Punch Rivet Cylindrical Ring Surface Composite Joining
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Solution Overview
Problem
Current methods for joining components made of fiber or fabric reinforced plastic are inefficient and prone to fatigue, with existing punch rivets often failing to provide a strong, reliable connection without risking tear-out or undesired deformation.
Innovation Solution
A punch rivet design with a flange of larger diameter, a rivet section of smaller diameter, and a ring-like contact surface, where the rivet section has a ring surface at its free end that is substantially perpendicular to the central axis, allowing full penetration and dilation to form a high-quality rivet bead, enhancing the connection strength and fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional punch rivets with conical spreading surfaces are used, then the rivet section is spread in trumpet-like manner during pressing, but this causes the punch rivet to potentially tear out of composite material components or create undesired fatigue effects over time
Solution Approach 1:
The invention changes the geometric parameters of the rivet section from a conical spreading surface to a cylindrical shape with a ring surface perpendicular to the central axis. This parameter change eliminates the trumpet-like spreading that causes material tearing and fatigue, while still enabling effective connection through controlled dilation and rivet bead formation.
Solution Approach 2:
The invention applies local quality by creating a specific ring surface at the free end of the rivet section that is substantially perpendicular to the central axis. This localized geometric feature enables the rivet to fully penetrate the composite material and form a high-quality rivet bead without the harmful spreading effects of a conical surface, improving both reliability and manufacturing ease.
2Strength
If the rivet section is designed to spread in trumpet-like manner, then the components are held together by wedge action, but this design is unsuitable for fiber or fabric reinforced plastic components due to tear-out risk
Solution Approach 1:
The invention changes the geometric parameters of the rivet section from a conical shape designed for wedge action to a cylindrical shape with a perpendicular ring surface. This parameter change eliminates the harmful tear-out effect in composite materials while maintaining connection strength through an alternative mechanism of full penetration and controlled dilation.
Solution Approach 2:
The invention extracts the harmful conical spreading feature from the rivet design, removing the cause of tear-out in composite materials. The remaining cylindrical rivet section with a perpendicular ring surface retains the essential function of joining components without the detrimental wedge action that damages fiber or fabric reinforced plastics.
3Reliability
If existing punch rivet designs are used for composite materials, then joining can be achieved, but the process is complicated, expensive, and disturbs the manufacturing process sequence
Solution Approach 1:
The invention creates a universal punch rivet design with a cylindrical rivet section and perpendicular ring surface that can effectively join both metal and fiber or fabric reinforced plastic components. This multi-functional design eliminates the need for specialized rivet designs for different material types, simplifying the manufacturing process and reducing complexity while maintaining connection reliability.
Solution Approach 2:
Instead of adapting the rivet design to accommodate the limitations of composite materials (as done in conventional approaches), the invention inverts the approach by designing a rivet that fully penetrates the composite material and forms a controlled rivet bead. This inverted strategy simplifies the manufacturing process by eliminating the need for pre-drilled holes or embedded reinforcement plates.
4Ease of manufacture
If the rivet section does not fully penetrate the components, then the pressing process is simpler, but a high-quality rivet bead cannot be generated and connection strength is reduced
Solution Approach 1:
The invention changes the geometric parameters of the rivet section to a cylindrical shape with a ring surface perpendicular to the central axis, enabling full penetration of the components. This parameter change allows the rivet to extend through the entire thickness and form a high-quality rivet bead on the opposite side, improving connection strength while maintaining pressing process simplicity through the controlled dilation mechanism.
Solution Approach 2:
The invention applies preliminary action by designing the rivet section with a specific cylindrical geometry and perpendicular ring surface that prepares the rivet for full penetration and controlled dilation. This preliminary geometric configuration enables the rivet to automatically form a high-quality rivet bead upon insertion and pressing, without requiring complex multi-step processes, thus maintaining ease of manufacture while achieving superior connection strength.
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 solution provides a strong, reliable connection between components, minimizing the risk of tear-out and fatigue, while allowing for efficient processing and reuse of tools, ensuring a high-quality rivet joint without the need for disposable mandrels.
Implementation Method 1
moving a plunger (114) through the passage (112) of the hold-down member (110) and through the passage (36) of the punch rivet (10), with the plunger (114) having a front end region (116) and a ring shoulder (118) arranged behind the front end region (116), with the front end region (116) of the plunger (114) pressing the piercing slugs (56) through the passage (36) of the punch rivet and with the free end region (15) of the rivet section (14) which projects at the side of the components (40, 42) remote from the flange (12) being shaped by the ring shoulder (118) into a rivet bead (120)
Implementation Method 2
The rivet section (14) has at its free end (20) a ring surface (22) for the piercing of the two components (40, 42) that stands at least substantially perpendicular to the central longitudinal axis (24) of the punch rivet (10)
Implementation Method 3
forming a rivet bead (120) by shaping the free end region (15) of the rivet section (14) in order to clamp the components (40, 42) between the flange (12) and the rivet bead (120)
Data Source
AI summary
A hollow punch rivet is described having a flange and a rivet section. Furthermore, a method for the attachment of individual components to one another using a punch rivet is described, with at least one of the components being formed by a material of the composite material. The method includes the following steps:a) arrangement of the die button against one of the two components to be secured to one another, which are placed on one another, wherein the die button has a bore which is dimensioned to receive the rivet section,b) carrying out a relative movement of the punch rivet with the free end of the rivet section to the fore towards the components arranged on one another and in the direction of the die button,c) piercing of the components with the free end of the rivet section and introduction of the rivet section into the bore of the die button until the component contact surface comes into contact and the component adjacent to the flange,d) using a plunger in order to dilate the punch rivet at least locally ande) forming a rivet bead by reshaping the free end region of the rivet section.