Die and Sleeve Washer Retention for Dissimilar Material Joining
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Solution Overview
Problem
Conventional joining methods, such as self-piercing riveting, face challenges in assembling dissimilar materials like metal and plastic composites with varying thicknesses and ductilities, and require complex implementations with disc-shaped counter-bearings that are difficult to position and maintain during the joining process.
Innovation Solution
A system comprising a die with a die shank and head, a sleeve, and a supporting body that securely holds a washer, allowing for flexible use in joining components with different thicknesses and ductilities, featuring a recess for the washer and an elastic sleeve for automatic feeding and centering, ensuring correct positioning and reducing damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a disc-shaped counter bearing (washer) is used to connect components with strength more than 300MPa, then the connection reliability is improved and stress concentrations are reduced, but the device complexity increases and the ease of operation deteriorates due to the need to provide and maintain the washer in position during the joining process
Solution Approach 1:
The patent combines the washer and the die into a single integrated component. The die includes a counterbearing portion that performs the function of the washer, eliminating the need for a separate washer component. This merging resolves the contradiction by maintaining the stress distribution and connection reliability functions while reducing device complexity and ease of operation issues associated with handling separate washer components.
Solution Approach 2:
The die is designed to perform multiple functions: it provides the piercing action for the self-piercing rivet and simultaneously serves as a counterbearing (washer) for stress distribution. This multi-functionality resolves the contradiction by eliminating the need for a separate washer while maintaining the stress distribution function, thereby reducing device complexity without compromising connection reliability.
2Object-affected harmful factors
If a disc-shaped counter bearing (washer) is used to distribute tensile stresses, then the stress distribution is improved and damage risk is reduced, but the ease of operation deteriorates due to the need to maintain the washer in position during the joining process
Solution Approach 1:
The counterbearing function is merged into the die structure itself. The die includes a counterbearing portion that contacts the workpiece and distributes tensile stresses, eliminating the need for a separate washer. This resolves the contradiction by maintaining stress distribution benefits while eliminating the operational complexity of positioning and maintaining a separate washer during the joining process.
Solution Approach 2:
The die automatically performs the counterbearing function as part of its inherent structure and operation. Since the die is already positioned and secured in the joining apparatus, its integrated counterbearing portion automatically provides stress distribution without requiring separate positioning or maintenance operations, thereby improving ease of operation while maintaining stress distribution benefits.
3Ease of manufacture
If conventional joining methods are used to assemble dissimilar materials with varying thicknesses and ductilities, then the manufacturing process is simpler, but the manufacturing precision deteriorates and the reliability of the joint decreases
Solution Approach 1:
The patent modifies the geometry and parameters of the die, specifically incorporating an integrated counterbearing portion with optimized dimensions and material properties. This allows the die to adapt to dissimilar materials with varying thicknesses and ductilities by providing appropriate support and stress distribution, thereby improving manufacturing precision and joint reliability while maintaining ease of manufacture through a single integrated component.
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5H
AI summary
Apparatus (14) for joining at least one first component and one second component comprising: - a die (12) with a die shank and a die head, wherein the die head comprises a first surface and a second surface, - a supporting body (18) comprising an aperture in which the die shank extends and a receiving surface supporting the first surface of the die head. The apparatus further comprises a sleeve (16) extending between a first end and a second end, the sleeve being arranged around a portion of the supporting body and around the die head, wherein the sleeve extends beyond the die hand such that a recess between the second end of the sleeve and the second surface of the die head, the recess being adapted to receive a washer (46).