Short answer

Consider hidden fastening techniques like injection lap riveting when designing components where surface aesthetics, space constraints, and thermal/electrical performance are critical.

Field: Final Production
Source: The International Journal of Advanced Manufacturing Technology (2023)
Method: Combined experimental testing and finite element modeling.
Evidence: Strong effect

A novel double-sided injection lap riveting process creates flush joints that significantly improve the thermo-electrical performance compared to conventional bolted connections. This final production research insight is drawn from a 2023 study published in The International Journal of Advanced Manufacturing Technology. Using Combined experimental testing and finite element modeling., researchers explored how this design variable affects real-world outcomes. The key design takeaway: Consider hidden fastening techniques like injection lap riveting when designing components where surface aesthetics, space constraints, and thermal/electrical performance are critical.

Study

Final ProductionRecentStrong effect

Hidden Lap Riveting Enhances Thermo-Electrical Performance in Busbar Joints

A novel double-sided injection lap riveting process creates flush joints that significantly improve the thermo-electrical performance compared to conventional bolted connections.

The International Journal of Advanced Manufacturing Technology · 2023

Key Findings

01The double-sided injection lap riveting process results in joints with no material protrusions.
02The riveted joints exhibit superior thermo-electrical performance compared to bolted joints.
03The process offers savings in assembly space due to the flush joint design.

Application

Design takeaway

Consider hidden fastening techniques like injection lap riveting when designing components where surface aesthetics, space constraints, and thermal/electrical performance are critical.

How to apply

When designing electrical enclosures, power distribution units, or any application requiring smooth surfaces and efficient current flow, explore joining methods that embed fasteners or create seamless connections.

Project actions

01When choosing a joining method, think about how it affects the final product's appearance and performance, not just how strong it is.
02Consider the 'hidden' aspects of a design – how internal components or joining methods can impact external qualities.

Method & Evidence

AimTo investigate the thermo-electrical performance and structural integrity of double-sided injection lap riveted joints compared to conventional bolted joints for busbar applications.

MethodCombined experimental testing and finite element modeling.

ProcedureTwo overlapped aluminum sheets were joined using tubular rivets injected via compression into pre-machined dovetail ring holes. The resulting joints were tested for thermo-electrical performance and compared against identical joints fabricated using conventional bolting. Finite element models were developed to simulate the joining process and analyze stress distribution and thermal conductivity.

ContextFabrication of aluminum busbar joints for energy distribution systems.

Variables

IVJoining method (double-sided injection lap riveting vs. conventional bolting).

DVThermo-electrical performance (e.g., resistance, temperature rise), structural integrity.

CVMaterial of sheets (aluminum), geometry of sheets, type of rivet/bolt, environmental conditions during testing.

Strengths & Limitations

Strengths

+Direct comparison between a novel and a conventional joining method.
+Integration of experimental data with simulation for comprehensive analysis.

Limitations

The specific tooling and machinery required for injection lap riveting might be specialized and not readily available for all design projects.

Reliability & validity

The use of both experimental testing and finite element modeling enhances the reliability and validity of the findings. However, the specific parameters of the 'room temperature' joining process and the long-term effects would require further investigation for complete validation.

Think critically

How might the initial investment in specialized tooling for processes like injection lap riveting be justified against the long-term gains in performance and assembly space?

Design Principles

"Integrate fastening mechanisms to be part of the component's form and function, rather than an addition."

This process offers a manufacturing advantage by eliminating post-assembly finishing and reducing space requirements. Crucially, the improved electrical conductivity and thermal dissipation are vital for applications where efficiency and heat management are critical, such as in energy distribution systems.

What This Means for Your Design

A new way to join metal sheets uses special rivets that push into holes, making the joint smooth on both sides. This makes electrical connections work better and saves space, which is great for things like electrical power bars.

How to use in your project

1.Reference this study when exploring alternative joining methods for your design project, particularly if your design involves electrical conductivity, thermal management, or aesthetic considerations.

Add to My Project

Quick Cite

Paragraph starter

The study by Pragana et al. (2023) highlights the significant thermo-electrical performance benefits of employing hidden joining techniques, such as double-sided injection lap riveting, over conventional visible fasteners like bolts. This research is relevant to design projects requiring optimized electrical conductivity and thermal dissipation, suggesting that the method of assembly can be a critical design parameter influencing overall product efficiency and spatial integration.

Source

The International Journal of Advanced Manufacturing Technology

Double-sided injection lap riveting

journal · 2023

View source

Questions About This Research

What does the research say about hidden lap riveting enhances thermo-electrical performance in busbar joints?: Consider hidden fastening techniques like injection lap riveting when designing components where surface aesthetics, space constraints, and thermal/electrical performance are critical. Evidence: The International Journal of Advanced Manufacturing Technology (2023).
Why does "Hidden Lap Riveting Enhances Thermo-Electrical Performance in Busbar Joints" matter for design?: This process offers a manufacturing advantage by eliminating post-assembly finishing and reducing space requirements. Crucially, the improved electrical conductivity and thermal dissipation are vital for applications where efficiency and heat management are critical, such as in energy distribution systems.
How can designers apply this research?: Consider hidden fastening techniques like injection lap riveting when designing components where surface aesthetics, space constraints, and thermal/electrical performance are critical.
What were the main findings?: The double-sided injection lap riveting process results in joints with no material protrusions.. The riveted joints exhibit superior thermo-electrical performance compared to bolted joints.. The process offers savings in assembly space due to the flush joint design.
What research method was used?: Combined experimental testing and finite element modeling..
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2023 journal from The International Journal of Advanced Manufacturing Technology.
What should I do differently in my next project?: When designing electrical enclosures, power distribution units, or any application requiring smooth surfaces and efficient current flow, explore joining methods that embed fasteners or create seamless connections.
What are the limitations?: The study focuses on aluminum busbars; performance may vary with different materials and sheet thicknesses. The long-term durability and resistance to vibration were not extensively detailed.