Rounded Tip Welding Auxiliary Part for Clean Joint Formation
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Solution Overview
Problem
Existing auxiliary welding joining parts face challenges in optimizing the upstream setting process, leading to increased processing costs and difficulties in subsequent welding due to material displacement issues and complex fastening methods, especially when joining non-weldable and weldable materials.
Innovation Solution
The development of an auxiliary welding joining part with a rounded tip and a truncated cone-shaped area, designed to displace material from the first component effectively during the setting process, combined with a die geometry that creates a material displacement gap to form a clean welding head, facilitating a reliable weld without residual material interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an auxiliary welding joining part with a sharp tip is pressed into a non-weldable component, then the setting process is simplified, but material residues remain in the welding zone causing welding difficulties
Solution Approach 1:
The patent applies a rounded tip geometry instead of a sharp tip. The rounded tip with a specified radius range (0.5mm ≤ SR ≤ 8mm) enables complete displacement of material residues from the welding zone while maintaining ease of setting. This curved geometry allows the tip to push material residues outward effectively without leaving contaminants in the welding area, thus resolving the contradiction between easy setting and reliable welding.
2Reliability
If a rivet with T-shape or double-T-shape is used, then advantageous contact points are provided for resistance welding, but complex fastening and waste slug removal are required
Solution Approach 1:
The patent extracts the unnecessary complexity of T-shaped or double-T-shaped rivets by using a simple rounded tip geometry. The rounded tip provides sufficient contact area for resistance welding without requiring complex fastening mechanisms or waste slug removal processes. This simplifies the device structure while maintaining reliable welding contact.
3Speed
If a sharp tip auxiliary welding joining part is used, then initial penetration is easier, but material residues interfere with subsequent welding process
Solution Approach 1:
The rounded tip geometry maintains adequate penetration capability while eliminating material residue interference. The curved surface of the rounded tip allows material to be displaced smoothly outward during setting, clearing the welding zone completely. This resolves the contradiction by providing both sufficient penetration performance and clean welding conditions.
4Manufacturing precision
If the tip radius is small, then precise positioning is achieved, but material displacement during setting is insufficient
Solution Approach 1:
The patent optimizes the tip radius parameter to a specific range (0.5mm ≤ SR ≤ 8mm) that balances positioning precision with material displacement efficiency. This parameter optimization ensures that the tip is neither too sharp (leaving residues) nor too blunt (poor positioning), thus resolving the contradiction between precise positioning and effective material displacement.
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
This solution minimizes processing costs and simplifies the welding process by ensuring complete material displacement, resulting in a strong and reliable weld between non-weldable and weldable materials with reduced time and effort.
Implementation Method 1
designed to displace material from the first component effectively during the setting process
Implementation Method 2
combined with a die geometry that creates a material displacement gap to form a clean welding head
Implementation Method 3
subsequent welding to at least a second component made of weldable material
Data Source
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AI summary
wherein SR designates a tip radius of the rounded tip of the welding auxiliary joining part.