Radar Support Welding Structure With Buffer Apertures
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Solution Overview
Problem
Existing radar support welding methods require high tensile force and result in welding marks due to thermal expansion and deformation, which are difficult to eliminate while maintaining the necessary tensile force requirements.
Innovation Solution
A support structure with crisscross ribs and buffer apertures is designed, where the solder joints are located on the crisscross ribs, allowing for increased molten material and providing deformation space through the buffer apertures to absorb thermal expansion, preventing overall deformation and thus eliminating welding marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If intersected grid ribs are provided in the welding area to increase welding tensile force, then the welding tensile force increases, but the grid ribs expand and deform during heating, producing welding marks that affect appearance
Solution Approach 1:
The welding part is segmented into multiple independent crisscross ribs instead of using interconnected grid ribs. Each crisscross rib is disconnected from others, allowing independent thermal expansion and deformation without affecting the entire structure. This segmentation enables the welding area to accommodate thermal stress locally while maintaining overall structural integrity and avoiding visible welding marks.
Solution Approach 2:
The buffer apertures are strategically positioned at specific locations where thermal expansion occurs, providing localized deformation space only where needed. The crisscross ribs maintain sufficient strength at welding joints while having reduced material density in non-critical areas, achieving local optimization of both strength and thermal expansion accommodation.
2Shape
If the depth of welding is reduced to improve weld marks, then the appearance improves, but the welding tensile force decreases and cannot satisfy requirements
Solution Approach 1:
The welding structure is divided into multiple crisscross ribs with buffer apertures, distributing the welding load across multiple segments. This allows each individual weld joint to be shallower (reducing marks) while the cumulative effect of multiple joints maintains the required overall tensile force.
Solution Approach 2:
Instead of relying on single deep welds, the solution transitions to a multi-dimensional array of shallower welds distributed across the crisscross rib structure. The buffer apertures add a vertical dimension for thermal expansion, allowing shallower welds that would otherwise be insufficient for strength requirements.
3Strength
If the entire support structure is made rigid to maintain structural integrity, then the structural strength is maintained, but thermal expansion during welding causes deformation and welding marks
Solution Approach 1:
The support structure is segmented into rigid crisscross ribs connected by buffer apertures. The ribs themselves maintain rigidity for structural integrity, while the buffer apertures create compliant zones that accommodate thermal expansion, preventing stress concentration and deformation in the rigid portions.
Solution Approach 2:
The buffer apertures act as flexible zones within the rigid support structure. These aperture regions can deform and expand during welding heating, absorbing thermal stress while the surrounding rigid rib structures maintain overall structural integrity and shape.
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 effectively increases welding tensile force while eliminating thermal expansion and contraction stress, ensuring high tensile force without welding marks by distributing expansion and contraction locally through the buffer apertures.
Implementation Method 1
when heated during welding, the whole grid ribs 101 will expand and deform
Implementation Method 2
a radar support is generally mounted to an automobile bumper by welding
Data Source
Figure 1~3
Figure 4~5
AI summary
The present invention relates to a support structure comprising: a support body (11); a welding part (12) arranged at a periphery of the support body (11) and including a plurality of buffer apertures (121) spaced apart from each other and crisscross ribs (122) being arranged between two adjacent buffer apertures (121), a solder joint being located on the crisscross ribs (122).