Pin Welding Joint for Stable Metal-Composite Layer Joining
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Solution Overview
Problem
Existing methods for joining material layers, particularly in the automotive industry, lack stability and are unable to effectively absorb shearing forces, especially when connecting metal and non-metallic layers like glass-fibre-reinforced plastic to steel components.
Innovation Solution
A tool and method that utilize a pin driven through material layers, with a driving-in device to penetrate and a welding device to securely weld the pin to a metal layer, enhancing the connection's stability by resisting shearing forces through resistance welding or inductive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin is driven through material layers by mechanical means alone, then the joining process is simple, but the connection is unstable and cannot effectively absorb shearing forces
Solution Approach 1:
The patent combines mechanical pin insertion with welding in a single integrated joining process. The pin is first driven through the material layers mechanically, then welded to the metal layer to create a stable connection that can absorb shearing forces, resolving the contradiction between simplicity and reliability.
Solution Approach 2:
The pin is preliminarily positioned and driven through the material layers before welding. This preliminary mechanical insertion ensures proper alignment and contact, followed by welding that permanently secures the connection, achieving both simplicity of positioning and reliability of the final bond.
2Strength
If a nail is used for joining material layers, then the joining process is simple, but the resistance against axial pull-out is relatively little
Solution Approach 1:
The patent replaces purely mechanical fastening (nail) with a combination of mechanical insertion and thermal welding. The welding process creates a metallurgical bond that significantly increases resistance against axial pull-out compared to mechanical fastening alone, while maintaining process simplicity.
3Adaptability or versatility
If spot welding is used to join metal material layers, then the connection is strong, but the process cannot effectively join metal layers with non-metallic layers
Solution Approach 1:
The patent segments the joining process into two distinct stages: mechanical pin insertion that penetrates all material layers (metal and non-metallic), followed by welding that creates strong bonds at the pin-metal layer interfaces. This segmentation allows the process to handle diverse material combinations while maintaining connection strength.
Solution Approach 2:
The pin acts as an intermediary element that bridges metal and non-metallic material layers. It mechanically penetrates the non-metallic layer and provides conductive contact with metal layers for welding, enabling the joining of dissimilar materials while maintaining strong connections.
4Force
If conventional welding tongues are used to conduct current, then the welding process is simple, but only small pressure can be exerted on the joining element
Solution Approach 1:
The patent merges the welding device with the pin insertion tool, creating an integrated system that can apply substantial pressure during pin insertion and maintain that pressure during welding. This combination allows high force application without requiring separate complex tooling systems.
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 secure and stable connection between material layers, capable of withstanding lateral forces and pressures, particularly beneficial for joining metal and composite materials like GFRP to steel components.
Implementation Method 1
at least one first section of the pin is welded to a metal material layer
Implementation Method 2
resistance welding or inductive heating
Data Source
AI summary
A tool configured to join at least two material layers, of which at least one material layer is in the form of a metal material layer, by a pin. The tool includes a driving-in device which drives the pin through the at least two material layers to be joined, and a welding device which, after the driving-in of the pin, welds at least one first section of the pin to the at least one metal material layer.