Sheet Metal Imprint for Rotational Security
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Solution Overview
Problem
Existing methods for attaching functional elements to sheet metal parts often require features on the functional elements for security against rotation, which can be costly and complex to manufacture, and may not be necessary if the sheet metal part is properly pre-imprinted with raised and recessed regions.
Innovation Solution
The sheet metal part is pre-imprinted with a sequence of raised and recessed regions before attachment, allowing the imprint to create a complementary shaping of the functional element that ensures security against rotation, potentially eliminating the need for features on the functional element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If features providing security against rotation are provided on the functional element, then security against rotation is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of providing security against rotation features on the functional element, the invention inverts the approach by providing corresponding features on the sheet metal part (imprint with raised and recessed regions). The functional element remains simple while the sheet metal part carries the complexity, thereby reducing overall device complexity and manufacturing cost while maintaining security against rotation.
Solution Approach 2:
The invention creates a complementary copy of the security against rotation features on the sheet metal part (imprint) that mirrors the functionality needed on the functional element. This copying approach allows the functional element to be simpler while the imprint on the sheet metal part provides the necessary geometric interlocking for security against rotation.
2Reliability
If features providing security against rotation are provided on the functional element, then security against rotation is improved, but manufacturing cost increases
Solution Approach 1:
The invention inverts where the security against rotation features are located - moving them from the expensive functional element to the sheet metal part as an imprint. This reduces manufacturing cost since the functional element can be made from lower strength materials with simpler geometry, while the imprint is formed as part of the sheet metal shaping process.
Solution Approach 2:
The invention allows the functional element to be made from cheaper, lower strength materials since the security against rotation is provided by the durable sheet metal part imprint rather than features on the functional element itself. This substitution of materials reduces manufacturing cost while maintaining functional performance.
3Device complexity
If the sheet metal part is pre-imprinted with raised and recessed regions, then security against rotation is achieved without features on the functional element, but the sheet metal part requires additional processing
Solution Approach 1:
The invention merges the imprint formation process with the existing sheet metal part manufacturing process. The imprint with raised and recessed regions is formed during the shaping of the sheet metal part, combining multiple operations into one integrated process rather than adding a separate post-processing step, thereby maintaining ease of manufacture while achieving the desired geometric features.
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 enhances security against rotation while reducing manufacturing costs and complexity by leveraging the work hardening of the sheet metal part and local surface pressures, allowing for the use of less expensive functional elements with lower strength materials.
Implementation Method 1
The success of this method may have something to do with the fact that through the imprinting of the sheet metal part it experiences a type of work hardening whereby the hardness of a sheet metal part, i.e. the strength of a sheet metal part is increased
Implementation Method 2
the imprint of the sheet metal part leads to a complementary shaping of the functional element in the region of the functional element which comes into contact with the imprint
Data Source
AI summary
A method for the manufacture of a component assembly comprising a sheet metal part and a functional element attached to it by a riveting process or by a riveting and piercing process or by a press-in process, wherein the sheet metal part is provided with an imprint, is wherein the imprint is produced prior to attachment of the functional element and consists of a sequence of regions which are raised and recessed relative to one another and wherein, during the attachment of the functional element this is pressed against the sheet metal part in such a way that the imprint of the sheet metal part leads to a complementary shaping of the functional element in the region of the functional element which comes into contact with the imprint. A sheet metal part and a functional element are also claimed.