Systems and methods for joining components by heat staking
AssigneeGM Global Technology Operations LLC
InventorsPEI-CHUNG WANG, BRADLEY J. BLASKI
Life of this patent
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Abstract
The present technology discloses methods for joining a first workpiece and a second workpiece through a heat stake, and products formed thereby. The first workpiece has an aperture configured to receive a stud positioned on a second workpiece. The system is formed by applying energy to the first workpiece using electrodes, which indirectly heats the stud, at least partially softening material of the stud. Pressure is then applied to the softened material of the stud, and causing the material to form according to a predetermined geometry. After pressure is released, the stud forms a stake forming an interlocked joint connecting the workpieces.
Claims20
An apparatus, for joining a first workpiece to a second workpiece, the first workpiece having a first surface, a second surface opposite the first surface, and an aperture having a first width, the second workpiece having a third surface, the apparatus comprising:
- a first electrode configured and arranged in the apparatus to, in operation, contact the first surface adjacent the aperture and adjacent a stud extending from the third surface and, with the first electrode, soften material of the stud by heating the first workpiece;
- a second electrode electrically isolated from the first electrode and configured and arranged in the apparatus to, in operation, contact the first surface adjacent the aperture and adjacent the stud and, with the second electrode, soften material of the stud by heating the first workpiece, the first electrode and the second electrode forming a passage between them having a second width being greater than the first width;
- and
- a punch configured and arranged in the apparatus for being movably positioned in the passage for selectively applying force on the softened material of the stud, forcing material of the stud into a space formed in the passage outside of the first width, yielding a stake joining the second workpiece to the first workpiece.
A method, for joining a first workpiece to a second workpiece, the first workpiece having a first surface, a second surface opposite the first surface, and an aperture having a first width, the second workpiece having a third surface and a stud extending from the third surface, the method comprising:
- positioning the first workpiece adjacent the second workpiece with the second surface contacting the third surface where the stud extends through the aperture;
- positioning, axial to a centerline of the stud, a punching apparatus comprising (i) a first electrode arranged and configured to contact the first surface adjacent the aperture and adjacent the stud, (i) a second electrode, electrically isolated from the first electrode and arranged and configured to contact the first surface adjacent the aperture and adjacent the stud, and (iii) a punch movably positioned between the first electrode and the second electrode;
- applying energy using the first electrode and the second electrode to soften material of the stud by heating the first workpiece;
- and
- compressing, using the punching apparatus, the softened material of the stud, yielding a stake forming a joint connecting the first workpiece and the second workpiece.
A heat-stake-joined system comprising:
- a first workpiece having a first surface, a second surface opposite the first surface, and an aperture having a first width;
- and
- a second workpiece having a third surface contacting the second surface, the second workpiece being joined to the first workpiece by a stake extending from the third surface, through the aperture at the second surface, and out of the aperture at the first surface and comprising a head outside of the aperture having a second width greater than the first width thereby securing the stake, and so the second workpiece, to the first workpiece,
- wherein the system is formed by:
- positioning the first workpiece adjacent the second workpiece with the second surface contacting the third surface where the stud extends through the aperture;
- positioning, axial to a centerline of the stud, a punching apparatus comprising (i) a first electrode arranged and configured to contact the first surface adjacent the aperture and adjacent the stud, (i) a second electrode, electrically isolated from the first electrode and arranged and configured to contact the first surface adjacent the aperture and adjacent the stud, and (iii) a punch movably positioned between the first electrode and the second electrode;
- applying energy using the first electrode and the second electrode to soften material of the stud by heating the first workpiece;
- and
- compressing, using the punching apparatus, the softened material of the stud, yielding a stake forming a joint connecting the first workpiece and the second workpiece.
Dependencies are inferred from the claim text.