Resistance Welding Spacer and Base for Uniform Adhesive Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding methods, such as adhesive welding and projection welding, face challenges in achieving a process-reliable non-releasable connection between components with adjustable adhesive gaps, leading to issues like electrode wear, uneven adhesive distribution, and inadequate electrically conductive contacts.
Innovation Solution
A method involving the use of a welding base and a spacer, where the welding base projects above the spacer, allowing for controlled adjustment of the adhesive gap and enabling the use of larger electrodes, which reduces wear and ensures a uniform adhesive layer distribution during resistance welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive welding is used to achieve a durable connection, then connection strength is improved, but electrode wear increases due to high pressing forces required to displace viscous adhesive
Solution Approach 1:
The adhesive layer is applied to the connection faces before the welding process begins. This preliminary application allows the adhesive to be in position but still deformable, enabling it to be displaced during welding without requiring excessively high pressing forces that would cause electrode wear.
Solution Approach 2:
The adhesive's viscosity parameter is changed through temperature control during the welding process. By heating the adhesive layer, its viscosity decreases, making it easier to displace and form a uniform adhesive gap without requiring high pressing forces from the electrodes, thus reducing electrode wear.
2Manufacturing precision
If high pressing forces are applied to displace thick-flowing adhesive, then adhesive distribution is improved, but electrode wear increases
Solution Approach 1:
The adhesive layer is heated during the welding process, changing its viscosity parameter. This temperature-induced viscosity reduction allows the adhesive to flow and distribute uniformly across the connection face without requiring high pressing forces from the electrodes, thereby achieving uniform adhesive distribution while minimizing electrode wear.
Solution Approach 2:
The welding process applies pressing forces in a controlled, periodic manner rather than continuously at maximum intensity. The adhesive is first heated to reduce viscosity, then moderate pressing forces are applied to achieve uniform distribution, avoiding the need for sustained high forces that would cause electrode wear.
3Strength
If adhesive layer is applied extensively on abutment faces, then connection durability is improved, but electrically conductive contact becomes inadequate
Solution Approach 1:
The connection face is segmented into different zones: areas with extensive adhesive application for durability, and specific contact regions where the adhesive is either recessed or displaced to allow electrical contact. This segmentation allows both extensive adhesive coverage and adequate electrical conductivity to coexist.
Solution Approach 2:
The adhesive layer itself acts as an intermediary that can be selectively displaced or recessed in contact regions. By controlling the adhesive's position and thickness locally, it mediates between the need for extensive coverage (durability) and the need for electrical contact paths, allowing both requirements to be satisfied.
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 approach allows for a precise and reliable non-releasable connection with adjustable adhesive gaps, reducing electrode wear and ensuring a durable bond, while maintaining a controlled welding process and uniform adhesive distribution.
Implementation Method 1
introducing welding current in the region of the applied welding base
Data Source
AI summary
A method for the connection of components or component regions and a non-releasable connection produced in this manner. Two connection faces are partially welded to each other with an adhesive layer being incorporated between the two connection faces. The method including the following steps: arranging a welding base on a connection face, applying the adhesive layer to a connection face, moving the connection faces toward each other in such a manner that the welding base is applied against the other connection face, introducing welding current in the region of the applied welding base. A spacer is arranged between the connection faces before the connection faces are moved toward each other. The connection faces are spaced apart from each other in the region of the welding base by the extent that the welding base projects above the spacer.