Invisible resistance seam welding system and method

Abstract

The present invention relates to a resistance seam welding system and method used for welding iron, aluminium, sheet metal materials to each other so as to form a smooth surface.

Description

[0001] INVISIBLE RESISTANCE SEAM WELDING SYSTEM AND METHOD

[0002] Field of the Invention

[0003] The present invention relates to a resistance seam welding system and method used for welding iron, aluminium, sheet metal materials to each other without leaving any traces.

[0004] In particular, the present invention relates to an invisible resistance seam welding system and method which ensures that the two parts to be joined at the ends are welded to each other so as to form a smooth surface by being compressed by means of a Z-shaped disc electrode from the upper surface and a lower electrode from the lower surface and by being heated with electric current.

[0005] Present State of the Art

[0006] Resistance seam welding is applied in different ways so as to join iron, aluminium and sheet metal materials. The parts to be welded are basically joined together by melting them with the current passing between two copper electrodes in said resistance seam welding.

[0007] Since the environments of the parts to be welded are empty, the necessary form cannot be given and the melt spreads randomly on the welding surface in the resistance seam welding method applied in the state of the art. Slag is formed on the surface of the welded part, which is called the aesthetic surface, is clearly visible to the users as a consequence of this random spreading. Therefore, material residues called burrs, scale or slag in different thicknesses form on a part welded together with said method and when said part is covered with enamel after welding, enamel burns and enamel wastes occur in these areas. Therefore, the part cannot be used and is directly scrapped since an aesthetic surface cannot be obtained on the welding joint surface of the part. A gap of 1 ,5-2mm is left between the parts to be joined by means of welding so as to eliminate said disadvantage. The problem experienced in the enamel coating process is solved with said joining process. However, it is possible that the cooking oils formed or splashed during cooking in the ovens enter these surfaces that the hand cannot reach and create an area that is difficult to clean here when said part is used as a cooking utensil in the kitchens. Therefore, an environment suitable for the reproduction of bacteria is formed on these surfaces and a hygienic surface cannot be provided as a result of the accumulation of food residues. Accordingly, there is a need for a system and method in the state of the art that provides an invisible welding process in the resistance seam welding method and makes it possible to produce products with aesthetic surfaces, non-bacterial, hygienic and easy to clean, and which does not harm the user.

[0008] Document numbered W003028936 can be shown as an example to the state of the art in the research made in the literature. Said document relates to the workpiece resistance welding device. In said invention, a device that allows two parts placed on top of each other to be welded together from the inner surface is disclosed. However, said device is not suitable for welding on parts that need to be joined end to end and have an even surface.

[0009] As a result, in order to solve the abovementioned problems and the insufficiency of the current solutions makes it necessary to make a development in the relevant technical field.

[0010] Aim of the Invention

[0011] The present invention relates to an invisible resistance seam welding system and method which eliminates the abovementioned disadvantages and brings new advantages to the relevant technical field.

[0012] The main aim of the invention is to obtain an invisible resistance seam welding system and method which ensures that the two parts to be joined at the ends are welded to each so as to form a smooth surface by being compressed by means of a Z-shaped disc electrode from the upper surface and a lower electrode from the lower surface and by being heated with electric current.

[0013] The aim of the invention is to obtain an invisible welding surface that does not leave any traces on the surface of the parts that are joined to each other. Another aim of the invention is to fill the molten metal into the said cavity during the welding process by obtaining a weld gap between the first sheet metal part and a second sheet metal part whose end part is shaped in Z-shape and to ensure that the first and second sheet metal parts are seamlessly joined to each other and an invisible welding surface is obtained on the joint surfaces of the parts.

[0014] Another aim of the invention is to produce smooth products with aesthetic surfaces, non-bacterial, hygienic and easy to clean, and which does not harm the user by means of joining with invisible resistance seam welding to each other.

[0015] In order to fulfil all aims that may arise from the above-mentioned and detailed explanation the present invention is an invisible resistance seam welding system used for welding iron, aluminium, sheet metal materials to each other without leaving any traces, comprising the following;

[0016] - a first part,

[0017] - a second part that is positioned on the first part and has a Z-shaped bending surface on the surface of said first par that joins with the surface,

[0018] - weld gap that is formed between the first part and the second part by means of the bending surface by positioning the second part on the first part, lower copper electrode that performs welding process with electric current from the lower surface of the first part and the second part positioned in a slot thereon so as to join the first part and the second part to each other, upper copper disc electrode with a Z-shaped lower surface that performs welding process with electric current passing over the same by applying downward pressure on the first part and the second part on the lower copper electrode and contacts the bending surface to allow the molten metal to fill the weld gaps.

[0019] The present invention also relates to an invisible resistance seam welding method that is used for welding iron, aluminium, sheet metal materials to each other without leaving any traces. a) Z-form bending of the joint surface of the second sheet part to be joined with the flat form surface of the first part and the first part and obtaining a Z-shaped bending surface on the surface of the second part, b) Placing the first part and the second part on top of each other on the lower copper electrode, c) Compressing the first part and the second part by applying pressure on the lower copper electrode by moving the upper copper disc electrode downwards over the first part and the second part, d) Forming molten metal with the increase in temperature by forming a certain voltage on the first part and the second part by sending electric current to the lower copper electrode and the upper copper disc electrode, e) Filling of the molten metal into the welding gaps between the first part and the second part with the help of Z-shape of the contact surface on the bending surface of the upper copper disc electrode and welding the first part and the second part together with an invisible welding surface.

[0020] The structural and characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings. Therefore the evaluation shall be made by taking these figures and the detailed description into consideration.

[0021] Figures Clarifying the Invention

[0022] Figure 1 is a representative view of the inventive invisible resistance seam welding system.

[0023] Figure 2a is a representative plain view of the second part of the inventive invisible resistance seam welding system.

[0024] Figure 2b is a representative bended view of the second part of the inventive invisible resistance seam welding system.

[0025] Figure 2c is a representative view of the second part on the first part of the inventive invisible resistance seam welding system

[0026] Figure 3 is a detailed view of the second part on the first part of the inventive invisible resistance seam welding system.

[0027] Figure 4 is a representative view of the first part and second part of the inventive invisible resistance seam welding system.

[0028] Figure 5 is a representative perspective view of the second part on the first part of the inventive invisible resistance seam welding system.

[0029] Description of the Part References

[0030] 10. First part 20. Second part

[0031] 21 . Bending surface

[0032] 22. Angled form surface

[0033] 30. Weld gap

[0034] 40. Upper copper disc electrode

[0035] 50. Lower copper electrode

[0036] Detailed Description of the Invention

[0037] In this detailed description, the preferred alternatives of the inventive invisible resistance seam welding system and method is described only for clarifying the subject matter such that no limiting effect is created.

[0038] The present invention relates to an invisible resistance seam welding system which is used for welding iron, aluminium, sheet metal materials to each other without leaving any traces. A representative view of the inventive invisible resistance seam welding system is given in Figure 1. Accordingly, invisible resistance seam welding system mainly comprises the following; a first part (10), a second part (20) that is positioned on the first part (10) and has a Z-shaped bending surface (21 ), lower copper electrode (50) which performs welding process from the bottom surface of the first part (10) and the second part (20) which are placed within a slot so as to be joined to each other, upper copper disc electrode (40) with a Z-shaped lower surface that performs welding process with electric current passing over the same by applying downward pressure on the first part (10) and the second part (20), welding gap (30) that is located between the first part (10) and the second part (20) and enables the first part (10) and the second part (20) to be joined to each other by filling the molten metal into it as a result of heating the first part (10) and the second part (20) in the welding process applied with the upper copper disc electrode (40) and the lower copper electrode (50).

[0039] The end of the first part (10) is in a flat form in the inventive invisible resistance seam welding system. On the other hand, the second part (20) is configured in Z form to prevent the formation of welding tracks on the joint surface with the first part (10). Therefore, the second part (20) in flat form, as seen in figure 2a, is bent on a special workbench, and, as seen in figure 2b, a Z-shaped bending surface (21 ) is obtained on the surface of the second part (20). Also, an angled form surface (22) extending upwards is formed at the end of said bending surface (21 ). Said angled form surface (22) provides a comfortable mouthing when the first part (10) and the second part (20) are fed to each other by means of a robot or a manipulator.

[0040] The thickness of the bending surface (21 ) of the second part (20) is less than the thickness of the first part (10). Thus, when the first part (10) and the second part (20) are positioned on top of each other and joined by resistance seam welding, it is ensured that the surface of the first part (10) and the second part (20) are at the same level.

[0041] When the second part (20) is positioned on the first part (10) by means of the bending surface (21 ) formed on the joint surface of the second part (20) with the first part (10), as seen in figure 3, weld gaps (30) are obtained between the first part (10) and the second part (20). In order to enable the first part (10) and the second part (20) to be joined to each other, said weld gaps (30) are the spaces where the molten metal is filled during the resistance seam welding applied with the lower copper electrode (50) and the upper copper disc electrode (40).

[0042] The first part (10) and the second part (20) are placed in a slot located on a lower copper electrode (50) having high conductivity so as to ensure that the first part (10) and the second part (20) are joined to each other by means of resistance seam welding. Welding process is performed between the lower copper electrode (50) and the upper copper disc electrode (40) by applying pressure on the first part (10) and the second part (20) on said lower copper electrode (50) with an upper copper disc electrode (40) with high conductivity and upward and downward motion. The lower surface of said upper copper disc electrode (40) in contact with the bending surface (21 ) is also configured in Z-shape in accordance with the bending surface (21 ) of the second part (20).

[0043] The present invention also relates to an invisible resistance seam welding method that is used for welding iron, aluminium, sheet metal materials to each other without leaving any traces. The process steps of said invisible resistance seam welding method are as follows; a) Z-form bending of the joint surface of the second sheet part (20) to be joined with the flat form surface of the first part (10) and the first part (10) and obtaining a Z-shaped bending surface (21 ) on the surface of the second part (20), b) Placing the first part (10) and the second part (20) on top of each other on the lower copper electrode (50), c) Compressing the first part (10) and the second part (20) by applying pressure on the lower copper electrode (50) by moving the upper copper disc electrode (40) downwards over the first part (10) and the second part (20), d) Forming molten metal with the increase in temperature by forming a certain voltage on the first part (10) and the second par (20) by sending electric current to the lower copper electrode (50) and the upper copper disc electrode (40), e) Filling of the molten metal into the welding gaps (30) between the first part (10) and the second part (20) with the help of Z-shape of the contact surface on the bending surface (21 ) of the upper copper disc electrode (40) and welding the first part (10) and the second part (20) together with an invisible welding surface.

[0044] An angled form surface (22) that extends upwards at an angle at the end of the bending surface (21 ) so as to ensure that the first part (10) and the second part (20) are fed to each other by means of a robot or a manipulator so as to provide a comfortable mouthing can be formed in said process step (a).

[0045] The thickness of the bending surface (21 ) of the second part (20) is less than the thickness of the first part (10) in said process step (a).

Claims

8CLAIMS An invisible resistance seam welding system used for welding iron, aluminium, sheet metal materials to each other without leaving any traces, characterized by comprising the following;- a first part (10),- a second part (20) that is positioned on the first part (10) and has a Z- shaped bending surface (21 ) on the surface of said first par (10) that joins with the surface,- weld gap (30) that is formed between the first part (10) and the second part (20) by means of the bending surface (21 ) by positioning the second part (20) on the first part (10), lower copper electrode (50) that performs welding process with electric current from the lower surface of the first part (10) and the second part (20) positioned in a slot thereon so as to join the first part (10) and the second part (20) to each other, upper copper disc electrode (40) with a Z-shaped lower surface that performs welding process with electric current passing over the same by applying downward pressure on the first part (10) and the second part (20) on the lower copper electrode (50) and contacts the bending surface (21 ) to allow the molten metal to fill the weld gaps (30). The invisible resistance seam welding system according to claim 1 , characterized by comprising said bending surface (21 ) thickness is less than the thickness of the first part (10). The invisible resistance seam welding system according to claim 1 , characterized by comprising an angled form surface (22) that is located at the end of said bending surface (21 ) and extends upwards angularly. The invisible resistance seam welding method used for welding iron, aluminium, sheet metal materials to each other without leaving any traces, characterized by comprising the following process steps; a) Z-form bending of the joint surface of the second sheet part (20) to be joined with the flat form surface of the first part (10) and the first part (10)9 and obtaining a Z-shaped bending surface (21 ) on the surface of the second part (20), b) Placing the first part (10) and the second part (20) on top of each other on the lower copper electrode (50), c) Compressing the first part (10) and the second part (20) by applying pressure on the lower copper electrode (50) by moving the upper copper disc electrode (40) downwards over the first part (10) and the second part (20), d) Forming molten metal with the increase in temperature by forming a certain voltage on the first part (10) and the second par (20) by sending electric current to the lower copper electrode (50) and the upper copper disc electrode (40), e) Filling of the molten metal into the welding gaps (30) between the first part (10) and the second part (20) with the help of Z-shape of the contact surface on the bending surface (21 ) of the upper copper disc electrode (40) and welding the first part (10) and the second part (20) together with an invisible welding surface. The invisible resistance seam welding method according to claim 4, characterized by comprising the process step of forming an angled form surface (22) extending upwards at the end of the bending surface (21 ) so as to ensure that the first part (10) and the second part (20) are fed to each other by means of a robot or a manipulator, to provide a comfortable mouthing in said process step (a). The invisible resistance seam welding method according to claim 4, characterized by comprising the thickness of the bending surface (21 ) of the second part (20) is less than the thickness of the first part (10) in said process step (a).

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