US 11,999,005 B2 · Device and methods of multiple spot welding for automotive applications using vaporizing foil actuator welding

Abstract

A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate. The rapidly expanding gas particles accelerate the flier, completing the weld.

Claims20

Dependent claims

A multiple spot vaporization weld system, comprising:

a first stabilizing component;
a target sheet layer secured relative to the first stabilizing component;
a flier sheet layer;
a plurality of standoff components arranged sandwichably between the target layer and the flier sheet layer;
a first electrically insulating layer sandwichably located between the flier layer and a vaporizable component sheet layer, wherein the vaporizable component sheet layer includes:
at least two vaporizing subsections vaporizable so as to produce a plurality of welds;
at least three dividing subsections configured to separate the vaporizing subsections;
wherein a first volume of conductive material is reduced in each of the at least two vaporizing subsections as compared to a second volume of conductive material in each of the at least three dividing subsections;
a source of voltage selectively connectable with the vaporizable component sheet layer;
and
a second stabilizing component electrically insulated relative to the vaporizable component sheet layer interoperable with the first stabilizing component to counteract force applied to the first stabilizing component during production of the plurality of welds.

8 more elements

A method for welding multiple spots, the method including:

securing a target sheet layer relative to a first stabilizing component;
locating a plurality of standoff components between a flier sheet layer and the target sheet layer;
positioning an electrically insulating material layer on the flier sheet layer;
securing a vaporizable component sheet layer between the electrically insulating material layer and an electrically insulated second stabilizing component, the vaporizable component sheet layer including at least two vaporizing subsections and at least three subsections interspersed with the at least two vaporizing subsections, wherein a first volume of conductive material is reduced in each of the at least two vaporizing subsections as compared to a second volume of conductive material in each of the at least three dividing subsections;
securing the second stabilizing component relative to the first stabilizing component;
completing a circuit between the vaporizable component sheet layer and a source of voltage and the vaporizable component sheet layer;
and
communicating a current from the source of voltage with the vaporizable component sheet layer via at least two of the at least three interspersed subsections of the vaporizable component sheet layer to produce sublimation of each of the at least two vaporizing subsections, wherein the sublimation contained between the first stabilizing component and the second stabilizing component produces a high force that joins the flier sheet and the target sheet to one another.

5 more elements

Dependencies are inferred from the claim text.

Device and methods of multiple spot welding for automotive applications using vaporizing foil actuator welding

Life of this patent

Device and methods of multiple spot welding for automotive applications using vaporizing foil actuator welding

Life of this patent

Abstract

Claims20