Blind Rivet Mandrel Segmentation for Variable Thickness Fastening
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Solution Overview
Problem
Existing blind rivets are limited in their ability to securely fasten a wide range of material thicknesses, as they lack versatility in locking mechanisms and breakage points, which restricts their application across various metalworking industries.
Innovation Solution
A blind rivet design featuring a mandrel with multiple locking regions, a selectably breakable region with defined breakable locations, and a gripping region, along with a riveting tool that deforms the rivet body into locking engagement with these regions, allowing for secure fastening across varying material thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a blind rivet uses a single locking region design, then the structure is simple, but it cannot securely fasten a wide range of material thicknesses
Solution Approach 1:
The mandrel is segmented into multiple functional regions: a first locking region with circumferential grooves for initial engagement, a selectably breakable region with defined breakable locations for controlled fracture, and a second locking region for additional engagement. This segmentation allows the single mandrel to provide multiple locking mechanisms that adapt to various material thicknesses while maintaining structural integrity.
Solution Approach 2:
Different regions of the mandrel are given different local qualities: the first locking region has circumferential grooves for grip, the selectably breakable region has reduced cross-section at specific locations for controlled breaking, and the second locking region provides additional engagement features. This local differentiation enables the mandrel to perform multiple functions (locking, breaking, re-locking) within a single component, expanding adaptability without proportionally increasing overall complexity.
2Adaptability or versatility
If a blind rivet includes multiple locking regions and breakable locations, then it can fasten various material thicknesses, but the manufacturing complexity increases
Solution Approach 1:
The selectably breakable region is pre-formed during mandrel manufacturing with defined breakable locations (such as reduced cross-section areas or notches). This preliminary action ensures that when the mandrel is installed and pulled, it will break at the predetermined locations, providing controlled functionality without requiring complex post-manufacturing operations. The circumferential grooves and locking regions are also pre-formed, simplifying the overall manufacturing process while achieving the desired adaptability.
3Reliability
If the mandrel has a selectably breakable region with defined breakable locations, then controlled breaking occurs for secure fastening, but the structural integrity is reduced
Solution Approach 1:
The mandrel's strength is segmented into different zones: the locking regions maintain full strength for secure engagement, while the selectably breakable region has intentionally reduced strength at specific locations. This segmentation allows the mandrel to be strong where needed (locking regions) while having controlled weak points (breakable locations) that enable reliable fastening through controlled breaking, achieving both reliability and appropriate strength distribution.
Data Source
AI summary
A blind rivet including a mandrel having a head and a rivet body surrounding the mandrel adjacent the head, the mandrel including at least one locking region for locking engagement therewith of the rivet body, adjacent the head, a selectably breakable region adjacent the at least one locking region and defining a plurality of breakable locations along the mandrel and a gripping region adjacent the selectably breakable region.