Thermally Conductive Pressure Pads for Thin Induction Welds
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Solution Overview
Problem
Conventional induction welding systems are limited in thickness capability due to inadequate heat removal on the non-coil side of the weld, preventing the induction welding of thinner components.
Innovation Solution
A thermally conductive pressure pad is used on the non-coil side to distribute compression loads and remove heat, ensuring even thermal distribution and preventing deconsolidation during induction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is applied to the weld interface and removed from the coil side, then proper thermal distribution is achieved, but heat removal on the non-coil side is inadequate, limiting component thickness capability
Solution Approach 1:
A heat spreader layer is introduced as an intermediary component between the non-coil side tooling and the component. This heat spreader is made of thermally conductive material and actively removes heat from the non-coil side of the weld interface, enabling effective thermal management for thinner components that would otherwise overheat on the non-coil side
2Force
If compression force is applied at the side opposite to the coil, then weld interface elements are pressed together, but heat accumulates on the non-coil side causing deconsolidation
Solution Approach 1:
The heat spreader acts as a thermal intermediary that actively manages heat accumulation on the non-coil side. By conducting heat away from the compressed weld interface region, it prevents deconsolidation while allowing the compressive force to effectively press the weld elements together
Solution Approach 2:
The system changes the thermal parameters on the non-coil side by introducing active heat removal. The heat spreader modifies the temperature distribution, maintaining thermal stability in the compressed region while allowing the compressive force parameter to remain effective
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
Enables the welding of thinner components by effectively managing heat and pressure distribution, enhancing weld quality and preventing surface defects.
Implementation Method 1
Induction welding uses electromagnetic induction to heat components without contacting the components
Implementation Method 2
heat is transferred from the surface of the weldment nearest the coil and into a heat sink on the coil side of the weld
Implementation Method 3
A thermally conductive pressure pad is used on the non-coil side to distribute compression loads and remove heat
Data Source
Figure 1~2B
Figure 2C~3B
Figure 3C~4A
AI summary
A compression load distributor includes a support layer (304, 404) and a heat spreading layer (301, 401). The support layer (304, 404) includes a flexible carrier (305, 405) configured to distribute a load from a compression load applying device. The heat spreading layer (301, 401) is coupled to and carried on the support layer (304, 404), the heat spreading layer (301, 401) comprising a heat sink (302, 402) configured to transfer heat throughout the compression load distributor. The heat sink (302, 402) is thermally conductive and electrically non-conductive.