3D Profiled Metal Sandwich Panel Resistance Weldability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sandwich panel structures with non-metallic interlayers are not resistance-weldable due to electrical isolation, preventing their use in subsequent processing industries for joining with other materials or components through resistance welding processes.
Innovation Solution
A method involving a three-dimensional metal sheet with a non-metallic material filled into recess spaces between two metal layers, ensuring direct mechanical and electrical contact, allowing for resistance weldability without additional processing steps or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a non-metallic interlayer is positioned between metal layers in a sandwich panel, then mechanical coupling and structural integrity are improved, but resistance weldability deteriorates due to electrical isolation
Solution Approach 1:
The non-metallic interlayer is positioned only in recess spaces between the metal layers, leaving the peaks of the three-dimensionally profiled metal layer exposed. This creates local electrical contact points at the peaks while maintaining mechanical coupling through the non-metallic material in the recesses, thereby preserving both structural integrity and resistance weldability
Solution Approach 2:
The invention transitions from a flat, two-dimensional metal layer configuration to a three-dimensionally profiled metal layer with peaks and recesses. This dimensional change allows the non-metallic interlayer to be positioned in the recess spaces while leaving the peaks exposed for electrical contact, resolving the contradiction between mechanical coupling and electrical conductivity
2Reliability
If additional processing steps are added to enable resistance welding of sandwich panels, then resistance weldability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The three-dimensionally profiled metal layer with exposed peaks is created during the initial sandwich panel manufacturing process, before any welding operations. This preliminary structuring ensures that resistance weldability is inherently built into the panel design, eliminating the need for additional processing steps or specialized equipment later in the manufacturing chain
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
Enables direct resistance weldability of sandwich panels in their initial state, simplifying manufacturing, reducing costs, and increasing production efficiency by eliminating the need for additional processing steps, while maintaining mechanical, stiffness, and sound features.
Implementation Method 1
the physical law of Joule for resistance heating is used. That means the transformation of electrical energy into ohmic resistance and then further into thermal energy
Implementation Method 2
The machine parts are made of copper to have a good current transmission with low resistance
Data Source
AI summary
The invention relates to a method for manufacturing a sandwich panel as a semi-finished product where at least one layer of a non-metallic material is positioned between at least two metallic layers. At least one of the metal layers is shaped into a three dimensional layer, and the metal layers are in direct mechanical contact to enable resistance weldability of the semi-finished product in order to connect the semi-finished product to a desired combination of solutions in a subsequent manufacturing process.