Resistance Welding Insert With Thermal Decoupling for Multi-Material Assembly

Solution Overview

Problem

Current methods for multi-material assemblies, such as those in the automotive and aerospace industries, face challenges in efficiently joining dissimilar materials like steel, aluminum, and composite materials using electric resistance welding, due to issues like material weakening, high costs, and the need for complex equipment and heat management.

Innovation Solution

An insert with a head portion for electrode docking and a body portion for welding, featuring a thermal decoupling element to manage heat and a reduced section for minimal material usage, allowing for robust multi-material assemblies with reduced equipment investment and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If welding patches are used to enable multi-material assemblies, then assembly versatility is improved, but material cost and mass increase

Engineering Contradiction:

Improveassembly versatilityVSAvoidinsert mass

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The insert features a head portion with a first section and a body portion with a second section smaller than the first section. The reduced cross-sectional area of the body portion minimizes material usage and mass while maintaining the necessary functionality for welding and structural support.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If welding patches are used to enable multi-material assemblies, then assembly versatility is improved, but material cost increases

Engineering Contradiction:

Improveassembly versatilityVSAvoidmaterial cost

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The insert features a head portion with a first section and a body portion with a second section smaller than the first section. The reduced cross-sectional area of the body portion minimizes material usage and mass while maintaining the necessary functionality for welding and structural support.

Inventive Principle:

Principle #3Local quality

3Temperature

If welding patches are used to enable multi-material assemblies, then heat dissipation is improved, but structural strength deteriorates

Engineering Contradiction:

Improveheat dissipationVSAvoidstructural strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The insert is divided into a head portion and a body portion with different cross-sectional areas. The head portion with the larger first section dissipates welding heat effectively, while the body portion with the smaller second section minimizes structural weakening of the first part.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert features a head portion with a first section and a body portion with a second section smaller than the first section. The reduced cross-sectional area of the body portion minimizes material usage and mass while maintaining the necessary functionality for welding and structural support.

Inventive Principle:

Principle #3Local quality

4Ease of operation

If conventional welding patches are used, then electrode docking is improved, but equipment complexity increases

Engineering Contradiction:

Improveelectrode dockingVSAvoidequipment complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The insert is divided into a head portion and a body portion with different cross-sectional areas. The head portion with the larger first section dissipates welding heat effectively, while the body portion with the smaller second section minimizes structural weakening of the first part.

Inventive Principle:

Principle #1Segmentation

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 efficient, cost-effective, and robust multi-material assemblies by concentrating welding energy, minimizing heat transmission to the first part, and reducing structural weakening, while allowing for the use of existing resistance welding equipment.

Implementation Method 1

a thermal decoupling element extending around the body portion to prevent a transmission of the heat released by the body portion to the first part during the welding operation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

electric resistance welding of the insert and of the second part

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

electric resistance welding

Methodology Applied

Scientific EffectElectric resistance: Electrical Resistance

Data Source

PatentUS11898596B2Insert intended for the assembly of a first part and a second part by electric resistance welding, and assembly method using this insert

Publication Date: 2024.02.13 GROJEAN MAXIME

AI summary

An insert including: a head portion including a docking face configured to receive a welding electrode and a bearing surface configured to come to bear on the first part in order to keep the first part assembled to the second part, a body portion intended to be inserted into the first part, including a welding surface configured to be welded to the second part, the body portion having a cross section smaller than that of the head portion, and thermal decoupling means extending around the body portion to prevent heat released by the body portion from being transmitted to the first part during the welding operation.