Multi-Tubular Vehicle Beam Venting for Galvanized Laser Welding
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Solution Overview
Problem
Welding galvanized metal in vehicle components generates hazardous zinc oxide fumes that can affect operator health and weld quality if not properly ventilated, and existing methods do not effectively address this issue.
Innovation Solution
A multi-tubular beam design with ventilation openings formed by protrusions or dimples along the weld seams, allowing zinc oxide fumes to escape during laser welding, combined with a roll forming process that maintains a narrow heat affect zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanized metal is welded to protect against rust, then corrosion resistance is improved, but hazardous zinc oxide fumes are generated affecting operator health and weld quality
Solution Approach 1:
The patent utilizes the harmful zinc oxide fumes generated during welding of galvanized metal by providing ventilation openings that allow these fumes to escape. This converts the harmful byproduct into a vented exhaust, preventing fume accumulation that would otherwise compromise weld quality and operator health, while maintaining the beneficial corrosion protection of the galvanized coating
Solution Approach 2:
The patent introduces ventilation openings (porosity) into the beam structure at strategic locations near weld zones. These openings create a porous pathway system that allows zinc oxide fumes to escape during welding operations, resolving the contradiction between maintaining galvanized coating integrity for corrosion resistance and enabling fume ventilation for safe welding
2Strength
If high heat welding is used to join metal components, then welding strength is improved, but the heat affect zone expands causing potential damage to surrounding areas
Solution Approach 1:
The patent applies local quality by providing ventilation openings specifically at locations where welding occurs, rather than uniformly throughout the entire beam structure. This localized approach allows fume extraction precisely where needed during welding operations while maintaining structural integrity elsewhere, enabling strong welds without excessive heat affect zone expansion
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 design effectively ventilates zinc oxide fumes, ensuring a consistent weld quality while minimizing health risks and maintaining structural integrity of the beam.
Implementation Method 1
The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The weld material of the first weld joint includes molten metal of the first edge portion and the center wall, such as formed from a laser directed at an end section of the center wall that overlaps with the first edge portion.
Implementation Method 2
The ventilation openings allow zinc oxide fumes generated during welding to escape the interior of the beam
Implementation Method 3
The ventilation openings allow zinc oxide fumes generated during welding to escape the interior of the beam
Data Source
AI summary
A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.