Rivet-Type Contact Flange Embedding for Durability
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Solution Overview
Problem
Conventional two-layer rivet-type contacts suffer from early damage due to separation and dropout of the contact material, particularly under heat and friction loads, leading to reduced durability life.
Innovation Solution
A two-layer rivet-type contact design where the base material is not exposed to the side surface of the head part, and the joined interface of different materials is avoided by embedding a flange part with a larger diameter than the leg part into the head part, ensuring a sufficient joining strength and preventing caulked wrinkles during caulking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a two-layer rivet-type contact is used to reduce material cost, then the material cost decreases, but the durability life becomes inferior and damage occurs earlier
Solution Approach 1:
The flange part is embedded within the head part, creating a nested structure where the base material (flange) is housed inside the contact material (head). This nested configuration prevents the base material from being exposed to side surfaces, eliminating the separation and dropout issues that reduce durability, while maintaining the cost-saving two-layer structure.
Solution Approach 2:
The invention transitions from a conventional side-by-side or stacked two-layer configuration to a nested three-dimensional structure. By embedding the flange part within the head part, the solution utilizes internal spatial arrangement rather than external layering, preventing exposure of the base material to lateral forces that cause damage.
2Ease of manufacture
If the base material is exposed to the side surface of the head part, then the manufacturing is simpler, but the contact material separates and drops out under heat and friction loads
Solution Approach 1:
The flange part is embedded within the head part, creating a nested structure where the base material (flange) is housed inside the contact material (head). This nested configuration prevents the base material from being exposed to side surfaces, eliminating the separation and dropout issues that reduce durability, while maintaining the cost-saving two-layer structure.
3Device complexity
If the joined interface of different materials is located at the leg part, then the structure is simpler, but caulked wrinkles occur during caulking processing
Solution Approach 1:
The joined interface is relocated from the leg part to the interior of the head part, where the flange is embedded. This moves the material interface away from the caulking zone, preventing caulked wrinkles from forming at the joint while maintaining structural simplicity through the nested configuration.
Solution Approach 2:
The flange part acts as an intermediary element that connects the leg part to the head part from the interior. This intermediary structure allows the joined interface to be positioned within the head part rather than at the leg part, avoiding caulking defects while maintaining structural integrity.
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 design effectively suppresses separation and dropout of the contact material, enhancing the durability life of the rivet-type contact while maintaining a two-layer structure that combines a contact material and a base material, thus improving reliability and reducing material costs.
Implementation Method 1
causing a first billet made of a contact material and a second billet made of a base material to butt against each other and pressure-welding the first billet and the second billet
Data Source
AI summary
A rivet-type contact of the present invention has a head part made of a contact material, and a leg part narrower than the head part in width and configured to be deformed at fixation. The leg part includes a flange part larger than the leg part in diameter, in an end part of the side of the head part, the flange part is embedded in the head part such that a lower end surface of the flange part and a lower end surface of the head part become approximately flat, and a length (l) between an endmost part of the flange part and a starting point of the leg part satisfies l<L with respect to a length (L) between an endmost part of the head part and the starting point of the leg part. Specifically, it is favorable that l satisfies 0.5 L≤l≤0.9 L with respect to L.