Pierce Nut and Collar Attachment Without Thermal Strain

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Solution Overview

Problem

Existing methods for attaching nuts and collars to plate materials in automotive applications face issues with thermal strain and attachment workability, particularly when using welding, which can lead to misalignment and reduced peeling strength and idling torque, especially when working with aluminum materials.

Innovation Solution

A method involving caulking a nut to a plate material and press-fitting a collar protrusion into a recessed groove on the opposite surface, eliminating the need for welding and ensuring perpendicular attachment without thermal strain, using a pierce nut with an inner and outer cylinder and a recess for metal flow, and an annular protrusion for secure fixation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is performed to attach nut and collar to plate material, then attachment strength is improved, but thermal strain occurs causing misalignment and reduced fastening quality

Engineering Contradiction:

Improveattachment strengthVSAvoidalignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the welding process (thermal field) with a mechanical press-fitting process. The collar is attached by pressing it into a recessed groove formed on the plate material surface, eliminating thermal strain and misalignment issues while maintaining secure attachment through mechanical interference fit

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If welding is performed to attach collar to plate material, then attachment is achieved, but peeling strength and idling torque are reduced due to thermal influence

Engineering Contradiction:

Improveattachment processabilityVSAvoidpeeling strength and idling torque

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent replaces welding with a mechanical press-fitting process that avoids thermal influence on the pierce nut's metal flow structure. The collar is secured by pressing into a pre-formed recessed groove, maintaining peeling strength and idling torque without thermal degradation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If welding is used to attach collar, then attachment is achieved, but the process cannot be applied to aluminum plate materials

Engineering Contradiction:

Improvematerial compatibilityVSAvoidprocess applicability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces welding with a mechanical press-fitting process that is universally applicable to various plate materials including aluminum. The collar is attached by pressing into a recessed groove formed on the plate surface, eliminating material-specific welding constraints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The press-fitting attachment method serves as a universal solution that can be applied to different plate materials (steel, aluminum, etc.) without requiring material-specific process adjustments, unlike welding which has limitations with certain materials

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach allows for secure attachment of both the nut and collar to both surfaces of the plate material without thermal strain, maintaining alignment and enhancing attachment strength, even with aluminum materials, by avoiding welding and utilizing a dedicated die for caulking and press-fitting, thereby improving peeling strength and torque resistance.

Implementation Method 1

The pierce nut is firmly fixed to the plate material 2 by causing a metal to plastically flow into a recess formed between the inner cylinder and the outer cylinder

Methodology Applied

Scientific EffectPlastic flow: Plasticity

Implementation Method 2

press-fitting a protrusion at an end of a collar into a recessed groove generated on the opposite surface of the plate material at the time of the caulking fixation

Methodology Applied

Scientific EffectPress-fitting: Mechanical Force

Data Source

PatentUS11015630B2Method for attaching nut and collar to plate material and attachment structure of nut and collar to plate material

Publication Date: 2021.05.25 AOYAMA SEISAKUSHO CO LTD

AI summary

A nut is caulked and fixed to a plate material and a protrusion at an end of a collar is press-fitted into a recessed groove generated on the opposite surface of the plate material at the time of the caulking fixation, thereby fixing the nut and the collar to both surfaces of the plate material, respectively. The plate material is, for example, a metal panel, and the nut is, for example, a pierce nut. Since the collar is caulked and fixed, thermal strain is not generated.