Bi-Compositional Screw Welding Mechanism for Pore-Free Joints

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional welding mechanisms for manufacturing bi-compositional screws generate air and pores inside the joint, reducing the strength and quality of the screw, and result in waste formation due to frictional heat, increasing processing costs and complexity.

Innovation Solution

A welding mechanism with a carrier and operating set that positions and rotates the front and rear sections to allow a circumferential welding process, preventing air and pores from forming inside the joint, and reducing waste by ensuring close contact between the welding surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the conventional rubbing operation is used to weld the front and rear sections, then the joint temperature increases to melt and combine the sections, but air and pores are generated inside the joint reducing strength and quality

Engineering Contradiction:

Improvejoint temperatureVSAvoidjoint quality

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

Instead of using a rubbing operation that generates harmful air and pores, the invention inverts the approach by using a pressing operation that applies unidirectional force to force air and pores outwards from the joint during welding, thereby improving joint quality while maintaining the necessary temperature increase for welding

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If the rubbing operation is used to weld the sections, then the joint combines to form the bi-compositional screw, but waste is pressed outwards requiring softening and additional removal processes

Engineering Contradiction:

Improvewelding processVSAvoidprocessing steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention extracts and removes waste material in real-time during the welding process through the outwards pressing action, eliminating the need for subsequent softening and removal processes. This reduces the number of processing steps while maintaining effective welding

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If the rubbing operation is used to weld the front and rear sections, then the sections are combined, but the waste formation increases processing costs

Engineering Contradiction:

Improvejoint strengthVSAvoidwaste material

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The invention converts the harmful effect of waste material formation during welding into a beneficial outcome by using the pressing operation to force waste outwards while simultaneously strengthening the joint. The same mechanical action that removes waste also ensures proper bonding, eliminating the need for separate waste removal steps and reducing overall material loss

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution enhances processing quality and reduces costs by preventing air and pore formation, improving the strength and quality of the bi-compositional screw through circumferential welding, while minimizing waste and processing difficulties.

Implementation Method 1

the pushing member pushes the rear section toward a direction of the holding member to further cause a front welding surface of the front section to closely contact a rear welding surface of the rear section

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 2

the power source carries out a rotation of the operating set and simultaneously rotates the front and rear sections

Methodology Applied

Scientific EffectRotational motion:

Implementation Method 3

the welding device welds the front and rear sections at the joint circumferentially to produce a bi-compositional screw

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 4

rub the front welding surface against the rear welding surface to increase the temperature of the joint. The joint of the front welding surface and the rear welding surface further melts caused by the frictional heat

Methodology Applied

Scientific EffectFrictional heat: Friction

Data Source

PatentUS11498159B2Welding mechanism for manufacturing a bi-compositional screw

Publication Date: 2022.11.15 TAIWAN SHAN YIN INT CO LTD

AI summary

A welding mechanism for welding different blank sections includes a welding device and a carrier. The carrier has a base, two opposite positioning members, an operating set disposed between the positioning members and driven by a power source, and a holding member and a pushing member which are respectively disposed relative to the positioning members. The blank sections, including a front section and a rear section, are separately placed on the operating set. The front section is restricted by the holding member. The pushing member pushes the rear section, so the two sections meet at a joint. When the two sections rotate synchronously along with the rotation of the operating set, the welding device welds the two sections at the joint circumferentially to produce a bi-compositional screw, thereby preventing the generation of air and pores inside the joint after welding, increasing processing quality, and reducing processing costs.