Pilot-Groove Coupling Member for Dissimilar Metal Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coupling technologies face challenges in efficiently joining metals with different melting points using a single pressure-electrification step, often resulting in insufficient contact and incomplete coupling due to differences in melting points.
Innovation Solution
A coupling device employing a coupling member with a pilot portion and discharge grooves or a ring-shaped wall, which melts and discharges the facing portion of a lower-melting-point metal into these features, ensuring contact and solidification with a higher-melting-point metal, thereby achieving effective coupling through resistance welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single pressure-electrification step is used to join metals with different melting points, then the process efficiency is improved, but the coupling completeness deteriorates due to insufficient contact caused by metal accumulation
Solution Approach 1:
The invention extracts and removes the accumulated lower-melting-point metal from the interface between the two metals using grooves or a suction device. This prevents the accumulation from interfering with the coupling process, allowing the higher-melting-point metal to make sufficient contact with the lower-melting-point metal for complete coupling while maintaining single-step process efficiency.
2Strength
If pressure is applied to ensure contact between metals, then the coupling strength is improved, but the melted metal accumulates and prevents sufficient contact
Solution Approach 1:
The invention converts the harmful effect of melted metal accumulation into a beneficial process by using the grooves to channel and collect the accumulated lower-melting-point metal. This allows pressure to be applied for strong coupling while the grooves prevent the accumulation from blocking contact, as the metal is directed into the grooves rather than accumulating at the interface.
3Device complexity
If the coupling member structure is simplified, then the device complexity is reduced, but the ability to remove accumulated metal is insufficient
Solution Approach 1:
The invention uses grooves as simple structural features on the coupling member that function similarly to porous structures - they provide pathways for the melted lower-melting-point metal to flow into and be collected. This simple groove structure effectively removes accumulated metal without requiring complex devices, maintaining low device complexity while achieving sufficient metal removal.
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 ensures a robust and complete coupling between metals with different melting points by preventing the accumulation of melted metal and ensuring sufficient contact, facilitating a single-step pressure-electrification process for effective joint formation.
Implementation Method 1
The controller is configured to, while maintaining the contact state, control the power source to electrify the coupling member, the first plate, and the second plate while controlling the driver to apply pressure to the coupling member, the first plate, and the second plate so as to: melt a facing portion of the first plate facing the pilot portion of the coupling member
Implementation Method 2
remove the melted facing portion to a farther side of the pilot portion through the plurality of discharge grooves formed on the coupling member
Implementation Method 3
melt and solidify the leading end of the pilot portion and the joint portion of the second plate to couple the leading end of the pilot portion and the joint portion of the second plate to each other
Data Source
AI summary
A coupling device couples, using a coupling member, a first plate of a first metal to a second plate of a second metal. A power source is connected to first and second electrodes. A driver moves the first and second electrodes relative to the coupling member and the first and second plates. A controller controls the power source and the driver to electrify the coupling member and the first and second plates under pressure. The coupling member includes a third metal approximately identical to the second metal. The first metal has a melting point lower than melting points of the second and third metals. The coupling member includes a pilot portion that is located about a center of a flat surface of a body of the coupling member and that protrudes in an extending direction. The flat surface has discharge grooves radially extending from the pilot portion.