Multi-Layer Sheet Metal Clinching With Access Openings
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Solution Overview
Problem
Existing methods for joining sheet metal layers, such as welding, can damage heat-sensitive components due to thermal loads, while mechanical solutions like screwing increase weight and size, and clinching may not provide sufficient bonding strength, especially for multi-layer assemblies.
Innovation Solution
A stack of sheet metal is joined using clinching joints, where each pair of layers has an access opening aligned with the clinching joint, allowing for plastic deformation and creation of a projection without thermal stress, and using different access openings to specify the direction of joining and prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join sheet metal layers, then a reliable positive substance-fit connection is created, but high thermal load damages heat-sensitive components
Solution Approach 1:
The patent replaces thermal welding processes with a mechanical clinching process. A clinching tool mechanically interlocks sheet metal layers by forming a projection that deforms and anchors into the material, eliminating thermal exposure while maintaining connection strength through mechanical interlocking and plastic deformation.
Solution Approach 2:
The invention changes the fundamental joining parameter from thermal energy (welding temperature) to mechanical energy (clinching force and plastic deformation). This parameter transformation allows joining heat-sensitive materials without thermal damage while achieving reliable mechanical connections through controlled plastic deformation and friction.
2Strength
If screwing is used to join sheet metal layers, then a mechanical connection is achieved, but weight and size of the assembly increase
Solution Approach 1:
The patent merges the joining function and the structural material into a single integrated process. The clinching tool directly forms the connection by deforming the sheet metal itself, eliminating the need for separate fasteners like screws. This merging reduces component count, assembly weight, and overall size while maintaining mechanical connection strength.
Solution Approach 2:
The sheet metal layers serve their dual function: they are both the structural material being joined and the material that forms the connection itself. The clinching process utilizes the sheet metal's own material properties to create the interlocking projection, eliminating the need for additional joining components and reducing overall assembly weight.
3Ease of manufacture
If traditional clinching is used to join sheet metal layers, then a mechanical connection is created, but bonding strength is insufficient for multi-layer assemblies
Solution Approach 1:
The patent segments the multi-layer assembly into pairs of layers, with each pair being independently clinched. Access openings are strategically positioned to allow the clinching tool to reach specific layer pairs, enabling controlled sequential joining that ensures adequate bonding strength for each interface while maintaining ease of manufacture through a systematic approach.
Solution Approach 2:
The invention applies local quality by creating access openings at specific locations where clinching is required. This allows the clinching tool to apply concentrated mechanical energy precisely where needed, ensuring sufficient bonding strength at each joint interface while maintaining the overall integrity and ease of manufacturing the multi-layer assembly.
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 provides a strong, stable, and compact connection suitable for heat-sensitive components and varying material thicknesses, preventing material deformation and ensuring reliable bonding without additional materials, suitable for high-voltage or high-current applications.
Implementation Method 1
allowing for plastic deformation and creation of a projection without thermal stress
Data Source
AI summary
An assembly includes at least three layers of sheet metal lying directly on top of one another and joined in a stack of sheet metal. The layers of sheet metal are each joined in pairs by a clinching joint. At least one layer of sheet metal arranged between one of the pairs of layers of sheet metal joined by the clinching joint and an outer side of the stack each have an access opening aligned with the clinching joint.