Dual-Diameter Rivet Assembly for Play-Free Fastening
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Solution Overview
Problem
Double riveting methods are time-consuming and prone to errors due to end deformation, requiring complex and expensive conical hole shaping in parts to be joined, leading to misalignment and increased assembly risks.
Innovation Solution
A rivet assembly with dual diameters, allowing easy insertion and play-free connection without additional deformation, using a first portion with a larger diameter for optimal fixing and a second portion with a smaller diameter for insertion, facilitated by grooves for localized deformation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sealing element is used in conjunction with a rivet, then sealing performance is improved, but device complexity and installation time increase
Solution Approach 1:
The sealing function is merged with the rivet by forming an integrated sealing head on the rivet. The sealing head is created by deforming the rivet shank against a counterbored recess, causing material to flow and form a sealing surface that directly contacts the workpiece. This eliminates the need for separate sealing elements while maintaining effective sealing performance.
Solution Approach 2:
The rivet is designed to perform multiple functions simultaneously: mechanical fastening and sealing. The sealing head formed on the rivet provides sealing capability while the rivet body provides structural fastening. This multi-functionality reduces the total number of components needed in the assembly.
2Reliability
If a separate sealing element is used with a rivet, then sealing performance is improved, but installation time and processing steps increase
Solution Approach 1:
The sealing operation is combined with the riveting operation into a single process step. As the rivet is set and the shank is deformed against the counterbored recess, the sealing head is formed simultaneously. This eliminates separate sealing steps and reduces total installation time.
Solution Approach 2:
The counterbored recess is pre-formed in the workpiece with dimensions designed to create the sealing head when the rivet is set. This preliminary preparation of the recess geometry enables the sealing action to occur automatically during the riveting process without requiring additional operations.
3Ease of manufacture
If conventional rivets are used without integrated sealing, then manufacturing simplicity is maintained, but sealing performance deteriorates
Solution Approach 1:
The rivet is segmented into functional zones: the shank for fastening, the sealing head for sealing, and the protrusion for engagement. The sealing head is created by localized deformation of the shank material against the counterbored recess, separating the sealing function from the fastening function while maintaining a single-component structure.
Solution Approach 2:
The sealing performance is achieved by changing the physical state and geometry of the rivet material through plastic deformation. As the rivet is set, the shank material flows and deforms to form the sealing head, changing from a cylindrical shape to a contoured sealing surface that conforms to the recess geometry.
4Manufacturing precision
If the rivet requires precise alignment features like protrusions and recesses, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The rivet and workpiece feature asymmetric geometries that provide self-aligning capabilities. The protrusion on the rivet fits into a corresponding recess in the workpiece, creating a unique orientation. The counterbored recess has an asymmetric shape that guides the rivet into proper alignment during installation, eliminating the need for complex alignment procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dual-diameter rivet design optimizes assembly time and reduces stress on components while ensuring a secure, cost-effective connection without the need for complex hole shaping, minimizing errors and assembly time.
Implementation Method 1
the setting of the rivet (20) comprises compressing the rivet (10) against the workpiece (30) so that material of the rivet (10) deforms to form a sealing head (15)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Rivet (30) extending axially between a head (31) and a foot (32), and comprising a body (33) located axially between the head and the foot, the body comprising a first portion (34) and a second portion (35), the first portion (34) having a first diameter (D1) and the second portion (35) having a second diameter (D2) smaller than the first diameter (D1).