Clinching fastener assembly and method

Abstract

A method for attaching a clinching fastener includes providing a die button that defines a channel. A set ring extends from the top end of the die button, spaced from the channel. The method also includes providing a clinching fastener. A deformation ring extends about a lower region of the clinching fastener. The method also includes positioning a sheet of metal on a top of the set ring. The method also includes positioning the lower end of the clinching fastener in a hole of the sheet which is larger than the deformation ring such that a gap is between the sheet, the die button and the lower region of the clinching fastener. The method also includes driving the clinching fastener toward the die button such that the deformation ring deforms against the die button and flows into the gap to clinch the clinching fastener to the sheet.

Description

CLINCHING FASTENER ASSEMBLY AND METHODCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63 / 547,794, filed November 8, 2023, titled “Clinching Fastener Assembly And Method,” the entire disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure

[0002] The present disclosure relates fasteners. More particularly, the present disclosure relates to clinching fasteners that are permanently connected to sheets of metal.2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Piercing and clinching fasteners (“clinching fasteners”) are known in the art, notably in the automobile industry, for providing fastening devices on sheet metal that have a greater holding capacity than can be obtained by simply threading an opening in the sheet metal alone. More particularly, clinching fasteners are installed onto the sheet metal via cold forming processes to provide a permanent connection.

[0005] A conventional clinching fastener assembly 10 is shown in FIGS. 1-2B. The assembly 10 includes a generally tube-shaped die button 12 that has a top face 14 and defines a bore 16. A set ring 18 is located at the top face 14 along the bore 16. A clinching fastener 20 is received by the bore 16. The clinching fastener 20 has a tubular body 24, 26 that extends between an upper region 24 and a lower region 26 and defines an axial channel 28. The upperregion 24 has an outer diameter that is larger than an outer diameter of the lower region 26. A pilot ring 30 extends radially outwardly from the lower region 26. During use, a sheet of metal 32, i.e., a floor sheet, is positioned on top of the set ring 18 of the die button 12. The sheet of metal 32 defines an opening 33 that receives the lower region 26 of the clinching fastener 20. Initially, the pilot ring 30 overlies the sheet of metal 32. In order to secure the clinching fastener 20 to the sheet of metal 32, an upper slide presses the clinching fastener 20 downwardly toward the die button 12. As shown in FIGS. 2A-2B, the set ring 18 shears the edge of the sheet of metal 32 adjacent to the opening 33, which causes material of the sheet of metal 32 to flow outwardly to secure the clinching fastener 20 to the sheet of metal 32. This approach is intended to result in the edge of the sheet of metal 32 being positioned vertically between the pilot ring 30 and the bottom of the upper region 24 of the clinching fastener 20, but as shown in FIG. 2B, can result in material of the clinching fastener 20 being vertically aligned with the sheet of metal 32. This can result in a poor connection of the clinching fastener 20 to the sheet of metal 32, leading to material loss.

[0006] There remains a need for continued improvements to clinching fasteners and associated processes for attaching clinching fasteners to sheet metal.SUMMARY OF THE DISCLOSURE

[0007] According to an aspect of the disclosure, a method for attaching a clinching fastener to a sheet of metal includes providing a die button that extends about and along an axis between a top end and a bottom end. The die button defines a channel that extends axially therethrough. A set ring extends axially from the top end of the die button. The set ring is radially spaced from the channel. The method also includes providing a clinching fastener that extends about and along the axis, and extends axially between an upper region and a lowerregion. The upper region has an outer diameter that is larger than an outer diameter of the lower region. A deformation ring extends about the lower region below the upper region. The method also includes positioning a sheet of metal on the top end of the set ring of the die button. The sheet of metal defines a hole along the axis. The method also includes positioning the lower end of the clinching fastener in the hole of the sheet of metal such that the sheet of metal is located between the die button and the upper region of the clinching fastener. The hole of the sheet of metal has a diameter that is larger than a diameter of the deformation ring of the clinching fastener such that a gap is defined between the sheet of metal, the top end of the die button and the lower region of the clinching fastener. The method also includes driving the clinching fastener toward the die button such that the deformation ring deforms against the die button and flows into the gap, resulting in material of the clinching fastener being located above and below the sheet of metal to clinch the clinching fastener to the sheet of metal.

[0008] According to another aspect of the disclosure, a clinching fastener assembly is provided for being clinched to a sheet of metal. The clinching fastener assembly includes a die button extending about and along an axis between a top end and a bottom end. The die button defines a channel that extends axially therethrough. The die button also includes a set ring that extends axially from the top end of the die button. A clinching fastener extends about and along the axis between an upper region and a lower region, where the upper region has a larger outer diameter than the lower region. The lower region is received by the channel of the die button. A deformation ring extends about the lower region beneath the upper region. A sheet of metal is positioned on top of the set ring of the die. The sheet of metal defines a hole that receives the lower region of the clinching fastener. The set ring is radially spaced from the channel fastener such that a gap is defined between the sheet of metal, the top end of the die button and the lowerregion of the clinching fastener such that material of the deformation ring flows into the gap in response to the clinching fastener being pressed against the die button to clinch the clinching fastener to the sheet of metal.

[0009] This process of clinching the fastener to the sheet of metal provides retention of the clinching fastener to the sheet of metal with a minimal required driving / pushing force against the clinching fastener and without damaging the die button during use. Furthermore, this process does not require shearing of the sheet of metal to attached the clinching fastener.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other advantages of the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

[0011] FIG. 1 is perspective view of a conventional clinching fastener assembly;

[0012] FIGS. 2A is a side, cross-sectional view of a conventional arrangement of a clinching fastener, a die button and sheet of metal prior to connecting the clinching fastener to the sheet of metal;

[0013] FIG. 2B is a side, cross-sectional view of the arrangement of FIG. 2A, illustrating the clinching fastener after being connected to the sheet of metal;

[0014] FIG. 3A is a side view of a first embodiment of a clinching fastener assembly, according to an aspect of the disclosure, illustrating the clinching fastener prior to a deformation step;

[0015] FIG. 3B, is a side cross-sectional view of the first embodiment of the clinching fastener assembly, again illustrating the clinching fastener prior to the deformation step;

[0016] FIG. 3C is a magnified view of a pilot ring of the clinching fastener relative to a set ring and piece of sheet metal of FIG. 3B;

[0017] FIG. 4A is a side view of the first embodiment of the clinching fastener assembly, according to an aspect of the disclosure, illustrating the clinching fastener after the deformation step;

[0018] FIG. 4B, is a side cross-sectional view of the first embodiment of the clinching fastener assembly, again illustrating the clinching fastener after the deformation step;

[0019] FIG. 4C is a magnified view of the pilot ring relative to the set ring and piece of sheet metal of FIG. 4B;

[0020] FIG. 5A is a perspective view of jig assembly including a top slide prior to initiating securement of the first embodiment of the clinching fastener a sheet of metal;

[0021] FIG. 5B is a perspective view of jig assembly including a top slide while initiating engagement of the first embodiment of the clinching fastener to the sheet of metal;

[0022] FIG. 6A is a side, cross-sectional view of a view of a second embodiment of the clinching fastener assembly, illustrating the clinching fastener before a deformation step;

[0023] FIG. 6B is a side, cross-sectional view of a view of the second embodiment of the clinching fastener assembly, illustrating the clinching fastener after the deformation step; and

[0024] FIG. 7 is a flow diagram of a method of attaching a clinching fastener to a sheet of metal.DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

[0025] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to clinching fastener assemblies and methods of clinching fasteners to sheet metal. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey thescope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0026] FIGS. 3A-6B present improved clinching fastener assemblies 100, 200. The clinching fastener assembly 100, 200 is configured to connect a clinching fastener 102 to a piece of sheet of metal 104. According to the preferred arrangement, the clinching fastener 102 is a spacer, but the principles described herein could be used with other types of fasteners, e g., a nut.

[0027] With reference to the arrangement shown in FIGS. 3A-5B, the assembly 100 includes a lower housing 106 that extends about and along an axis A between a bottom side 108 and a top side 110 and defines a chamber 112. The top side 110 of the lower housing 106 defines an opening 114. An actuator 116, such as a nitrogen cylinder 116 is located within the cylinder 112. The nitrogen cylinder 116 has a top surface 118 and a bottom surface 120. The top surface 118 of the nitrogen cylinder 116 defines a recess 121. The nitrogen cylinder 116 also includes a moving component 123 that is axially moveable in the recess 121.

[0028] A die button 122 is positioned on the top side 110 of the lower housing 106. The die button 122 extends about and along the axis A between a top end 124 and a bottom end 126, with the bottom end 126 engaging the top side 110 of the lower housing 106 about the opening 114. The die button 122 defines a channel 128 along the axis A. A set ring 130 extends upwardlyfrom the top end 124 of the die button 122 and extends annularly about the channel 128 in spaced relationship with the channel 128.

[0029] An ejector insert 132 is disposed in the channel 128 of the die button 122 and is axially moveable within the channel 128 by the moving component 123 of the actuator 116. The actuator 116 is configured to selectively move the ejector insert 132 to facilitate removal of the clinching fastener 102 after the clinching fastener 102 has been connected to the sheet of metal 104. Of note, the ejector insert 132 is present for scenarios in which the clinching fastener 102 sticks / gets locked to the die button 122.

[0030] The clinching fastener 102 is tube-shaped and received by the channel 128 of the set ring 130 and defines a bore 138 that receives the upper end 134 of the ejector insert 132. The clinching fastener 102 has an upper region 140 and a lower region 142, where the upper region 140 has an outer diameter that is larger than an outer diameter of the lower region 142. As best shown in FIGS. 3C, 4C and 6A-6B, the clinching fastener 102 further has a deformation ring 144 that extends annularly about the lower region 142 below the upper region 140. As shown, the deformation ring 144 generally has a concave arc-shaped cross section prior to fastening the clinching fastener 102 to the sheet of metal 104.

[0031] The sheet of metal 104 has a hole 146 which receives the lower region 142 of the clinching fastener 102 and the upper end 134 of the ejector insert 132. The sheet of metal 104 engages the top end 124 of the die button 122. As best shown in FIGS. 3C and 6A, when the sheet of metal 104 is positioned on top of the die button 122, a gap 131 is defined between the sheet of metal 104, the set ring 130, and the lower region of 142 of the clinching fastener 102.

[0032] An upper slide 148 is positioned above the clinching fastener 102 for pressing down on the clinching fastener 102 to ultimately secure the clinching fastener 102 to the sheet ofmetal 104. As will be discussed in further detail below, and as best shown in FIGS. 4C and 6B, when the upper slide 148 drives the clinching fastener 102 downwardly, the deformation ring 144 is pressed against the top end 124 of the die button 122, which causes material of the deformation ring 144 to flow under the sheet of metal 102 in the gap 131, to clinch the clinching fastener 102 to the sheet of metal 102. After this clinching operation, the actuator 216 drives the upper slide 248 upwardly via the die button 122. The upper slide 248 could also be configured to return to its original position on its own.

[0033] A method 300 of securing a clinching fastener to 102 to a sheet of metal 104 is also provided. As shown in FIG. 7, the method includes 302 positioning the lower region 142 of the clinching fastener 102 into the hole 146 of the sheet of metal 104 (e.g., as illustrated in FIGS. 3B). In this position, a diameter of the hole 146 is larger than a diameter of the deformation ring 144 of the clinching fastener 102, thus permitting the deformation ring 144 to pass through the hole 146. As best shown in FIG. 4B, the method continues with 304 moving the upper slide 148 downwardly against the upper region 140 of the clinching fastener 102. As best shown in FIGS. 4B and 4C, during this step, the deformation ring 144 of the clinching fastener 102 axially passes the sheet of metal 104 and engages the top end 124 of the die button 122. The method also includes 306 continuing to move the clinching fastener downwardly to cause the deformation ring 144 to deform against the die button 122 and flow into the gap 131 under the sheet metal 102. This results in material of the clinching fastener 102 to be located both above and below the sheet of metal 104 to clinch the clinching fastener 102 to the sheet of metal 104. As shown inFIG. 5B, after this step, an outside diameter of the deformation ring 144 is greater than a diameter of the hole 146 of the sheet of metal 102. The method continues with 308 axially moving the ejector insert 132 with the actuator 116 axially upwardly to release the finished sheetof metal 104 and clinching fastener 102 from the die button 122. The actuator 116 may also drive the upper slide 148 upwardly, or the upper slide 148 may be configured to move on its own.

[0034] FIGS. 6A-6B present a second embodiment of the clinching fastener assembly 200. According to this embodiment, instead of including a standalone lower housing, the actuator 216 is slideably disposed in the die button 222. Furthermore, this embodiment does not include an ejector insert. Instead, the upper slide 248 extends through the chamber 238 of the clinching fastener 202 into engagement with the actuator 216, such that the actuator 216 drives the upper slide 248 upwardly after compressing the clinching fastener 202 against the die button 222 to release the upper slide 248. In place of the ejector insert, this embodiment includes a release coating 223, such as a TiCN (Titanium Carbo-Nitride) coating, which contributes to preventing the clinching faster 202 from sticking to the die button 222. It should be appreciated that alternatively, a combination of a release coating and ejector insert could be used in either embodiment.

[0035] The clinching fastener assembly 100, 200 provides retention of the clinching fastener 102, 202 to the sheet of metal 104, 204 with a minimal required driving / pushing force against the clinching fastener 102, 202 and without damaging the die button 122, 222 during use. The clinching fastener assembly 100, 200 advantageously does not require thinning of the sheet of metal 104, 204. The subject clinching fastener assembly 100, 200 instead requires a relatively small force to provide intentional deformation of the deformation ring 144, 244 to swedge the sheet of metal 104, 204 to provide a desired clinching effect.

[0036] Obviously, many modifications and variations of the present disclosure are possible in light of the above teachings and may be practiced otherwise than as specifically described.

Claims

CLAIMSWhat is claimed is:

1. A method for attaching a clinching fastener to a sheet of metal, comprising: providing a die button extending about and along an axis between a top end and a bottom end, wherein the die button defines a channel extending axially therethrough, wherein a set ring extends axially from the top end of the die button, and wherein the set ring is radially spaced from the channel; providing a clinching fastener extending about and along the axis and extending between an upper region and a lower region, wherein the upper region has a larger outer diameter than the lower region, and wherein a deformation ring extends about the lower region below the upper region; positioning a sheet of metal on the top end of the set ring of the die button, wherein the sheet of metal defines a hole along the axis, wherein the hole has a diameter that is larger than a diameter of the deformation ring of the clinching fastener such that a gap is defined between the sheet of metal, the top end of the die button and the lower region of the clinching fastener; positioning the lower end of the clinching fastener in the hole of the sheet of metal such that the sheet of metal is located between the die button and the upper region of the clinching fastener; and driving the clinching fastener axially toward the die button such that the deformation ring deforms against the die button and flows into the gap, resulting in material of the clinching fastener being located above and below the sheet of metal to clinch the clinching fastener to the sheet of metal.

2. The method as set forth in claim 1, wherein prior to deformation of the deformation ring, a radially outer surface of the deformation ring has a concave shape.

3. The method as set forth in claim 1, wherein an upper slide is positioned above the clinching fastener, and wherein the step of driving the clinching fastener axially downwardly includes pressing the upper slide against the upper region of the clinching fastener.

4. The method as set forth in claim 3, further including moving an ejector insert axially upwardly after driving the clinching fastener axially downwardly in order to free the clinching fastener and sheet metal from the die button.

5. The method as set forth in claim 4, wherein the ejector insert is moved axially upwardly via actuation from an actuator.

6. The method as set forth 4, wherein the ejector insert is axially moveable inside the channel of the die button.

7. The method as set forth 6, wherein the lower region of the clinching fastener is axially moveable inside the channel of the die button.

8. The method as set forth in claim 7, wherein the ejector insert has a cylindrical - shaped lower segment and a cylindrical-shaped upper segment protruding upwardly from thelower segment, wherein the lower segment has a larger diameter than the upper segment such that a rim is defined between the lower and upper segments, and wherein the lower region of the clinching fastener is disposed about the upper segment of the ejector insert and engages the rim.

9. A clinching fastener assembly for being clinched to a sheet of metal, comprising: a die button extending about and along an axis between a top end and a bottom end, the die button defining a channel extending axially therethrough; the die button including a set ring extending axially from the top end of the die button; a clinching fastener extending about and along the axis and extending between an upper region and a lower region, wherein the upper region has a larger outer diameter than the lower region, wherein the lower region is received by the channel of the die button, and wherein a deformation ring extends about the lower region beneath the upper region; a sheet of metal positioned on top of the set ring of the die, and wherein the sheet of metal defines a hole receiving the lower region of the clinching fastener; and the set ring being radially spaced from the channel of the fastener such that a gap is defined between the sheet of metal, the top end of the die button and the lower region of the clinching fastener such that material of the deformation ring flows into the gap in response to the clinching fastener being pressed against the die button to connect the clinching fastener to the sheet of metal.

10. The clinching fastener assembly as set forth in claim 9, wherein a radially outer surface of the deformation ring has a concave shape.

11. The clinching fastener as set forth in claim 9, wherein an upper slide is positioned above the clinching fastener and configured to press downwardly against the upper region of the clinching fastener to cause the deformation ring to flow into the gap.

12. The clinching fastener as set forth in claim 11, further including an ejector insert positioned axially below the lower region of the clinching fastener and configured to axially move upwardly against the lower region of the clinching fastener for releasing the clinching fastener and the sheet metal from the die button after the clinching fastener has been connected to the sheet of metal.

13. The clinching fastener as set forth in claim 12, further including an actuator configured to move the ejector insert.

14. The clinching fastener as set forth in claim 9, wherein the ejector insert is axially moveable inside the channel of the die button, and wherein the lower region lower region of the clinching fastener is axially moveable inside the channel of the die button.

15. The clinching fastener as set forth in claim 9, wherein the ejector insert has a cylindrical-shaped lower segment and a cylindrical-shaped upper segment protruding upwardly from the lower segment, wherein the lower segment has a larger diameter than the upper segment such that a rim is defined between the lower and upper segments, and wherein the lower regionof the clinching fastener is disposed about the upper segment of the ejector inert and engages the rim.

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