High-Speed Nail Connection with Adhesive Collar Formation
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Solution Overview
Problem
Existing methods for fastening sheets to components with closed cross-sections or internal high-pressure reshaped components, such as in vehicle construction, require preholing and multiple process steps, and often lack reliability in forming a secure connection.
Innovation Solution
A method involving a nail with a nail head, shank, and point driven at high speed into components with an adhesive layer between them, forming a material collar for stabilization without preholing, allowing for quick and high-quality connection with one-sided accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a nail is driven at high speed into components without preholing, then productivity is improved and process complexity is reduced, but manufacturing precision and connection reliability may deteriorate
Solution Approach 1:
Adhesive is applied to at least one component before the nail is driven in, creating a pre-prepared bonding interface that ensures reliable connection formation during the high-speed jointing process
Solution Approach 2:
The nail is driven in with controlled parameters (speed, angle, depth) to optimize both the forming of the material collar and the adhesive bonding, achieving reliable connections without preholing while maintaining high productivity
2Loss of time
If a nail is driven in without rotation in a single step, then the process is simplified and time is reduced, but connection reliability may be compromised
Solution Approach 1:
The insertion and setting functions are merged into a single integrated nail component, allowing the nail to be driven in without rotation while still forming a reliable connection through the combination of adhesive bonding and material collar formation
Solution Approach 2:
The connection reliability is achieved through a composite approach combining chemical bonding (adhesive) with mechanical interlocking (material collar formed by the nail), providing reliable fastening without requiring multiple process steps
3Stability of the object's composition
If adhesive is applied between components with a gap, then connection stability is improved, but maintaining constant adhesive layer thickness becomes difficult
Solution Approach 1:
The nail serves a dual function: it fastens the components together and simultaneously levels the adhesive layer by bridging the gap and distributing the adhesive evenly, achieving both connection stability and uniform adhesive thickness through a single operation
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
This method enables a simple, rapid, and high-quality connection without rotation of the nail, maintaining adhesive layer thickness and stability, suitable for various materials like steel, aluminum, and plastic, with reduced cycle times and increased connection reliability.
Implementation Method 1
the nail is driven into these parts to connect two components in a joint area... the nail is driven in a mainly non-rotating and axial manner into the non-preholed components in the joint area at a high speed
Implementation Method 2
adhesive is applied to at least one of the components so that the adhesive is arranged between the two components... the adhesive layer has an almost constant thickness despite the joint and also at least contributes to the deformation of the nail-head-side component for a stabilization of the connection
Implementation Method 3
only one material collar is formed in the nail-head-side component, which protrudes from the nail-head-side component in the direction facing away from the nail head... the material collar only protrudes from the nail-head-side component in the driving direction
Data Source
AI summary
A method for establishing a nail connection between two components and a nail for this purpose are described. The nail 6 is driven through the non-preholed components in the joint area at a high speed such that the nail point completely penetrates both components and a material collar, which extends into an adhesive layer between the two components, is only formed in the to driving direction in the nail-head-side component.