Resistance Welding Insert With Thermal Decoupling for Multi-Material Joints
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Solution Overview
Problem
Current methods for assembling multi-material components, such as steel, aluminum, and composite materials, using electric resistance welding are inefficient due to the need for large welding patches that increase material costs, weaken the components, and are difficult to integrate, especially with materials like plastic or composite materials.
Innovation Solution
An insert with a head part for receiving the welding electrode and a body part with a smaller section for welding, featuring thermal decoupling means to prevent heat transfer and a differential section design to concentrate welding energy, allowing for robust multi-material assemblies with reduced material costs and minimal structural weakening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large welding patches are used to ensure electrode positioning and dissipate heat, then welding reliability is improved, but material cost and component weight increase
Solution Approach 1:
The insert is divided into two distinct parts: a head portion with a first cross-sectional area that receives the welding electrode, and a body portion with a second cross-sectional area that is inserted into the workpiece. This segmentation allows the electrode-contacting head to be larger for better positioning and heat dissipation, while the inserted body can be smaller to reduce weight and material cost.
Solution Approach 2:
Different portions of the insert have different cross-sectional areas optimized for their specific functions. The head portion has a larger cross-section for electrode support and heat management, while the body portion has a smaller cross-section for minimal intrusion into the workpiece. This local differentiation resolves the contradiction between needing large size for welding reliability and small size for weight reduction.
2Reliability
If large welding patches are used to dissipate heat during welding, then welding process stability is improved, but heat transfer to the workpiece increases causing material damage
Solution Approach 1:
The insert is divided into a head portion that contacts the electrode and a body portion that contacts the workpiece. The head portion can be larger to dissipate heat away from the workpiece, while the body portion is smaller to minimize heat transfer to the workpiece material, thus maintaining welding stability while preventing damage.
Solution Approach 2:
The differential cross-sectional design creates local thermal management zones. The larger head portion acts as a heat sink to absorb excess heat, while the smaller body portion limits the heat flux reaching the workpiece, resolving the contradiction between process stability and preventing thermal damage.
3Ease of manufacture
If large diameter holes are drilled to integrate welding patches, then insert installation is facilitated, but structural strength of the workpiece is reduced
Solution Approach 1:
The body portion of the insert has a smaller cross-sectional area optimized for the minimum hole diameter needed for installation. This reduces the size of the hole required in the workpiece, thereby minimizing the structural weakening effect while still allowing for practical insertion and assembly.
4Adaptability or versatility
If welding patches are used to enable multi-material assembly by resistance welding, then material versatility is improved, but device complexity and material cost increase
Solution Approach 1:
The segmented design with differentiated cross-sectional areas allows the insert to maintain the necessary functions (electrode reception and workpiece insertion) with minimized material usage. The body portion can be made from material suitable for welding to the workpiece, while the head portion provides structural support, enabling material optimization and cost reduction while maintaining multi-material assembly capability.
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 insert enables efficient electric resistance welding of multi-material assemblies with reduced material costs, minimal heat transfer to the first part, and reduced mechanical weakening, facilitating the assembly of components with different materials without the need for additional positioning systems or expensive equipment.
Implementation Method 1
thermal decoupling means extending around the body portion to prevent transmission of heat released by the body portion to the first part during the welding operation
Implementation Method 2
electric resistance welding of the insert and the second part
Implementation Method 3
electric resistance welding
Data Source
Figure 1~4A
Figure 4B~5B
Figure 6A~9
AI summary
This insert (1) comprises: a head portion (2) including a docking face (20) configured to receive a welding electrode and a bearing surface (22) configured to bear against the first part (100) in order to hold the first part (100) assembled to the second part (200), a body portion (4) intended to be inserted into the first part (100), including a welding surface (40) configured to be welded to the second part (200), the body portion (4) having a cross-section smaller than that of the head portion (2), and thermal decoupling means extending around the body portion (4) to prevent transmission of heat released by the body portion (4) to the first part (100) during the welding operation.