0072]    Preferably, for the welding structure parallel to the vibration direction, the above dimensions meet the following relationship: 
         [0073]    Value of Wa and Ha is determined according to the welding strength requirements, and for the high strength welding requirements, generally Wa=2˜4, Ha=1˜2; 
         [0074]    Wd≧Wa+K; 
         [0075]    Wb≧0.5(Wa+K), Wc=0.5K; 
         [0076]    The width of the top surface of the auxiliary welding rib is no less than 0.3 mm, Hb≈0.3 Ha, that is he welding cross-sectional area of the auxiliary welding rib is required to be as small as possible meanwhile to ensure sealing inside of the spillage cavity. 
         [0077]    Hc≧5 ×Ha. 
         [0078]    Preferably, for the welding structure perpendicular to the vibration direction, the above dimensions meet the following relationship: 
         [0079]    Wd≧Wa+K+2×2, That is, Wd is equal to or greater than the width of the welding rib plus the relative dimension deviation and plus double amplitudes; 
         [0080]    Wb≧0.5×Wa+2, The reason why the cross-sectional width Wb at this time requires contact with relative dimensional deviation is that the space with an amplitude of 2 mm is returned to the vibration origin after the vibration friction welding is completed. 
         [0081]    Wc=2. 
         [0082]    The significant difference between the welding structure of embodiment-1 and embodiment-2 and that of the general vibration friction is that the material-blocking plate is provided with an auxiliary welding rib, which is welded to the opposite side when the main welding rib approaches to the end of welding, so that influence on the power of welding equipment is small, and meanwhile the appearance is affected hardly due few welding spillage of the auxiliary welding itself. In the condition of the large relative dimension deviation of the components, the optional art trench can conceal the relative misalignment of two welding components, so as to improve the appearance of the products. 
         [0083]    While the preferred embodiments of the present invention have been described in detail above, it will be understood for those skilled in the art that various changes and modifications can be made therein without departing from the above teachings of the present invention. These equivalents are also intended to be within the scope of the claims appended hereto.