Method and device for the resistance welding of sandwich sheets

• US 10,702,943 B2
• Filed: 03/24/2016
• Issued: 07/07/2020
• Est. Priority Date: 03/26/2015
• Status: Active Grant

• Current Assignee: Thyssenkrupp AG, Thyssenkrupp Steel Europe AG (Thyssenkrupp AG), Thyssenkrupp System Engineering Gmbh (Thyssenkrupp AG)
• Original Assignee: Thyssenkrupp Steel Europe AG (Thyssenkrupp AG)
• Inventors: Chergui, Azeddine, Niesen, Andreas, Ralle, Thomas, Cornelius, Peter
• Primary Examiner(s): Akar, Serkan
• Assistant Examiner(s): Abdel-Rahman, Ahmad
• Application Number:
  US15/080,274
• Publication Number:
  US 20160279730A1
• Time in Patent Office: 1,566 Days
• CPC Class Codes: B23K 11/115 by means of two electrodes placed opposite one another on both sides of the welded parts
• CPC Class Codes: B23K 11/16 taking account of the properties of the material to be welded
• CPC Class Codes: B23K 2103/172 wherein at least one of the layers is non-metallic

Abstract

The present disclosure concerns devices and methods for resistance welding sandwich sheets to other components. Many sandwich sheets include a thermoplastic material layer disposed between two metallic cover layers. The sandwich sheet and the other component may be secured relative to one another by a clamping arrangement. A region of the sandwich sheet to be welded may be heated by a preheating current to soften and displace the thermoplastic material layer when the cover layers are pressed together. With respect to the preheating current, a first electrode arrangement may at least temporarily contact an electrically conductive contacting region of the clamping arrangement such that the preheating current can flow via the clamping arrangement. The cover layers may be welded to the other component with a welding current via the first welding electrode of the first electrode arrangement and a second welding electrode of a second electrode arrangement.

Claims

1. A method for resistance welding a sandwich sheet to a metallic component, wherein the sandwich sheet comprises a thermoplastic material layer disposed between two metallic cover layers, the method comprising:

using a clamping arrangement to secure the sandwich sheet relative to the metallic component, the clamping arrangement comprising a first arm and a second arm, wherein the first arm comprises an electrically conductive contacting region;

heating a region of the sandwich sheet to be welded by way of a preheating current so as to soften the thermoplastic material layer, wherein a first electrode of a first electrode arrangement directly contacts the electrically conductive contacting region of the clamping arrangement so that the preheating current flows via a brace or a clamp of the clamping arrangement and the preheating current does not flow via the sandwich sheet;

compressing the two metallic cover layers in the region to be welded so as to displace the thermoplastic material layer out of the region; and

welding at least one of the two metallic cover layers to the metallic component by way of a welding current via the first welding electrode of the first electrode arrangement and a second welding electrode of a second electrode arrangement.

2. The method of claim 1 wherein the clamping arrangement makes electrically conductive contact with the metallic component on a side opposite to the sandwich sheet.

3. The method of claim 1 wherein the clamping arrangement makes electrically conductive contact or electrically insulated contact with the sandwich sheet on a side opposite to the metallic component.

4. The method of claim 1 further comprising using multiple clamping arrangements simultaneously to secure the sandwich sheet relative to the metallic component, wherein the first electrode arrangement makes contact with the clamping arrangement via the electrically conductive contacting region of the clamping arrangement such that the region of the sandwich sheet to be welded is heated by way of the preheating current flowing via the clamping arrangement.

5. The method of claim 1 further comprising:

selecting the clamping arrangement from a stock of clamping arrangements; and

positioning the clamping arrangement on or about the sandwich sheet and the metallic component with a positioning system.

6. The method of claim 1 wherein an electrode cap of the second welding electrode directly contacts the metallic component.

7. The method of claim 1 wherein the welding current for the welding of the at least one of the two metallic cover layers to the metallic component flows between the first welding electrode and the second welding electrode-through at least one of the two metallic cover layers and the metallic component and bypasses the clamping arrangement.

8. The method of claim 1 further comprising arranging the electrically conductive contacting region of the clamping arrangement between the first welding electrode and the sandwich sheet, wherein an electrode cap of the first welding electrode contacts the electrically conductive contacting region of the clamping region.

9. The method of claim 1 wherein the electrically conductive contacting region of the clamping device is configured as a sliding contact that makes lateral contact with the first welding electrode of the first electrode arrangement.

10. The method of claim 1 wherein the first electrode arrangement comprises a set-down electrode that is electrically connected to the first welding electrode and contacts the electrically conductive contacting region of the clamping arrangement.

11. The method of claim 10 further comprising movably mounting the electrically conductive contacting region of the clamping arrangement by way of an elastic counterbearing.

12. The method of claim 1 wherein the first welding electrode contacts the electrically conductive contacting region of the clamping arrangement in a positively locking fashion.

20. The method of claim 1, wherein the clamping arrangement comprises a first arm in contact with a top face of the sandwich sheet and a second arm in contact with an opposing bottom face of the metallic component.

13. A device for resistance welding a sandwich sheet to a metallic component, wherein the sandwich sheet comprises a thermoplastic material layer disposed between two metallic cover layers, the device comprising:

a first electrode arrangement including a first welding electrode;

a second electrode arrangement including a second welding electrode;

circuitry configured to generate and transmit a welding current at least via the first welding electrode and the second welding electrode for producing a welded connection, wherein the circuitry is configured to generate a preheating current for heating a region of the sandwich sheet to be welded, with the preheating current capable of softening the thermoplastic material layer to an extent that the thermoplastic material layer is displaceable from the region when the two metallic cover layers are compressed; and

a clamping arrangement for securing the sandwich sheet relative to the metallic component, wherein the clamping arrangement comprises a first arm, a second arm, and a closing mechanism, wherein the first arm comprises an electrically conductive contacting region that directly contacts the first electrode arrangement and is disposed between the first electrode arrangement and one of the metallic layers, wherein the clamping arrangement is configured to conduct the preheating current generated by the circuitry, wherein the closing mechanism secures the clamping arrangement around the sandwich sheet and the metallic component, and wherein the preheating current flows via a brace or clamp of the clamping arrangement and does not flow via the sandwich sheet.

14. The device of claim 13 wherein the clamping arrangement is selected from a stock of clamping arrangements, wherein the device further comprises a positioning system for positioning the clamping arrangement on or about the sandwich sheet and the metallic component.

15. The device of claim 13 wherein a configuration of the clamping arrangement permits an electrode cap of the second welding electrode to directly contact the metallic component.

16. The device of claim 13 wherein the first electrode arrangement and the clamping arrangement are configured such that the electrically conductive contacting region of the clamping arrangement is positionable between the first welding electrode and the sandwich sheet, wherein an electrode cap of the first welding electrode contacts the electrically conductive contacting region of the clamping arrangement.

17. The device of claim 13 wherein the electrically conductive contacting region of the clamping arrangement is a sliding contact that makes lateral contact with the first welding electrode of the first electrode arrangement.

18. The device of claim 13 wherein the first electrode arrangement comprises a set-down electrode that is electrically connected to the first welding electrode and is configured to contact the electrically conductive contacting region of the clamping arrangement.

19. The device of claim 13 wherein the electrically conductive contacting region of the clamping device is configured to contact the first welding electrode of the first electrode arrangement in a positively locking fashion.