Self-Piercing Rivet Joining Dissimilar Plastic Metal Plates
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Solution Overview
Problem
The existing joining methods for plastic composite and metal plates, such as laser welding or spot welding, are ineffective due to their distinct physical properties, leading to limited joining modes and potential damage to the plastic composite plate when using self-piercing rivets, which compromises the joining force.
Innovation Solution
A self-healing capsule containing a self-healing agent and catalyst within the plastic composite plate, which polymerizes to fill cracks and adhere the self-piercing rivet to the pierced portion, enhancing the joining force with a metal plate, and an adhesive capsule to ensure strong bonding between the rivet and plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If self-piercing rivet is used to join plastic composite plate and metal plate, then mechanical joining is achieved, but damage occurs to the periphery of the pierced portion of the plastic composite plate
Solution Approach 1:
A reinforcing layer is introduced as an intermediary between the self-piercing rivet and the plastic composite plate. This reinforcing layer absorbs the mechanical stress and damage caused by the rivet piercing process, preventing direct damage to the plastic composite plate periphery while maintaining the mechanical joining capability.
Solution Approach 2:
The solution employs a composite structure consisting of the plastic composite plate, reinforcing layer, and metal plate. This multi-layer composite configuration distributes the mechanical loads and protects the plastic composite plate from direct rivet-induced damage while achieving robust mechanical joining.
2Ease of manufacture
If self-piercing rivet is used to join plastic composite plate and metal plate, then joining is achieved, but joining force deteriorates due to simple contact without bonding
Solution Approach 1:
The solution merges mechanical joining (self-piercing rivet) with chemical bonding (adhesive) to create a hybrid joining system. The adhesive is applied between the reinforcing layer and metal plate, combining the mechanical interlocking of the rivet with the bonding strength of the adhesive to significantly enhance the overall joining force.
Solution Approach 2:
The joining system uses a composite approach combining different joining mechanisms - mechanical interlocking through the self-piercing rivet and chemical adhesion through the adhesive. This composite joining strategy leverages the advantages of both methods to achieve superior joining strength.
3Adaptability or versatility
If laser welding or spot welding is used to join plastic composite plate and metal plate, then joining is attempted, but welding cannot be properly performed due to distinct physical properties
Solution Approach 1:
The reinforcing layer acts as an intermediary that enables mechanical joining between dissimilar materials (plastic composite and metal) that cannot be welded together. This intermediate layer bridges the gap between materials with vastly different physical properties, allowing successful joining where direct welding would fail.
Solution Approach 2:
The solution changes the joining mechanism from thermal (welding) to mechanical (riveting with adhesive bonding). By changing the fundamental joining parameter from heat-based to force-based, the system overcomes the incompatibility between plastic composite and metal materials that prevents welding.
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
Minimizes damage to the plastic composite plate's periphery and increases the joining force with the metal plate by using self-healing and adhesive agents, ensuring robust bonding and improved structural integrity.
Implementation Method 1
a self-healing capsule containing a self-healing agent in a base material of a plastic resin and a catalyst being polymerized with the self-healing agent
Implementation Method 2
a self-piercing rivet piercing through the plastic composite plate to be pressed onto the metal plate and subjected to plastic deformation
Data Source
AI summary
Disclosed is a joining structure for joining dissimilar materials, such as a plastic plate and a metal plate. The joining structure is positioned or formed at where a plastic plate and a metal plate are joined. The joining structure includes: a self-piercing rivet piercing through the plastic plate to be pressed onto the metal plate and subjected to plastic deformation. In particular, the plastic plate includes a self-healing capsule containing a self-healing agent in a base material of a plastic resin and a catalyst being polymerized with the self-healing agent. The self-healing capsule is broken by a crack of the base material at a periphery of a pierced portion of the plastic plate, and the self-healing agent flowing out of the self-healing capsule fills a gap of the crack and causes polymerization with the catalyst to cure the crack portion.