Metal Sheet Clinching with Stacked Interlock for Thin Gauges
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Solution Overview
Problem
Existing methods for joining metal sheets by punching and clinching are inadequate for thin metal sheets with thicknesses below 0.35 mm, as they fail to provide sufficient joint strength due to insufficient overlap.
Innovation Solution
The method involves dividing metal sheets into two stacks, punching a hole in one stack and contour-cutting the other stack to allow deformation, enabling the deformed region of the second stack to penetrate the first stack, thereby achieving sufficient overlap and strength for reliable joining, even with sheets as thin as 0.05 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional punching and clinching method is used, then the process is simple and fast, but the joint strength is insufficient for thin metal sheets (0.35 mm and below)
Solution Approach 1:
The method divides the joining process into two distinct stacks: a first stack where holes are punched in each metal sheet individually, and a second stack where contours are cut and regions are deformed. This segmentation allows each stack to be processed independently with optimized operations, enabling sufficient overlap and joint strength even for thin metal sheets while maintaining operational simplicity
Solution Approach 2:
The method performs preliminary actions by first punching holes in the first stack and cutting contours in the second stack before the actual joining deformation. This preliminary preparation ensures that when the second stack is deformed, the deformed region can properly penetrate through the holes and achieve sufficient overlap with underlying sheets, guaranteeing adequate joint strength
2Weight of moving object
If metal sheets are made thinner to reduce weight, then weight reduction is achieved, but overlap between sheets becomes insufficient for reliable joining
Solution Approach 1:
The method transitions from relying on lateral overlap (two-dimensional) to utilizing the thickness dimension (three-dimensional) for joining. By deforming a region of the second stack to penetrate through the holes in the first stack in the stack direction, the joining strength is achieved through vertical penetration and interlocking rather than horizontal overlap, enabling reliable joining of extremely thin sheets down to 0.05 mm while maintaining weight reduction
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 allows for reliable joining of thin metal sheets by compensating for their small thickness through stacking and deformation, enhancing joint strength and enabling the use of thinner metal sheets in applications like electrical machine rotors and transformer cores.
Implementation Method 1
the metal sheets of the second stack are plastically deformed during deformation in such a way that an interlocking results between the respective deformed region of a metal sheet of the second stack and at least one underlying metal sheet
Data Source
AI summary
Metal sheets are connected in that a hole is introduced into metal sheets of a first stack, and a region of metal sheets of a second stack are deformed in a stack direction. The deformed region can be plastically deformed in such a way that there is interlocking of the deformed region with at least one metal sheet lying below same. In embodiments, the hole has a shape with a reduced width at the center.