Exhaust Component Resistance Welding With Curved Insertion Surfaces

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Solution Overview

Problem

Existing methods for resistance welding in exhaust systems of internal combustion engines lack flexibility in positioning components, leading to limitations in achieving a stable and gas-tight connection, especially when components are not oriented at right angles.

Innovation Solution

A method involving a first component with an insertion opening surrounded by a welding area and a second component with a curved insertion area that can be inserted to maintain contact along the entire edge, allowing for varied positioning and ensuring electrical current flows for melting and welding, even with small gaps between the components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional resistance welding is used with flat surfaces, then the welding process is simple, but the components must be precisely oriented at right angles limiting positioning freedom

Engineering Contradiction:

Improvepositioning freedomVSAvoidsurface geometry complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies spherical curvature to the welding surfaces of both components. The first component has a spherical welding surface, and the second component has a complementary spherical welding surface. This curved geometry allows the components to be positioned at various angles while maintaining adequate contact area for resistance welding, thereby achieving positioning freedom without requiring precise right-angle orientation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If components are positioned at non-right angles, then positioning freedom increases, but contact area between welding surfaces decreases

Engineering Contradiction:

Improvepositioning freedomVSAvoidcontact area

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The spherical welding surfaces are designed with specific radii of curvature that ensure adequate contact area is maintained even when components are positioned at non-right angles. The curved geometry allows the surfaces to conform to each other at various orientations, preserving sufficient contact area for effective resistance welding while enabling positioning freedom.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If curved surfaces are used instead of flat surfaces, then positioning freedom improves, but manufacturing complexity increases

Engineering Contradiction:

Improvepositioning freedomVSAvoidsurface formation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The spherical welding surfaces can be formed using conventional machining processes such as spherical end mills or by adding spherical attachments to cylindrical components. This approach allows curved surfaces to be created with standard manufacturing equipment, reducing the increase in manufacturing complexity while still achieving the benefits of positioning freedom.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Adaptability or versatility

If contact area is reduced for angled positioning, then positioning flexibility increases, but welding quality may deteriorate

Engineering Contradiction:

Improvepositioning flexibilityVSAvoidwelding quality

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The spherical surfaces are designed with optimized radii of curvature that ensure the contact area remains sufficient for high-quality welding even at angled positions. The curved geometry naturally maintains adequate contact area across various orientations, ensuring welding quality is not deteriorated while achieving positioning flexibility.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

This approach enables flexible positioning of components while ensuring a stable and gas-tight welded connection without the need for projection-like elevations, effectively addressing the limitations of traditional resistance welding.

Implementation Method 1

applying an electrical voltage to the two components for the resistance welding of the first component to the second component

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11801568B2Method for welding together two components, preferably of an exhaust system of an internal combustion engine, by resistance welding

Publication Date: 2023.10.31 PUREM GMBH

AI summary

A method welds together two components of an internal combustion engine exhaust system, by resistance welding, to provide greater positioning freedom of two components welded together. A first component is provided with a welding area including an insertion opening edge surrounding an insertion opening. A second component is provided with a welding area including an insertion area to be inserted into the insertion opening. The insertion area is inserted into the insertion opening such that the insertion area is in contact with the first the entire insertion opening edge. An electrical voltage is applied to resistance weld the first component to the second component. The surface (28) of the insertion area is curved about two axes that are not parallel or is curved about an axis that is parallel to the surface of the insertion area, or/and an insertion surface of the insertion opening edge is located in one plane.