Self-Piercing Rivet Joining Metal Shielding and Textile Insulation
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Solution Overview
Problem
Existing methods for producing shielding parts with metallic and textile layers are complex and expensive, especially when using thicker metallic layers, as they require punching tools and adhesives, limiting their applicability and increasing costs.
Innovation Solution
A method using punch riveting to connect a metallic shielding layer with a textile insulating layer, allowing for the formation of a three-dimensional composite without adhesives, using punch rivets to create a strong and stable connection suitable for thicker metallic layers, such as stainless steel sheets up to 0.7 mm thick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blind rivets or staples are used to connect thicker metallic shielding layers (≥0.2 mm) with textile insulating layers, then the connection strength is improved, but the device complexity and manufacturing cost increase due to requiring perforation tools and multiple joining steps
Solution Approach 1:
The patent combines the perforation and joining operations into a single self-piercing riveting step. The rivet automatically creates its own hole through the metallic layer and textile layer simultaneously, eliminating the need for separate perforation tools and reducing manufacturing complexity while maintaining connection strength.
Solution Approach 2:
The self-piercing rivet performs the perforation function itself during the joining process. The rivet's design allows it to pierce through the metallic shielding layer and create its own mounting hole without external assistance, making the system self-sufficient and eliminating additional equipment requirements.
2Ease of manufacture
If adhesives or joining agents are used to bond metallic shielding layers with textile insulating layers, then the manufacturing cost is reduced, but the reliability and dynamic stability of the connection deteriorate
Solution Approach 1:
The patent replaces chemical bonding (adhesives) with a mechanical joining system (self-piercing rivets). This substitution provides reliable mechanical interlocking and rigid connection that maintains dynamic stability under thermal and mechanical loads, while avoiding the cost and complexity of adhesive application processes.
3Ease of manufacture
If the metallic shielding layer is bonded in its undeformed flat state and then formed into three-dimensional shape, then the manufacturing process is simplified, but this method is no longer effective for thicker metallic layers (≥0.2 mm)
Solution Approach 1:
The patent performs the joining action (self-piercing riveting) before the forming process. By connecting the metallic layer and textile layer in a pre-formed or partially deformed state, the rivet creates a stable mechanical bond that can subsequently withstand the forming process, enabling the method to work with thicker materials that cannot be bonded in the flat state.
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 enables the production of inexpensive, strong, and dynamically stable shielding parts by forming a composite with high pull-out forces and resistance, suitable for various geometries and thermal loads, without the need for adhesives or additional joining agents.
Implementation Method 1
the rivet forms a flange in the metallic shielding layer and is held there in a form-fit manner
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing a shielding part (1) comprising at least one metal shielding layer (3) and a textile insulating layer (2), said method at least comprising steps a) providing a metal shielding layer (3) and a textile insulating layer (2), and b) joining the textile insulating layer (2) to the shielding layer (3) using at least one punched rivet connection.