Auxiliary Welding Joining Part With Clamping Ring for Aluminum
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Solution Overview
Problem
Existing auxiliary welding joining parts face challenges in being pressed into components made of difficult-to-weld materials like aluminum, leading to material displacement and compressive stresses that hinder the welding process, and previous designs either protrude excessively or fail to provide effective sealing.
Innovation Solution
The proposed auxiliary welding joining part features a punching shank with a clamping ring and embossing rings that allow for radial material displacement without obstructive material accumulation, ensuring secure attachment and sealing by redirecting material flow and using a countersunk head to minimize protrusion, facilitating resistance welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the annular bead is arranged on the radial outer edge of the underside of the element head, then deep penetration of the auxiliary welding joining part into the aluminum component is supported, but material accumulates radially outwards which can flow off without restriction and the shank and part of the element shaft protrude beyond the free surface of the first component thereby hindering a subsequent welding process
Solution Approach 1:
The element head is divided into multiple functional zones: an annular groove for material accumulation, an annular bead for sealing, and a countersunk head for minimizing protrusion. This segmentation allows each zone to perform its specific function independently, resolving the contradiction between penetration depth and welding accessibility.
Solution Approach 2:
The invention transitions from a simple radial material displacement to a three-dimensional material flow control system. The annular groove creates a vertical dimension for material accumulation, while the countersunk head creates an inclined surface that redirects material flow, preventing radial accumulation that would hinder subsequent welding.
2Reliability
If at least two rigid, closed peripheral embossing rings are provided on the underside of the element head, then sealing of the joint is achieved by preventing corrosive media from penetrating into the gap, but material displacement leads to material accumulation which generates compressive stresses on the component surface counteracting penetration
Solution Approach 1:
The invention extracts the sealing function from the material displacement function. Instead of using multiple embossing rings that perform both sealing and material displacement, the invention uses a single annular bead for sealing while the annular groove manages material flow separately. This separation eliminates the harmful compressive stresses while maintaining sealing reliability.
Solution Approach 2:
The invention converts the harmful material accumulation effect into a beneficial sealing mechanism. The annular groove captures the radially displaced material and redirects it to form an annular bead that seals the joint, transforming the harmful compressive stress into a useful sealing force.
3Strength
If the auxiliary welding joining part is pressed into the first component with deep penetration, then secure attachment is achieved, but the shank and element shaft protrude beyond the free surface of the first component
Solution Approach 1:
The invention uses a countersunk head design that creates an inclined surface, transitioning from vertical penetration to angular insertion. This allows the auxiliary welding joining part to achieve secure attachment through the inclined surface while the main shaft remains recessed, minimizing protrusion length without sacrificing attachment strength.
Solution Approach 2:
Instead of having the shaft protrude to provide attachment strength, the invention inverts the design by having the countersunk head provide the attachment function through its inclined surface, while the shaft remains recessed. This reverses the traditional approach and resolves the contradiction between strength and protrusion.
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 design enables reliable and efficient welding connections between difficult-to-weld materials and weldable components, reducing material displacement issues and compressive stresses, while ensuring effective sealing and minimizing protrusion for improved process efficiency.
Implementation Method 1
the clamping ring is pressed into the first component and as a result portions of the material of the first component are displaced radially inward in the direction of the punching shank, so that the punching shank is clamped by the displaced material
Implementation Method 2
the embossed rings are pressed or embossed into the surface of the first component facing the underside of the head. As a result, corrosive media, such as moisture and/or dirt, are prevented from penetrating into the gap between the element head and the adjacent component
Implementation Method 3
During resistance welding, a high current flow is generated in the auxiliary welding joining part, so that in the contact area between the auxiliary welding joining part and at least one second component, material is fused and thus a welded joint is produced
Implementation Method 4
The auxiliary welding joining part has a punching shank with a welding contact zone protruding in the axial direction from the punching shank
Data Source
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AI summary
The present invention relates to a welding auxiliary joining part (1) with which a welding connection, more particularly a resistance welding connection, can be produced between a first component A made of a difficult-to-weld material and a second component made of weldable material. The welding auxiliary joining part is characterised by a cylindrical punch shaft (10) that can be punchingly pressed into the first component A almost without rotation. The punch shaft (10) has an element head (30) on the head underside (34) of which only a continuous circumferential clamping ring (40) that projects axially in the direction of the punch ring (10) is arranged.