Wire Mesh Rivet for Compact Heat Shield Isolator Formation
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Solution Overview
Problem
The challenge is to form wire mesh isolators in limited spaces, such as the concave sides of heat shields in vehicle exhaust systems, where traditional equipment is not feasible due to space constraints, and to simplify the installation process while reducing costs.
Innovation Solution
The solution involves using a unitary wire mesh rivet with a central bore and a collar and shank of varying densities, along with a metal insert and a flexible dispensing strip, to facilitate the formation and installation of wire mesh isolators. The rivet is formed using a tool that compresses the wire mesh tube to create a collar and shank with different densities, and a dispensing strip with flexible fingers to automate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional wire mesh isolator forming equipment is used, then isolators can be formed with sufficient density and structural integrity, but the equipment is too bulky to fit in limited spaces such as concave sides of heat shields
Solution Approach 1:
The isolator forming process is segmented into two distinct stages: first forming a collar with initial density, then compressing the shank region to achieve final density. This segmentation allows each stage to be optimized independently, enabling compact equipment design while maintaining manufacturing precision through controlled sequential compression.
Solution Approach 2:
The collar is formed in advance with a predetermined density before the shank compression occurs. This preliminary action allows the collar to be pre-positioned and pre-compressed to the correct density, eliminating the need for bulky equipment to simultaneously compress both regions and enabling the use of more compact forming tools.
2Volume of moving object
If wire mesh isolators are formed in limited spaces, then equipment size is reduced, but the complexity of the forming process increases
Solution Approach 1:
The forming process utilizes controlled changes in compression parameters (force, duration, distribution) to achieve different density levels in different regions. By varying these parameters sequentially rather than simultaneously, the process manages complexity while achieving the desired density uniformity in compact spaces.
3Adaptability or versatility
If multi-piece isolators are used, then assembly flexibility is improved, but assembly difficulties and component separation problems increase
Solution Approach 1:
The collar and shank components are merged into a single unitary wire mesh structure formed in one continuous process. This merging eliminates the assembly steps required for multi-piece isolators, removing the risk of component separation during shipping and installation while maintaining the adaptability of the isolator design.
Solution Approach 2:
The unitary structure forms its own collar and shank regions through controlled compression during a single forming operation. The wire mesh material itself provides the structural integrity and density variation needed, eliminating the need for separate components and their associated assembly complexities.
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 approach allows for efficient formation and installation of wire mesh isolators in constrained spaces, reducing the need for bulky equipment and minimizing material costs, while ensuring effective thermal and acoustical isolation with equal density collars and reduced handling risks.
Implementation Method 1
compressing the portions of the sleeve that extend on either side of the substrate into collars larger than the bore
Data Source
AI summary
A wire mesh rivet (13) is provided which is used to produce a wire mesh isolator (11) in a bore (9) of a substrate such as a heat shield (7) for a vehicle exhaust system. The rivet (13) comprises a unitary wire mesh structure (19) which has a collar (15) and a shank (17). The collar (15) has a higher density than the shank (17), e.g., the collar (15) has the density of the finished isolator (11). The rivet (13) is formed into the finished isolator (11) by compressing the shank (17) to form a second collar, while restraining the original collar (15) from substantially changing its shape. The rivet (13) can include a metal insert (23) which prevents the wire mesh of the finished isolator (11) from experiencing high levels of compression when the substrate is fastened to its supporting structure. The rivets (13) can be carried by a dispensing strip (31) and can be formed into the finished isolator (11) using forming equipment (39) whose dimensions are compatible with the limited space available with some substrates.