Fastener die member

Details Fastener die member Fastener die member

1999-04-29

2001-05-08

Hughes, S. Thomas (Department: 3726)

Metal working

Method of mechanical manufacture

Assembling or joining

C029S243500

Reexamination Certificate

active

06226854

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates to die members, panels and fastener assemblies and methods for the installation of fasteners into a workpiece such as for example panel metal. More particularly, the present invention relates to an improved die member and method of installation that provides a better fastener installation and has a much longer life than previous die members. The main objective of the die member of the present invention is to reduce the stress on and breakage of the die member that was experienced by conventional die members, and to push more metal into the groove of the fastener to provide a more secure attachment.
The die member of the present invention is used in a fastener installation process shown generally in for example U.S. Pat. No. 4,630,363. The die member typically sits below the panel into which a fastener is to be installed and is mounted in the bottom platen of a press. An installation head which holds the fastener to be installed is mounted to the upper press platen and positioned on the other side of the panel. When the press closes, the installation head drives the fastener into the panel and the die member causes the panel to be deformed into the locking grooves and around the ends of the fastener.
One difficulty with standard die members is that the die members can break during the installation process. This results in a bad installation in the panel and the need to stop the press to replace the die member. As will be appreciated by those of ordinary skill in the art, when a press is shut down the cost in lost production time can be considerable. Therefore, a die member that has increased life will result in less downtime and increased production capabilities for each press.
SUMMARY OF THE INVENTION
The present invention overcomes the above difficulties experienced in standard die buttons and fastener and panel assemblies. The die button of the present invention has an end face with a pair of opposed clinching lips which protrude from the end face. The clinching lips are generally parallel to one another and have a generally flat end face for engaging a panel to which a fastener is to be installed. The clinching lips include a base which is integral to the end face of the die member and an outer sidewall which joins the end surface and the base. The end surface has a mid-point and opposed ends with the end surface being wider at the mid-point than at the ends and the base is wider than the end surface. The die button is used to attach a fastener having opposed, parallel grooves to a panel metal. The grooves have a base and sidewalls. The die member generally mates with these grooves and drives panel material into these grooves to fill the grooves. The configuration of the clinching lips of the die member is such that the panel metal is plowed from adjacent the mid-point to the sides of the groove and to the ends of the groove to completely fill the groove and still maintain the die button integrity.
In one embodiment, the die button end surface narrows gradually from about the mid-point to the opposed ends. In another embodiment the end surface begins to narrow gradually a spaced difference on either side of the mid-point.
The invention further teaches a novel panel and fastener assembly which comprises a fastener having generally parallel channel-shaped grooves with each groove having a bottom wall, opposed sidewalls, a mid-point portion and opposed open end portions. The panel is plastically deformed into these grooves to define a mating region of the panel. The mating region is forced against the bottom wall and opposed side walls of the grooves. The mating region defines a panel bottom surface adjacent the bottom wall, a first side surface adjacent one of the opposed sidewalls and a second side surface adjacent one of the other opposed sidewalls. The first side surface has a greater width at the opposed open end portions than at the mid portion.
In one embodiment, the first side surface width of the panel metal increases from about the mid-point to the opposed open end portion. In a second embodiment, the first side surface of the panel metal has a generally uniform width along a middle portion of the first side surface adjacent the mid portion and opposed outer portions which are generally wedge-shaped.
The present invention also discloses a method of attaching a fastener to a deformable metal panel by locating the panel on a die member having spaced generally parallel projecting lips adapted to be received in the fastener grooves of the fastener. A fastener is located opposite the panel with the fastener grooves aligned with the die member lips. The fastener and panel are driven together driving the die member lips into the fastener grooves shearing a slug and deforming portions of the panel into the fastener grooves. The die member lips substantially simultaneously drive the panel portions in the fastener grooves longitudinally toward the open end portions of the grooves and laterally toward the sidewalls of the grooves.


REFERENCES:
patent: 4484385 (1984-11-01), Woods
patent: 5208963 (1993-05-01), Ladouceur
patent: 5239740 (1993-08-01), Ladouceur
patent: 5502888 (1996-04-01), Takahashi et al.

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