Self-Clinching Fastener Pilot Structure for Hollow Metal Tubes

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Solution Overview

Problem

Conventional self-attaching construction elements fail to provide sufficient rotational and push-out resistance when attached to complex metal substrates like hollow-metal tubes, often deforming the substrate and compromising its structural integrity.

Innovation Solution

A self-clinching construction element with a body portion, punch portion, pilot embossment, and lugs that plastically deform the metal substrate, creating a recessed pocket to secure the element without deforming the substrate, ensuring sufficient rotational and push-out resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional construction elements are attached to complex metal substrates like hollow-metal tubes, then attachment is achieved, but rotational and push-out resistance are insufficient and substrate structural integrity is compromised

Engineering Contradiction:

Improveattachment reliabilityVSAvoidsubstrate structural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The construction element is divided into distinct functional segments: a body portion for engagement, a punch portion for material displacement, and multiple lugs for rotational resistance. This segmentation allows each part to perform its specific function optimally without compromising the substrate

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The punch portion performs preliminary action by plastically deforming the substrate material and forming a recessed pocket before final engagement. This preliminary material displacement creates a predetermined engagement path that ensures proper installation and maximizes attachment strength without surprising deformations

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional construction elements are forced into complex metal substrates, then attachment is achieved, but the substrate is structurally deformed and becomes unusable

Engineering Contradiction:

Improveattachment reliabilityVSAvoidsubstrate deformation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The construction element applies localized quality changes by concentrating plastic deformation only in the immediate engagement zone where the punch portion interacts with the substrate. The rest of the substrate maintains its original structural properties, allowing the component to remain usable after attachment

Inventive Principle:

Principle #3Local quality

3Reliability

If construction elements are designed for thin metal panels, then satisfactory rotational and push-out resistance are achieved, but they fail on complex geometries like hollow-metal tubes

Engineering Contradiction:

Improverotational and push-out resistanceVSAvoidsubstrate geometry adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The construction element achieves universality by incorporating multiple functional features: the body portion engages the substrate, the punch portion creates material displacement and forms a recessed pocket, and the lugs provide rotational resistance. This multi-functionality allows the same element design to work effectively across diverse substrate geometries including hollow-metal tubes

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention utilizes dimensional adaptation by modifying the engagement geometry to accommodate three-dimensional complex substrates. The punch portion extends axially to engage hollow structures, and the lugs are positioned to provide rotational resistance in multiple orientations, enabling attachment to substrates with varying geometries

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 effectively attaches to complex metal substrates like hollow-metal tubes with enhanced rotational and push-out resistance, maintaining the substrate's structural integrity and preventing separation under external forces.

Implementation Method 1

The pilot embossment is configured to engage and plastically deform the metal substrate such that the metal substrate flows into a recessed pocket defined in the outer peripheral surface of the punch portion

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11913488B2Self-clinching and self-piercing construction element with multi-purpose pilot

Publication Date: 2024.02.27 RB&W MANUFACTURING LLC

AI summary

A self-clinching and self-piercing construction element for attachment to a plastically deformable metal panel. The construction element includes a body portion with a central axis and a punch portion being coaxial with the central axis and extending from the body portion. A pilot embossment is coaxial with the central axis and extends from the body portion such that the pilot embossment is concentrically disposed between an annular-shaped surface of the body portion and the punch portion. The pilot embossment being configured to engage and plastically deform the metal substrate such that the metal substrate flows into a recessed pocket defined in an outer peripheral surface of the punch portion. A plurality of spaced apart lugs axially project outwards from the annular-shaped surface and extend radially outwards from the pilot embossment.