Flanged Weld Element with Annular Seal for Vehicle Components
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Solution Overview
Problem
Existing weld elements fail to effectively prevent contaminants, such as gases and liquids, from passing through during the welding process, which can lead to poor weld quality and potential damage to vehicle components.
Innovation Solution
A flanged weld element with a radially extending flange and an annular projection weld ring that forms a continuous seal around the barrel, preventing contaminants from transmitting through the weld element and allowing for efficient outgassing during the welding process, ensuring a high-quality seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a weld element is used to join vehicle components, then the connection strength is improved, but contaminants can pass through the weld element causing poor weld quality
Solution Approach 1:
The weld element is segmented into functional zones: a sealed bore region that blocks contaminant transmission paths, a welding region for structural connection, and a venting region that safely directs gases away from the seal. This segmentation allows the element to simultaneously provide strong connection and contaminant protection.
Solution Approach 2:
The sealed bore acts as an intermediary barrier between the two sides of the workpiece, preventing direct contaminant transmission through the weld element while maintaining structural integrity. The venting structure serves as an intermediary pathway that redirects harmful gases away from the critical sealing interface.
2Object-affected harmful factors
If a sealed structure is added to prevent contaminant transmission, then contaminant protection is improved, but the welding process complexity increases
Solution Approach 1:
The sealing function, venting function, and structural connection function are merged into a single integrated weld element. The sealed bore, venting structure, and welding interface are combined in one component, eliminating the need for separate sealing elements and reducing overall system complexity despite adding contaminant protection capabilities.
Solution Approach 2:
The weld element is designed as a multi-functional component that simultaneously provides structural connection, contaminant sealing, and controlled venting. This universal design consolidates multiple functions into one element, avoiding the complexity that would arise from assembling multiple separate components.
3Object-affected harmful factors
If the bore is completely sealed to prevent contaminant transmission, then contaminant protection is improved, but outgassing during welding cannot escape causing weld defects
Solution Approach 1:
The weld element exhibits local quality differentiation: the bore is sealed in critical regions to block contaminant transmission paths, while designated venting regions remain open to allow outgassing escape. This localized variation in sealing quality enables simultaneous contaminant protection and safe gas venting during the welding process.
Solution Approach 2:
The venting structure is designed in advance to counteract the harmful effect of outgassing by providing a predetermined escape pathway. This preliminary anti-action prevents gas accumulation that would otherwise compromise the weld quality, while the sealed bore regions simultaneously prevent external contaminants from entering.
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 provides a contaminant-proof and vapor-proof seal that prevents gases and liquids from passing through the weld element, ensuring a reliable and durable connection between vehicle components while allowing for efficient gas escape during welding, thus enhancing weld quality and preventing damage to vehicle components.
Implementation Method 1
forming a gas and vapor proof weld seal between the weld element and the vehicle body part about the barrel portion of the weld element by causing the weld ring to weld to the vehicle body part
Implementation Method 2
A controlled electrical power source delivers a pulse of high amperage AC (or rectified AC) current through the facing electrodes, through the interposed weld nut, and the workpiece
Implementation Method 3
the higher density and momentary current flow through the projections tend to selectively melt the projections
Implementation Method 4
venting of any outgassing that occurs during the welding procedures
Data Source
AI summary
The projection weld element can include a barrel having a first axial end and a second axial end, a central axial bore being defined through the barrel from the first axial end towards the second axial end, and at least a portion of the central axial bore including an attachment structure, such as internal threads. A radial flange can extend from the second axial end of the barrel, with the flange including a distal axial face on a side of the flange facing away from the first axial end of the barrel and a proximal axial face on a side of the flange facing toward the first axial end of the barrel. The flange can include an annular projection weld ring formed along the proximal axial face of the flange on the same side of the flange as the barrel that extends from the flange. A method for joining a working piece with a weld element can include joining a working piece with the above-described weld element and heating the structures to effect a projection welding between the working piece and the weld element.