Integrated Rivet Fastening Unit for Die-Free Undercut Forming
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Solution Overview
Problem
Existing fastening technologies face challenges in connecting diverse components, especially in the motor vehicle sector, due to material properties and geometric constraints, making direct welding or screw connections difficult or impossible, particularly with thin components like sheet metal.
Innovation Solution
A fastening unit comprising a rivet element and a deforming element, coupled in a captive manner, where the deforming element can move relative to the rivet element to deform the rivet section radially, providing an integrated die for forming an undercut, eliminating the need for a separate die and allowing for efficient and reliable fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate die is used to deform the rivet section, then the riveting process can be performed, but the device complexity increases and positioning becomes difficult due to workpiece geometry constraints
Solution Approach 1:
The patent combines the die function directly into the forming element, which is already part of the fastening unit. The forming element includes a forming section that acts as an integrated die to deform the rivet section, eliminating the need for a separate die component and simplifying the overall device structure.
Solution Approach 2:
The forming element serves multiple functions: it guides the rivet section during insertion, provides the die function to deform the rivet section radially, and supports the fastening unit during the riveting process. This multi-functionality reduces the need for separate components.
2Manufacturing precision
If a separate die is required for the riveting process, then the rivet section can be formed, but the number of parts increases and pre-assembly is required
Solution Approach 1:
The die function is merged into the forming element of the fastening unit. The forming section of the forming element directly deforms the rivet section during the insertion process, eliminating the need for a separate die part and reducing the total number of components.
Solution Approach 2:
The forming element is pre-integrated into the fastening unit during manufacturing, so that the die function is already prepared and positioned correctly before the riveting process. This eliminates the need for pre-assembly of separate die components during installation.
3Productivity
If the fastening unit is inserted in a single axial movement, then the productivity increases, but the control of relative movement between elements becomes more challenging
Solution Approach 1:
The forming element is designed to move dynamically relative to the rivet section during the single axial insertion process. The coupling between elements allows for controlled relative movement while maintaining the overall single-direction insertion motion, enabling both high productivity and operational ease.
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
Enables efficient and reliable fastening of components by providing an integrated die within the fastening unit, simplifying the process and increasing mechanical stability, while reducing the need for pre-assembly and separate dies.
Implementation Method 1
the riveting section interacts with the forming section and can be formed by it in a radial direction
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention relates to a fastening unit for fastening to a workpiece, comprising a rivet element and a reshaping element coupled to the rivet element and movable relative thereto, the rivet element having a rivet portion and the reshaping element having a reshaping portion and a support portion arranged on a region of the reshaping element facing away from the reshaping portion for axially supporting the fastening unit on a stop. The rivet portion and the reshaping portion are designed in such a way that, during an axial relative movement produced between the rivet element and the reshaping element by an insertion movement, the rivet portion interacts with the reshaping portion and is reshaped thereby in a radial direction.