Resistance Weld Shielding Fixture for Complex Geometry Welds
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Solution Overview
Problem
Conventional welding techniques struggle to produce reliable welds for complex geometries in medical devices, particularly with oxygen-sensitive materials like titanium and molybdenum, due to inadequate shielding from the ambient atmosphere, leading to deformation and contamination issues.
Innovation Solution
A resistance weld shielding apparatus and method that employs a fixture with a gas delivery system to maintain a consistent, inert gas barrier around the parts being welded, using a nozzle configuration that is fixed in a physical relationship to the parts, ensuring optimal shielding and minimizing turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional welding techniques are used for complex geometries in medical devices, then welding can be performed on various geometries, but the weld quality deteriorates due to inadequate shielding from ambient atmosphere
Solution Approach 1:
The patent applies inert atmosphere shielding by directing inert gas (such as argon or nitrogen) onto the weld area during the resistance welding process. This creates a protective environment that prevents oxidation and contamination of the weld nugget, thereby improving weld quality and reliability for complex geometries that cannot be shielded by traditional geometric protection alone
2Reliability
If inert gas shielding is added to protect oxygen-sensitive materials, then weld quality improves, but device complexity increases due to additional gas delivery system
Solution Approach 1:
The patent merges the gas delivery system with the existing welding apparatus by integrating the inert gas delivery mechanism into the welding tool or fixture. This combination allows the shielding function to be added without requiring completely separate equipment, thereby improving weld quality while minimizing the increase in overall device complexity
Solution Approach 2:
The inert gas acts as an intermediary substance between the ambient atmosphere and the weld area. It provides a protective barrier that enables high-quality welding of oxygen-sensitive materials without requiring direct contact or complex mechanical shielding structures, thus improving weld quality while keeping the system relatively simple
3Object-affected harmful factors
If gas flow rate is increased to improve shielding, then protection from ambient atmosphere improves, but turbulence increases causing deformation
Solution Approach 1:
The patent optimizes the gas flow parameters by carefully controlling the flow rate, pressure, and distribution of the inert gas. By adjusting these parameters to optimal levels, the system achieves adequate shielding protection while maintaining laminar flow conditions that prevent turbulence-induced deformation of the workpiece or weld nugget
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 improved weld quality by reducing oxidation and deformation, increasing the strength and reliability of welds in complex geometries, such as those found in medical devices, by maintaining a precise inert gas flow and shielding environment during the welding process.
Implementation Method 1
a gas delivery system comprising a nozzle to direct an inert gas onto the part for shielding the part from the ambient atmosphere when the part is being welded
Implementation Method 2
at least one electrode to apply electrical energy to the part for welding the at least one part
Data Source
AI summary
A resistance weld shielding control system includes a computer that is executed to control a fixture to receive and hold at least one part to be welded. The computer also controls one or more electrodes to apply electrical energy to the part for welding the at least one part, and controls a gas delivery system to direct an inert gas onto the part for shielding the part from the ambient atmosphere via a nozzle. The nozzle is configured in the fixture such that the fixture holds the nozzle in a fixed physical relationship to the part.