Intersecting Weld Joint Reinforcement for Thin Panel Assembly
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Solution Overview
Problem
Laser brazing welding of thin panels with intersecting welding lines faces challenges in securing rigidity and preventing deformation and pinhole formation due to thermal stress and spring back phenomena, making it difficult to achieve desired product designs without welding defects.
Innovation Solution
A method and component design that includes forming rigidity-reinforcing parts on panels where preceding and following welds intersect, using laser welding, and strategically positioning these parts to enhance panel rigidity and prevent deformation, with the option to fill pinholes with sealer for smooth painting surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin panels are used for laser brazing welding, then welding quality and exterior design are improved, but panel rigidity deteriorates and deformation occurs due to external force clamping and spring back
Solution Approach 1:
The method performs preliminary actions before welding by clamping the panel at multiple points to pre-position it correctly, and by planning the welding sequence to address rigidity issues before they manifest as defects. The rigidity-reinforcing part is also formed in advance at locations where welding lines will intersect.
Solution Approach 2:
The invention applies local quality by forming a rigidity-reinforcing part at specific locations where welding lines intersect or where thermal stress concentrates. This localized reinforcement provides additional support precisely where needed without requiring the entire panel to be thicker, thus maintaining overall thin-panel design while preventing deformation at critical points.
2Adaptability or versatility
If welding lines are intersected to achieve desired product design, then design flexibility is improved, but thermal stress becomes excessive causing deformation and pinhole generation
Solution Approach 1:
The method performs preliminary actions by forming the rigidity-reinforcing part before welding and by planning the welding sequence to complete certain junctions before others. This preliminary preparation helps distribute thermal stress more effectively and prevents excessive stress concentration at intersection points.
Solution Approach 2:
The invention changes parameters by modifying the welding sequence (temporal parameter) and by adding structural features (geometric parameter) to alter how thermal stress distributes through the panel. The rigidity-reinforcing part changes the structural parameter to reduce thermal stress impact.
3Manufacturing precision
If welding lines do not overlap to prevent defects, then welding quality is improved, but realization of desired product design becomes difficult
Solution Approach 1:
The invention applies local quality by allowing welding line overlap only at specific locations where rigidity-reinforcing parts are formed, rather than avoiding overlap entirely. This localized approach enables desired design configurations with intersecting welding lines while preventing defects through the reinforcing structure at critical intersection points.
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
Prevents welding defects and deformation by enhancing panel rigidity, ensuring accurate assembly and painting quality, and effectively addressing thermal stress issues at intersection points.
Implementation Method 1
laser brazing welding
Implementation Method 2
thermal stress becomes excessive
Implementation Method 3
laser brazing welding
Data Source
AI summary
An embodiment provides a method of producing a component. A rigidity-reinforcing part is formed on a first part, a second part, or a third part adjacent to a point where a preceding weld and a following weld intersect each other. The first part and the second part are coupled to each other by performing the preceding weld in a state of overlapping and a part of a first junction part and a second junction part are pressurized. After performing the preceding weld, the first part, the second part, and the third part are coupled to each other by pressurizing and performing a following weld while overlapping a part of a third junction part with an opposite part of the first junction part and overlapping a remaining part of the third junction part with a cross junction part.