Clinching Tool

This invention relates to tools for fastening two sheets of material together without welding or riveting and, more particularly, to a tool in which the sheets of material are fastened together in a clinching operation.

Sheets of material are most commonly fastened together by the use of welding or by the use of rivets. However, each of these methods has disadvantages. Specifically, welding entails high power requirements and large capital investment and cannot be used to fasten certain dissimilar materials, and riveting also requires high capital investment and produces a rather bulky joint that is unacceptable in many applications. In an effort to overcome the disadvantages of welding and riveting, clinching tools have been developed in which the sheets of material are deformed in a clinching operation to securely join the sheets together without the use of rivets and without the use of welds. Whereas these clinching tools have proven to be generally satisfactory in terms of producing a satisfactory joint as between the sheets of material, the available clinching tools are relatively bulky and therefore difficult if not impossible to use in tight confines such, for example, as in applications where the two sheets of material are configured to define a narrow channel structure.

This invention is directed to the provision of a clinching tool which is readily usable to perform a clinching operation even in very tight confines.

The invention clinching tool comprises a punch adapted to be mounted in a punch retainer for movement along a longitudinal punch axis and a die assembly for coaction with the punch. According to the invention, the die assembly includes a collet having a clinching section including die portions movable laterally relative to each other and defining a die opening therebetween centered on the longitudinal punch axis for receiving the punch as the latter is moved along the punch axis, and a base section integral with the clinching section and disposed laterally of the clinching section and laterally of the punch axis; and an anvil positioned in the die opening in inset relation to the face of the clinching section facing the punch to define a die cavity with the die portions. This specific arrangement, wherein the clinching section and the mounting section are formed integrally and in side by side relation minimizes the overall height of the clinching tool and allows the tool to be used in tight confines such as in a channel configuration.

According to a further feature of the invention, the collect comprises a flat plate member with the clinching section defined adjacent one end of the plate member and the base section defined adjacent an opposite end of the plate member. This arrangement allows a relatively thin plate member to comprise both the clinching section and the mounting section of the collet.

According to a further feature of the invention, the die opening comprises a through opening extending from face to face of the plate member and the die portions are defined by a split in the plate opening in the die opening. This arrangement provides a convenient and effective means of allowing the required lateral movement of the die portion in coaction with the movement of the punch.

According to a further feature of the invention, the split extends from the clinching end of the plate member and passes through the die opening to an inboard end positioned between the die opening and the base end of the plate member. This arrangement provides maximum lateral deflectability for the die portion to facilitate their coaction with the punch.

According to a further feature of the invention, the plate member is cut away along its opposite side edges proximate the inboard end of the split. This arrangement provides a hinge axis adjacent the cut aways to further facilitate the ready lateral outward movement of the die portions.

According to a further feature of the invention, the plate member includes further splits extending radially with respect to the punch axis and opening in an outer edge of the plate member. These splits further facilitate the laterally outward, opening movement of the die portion.

According to a further feature of the invention, the plate member further includes splits extending radially with respect to the punch axis and opening in the die opening. These further splits provide yet further flexing capability for the die portions.

In the disclosed embodiment of the invention, these further splits are arranged in circumferentially spaced relation around the punch axis with a split opening in the die opening alternating with a split opening in the outer edge of the plate member, moving in circumferential manner around the punch axis.

According to a further feature of the invention, the die opening includes a counterbore adjacent the face of the plate member remote from the punch, and the anvil comprises a pin having a head portion sized to fit in the counterbore and a shank portion extending from the head portion within the die opening. This arrangement provides positive positioning of the pin within the die opening and positive locating of the free end of the pin in inset relation with respect to the face of the clinching section facing the punch.

According to a further feature of the invention, the clinching tool further includes a backing plate having a configuration generally corresponding to the configuration of the collet plate member and adapted to be positioned with a working face thereof positioned against the face of the collet plate member remote from the punch and, in the assembled relation of the collet plate member, the backing plate, and the anvil pin, the anvil pin bears at one end thereof against the working face of the backing plate with its other end inset with respect to the face of the collet plate member near the punch. This arrangement provides positive positioning of the anvil pin within the die opening and provides a firm backing for the anvil to facilitate the clinching operation.

According to a further feature of the invention, the split in the collet comprises a first split and the die opening comprises a first die opening; the collet further includes a second split formed in the clinching end of the plate member and extending toward the base end of the plate member in generally parallel laterally spaced relation to the first split to form further die portions on either side thereof; and arcuate cut aways are provided along the opposite edges of the second split at a location intermediate the ends of the second split to define a second, generally circular die opening laterally spaced from the first die opening. This arrangement allows the collet to be configured to provide a plurality of die openings capable of performing a plurality of clinching operations in closely spaced lateral relation.

According to a further feature of the invention, the collet further includes a third split formed in the clinching end of the plate member between the first and second splits and extending toward the base end of the plate member in generally parallel relation to the first and second splits. This arrangement provides definition as between the die portions associated with the first and second die openings and facilitates the laterally outward movement of the die portions of the respective die openings.

FIG. 1 is a fragmentary view of a clinching tool according to the invention;

FIG. 2 is an exploded perspective view of the invention clinching tool;

FIG. 3 is a detail view of a portion of the invention clinching tool;

FIG. 4 is a detail view showing the clinching flow of the sheets of material being joined;

FIG. 5 is a fragmentary top view showing the completed clinching joint;

FIG. 6 is a view of a modified form of collet for use in the invention clinching tool;

FIG. 7 is a view of a further modified form of the invention collet for use in the invention clinching tool; and

FIG. 8 is a fragmentary bottom view of the modified collet seen in FIG. 7.

The invention clinching tool includes a punch assembly 10 and a die assembly 12.

Punch assembly 10 includes a punch 14, a punch retainer 16, and a stripper 18 positioned in a cavity 16a defined by retainer 16 and urged downwardly by a compression spring 20. Punch 14 includes a main body portion 14a and a tip portion 14b.

Die assembly 12 is positioned beneath punch 14 and includes a collet 22, a backing plate 24, and an anvil 26. Die assembly 12 is mounted on a base or mounting member 28 which may comprise a separate support structure or may, as shown, be formed integrally with punch retainer 16 to constitute a C-shaped yoke 30 defining an opening 30a between die retainer 16 and base member 28.

Collet 22 is in the form of a flat plate and may for example comprise SAE L6 tool steel.

Collet plate 22 includes a clinching section 22a adjacent one end of the plate and a base or mounting section 22b adjacent the opposite end of the plate. A through split 22c opens in end edge 22d of the plate and extends toward the other end edge 22e of the plate to an inboard end 22f proximate but spaced from end edge 22e. Split 22 may be formed for example by drilling a small diameter hole in inboard split end 22f and then wire burning the split from the end edge 22d to the drilled hole 22f. Split 22c divides the clinching section of the collet into laterally opposed cantilevered die portions 22g and 22h. Arcuate cut-outs 22i are provided along the opposite side edges of split 22c and coact to define a generally circular die opening 22j positioned between collet end edge 22d and the inboard end 22f of the split but preferably closer to the collet end edge 22d than to the split inboard end 22f.

Collet plate 22 is further machined to provide beveled corner edges 22k and 221 and is further machined to provide V cut-outs 22m along each side edge of the plate defined in each case by an angled edge 22n and an angled edge 22p.

The clinching section 22a of the collet plate further includes further splits 22g extending radially with respect to die opening 22j and opening in the die opening and further splits 22r extending radially with respect to the die opening and opening in outer edges 22k, 221, and 22n of the collet plate. Each of the splits are formed by drilling a hole through the collet plate and then wire burning the split from the die opening, or from the outer edge of the plate, to the drilled hole. The further splits will be seen to be arranged in circumferentially spaced relation about the central axis of die opening 22j with the splits opening in the die opening alternating with the splits opening in the outer edges of the collet plate.

Clinching section 22b of the collet plate includes mounting means for the collet in the form of laterally spaced through holes 22s including counterbores 22t.

Collet plate 22 further includes laterally spaced dowel holes 22u on either side of split 22c in the vicinity of cut-outs 22m.

In a typical application, collet plate 22 may have a thickness of 0.375 inches, a length from end edge 22d to end edge 22e of 1.38 inches, and a width between the side edges 22v and 22w of 1.00 inches.

Arcuate cut-outs 22i defining die opening 22j are further provided with counterbore portions 22x so as to effectively provide a counterbore portion for die opening 22j at the face 22y of the collet plate remote from the punch 14.

Backing plate 24 is preferably formed of the same material as collet plate 22 (such for example as SAE L6 tool steel) and has a size and configuration generally matching the size and configuration of collet plate 22. Backing plate 24 includes apertures 24a corresponding to mounting holes 22s in collet plate 22 and dowel holes 24b corresponding to dowel holes 22u in collet 22. In the case of a collet plate having a thickness of 0.375 inches, backing plate 24 may have a thickness of 0.125 inches for an overall combined collet plate and backing plate thickness of 0.500 inches.

Anvil pin 26 is preferably formed of A2 tool steel and includes a head portion 26a and a shank portion 26b. Head portion 26a is sized to fit within the counterbore 22x defined by the collet plate and shank portion 26b has a diameter sized to fit snugly within die opening 22j in the relaxed position of the die portions of the collet plate and has a length such that, with head portion 26a positioned in counterbore 26x, the free end 26c of shank portion 26b is inset with respect to the face 22z of the collet plate so as to coact with die opening 22i to form a die cavity 32.

In the assembled relation of the collet plate 22, backing plate 24, and anvil pin 26, the working face 24c of the backing plate is positioned against the remote face 22y of the collet plate and the head portion 26a of the anvil pin bears against the working face 24c of the backing plate with the shank portion 26b of the anvil pin extending within the die opening 22j to an inset location with respect to the near face 22z of the collet plate to define the die cavity 32.

The die assembly, including collet plate 22, backing plate 24, and anvil pin 26, is mounted to the base member portion 28 of yoke 30 by the use of threaded and headed fastener members 34 passing through mounting holes 22s in collet plate 22 and through mounting holes 24a in backing plate 24 for threaded engagement with suitable tapped bores in base member 28 with the head portions 34a of the fasteners 34 seated in counterbores 22t, so as to present a flush disposition with respect to the near face 22z of the collet plate, and with dowel pins 36 passing through dowel holes 22u in collet plate 22 and through dowel holes 24b in backing plate 24 for receipt in dowel holes provided in base member 28. The fasteners 34 positively clamp the die assembly to the base member 28 and the dowel pins 36 coact with the fasteners to positively preclude movement of the die assembly relative to the base member 28.

The invention clinching tool is especially suitable for use in fastening together two sheets of material 38 and 40 which are configured to define a narrow channel section 42 presenting a tightly confined area which is difficult if not impossible to access using prior art clinching tools. Such channel sections are encountered for example on door headers for automobiles and along the flange portions of refrigerator doors. The invention tool assembly, by virtue of the extremely shallow profile provided by the collet plate in combination with the backing plate, may readily enter the channel 42 to position the die opening 22j beneath the plates 38 and 40 and in longitudinal alignment with the central axis of punch 14, whereafter the punch 14 may be actuated in suitable manner to deform the sheets 38 an 40 in coaction with 15 the die opening 22j and the anvil pin 26 to form a clinched joint 44 securely bonding the two sheets together.

Specifically, as the punch 14 is moved downwardly along the punch axis, the punch tip portion 14b contacts the upper sheet 40, and with continued downward movement, causes the adjacent material of sheets 38 and 40 to flow into the die cavity 32. This flowing movement, filling the inset defined by the anvil pin in coaction with the die portions 22g and 22h, is best seen in FIG. 4. As the punch continues, downwardly, cantilever die portions 22g and 22h move radially and laterally outwardly about the axis defined by split inboard end 22f to allow the adjacent material of sheets 38 and 40 to flow radially and laterally outwardly into the annular space defined by the laterally retreating die portions and the shank portion 26b of the anvil pin. As seen in FIG. 4, the radially outwardly flowing material also tends to flow downwardly around the sides of pin shank portion 26b to form a coin 44a extending around the periphery of the clinching joint. Because the die portions 22g and 22h move substantially laterally radially outwardly in response to the advancing punch, the coined edge 44a of the clinching joint 44 is thickest adjacent the lateral side edges of the joint and thinnest adjacent the forward and rearward edges of the joint so as to present a generally elliptical appearance, as seen in FIG. 5. The coined edge 44a of the joint is clinched or folded back up against the undersurface of sheet 38 through a full 180.degree. so as to be tightly pressed against the undersurface of sheet 38 and present a tight, low profile clinched joint which is effective to positively join the two sheet together but which is dimensionally and aesthetically unobtrusive. After the joint has been formed, punch 14 is moved upwardly and the joined sheets 38 and 40 are separated from the lower end of the punch by the action of stripper 18.

The invention clinching tool thus readily provides an effective clinching joint in a severely confined area. The joint formed by the invention clinching tool rigidly joins the sheets 38 and 40 together; has a low profile by virtue of the total folding of the coined edge 44a back up against the under surface of lower sheet 38; has an aesthetically pleasing appearance; and is leakproof since neither the material of upper sheet 38 nor the material of lower sheet 40 has been cut through in the clinching process. The joint formed by the invention clinching tool is particularly suited for joining relatively thin sheet material and may typically replace a weld joint.

The modified collet seen in FIG. 6 is utilized when it is desired to provide two clinch joints in relatively close laterally spaced relation. The collet plate 46 seen in FIG. 6 includes first and second clinching sections 46a and 46b proximate one end of the plate and a mounting portion 46c proximate the other end of the plate. Clinching section 46a is divided from clinching section 46b by a central split 46d extending from end edge 46e of the plate toward the opposite end edge 46f and terminating proximate but spaced from the edge 46f. As with the collet plate of FIGS. 1-5, split 46d may be formed by drilling a hole 46g through the plate and then wire burning the split 46d from edge 46e to hole 46g. Plate 46 further includes a second split 46h on one side of central split 46d and a third split 46i on the other side of central split 46d.

Split 46h extends from plate edge 46e to a location proximate but spaced from plate edge 46f in generally parallel relation to central split 46d and is provided with arcuate cut-outs 46j along its opposite side edges at a location between the ends of the splits to define a first die opening 46k.

Split 46d extends from plate edge 46e to a location proximate but spaced from plate edge 46f and is generally parallel to splits 46d and 46h. Arcuate cutouts 46l along the opposite side edges of the split at a location intermediate the ends of the split define a second die opening 46m in laterally spaced relation to first die opening 46k. Radial splits 46n are provided in association with die opening 46k and open in the die opening 46k, and radial splits 46p are provided in association with die opening 46m and open in the die opening 46m. All of the splits are formed by drilling a hole at the inboard end of the split and then wire burning the split. Plate 46 further includes dowel pin openings 46q and counterbored mounting holes 46 r.

It will be understood that a backing plate conforming in size and configuration to collet plate 46 will be provided; that anvil pins 26 will be provided in association with each die opening 46k and 46m, with each pin including a head portion 26a seating in a counter bore 46s provided in the associated die opening and bearing against the working surface of the backing plate; and that the die assembly, comprising the collet plate 46, the associated backing plate, and the associated anvil pins, will be mounted to a backing structure such as the structure 28 by the use of fasteners passing through mounting holes 46r and through the associated backing plate fastener holes and by dowel pins passing through dowel openings 46q and through the associated backing plate dowel holes, in the manner described with respect to the FIGS. 1-5 embodiment.

The collet plate of FIG. 6, when used in association with a plurality of matching punches, may be used in the narrow confines such as shown by the channel section of FIG. 1 and, additionally, may provide very tightly spaced clinch joints along the length of the channel section since the die openings 46k and 46m need only be spaced laterally by a distance sufficient to provide a narrow die portion 46s on either side of central split 46d. The invention of course contemplates that more than two closely spaced die openings may be provided by a single collet plate.

The modified collet seen in FIGS. 7 and 8 is generally similar to the collet described with respect to FIGS. 1-5 with the exception that the circular die opening 50a of the collet 50 is not provided with a counter bore at its lower end but rather the collect plate is relieved adjacent the free end of the clinching section 50b of the collet to provide a vertical shoulder 50c extending transversely of the collet rearwardly of the die opening 50a and a horizontal relief surface 50d extending from the vertical shoulder 50c to the free outer end of the clinching section. The distance from the vertical edge 50c to the nearest point on the cutout opening 50a approximates the difference between the radius of the head portion 26a of the anvil pin and the radius of the shank portion 26b of the anvil pin so that, with the anvil pin seated in die opening 50a, the outer periphery of head portion 26a is positioned against the vertical edge 50c so as to properly position the pin within the die opening 50a. Also as seen in the FIG. 7 and 8 embodiment, the top of the shank portion 26b of the pin need not be flat, as shown in the collet of FIGS. 1-5, but may instead be domed as seen at 26c. The domed head of the shank portion of the anvil pin has the effect of more readily forcing the center of the material of the sheets 38 and 40 radially outwardly to form the rivet so as to provide better material flow and less power requirements, at least for certain applications.

Whereas preferred embodiments of the invention have been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiments without departing from the scope or spirit of the invention.