Self-clinching fastener

Abstract

A self-clinching fastener for attachment to a deformable metal panel. The self-clinching fastener includes a body portion having a central axis, a swage portion extending from the body portion and coaxial with the central axis. The body portion forms a generally annular fastener face adjacent the swage portion, the swage portion having an inclined wall extending from the fastener face and forming a recess. A plurality of spaced-apart protrusions protrude from the fastener face and encircle the swage portion, and a plurality of spaced-apart recesses encircle the swage portion in the fastener face. The plurality of protrusions and the plurality of recesses form an abutment to improve torsional resistance of the fastener.

Description

Technical Field

[0001] A self-locking fastener. Background Technology

[0002] Self-locking fasteners are fasteners (e.g., nuts) installed in a substrate such as sheet metal. Installation may include: if the self-locking fastener is self-punching, pressing the fastener directly into the substrate, or pressing it into a pre-punched or pre-drilled hole in the substrate. Self-locking fasteners generally include geometric features, such as protrusions on the fastener face, that deform the substrate and flow into the area of ​​the self-locking fastener (e.g., the area between the protrusions). As a result, the geometry of the substrate engages with the self-locking fastener, creating a mechanical connection that holds the fastener in place. Self-locking fasteners may include female threads, etc., to receive screws or bolts for mounting objects onto sheet metal substrates.

[0003] However, conventional self-locking fasteners have various drawbacks, including but not limited to low push-out force threshold, low torsion force threshold, and the need for pre-punching or pre-drilling in the metal substrate to facilitate fastener installation. These drawbacks increase assembly costs and fastener failure. Summary of the Invention

[0004] On one hand, this disclosure relates to a self-engaging fastener for attachment to a deformable metal sheet, the self-engaging fastener comprising: a body portion having a central axis; a stamped portion extending from the body portion and coaxial with the central axis, the body portion forming a generally annular fastener surface adjacent to the stamped portion, the stamped portion having an inclined wall extending from the fastener surface and forming a recess; a plurality of spaced-apart protrusions projecting from the fastener surface and surrounding the stamped portion; and a plurality of spaced-apart recesses surrounding the stamped portion in the fastener surface, the plurality of protrusions and the plurality of recesses forming an abutment to improve the torsional resistance of the fastener.

[0005] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener includes 4 to 12 of a plurality of protrusions and 4 to 12 of a plurality of recesses.

[0006] In embodiments of this aspect, according to any of the above exemplary embodiments, a self-engaging fastener wherein a plurality of protrusions and a plurality of recesses alternately surround a stamped portion along the fastener face.

[0007] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener has a plurality of protrusions that are Y-shaped structures on the fastener surface.

[0008] In embodiments of this aspect, according to any of the above exemplary embodiments, each of the plurality of protrusions has a plurality of arms extending from a central portion of the protrusion, the plurality of arms forming a plurality of wedges, at least one of the plurality of wedges having a surface descending toward the fastener face.

[0009] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener includes a plurality of arms including a first arm that extends from the central portion of the protrusion along the inclined wall of the fastener face toward the stamped portion, the first arm having a first surface that descends toward the fastener face.

[0010] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener includes a plurality of arms including a second arm and a third arm that extend from the central portion of the protrusion along the fastener face toward the outer periphery of the fastener face, the second arm having a second surface that descends away from the central portion of the protrusion, the third arm having a third surface that descends away from the central portion of the protrusion, and the second arm and the third arm forming a common surface descending away from the central portion of the protrusion between the second arm and the third arm.

[0011] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener includes a plurality of recessed portions comprising a surface that gradually descends from the fastener face to the flat bottom surface of the recessed portion.

[0012] In embodiments of this aspect, according to any of the above-described exemplary embodiments, a plurality of recessed portions extend toward and intersect with the inclined wall of the stamped portion.

[0013] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener has a plurality of recessed portions having a recessed volume corresponding to a plurality of protrusion volumes.

[0014] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener wherein the inclined wall of the stamped portion defines a first diameter of the stamped portion at the fastener face and a second diameter at the opening of the stamped portion.

[0015] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener wherein the inclined wall of the stamped portion includes a curved transition portion that intersects with the fastener surface.

[0016] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener wherein the inclined wall of the stamped portion is a dovetail structure.

[0017] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener wherein the inclined wall of the stamped portion includes a flat portion forming an edge at the end of the stamped portion.

[0018] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener wherein the inclined wall of the stamped portion includes a self-piercing edge for piercing a deformable metal sheet.

[0019] In embodiments of this aspect, according to any of the above exemplary embodiments, the self-engaging fastener has an inner surface of the stamped portion including female threads for engagement with a bolt.

[0020] In one aspect, this disclosure relates to a method for attaching self-engaging fasteners to deformable metal plates. The method includes the following steps: positioning the fastener and a die component coaxially on opposite sides of the metal sheet at the location where the fastener will be fixed to the sheet metal, the fastener including a body portion having a central axis; a stamped portion extending from the body portion and coaxial with the central axis, the body portion forming a generally annular fastener face adjacent to the stamped portion, the stamped portion having an inclined wall extending from the fastener face and forming a recess; a plurality of spaced protrusions projecting from the fastener face and surrounding the stamped portion; a plurality of spaced recesses surrounding the stamped portion in the fastener face, the plurality of protrusions and the plurality of recesses forming an abutment to improve the torsional resistance of the fastener; and moving the die component and the fastener relative to each other in an axial direction to deform a portion of the sheet metal into the recess of the fastener, thereby improving the torsional resistance of the fastener, until a strong mechanical interlock is formed between the fastener and the sheet metal.

[0021] In embodiments of this aspect, the disclosed method of attaching a self-engaging fastener to any of the above example embodiments includes: moving the mold member and the fastener relative to each other in a direction along a central axis to force a plurality of protrusions to press a deformed portion of the plate into a recess, and pressing the deformed portion of the plate into a plurality of recesses.

[0022] In embodiments of this aspect, the disclosed method of attaching a self-engaging fastener to any of the above example embodiments includes: moving the mold member and the fastener relative to each other in a direction along a central axis to force the plurality of protrusions to press the deformed portion of the plate toward at least three different directions away from the central portion of the plurality of protrusions.

[0023] In embodiments of this aspect, the disclosed method of attaching a self-engaging fastener to any of the above example embodiments includes: moving the mold component and the fastener relative to each other in a direction along a central axis to force the edge of the stamped portion to pierce the deformable metal sheet. Attached Figure Description

[0024] To gain a more detailed understanding of the features described above, the present disclosure, which has been briefly summarized above, can be described in more detail by referring to exemplary embodiments, some of which are shown in the accompanying drawings. However, it should be noted that the drawings only illustrate exemplary embodiments of the present disclosure and should not be considered as limiting its scope, as the present disclosure may allow for other equivalent exemplary embodiments.

[0025] Figure 1A A perspective view of a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0026] Figure 1B A front view of a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0027] Figure 1C A side view of a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0028] Figure 2A A cross-sectional view of an installation tool and a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0029] Figure 2B A side view of an installation tool and a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0030] Figure 2C A perspective view is shown of an indentation in sheet metal caused by the installation of a self-locking fastener according to an exemplary embodiment of the present disclosure.

[0031] Figure 2D An analytical view of an indentation in sheet metal caused by the installation of a self-locking fastener, according to an example embodiment of the present disclosure, is shown.

[0032] Figure 3A Example embodiments according to this disclosure are shown. Figure 1A The front view of the self-locking fastener.

[0033] Figure 3B Example embodiments according to this disclosure are shown. Figure 1A The front view of the self-locking fastener.

[0034] Figure 3C Example embodiments according to this disclosure are shown. Figure 1AA detailed front view of the self-locking fastener.

[0035] Figure 3D Example embodiments according to this disclosure are shown. Figure 1A Side view of the self-locking fastener in the image.

[0036] Figure 3E Example embodiments according to this disclosure are shown. Figure 1A Side view of the self-locking fastener in the image.

[0037] Figure 3F A view of an installation tool and a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0038] Figure 4A A perspective view of another self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0039] Figure 4B Example embodiments according to this disclosure are shown. Figure 4A The front view of the self-locking fastener.

[0040] Figure 4C Example embodiments according to this disclosure are shown. Figure 4A Another front view of the self-locking fastener.

[0041] Figure 5 A flowchart illustrating the installation of a self-engaging fastener according to an example embodiment of the present disclosure is shown.

[0042] Figure 6 A block diagram of a molding machine according to an example embodiment of the present disclosure is shown. Detailed Implementation

[0043] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps illustrated in these exemplary embodiments do not limit the scope of the present disclosure. The following description of at least one exemplary embodiment is illustrative in nature only and is by no means intended to limit the present disclosure, its application, or its use. Techniques, methods, and apparatuses known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and apparatuses are part of the specification. In all examples described and discussed herein, any particular value should be interpreted as illustrative rather than restrictive. Therefore, other exemplary embodiments may have different values. Note that in the following figures, similar reference numerals and letters refer to similar items in the following figures; therefore, once an item is defined in a figure, further discussion in subsequent figures is unnecessary. Exemplary embodiments will now be described with reference to the accompanying drawings.

[0044] This disclosure relates to a solution for providing self-engaging fasteners (e.g., nuts) with various features that reduce installation costs and provide resistance to increased push-out and twisting forces (i.e., torsional forces). One such feature is a self-piercing edge that allows the self-engaging fastener to be directly pressed into a substrate (e.g., sheet metal) without pre-drilling or pre-punching. In other words, the self-engaging fastener can be installed in a single press-action movement, in which relative forces are applied between the self-engaging fastener and the substrate, causing a portion of the self-engaging fastener to punch a hole directly through the substrate, and causing another portion of the self-engaging fastener to deform and permanently fix the substrate to the substrate.

[0045] The self-engaging fasteners disclosed herein generally include three main geometric features for ensuring a firm bond with a target substrate. These geometric features may include an anti-push-out stamping portion, an anti-rotation protrusion, and an anti-rotation recess. The anti-push-out stamping portion may include a chamfered neck extending from an annular fastener face at the recess location toward a self-piercing edge of the fastener. The anti-rotation protrusion may include an inclined and raised geometry projecting from the fastener face. The anti-rotation recess may include a recess in the fastener face. In one configuration, the self-engaging fastener includes a plurality of anti-rotation protrusions and anti-rotation recesses, which are alternately positioned as adjacent portions surrounding the fastener face.

[0046] During installation, the self-engaging fastener is pressed into the substrate, or vice versa. When the self-piercing edge of the fastener contacts the substrate, it punches a hole in the substrate. Then, when the anti-rotation protrusion contacts the substrate, it deforms the substrate material and creates an indentation in the substrate. The mass of the substrate material deformed by the anti-rotation protrusion is forced (i.e., flows) into the recess (i.e., the bending transition) formed between the fastener face and the anti-pull-out neck, and into the anti-rotation recess on the fastener face. This binds the substrate material to the fastener geometry, such that the material in the recess between the fastener face and the anti-pull-out neck resists the push-out force applied to the fastener, while the anti-rotation protrusion embedded in the substrate material resists the twisting force applied to the fastener.

[0047] The self-locking fasteners described in this document can be installed in a variety of products, including electric vehicles (EVs), to provide fastening mechanisms within the EV. For example, self-locking fasteners can be installed into the sheet metal of an EV to provide mounting points for the battery, seats, etc. Although the application of self-locking fasteners is described with reference to installation in an EV, it should be noted that self-locking fasteners can be deployed in any platform where self-locking fasteners are required.

[0048] It should be noted that although the figures and descriptions in this disclosure are directed to self-locking nuts for attachment to sheet metal substrates, this disclosure is not limited to nuts or sheet metal substrates. Other types of self-locking fasteners can utilize the self-punching and self-locking features of self-locking nuts. These self-locking fasteners may include, but are not limited to, self-locking studs, self-locking bolts, etc.

[0049] Figure 1A A perspective view of a self-engaging fastener 100 is shown, including a body portion 114 and a stamped portion 108. The body portion 114 includes a fastener face 116 having a plurality of protrusions 104 with various arms (including corresponding wedge-shaped portions 102) and a plurality of recesses 106. In this example, the plurality of protrusions 104 and the plurality of recesses 106 are formed circumferentially around the fastener face 116 of the self-engaging fastener 100. The stamped portion 108 extends coaxially from the fastener face 116 with a central axis and includes a central opening 112 having an internal thread 110 and a self-piercing edge 118. Self-engaging fasteners are generally formed from a metal (e.g., an alloy) through a process that may include cutting a sheet of metal into the approximate shape of a nut, forging the nut into the desired shape (including the self-punching and self-engaging features described above), thread rolling the nut to form threads for receiving and engaging a screw or bolt, heat treating it to increase its strength and durability, and surface finishing (e.g., applying a protective coating to the nut). Structural and functional details of the self-punching and self-engaging features are now described with reference to the remaining figures.

[0050] Figure 1B A front view of the self-engaging fastener is shown, in which the self-engaging features are shown and described in detail. As described above, the fastener face 116 includes a protrusion 104 and a recessed portion 106.

[0051] In this example, the protrusion 104 (i.e., the rib) is Y-shaped, comprising three arms 104A, 104B, and 104C radiating outwards, one direction toward the stamped portion and the other toward the outer periphery of the fastener. Arm 104A is generally formed by a wedge-shaped surface 131 and inclined side surfaces 133 and 137. The wedge-shaped surface 131 slopes from a maximum height above the fastener face 116 at the top surface 132 to a minimum height above the fastener face 116 at the location of the recess where the fastener face 116 intersects with the stamped portion 108. In other words, the wedge-shaped surface 131 slopes downwards toward the recess where the fastener face 116 intersects with the stamped portion 108. Arms 104B and 104C are generally formed by a flat top surface 132 and inclined side surfaces 133, 134, 135, 136, and 137, which extend from a maximum height above the fastener face 116 at the top surface 132. (As...) Figure 1BAs shown, protrusions 104 can be alternately formed circumferentially around the fastener face 116 of the self-engaging fastener. Although in Figure 1B Eight protrusions are shown, but other configurations are possible and can fall into the range of, but not limited to, 4 to 12 protrusions.

[0052] In this example, the recessed portion 106 is rectangular in shape and includes a bottom portion 141 and sidewalls 142, 143, and 144. The sidewalls 142, 143, and 144 generally extend below the fastener face 116 to intersect with the bottom portion 141, which is generally located at a predetermined height below the fastener face 116. One or more of the sidewalls 142, 143, and 144 may be straight or inclined relative to the fastener face 116. The recessed portion 106 generally extends from a predetermined point on the fastener face 116 toward the recess where the fastener face 116 intersects with the stamped portion 108. Figure 1B As shown, the recessed portion 106 can be formed circumferentially around the fastener face 116 of the self-engaging fastener in an alternating manner relative to the protrusion 104. Although in Figure 1B Eight recessed portions are shown, but other configurations are possible and can fall within, but are not limited to, the range of 4 to 12 recessed portions.

[0053] It should be noted that although the protrusion 104 is shown as Y-shaped, other shapes are possible (e.g., various combinations of wedge-shaped legs and flat legs). For example, the protrusion 104 can have two legs in an I-shape, four legs in an X-shape, etc., as long as these legs force the deformed metal of the substrate to flow into the recesses and indentations of the stamping portion. Note that although the recess 106 is shown as rectangular, other shapes are possible. For example, the recess 106 can be triangular, circular, etc., as long as the internal volume of the recess 106 is sufficient to accommodate a portion of the deformed metal substrate flowing from the indentation caused by the protrusion 104. This configuration is advantageous because when the metal substrate is deformed by the protrusion 104, a portion of the metal flows into the recess 106, forming a strong mechanical bond between the substrate and the nut. This mechanical bond limits the unscrewing force of the nut (i.e., how much force is required after installation to unscrew the nut from the substrate). Without the recesses 106, the metal flowing away from the protrusions 104 would have nowhere to go except away from the fastener 100, which would cause unwanted substrate material bubbles to form outside the fastener diameter. In other words, the recesses 106 not only provide resistance to increased twisting forces, but they also allow the substrate to deform in a more uniform manner.

[0054] Figure 1CA side view of a self-engaging fastener is shown, illustrating and describing the self-engaging and self-punching features. As shown, the self-engaging fastener includes a side body surface 161, side punched portion surfaces 162 and 163, and a self-punching edge 164. The side body surface 161 may form a circular shape for the self-engaging fastener. However, the side body surface 161 is not limited to a circular shape. The side punched portion surface 162 is an inclined surface (i.e., an inclined wall) having a shape (e.g., a dovetail structure) extending from the fastener face 116 toward the chamfered surface 163. More specifically, the side punched portion surface 162 is inclined such that the diameter of the punched portion is minimum at the fastener face 116 and maximum at a height away from the fastener face 116 (e.g., at the self-punching edge 164). This configuration forms an annular recess 165 at the intersection of the side punched portion surface 162 and the fastener face 116. The recess 165 is advantageous because when the metal substrate deforms, a portion of the metal flows (i.e., is forced) into the recess 165, forming a strong mechanical connection between the substrate and the nut. This mechanical connection partially limits the push-out force of the nut (i.e., how much force is required to push the nut out of the substrate after installation).

[0055] Note that the self-piercing edge 164 can be a sharp edge that allows the nut to easily cut through the metal substrate during installation. In other words, the self-piercing edge 164 assists the installation process by punching a hole in the substrate when a relative force is applied between the nut and the substrate. This eliminates the need for pre-punching or pre-drilling in the metal substrate and allows the nut(s) to be installed in a single punching action, which will be described in more detail below.

[0056] Figure 2AA cross-sectional view of a self-engaging fastener inserted into an installation tool 200 is shown. In this example, the installation tool 200 is a stamping machine comprising an upper die member 201 having a hollow core 202 and a lower die member 205 including a recess 206 for receiving a self-engaging nut 100. Before stamping, the self-engaging nut 100 is positioned in the recess 206 of the lower die member 205, and a metal substrate 203 is positioned above the self-engaging nut 100. In this configuration, the self-piercing edge 164 of the self-engaging nut 100 faces the substrate 203. During stamping, force is applied to at least one of the die members, the upper die member 201 and / or the lower die member 205, forcing the dies toward each other. As the self-engaging nut 100 intersects with the substrate 203, the self-piercing edge 164 punches a piece out of the substrate, thereby forming a hole 204 in the substrate 203. This piece is received by the hollow core 202. When the substrate 203 then contacts the protrusion 104 on the fastener surface of the self-locking nut 100, the protrusion 104 deforms the substrate 203, causing a portion of the substrate material to flow out of the protrusion 104 and into the recess 106 and the recess 165, thereby creating a strong mechanical bond between the self-locking nut 100 and the substrate 203. When the mold retracts, the substrate 203 with the self-locking nut 100 installed can be removed from the mold as the installation of the nut is completed.

[0057] More specifically, during die stamping, when the substrate 203 contacts the protrusion 104 on the fastener surface of the self-locking nut 100, the top surface 132 of the protrusion 104 deforms the substrate 203, causing a portion of the substrate material to flow away from the side surfaces 133, 134, 135, and 137 of the protrusion toward the recess 106. This excess material flows into the gap defined by the recess 106 because the geometry of the protrusion is designed (e.g., at an angle) to direct the excess material toward the recess 106. Furthermore, when the substrate 203 contacts the protrusion 104 on the fastener surface of the self-locking nut 100, the wedge-shaped surface 131 of the protrusion 104 deforms the substrate 203, causing a portion of the substrate material to flow away from the wedge-shaped surface 131. Since the wedge-shaped surface 131 is inclined toward the annular recess 165, excess material flows into the recess due to the force generated by the wedge. The wedge-shaped surface 131 effectively pushes and presses a portion of the substrate into the recess.

[0058] Note that the force of the mold is sufficient to deform the substrate 203 due to the protrusion 104. However, an additional flange 207 may be included on the upper mold member 201 to increase the force applied by the protrusion, thereby increasing the flow of substrate material. In one example, the flange 207 is a protruding annular portion of the mold that aligns with the recess 106. One benefit of the flange 207 is that the added pressure is applied to a specific portion of the substrate above the recess 106, thereby ensuring that the substrate material is forcefully pressed into the recess 106 and the concave portion 165, thus improving resistance to rotation and mechanical bonding.

[0059] Figure 2B A side view of the installation tool 220 and the self-locking fastener is shown, with the substrate deformed by the molding process. As shown, the self-locking nut 100 begins to press against the substrate 203, which begins to deform due to the force applied to one side of the substrate by the protrusion 104 and the force applied to the other side of the substrate by the upper mold member 201. A portion of the substrate 203 begins to flow into the recess 106 (not shown) and into the recess 165 between surfaces 222 and 224. Figure 2B The diagram shows that recess 165 begins to fill with substrate material 203, and after stamping is complete, most (if not all) of the void space in recess 165 is filled with substrate material 203. Because recess 165 is located on the smaller diameter of stamped portion 108, the material in recess 165 resists the ejection movement of self-engaging nut 100 along the illustrated ejection axis (i.e., resists the nut from popping out of the substrate). Furthermore, most (if not all) of the void space in recess 106 is filled with substrate material 203, and protrusions are embedded in substrate material 203. As substrate material alternately flows into and out of recess 106 and covers protrusion 104, this material resists the twisting movement of self-engaging nut 100 along the illustrated twisting axis (i.e., resists the nut from twisting out of the substrate).

[0060] Figure 2CA perspective view of the indentation 240 in the substrate metal caused by the installation of the self-engaging fastener is shown. As shown, the substrate metal 241 includes indentations of a protrusion 104, a recess 106, and a recess 165. Specifically, indentation 242 is a raised (i.e., embossed) feature corresponding to the geometry of the recess 106, while indentation 243 is a recessed (i.e., concave) feature corresponding to the geometry of the protrusion 104. Furthermore, indentation 244 takes the form of an annular recess 165. These indentations help resist the force that removes the self-engaging fastener 100 from the substrate. Specifically, indentations / recesses 242 and 243 press against the side surfaces (sidewalls) of the recess 106 and the protrusion 104 to resist the twisting force on the indicated twisting axis, while indentation 244 presses against the surface of the recess 165 to resist the push-out force on the indicated push-out axis. As a result, the self-engaging fastener 100 is installed into the metal substrate in such a way that a strong mechanical bond is created that can resist common forces (e.g., push / pull forces, and rotational forces) applied to the self-engaging fastener. Figure 2D It shows the result of, as Figure 2C A close-up analytical view 260 shows the indentation in the sheet metal caused by the installation of the self-locking fastener. More specifically, Figure 2D As shown Figure 2C The opposite side (e.g., the lower side) of the substrate shown, wherein imprint 242 is a recessed (i.e., embossed) feature corresponding to the geometry of the recessed portion 106, and imprint 243 is a raised (i.e., embossed) feature corresponding to the geometry of the protrusion 104.

[0061] Now describing Figures 3A to 3F These accompanying drawings are mechanical drawings showing the dimensions of the self-engaging fastener 100 from various perspectives. Dimensions are indicated but not limited to any particular range. In other words, the value of each dimension and its relative size can be selected by the designer based on the specific application.

[0062] Figure 3A A front view 300 of a self-engaging fastener is shown. The self-engaging fastener 100 may include various features and dimensions, including but not limited to an outer diameter 301, radial spacing 302 between adjacent protrusions 104, radial spacing 303 between adjacent recesses 106, and radial spacing 304 between adjacent protrusions 104 and recesses 106. In the example shown, the self-engaging fastener 100 includes eight equally spaced protrusions 104 and eight equally spaced recesses 106; however, it should be noted that the number, spacing, and dimensions of the protrusions 104 and recesses 106 depend on the designer's needs based on the application requirements.

[0063] Figure 3BAnother front view 320 of the self-engaging fastener is shown. The self-engaging fastener 100 may include various features and dimensions, including but not limited to the outer width 321 of the protrusion, the protrusion spread angle 322, the protrusion central axis 323, the protrusion arm sweep angle 324, the inner width 325 of the protrusion, the fastener central axis 326, the inner dimension 327 of the recess, the outer dimension 328 of the recess, the vertical end 329 of the recess, the vertical top 330 of the recess, the end 331 of the recess, and the top 332 of the recess.

[0064] Figure 3C A front view detail 340 of the self-engaging fastener is shown. The self-engaging fastener 100 may include various features and dimensions, including but not limited to the protrusion arm length 342 measured from the protrusion arm line 341, the protrusion arm spacing 343, and the protrusion arm sweep angle 344.

[0065] Figure 3D A side view 350 of a self-engaging fastener is shown. The self-engaging fastener 100 may include various dimensions, including but not limited to a recess diameter 351 measured from the fastener face of the nut, a stamped portion height 352, a circular shape of a protrusion 355, a recess depth 353, and a protrusion height 354 measured from the back face of the nut.

[0066] Figure 3E A side view 360 of a self-engaging fastener is shown. The self-engaging fastener 100 may include various dimensions, including but not limited to the stamped portion diameter 361, the recess sweep angles 362 and 363 of the recess 364, the thread size 365, the stamped portion chamfer height 366, and the protrusion height 367.

[0067] Figure 3F View 370 shows the installation tool and the self-engaging fastener. The installation tool may include various dimensions, including but not limited to the outer flange diameter 371, inner flange diameter 372 and flange height 374 of the upper mold member 376, and the gap width 373 and gap height 375 of the lower mold member 377.

[0068] Figures 3A to 3E This is a mechanical drawing showing the dimensions of the self-engaging fastener 100 from various perspectives. However, it should be noted that other fastener configurations (e.g., different body shapes / sizes, different numbers / shapes / spacings of protrusions and recesses, etc.) are also possible. For example, Figure 4A and Figure 4B This is a mechanical drawing showing the dimensions of another self-engaging fastener 400 from various perspectives. Dimensions are indicated but not limited to any particular range. In other words, the value of each dimension and its relative size can be selected by the designer based on specific application scenarios.

[0069] Figure 4AA perspective view of a self-engaging fastener 400 is shown, including a body portion 414 and a stamped portion 408. The body portion 414 includes a fastener face 416 having a plurality of protrusions 404 with various arms (including corresponding wedge-shaped portions 402) and a plurality of recesses 406. The body portion 414 may be similar to... Figures 3A to 3E The main body shown may be different. For example, the main body 414 may have a hexagonal shape as shown. The protrusion 404 may be similar to... Figures 3A to 3E The protrusion shown may be different. For example, the arm of the protrusion may have a curved or inclined surface on its outer peripheral edge, as shown. Similarly, the recessed portion 406 may be similar to... Figures 3A to 3E The recessed portion shown may be different. For example, the recessed portion 406 may have a more curved shape and curved walls as shown. In either case, a plurality of protrusions 404 and a plurality of recessed portions 406 are formed circumferentially around the fastener face 416 of the self-engaging fastener 400. A stamped portion 408 extends coaxially from the fastener face 416 with a central axis and includes a central opening 412 having a female thread 410 and a self-piercing edge 418. Self-engaging fasteners are generally formed from metal (e.g., alloy) by a process that may include cutting a sheet of metal into the general shape of a nut, forging the nut into the desired shape (including the self-punching and self-engaging features described above), thread rolling the nut to form threads for receiving and engaging a screw or bolt, heat treating it to increase strength and durability, and surface finishing (e.g., applying a protective coating to the nut). Structural and functional details of the self-punching and self-engaging features will now be described with reference to the remaining figures.

[0070] Figure 4B A front view 420 of a self-engaging fastener is shown. The self-engaging fastener 400 can include various dimensions, including but not limited to an outer diameter 421, radial spacing 423 between adjacent protrusions, an outer perimeter 425, radial spacing 422 between adjacent recesses, and radial spacing 424 between adjacent protrusions and recesses. In the example shown, the self-engaging fastener 400 includes six equally spaced protrusions and six equally spaced recesses; however, it should be noted that the number of protrusions, recesses, and spacing depends on the designer's needs based on the application.

[0071] Figure 4CAnother front view 440 of the self-engaging fastener 400 is shown. The self-engaging fastener 400 may include various dimensions, including but not limited to the outer width 441 of the protrusion, the protrusion spread angle 442, the protrusion central axis 443, the protrusion arm sweep angle 444, the inner width 445 of the protrusion, the fastener central axis 446, the inner dimension 447 of the recess, the outer dimension 448 of the recess, the vertical end 449 of the recess, the vertical top 450 of the recess, the top 451 of the recess, and the end 452 of the recess.

[0072] Figures 3A to 3F as well as Figures 4A to 4C Various features and dimensions of the self-engaging fastener 100 and installation tools are shown. Note that the size of the fastener, the number of features (e.g., protrusions, recesses, etc.), their shapes, their spacing, and their dimensions depend on the needs of the application, as determined by the designer. For example, self-engaging fasteners can be manufactured in metric or standard fastener (e.g., nut) sizes. Some metric fastener sizes useful in automotive applications may include, but are not limited to, M5-M12 nuts, while their standard equivalent fastener sizes may be 3 / 16”-1 / 2” nuts. Similarly, the number of features (e.g., protrusions, recesses, etc.), their shapes, their spacing, and their dimensions may be based on the overall size of the fastener and / or the desired twisting and pulling forces. For example, an M5 fastener may have the same number and spacing of protrusions and recesses as an M12 fastener, but the protrusions and recesses of an M12 fastener may be larger than those of an M5 fastener. In another example, Ml2 fasteners can also be designed with a greater number of protrusions and recesses to resist greater torsion and push-out forces. In other words, the number of features (e.g., protrusions, recesses, etc.), their shapes, their spacing, and their dimensions can be designed based on a variety of factors, including but not limited to the size of the fastener, the desired torsion and push-out forces, the fastener material, the base material, and other usage factors.

[0073] As described above, installation tools (such as molding machines) are used to install one or more self-engaging fasteners into a substrate (such as sheet metal). Figure 5 A flowchart 500 illustrating an example installation of a self-engaging fastener is shown. Generally, a molding press can be configured to include one or more molding presses, each configured to install a corresponding self-engaging nut into a substrate. Figure 6Block diagram 600 illustrates an example molding machine comprising an upper mold base 606 (including one or more upper mold members 606A and 606B), a lower mold base (including one or more self-locking nuts 608A and 608B disposed within a cavity in the lower mold base), and an actuator 604 (e.g., a pneumatic actuator) controlled by a controller 602 (e.g., a processor, memory, software, input / output terminals, etc.) to move the upper mold base 606 and / or the lower mold base 608 toward each other, such that a substrate 610 is pressed between one or more upper mold members 606A and 606B and one or more self-locking nuts 608A and 608B, which are axially aligned with the upper mold members. Various sensors (not shown) may also be included and monitored by the controller to determine the pressure and position of the mold members relative to each other.

[0074] For example, during assembly, in step 501, the selected substrate 610 (e.g., sheet metal) is placed into a molding press. The substrate 610 can be placed into the molding press by a human technician, a robot, or a combination of both. In step 502, the substrate 610 is positioned between self-engaging nuts 608A and 608B and upper mold members 606A and 606B, such that the self-engaging nuts are oriented on one side of the substrate 610, while the flanged upper mold members 606A and 606B are on the opposite side of the substrate 610. More specifically, the substrate 610 is positioned such that the self-engaging nuts are located in the desired mounting position on the substrate 610. The position of the nuts can be predetermined in the press based on the design of the final product. For example, the nuts and molds can be positioned according to a specific floor design of the EV. Note that the molds can be positioned in a static location or can be moved by a robotic arm. In either case, in step 503, controller 602 controls actuator 604 to move the nut and upper die member toward each other, forcing the self-piercing edge of the nut to punch a hole in the substrate 610 and forcing the protrusion to deform the sheet metal, causing a portion of the sheet metal to be displaced and flow into both the recess and the indentation. As previously described, upper die members 606A and 606B may include corresponding flanges that increase pressure around the recessed location of the nut to force more substrate material into the recess. After the upper die member reaches a stop point and the nut is fully embedded in the substrate 610, controller 602 controls actuator 604 to retract the upper die member in step 504, allowing the substrate 610 to be removed in step 505. The final product is a sheet metal part comprising one or more self-engaging nuts embedded in desired locations. The sheet metal part can then proceed to the next assembly stage, such as integration into an EV.

[0075] Although self-engaging fasteners are described in the context of self-engaging nuts with female threads for use in EVs, it should be noted that self-engaging fasteners can take other forms and be used in other applications. For example, self-engaging fasteners may include external threads and function as self-engaging bolts that receive female-threaded nuts. Furthermore, self-engaging fasteners can be used in any application where self-engaging fasteners are beneficial. These applications may include, but are not limited to, furniture applications, appliance applications, etc.

[0076] The benefits of the disclosed self-locking fasteners include, but are not limited to, reduced installation time by providing a self-locking fastener that installs in a single stamping action. Pre-drilling or pre-punching is not required. Furthermore, self-locking fasteners offer enhanced push-out and twist-out forces compared to conventional self-locking fasteners.

[0077] It should be noted that self-engaging fasteners are generally made of a material harder than the base material. This ensures that the self-engaging fastener can pierce the base material with its self-piercing edge and uses protrusions to partially deform the base material and force it into the recesses and indentations. For example, if the base material is an aluminum alloy, the self-engaging fastener can be a steel alloy. Furthermore, the overall design (number / size of protrusions, recesses, indentations, threads, etc.) and dimensions of the self-engaging fastener, including but not limited to nut diameter, nut height, protrusion size, recess size, stamping height, and indentation size, can be selected based on the target base material and the performance thresholds of push-out and twisting forces for a specific application (e.g., installing equipment within an EV).

[0078] Furthermore, the geometries of the protrusions, recesses, and annular recesses can be designed relative to each other. In one example, the dimensions of the protruding arm (e.g., length, height, angle, displacement volume, etc.) can be designed to force a predetermined volume of deformed metal to flow into the recesses and annular recesses. Similarly, the dimensions of the recesses and annular recesses (e.g., shape, depth, volume, etc.) can be designed to receive a predetermined volume of deformed metal flowing out from the protrusions. In other words, the protrusions, recesses, and annular recesses can be designed to work together to ensure proper deformation and engagement (i.e., interlocking) of the substrate with the geometry of the self-locking nut.

[0079] While the foregoing describes exemplary embodiments herein, other and additional exemplary embodiments may be devised without departing from its essential scope. Those skilled in the art will understand that the foregoing examples are exemplary and not restrictive. All arrangements, enhancements, equivalents, and modifications that will be apparent to those skilled in the art upon reading the specification and studying the accompanying drawings are intended to be included within the true spirit and scope of this disclosure. Therefore, the appended claims are intended to cover all such modifications, arrangements, and equivalents that fall within the true spirit and scope of these teachings.

Claims

1. A self-engaging fastener for attaching to a deformable metal sheet, the self-engaging fastener comprising: The main body with a central axis; A stamped portion, the stamped portion extending from the main body portion and coaxial with the central axis, the main body portion forming a generally annular fastener surface adjacent to the stamped portion, the stamped portion having an inclined wall extending from the fastener surface and forming a recess; Multiple spaced protrusions protrude from the fastener face and surround the stamped portion; as well as Multiple spaced-apart recesses surround the stamped portion in the fastener face, and the multiple protrusions and the multiple recesses form an adjoining portion to improve the torsional resistance of the fastener.

2. The self-engaging fastener according to claim 1, wherein the fastener face includes 4 to 12 of the plurality of protrusions and 4 to 12 of the plurality of recesses.

3. The self-engaging fastener of claim 1, wherein the plurality of protrusions and the plurality of recesses alternately surround the stamped portion along the fastener surface.

4. The self-engaging fastener according to claim 1, wherein the plurality of protrusions are Y-shaped structures on the fastener surface.

5. The self-engaging fastener of claim 4, wherein each of the plurality of protrusions has a plurality of arms extending from a central portion of the protrusion, the plurality of arms forming a plurality of wedges, at least one of the plurality of wedges having a surface that descends toward the fastener face.

6. The self-engaging fastener of claim 4, wherein the plurality of arms includes a first arm extending from the central portion of the protrusion along the fastener face toward the inclined wall of the stamped portion, the first arm having a first surface descending toward the fastener face.

7. The self-engaging fastener of claim 4, wherein the plurality of arms includes a second arm and a third arm, the second arm and the third arm extending from the central portion of the protrusion along the fastener face toward the outer periphery of the fastener face, the second arm having a second surface descending away from the central portion of the protrusion, the third arm having a third surface descending away from the central portion of the protrusion, and the second arm and the third arm forming a common surface descending away from the central portion of the protrusion between the second arm and the third arm.

8. The self-engaging fastener of claim 1, wherein the plurality of recessed portions comprises a surface that gradually descends from the fastener face to a flat bottom surface of the recessed portion.

9. The self-engaging fastener of claim 8, wherein the plurality of recessed portions extend toward and intersect with the inclined wall of the stamped portion.

10. The self-engaging fastener of claim 8, wherein the plurality of recessed portions have recessed volumes corresponding to the protrusion volumes of the plurality of protrusions.

11. The self-engaging fastener of claim 8, wherein the inclined wall of the stamped portion defines a first diameter of the stamped portion at the fastener face and a second diameter at the opening of the stamped portion.

12. The self-engaging fastener of claim 8, wherein the inclined wall of the stamped portion includes a curved transition portion intersecting with the fastener surface.

13. The self-locking fastener according to claim 1, wherein the inclined wall of the stamped portion is a dovetail structure.

14. The self-engaging fastener of claim 13, wherein the inclined wall of the stamped portion includes a flat portion forming an edge at the end of the stamped portion.

15. The self-engaging fastener of claim 13, wherein the inclined wall of the stamped portion includes a self-piercing edge for piercing the deformable metal sheet.

16. The self-engaging fastener of claim 13, wherein the inner surface of the stamped portion includes female threads for engagement with a bolt.

17. A method for attaching a self-locking fastener to a deformable metal sheet, the method comprising the steps of: At the location where the fastener will be fixed to the metal plate, the fastener and the mold component are coaxially positioned on opposite sides of the metal plate, the fastener comprising: The main body with a central axis, A stamped portion extends from the main body portion and is coaxial with the central axis. The main body portion forms a generally annular fastener surface adjacent to the stamped portion. The stamped portion has an inclined wall extending from the fastener surface and forming a recess. Multiple spaced protrusions protrude from the fastener face and surround the stamped portion. A plurality of spaced-apart recesses surround the stamped portion in the fastener face, and the plurality of protrusions and the plurality of recesses form an abutment to improve the torsional resistance of the fastener; and The mold component and the fastener are moved relative to each other in the axial direction so that a portion of the plate is deformed into the recess of the fastener, thereby improving the torsional resistance of the fastener until a strong mechanical interlock is formed between the fastener and the plate.

18. The method of claim 17, comprising: The mold component and the fastener are moved relative to each other in a direction along the central axis to force the plurality of protrusions to press the deformed portion of the plate into the recess and to press the deformed portion of the plate into the plurality of recesses.

19. The method of claim 17, comprising: The mold component and the fastener are moved relative to each other in a direction along the central axis to force the plurality of protrusions to press the deformed portion of the plate toward at least three different directions away from the central portion of the plurality of protrusions.

20. The method of claim 17, comprising: The mold component and the fastener are moved relative to each other in a direction along the central axis to force the edge of the stamped portion to pierce the deformable metal sheet.

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