Metal Member Welding Structure With Gap-Controlled Heat and Strength
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Solution Overview
Problem
Existing welding structures of metal members fail to balance increased welding strength with reduced thermal influence on base materials and peripheral members, while also aiming for downsizing of the entire assembly.
Innovation Solution
A welding structure that includes a gap between opposing surfaces of metal members, where the welding portion penetrates one member and extends into the other, with specific ratios of welding width, thickness, and depth to enhance strength and minimize thermal impact, using laser welding with a protrusion and concave configuration to stabilize the gap and improve bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the welding portion area is increased to improve welding strength, then welding strength is improved, but thermal influence on base material and peripheral members increases
Solution Approach 1:
The patent applies local quality by creating a gap structure that concentrates the welding portion in a specific localized area rather than spreading it uniformly. The gap causes the welding portion to form primarily in the gap region, allowing high welding strength in the critical joint area while limiting thermal diffusion to surrounding base material and peripheral members.
Solution Approach 2:
The gap structure segments the welding process into distinct zones: the welding portion is concentrated in the gap region while thermal influence is separated from the base material and peripheral members. This spatial segmentation allows the welding strength to be enhanced in the joint area without proportionally increasing thermal damage to surrounding areas.
2Strength
If the welding portion area is increased to improve welding strength, then welding strength is improved, but the size of the whole members increases
Solution Approach 1:
By concentrating the welding portion in the localized gap region rather than distributing it across a larger area, the patent achieves high welding strength without increasing the overall member size. The gap structure allows the welding metal to be confined to a small, specific volume where it is most needed for joint strength.
Solution Approach 2:
The gap structure utilizes the depth dimension (z-axis) to concentrate welding strength. The welding portion extends in the depth direction within the gap, allowing sufficient weld metal volume for strength without increasing the planar footprint (x-y dimensions) of the members.
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 achieves improved welding strength and reduced thermal influence on base materials and peripheral members by increasing the joint area and stabilizing the gap formation, while maintaining a compact design, as demonstrated by increased load at fracture points and reduced thermal damage.
Implementation Method 1
laser welding the first member and the second member by irradiating with a laser beam a surface of the first member opposite to the first opposing surface
Data Source
AI summary
A welding structure of metal members includes a first member having a first opposing surface, a second member having a second opposing surface, and a welding portion fixing the first member and the second member to each other. A gap is formed between the first opposing surface and the second opposing surface. R1>R2 is satisfied where R1 represents a width of the welding portion in the gap and R2 represents a width of the welding portion on the first opposing surface of the first member. T2>T1 is satisfied where T2 represents a thickness of the second member in the portion where the welding portion is formed and T1 represents a thickness of the first member in the portion where the welding portion is formed. 0.8≤D1/T1≤1.2 is satisfied where D1 represents a depth of the welding portion in the second member from the second opposing surface.