U.S. patent application number 13/066100 was filed with the patent office on 2011-10-06 for aligner for use with a staked fastener.
Invention is credited to Clark A. Denslow.
Application Number | 20110239426 13/066100 |
Document ID | / |
Family ID | 38820410 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110239426 |
Kind Code |
A1 |
Denslow; Clark A. |
October 6, 2011 |
Aligner for use with a staked fastener
Abstract
An aligner and a method for its use in staking a fastener. More
specifically, the aligner guides a tip of a staking tool in some
portion of a staking operation properly into alignment with a
clinch portion of a staked fastener. As a result, the clinch
portion is shaped into a head of a generally higher quality than
would otherwise occur.
Inventors: |
Denslow; Clark A.; (Madison,
CT) |
Family ID: |
38820410 |
Appl. No.: |
13/066100 |
Filed: |
April 6, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11443767 |
May 31, 2006 |
7921538 |
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13066100 |
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Current U.S.
Class: |
29/271 |
Current CPC
Class: |
Y10T 29/49778 20150115;
B29C 65/7802 20130101; B29C 2793/0009 20130101; B29C 66/8322
20130101; Y10T 29/49895 20150115; B29C 65/601 20130101; Y10T
29/49915 20150115; B29C 66/81429 20130101; B29C 66/81423 20130101;
F16B 19/06 20130101; B29C 66/41 20130101; B29C 66/7392 20130101;
B29C 66/80 20130101; Y10T 29/4978 20150115; Y10T 29/49943 20150115;
Y10T 29/53717 20150115; Y10T 29/53913 20150115; B29C 66/1122
20130101; B29C 66/861 20130101; B29C 66/73921 20130101; Y10T
29/5118 20150115; B29C 65/10 20130101; B29C 2793/009 20130101; B29C
65/08 20130101 |
Class at
Publication: |
29/271 |
International
Class: |
B25B 27/14 20060101
B25B027/14 |
Claims
1. An aligner for use in a staking operation of a staked fastener
comprising: a housing having an interior surface defining a channel
with an entrance, the channel dimensioned to accept a tip of a
staking tool, and a base positioned within the channel, the base
defining a through bore dimensioned to accept a clinch portion of a
staked fastener, wherein the channel and bore are aligned one to
the other such that the tip can be guided by the channel into
alignment with the clinch portion within the base during a staking
operation.
2. The aligner of claim 1 wherein the housing has a base and the
base is at an angle that supports wobbling of the staking tool.
3. The aligner of claim 2 further including a hold-down connected
to the housing and having a bottom, the bottom being at an angle
such that the bottom supports wobbling of the staking tool.
4. The aligner of claim 1 wherein the interior surface has an angle
that supports wobbling of the staking tool.
5. The aligner of claim 1 further including a flash trap positioned
in the housing.
6. The aligner of claim 1 further including a depression defined by
the base.
7. The aligner of claim 1 further including a hold-down connected
to the housing.
8. The aligner of claim 7 wherein the hold-down has a bottom and
the housing has a base and the bottom is positioned above the
base.
9. The aligner of claim 7 wherein the hold-down is a pair of
cooperating appendages extending outwardly from the housing.
10. The aligner of claim 1 further including a stop, the stop being
positioned in the channel for positioning the base in the
channel.
11. The aligner of claim 1 further including a stop and a keeper
connected to the housing and positioned in the channel for securing
the base in the channel.
12. The aligner of claim 1 further including an observation slit
defined by the housing.
13. The aligner of claim 12 wherein the observation slit has an
open end.
14. The aligner of claim 1 further including a chamfer in the
channel for assisting placement of the tip therein.
15. The aligner of claim 1 wherein the base is of a material
suitable for use as a supplemental material for use with a fastener
of a suitable material to create a unified multi-part head.
16. The aligner of claim 1 further including a positioner.
17. The aligner of claim 16 wherein the positioner includes a
protrusion that interacts with another hole through which another
staked fastener will be placed, such that the bore aligns with a
hole through which the staked fastener is placed.
18. The aligner of claim 1 wherein the interior surface is angled
to permit wobbling of the tip when inserted therein.
19. The aligner of claim 1 wherein the housing has a bottom, and
the bottom has an angle relative to the housing that permits the
aligner to be wobbled when the tip is inserted therein.
20. The aligner of claim 1 wherein the housing as an exterior
surface and further including a grasp positioned on the exterior
surface.
21. The aligner of claim 1 wherein the housing and the base are
made in a single process such that the housing and base are one
piece.
22-34. (canceled)
35. The aligner of claim 1 wherein the base is secured in the
housing.
36. The aligner of claim 35 wherein the bore is a through bore.
37. The aligner of claim 1 wherein the bore is a through bore.
38. An aligner for use in a staking operation of a staked fastener
comprising: a housing having an interior surface defining a channel
with an entrance, the channel dimensioned to accept a tip of a
staking tool, and a base positioned within the channel, the base
defining a bore dimensioned to accept a clinch portion of a staked
fastener, wherein the channel and bore are aligned one to the other
such that the tip can be guided by the channel into alignment with
the clinch portion within the base during a staking operation and
further including a hold-down connected to the housing, and wherein
the hold-down has a bottom and the housing has a base and the
bottom is positioned above the base.
39. An aligner for use in a staking operation of a staked fastener
comprising: a housing having an interior surface defining a channel
with an entrance, the channel dimensioned to accept a tip of a
staking tool, and a base positioned within the channel, the base
defining a bore dimensioned to accept a clinch portion of a staked
fastener, wherein the channel and bore are aligned one to the other
such that the tip can be guided by the channel into alignment with
the clinch portion within the base during a staking operation
wherein the base is of a material suitable for use as a
supplemental material for use with a fastener of a suitable
material to create a unified multi-part head.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a staked fastener
and more specifically to an aligner for use with a staked fastener
having a shank to create a head thereon so that across numerous
staking operations the heads are more consistently aligned with the
shanks.
BACKGROUND
[0002] Staked fasteners are used in numerous applications, such as
securing multiple pieces of sheet material and mounting devices on
boards. Common staked fasteners include rivets and posts.
[0003] All staked fasteners function by having a clinch portion
that is staked in a staking operation. In the case of a typical
rivet, the rivet prior to the staking operation generally has a
head and a shank having a grip portion and a clinch portion. In an
application where a material combination, e.g., two pieces of sheet
material, is being secured together, the rivet is inserted into
aligned holes, one in each piece of sheet material, such that the
head is on one side of the material combination, the grip portion
is in the holes, and the clinch portion is projecting outwardly
from the other side of the material combination. The clinch portion
is then staked in a staking operation to form a head, thereby
trapping the material combination between the two heads.
[0004] Staking of the clinch portion can be accomplished using
numerous methods, and the choice of method depends on the material
from which the clinch portion of the rivet is made. That said, the
quality of the staking operation determines the quality of the head
formed thereby. As the staking operation defines the quality of the
head, it also defines the final mechanical properties of the
completed staked fastener.
[0005] Ideally, in a staking operation, the clinch portion is
shaped into a head such that loads acting on the created head are
properly transferred into the grip portion. For example, when a
circular head is created on a circular grip portion, it is
important that the centerlines of each align. It should be
appreciated that misalignment would tend to permit a torque couple
that could cause a failure of the staked fastener.
[0006] Where staking of several staked fasteners is performed
employing hand-held tools, variations in the quality of the formed
heads are particularly problematic. When a hand-held tool is used,
it is the skill of the operator of the tool that determines the
quality of the head. This is particularly true where the staked
fastener, or at least the clinch portion, is made from a plastic
and the staking method employed involves melting the plastic, such
as when the staking operation employs ultrasonics. When melting of
the staked portion is employed, the operator of a hand-held tool
must assure that during setup of the tool, the tool is properly
centered on the clinch portion, and then during the staking
operation the tool is forced down along the axis of the clinch
portion.
[0007] As anyone who has ever worked with a process involving the
shaping of plastic by melting with hand tools will attest, there is
a significant amount of skill required to achieve a proper result.
The process is at best problematic when the plastic is being formed
on a horizontal, flat surface, and gravity is acting in the
appropriate direction. The complexity only increases when any of
these conditions is not present. However, and almost more
importantly, a high degree of repeatability or uniformity
regardless of conditions across numerous units is all but
impossible.
[0008] In the case of a staked fastener, this process is further
complicated where the staked fastener employs a supplemental
material. Supplemental material is a second material applied around
the clinch portion of the fastener prior to performing the staking
operation, and it becomes part of the fastener. In some cases, the
supplemental material will also be melted during the staking
operation, which increases the skill required of a hand tool
operator to make repeatable, high-quality fasteners.
[0009] What is needed in the art is a better way of employing hand
tools to stake a staked fastener. More specifically, the art needs
a better way of staking a staked fastener where the staking
operation involves flowing, e.g., melting, of the clinch portion to
increase the consistency of the staking result across multiple
staking operations.
SUMMARY OF THE INVENTION
[0010] This invention is an aligner and a method for its use in
staking a staked fastener to form a head. More specifically, the
aligner defines a channel into which a tip of a staking tool is
placed. Then as the tip travels through the channel during a
staking operation, the channel guides the staking tool into
alignment with the relevant portion of the staked fastener to allow
an optimum head to be formed.
[0011] These and other features, aspects, and advantages of
embodiments of the present invention will become apparent with
reference to the following description in conjunction with the
accompanying drawings. It is to be understood, however, that the
drawings are designed solely for the purposes of illustration and
not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a cross-sectional view of the aligner with a rivet
(a type of staked fastener) to be staked placed therein.
[0013] FIG. 2 is the cross-sectional view of the aligner of FIG. 1
with a staking tool positioned therein.
[0014] FIG. 3 is a cross-sectional view of the aligner of FIG. 1
incorporating structure that permits wobbling of a tool positioned
therein.
[0015] FIG. 4 is a cross-sectional view of the aligner of FIG. 1
incorporating another structure that permits wobbling of a tool
positioned therein.
[0016] FIG. 5 is a collection of side views of the aligner
depicting various observation slit options.
[0017] FIG. 6 is a cross-sectional view of a second embodiment of
the aligner.
[0018] FIG. 7 is a cross-sectional view of a third embodiment of
the aligner.
[0019] FIG. 8 is a cross-sectional view of a hold-down tool for use
with the aligner.
[0020] FIG. 9 is a cross-sectional view of another hold-down tool
for use with the aligner.
[0021] FIG. 10 is a cross-sectional view of another hold-down tool
for use with the aligner.
[0022] FIG. 11 is a side view of a pry that may be used with the
aligner.
[0023] FIG. 12 is a side view of a hold-down tool that incorporates
a pry.
[0024] FIG. 13 is a top view of the hold-down tool depicted in FIG.
12.
[0025] FIG. 14 is a cross-sectional view of the aligner that
incorporates a placement guide.
DETAILED DESCRIPTION
[0026] As shown in FIGS. 1 and 2, an aligner, generally referred to
by reference number 10, for use in a staking operation of a staked
fastener includes a housing 12 and a base 14 (demarcation from
housing identified by dotted lines). As explained below when the
aligner 10 is used in a staking operation, the base 14 is
disassociated from the housing 12. The housing 12 has an exterior
surface 15, an interior surface 16 that defines a channel 18, and a
bottom 20. The base 14 is positioned in the channel 18. When the
aligner 10 is in use, the bottom 20 of the aligner 10 may be placed
upon an exposed surface 22 of a material 26. The base 14 defines a
through bore 28 and has a channel surface 30.
[0027] The point of demarcation between the housing 12 and the base
14 is illustrated by a dotted line, because the structure of the
demarcation depends in part upon how the aligner 10 is
manufactured. For example, if the aligner 10 is made in a single
process (e.g., injection molding), the housing 12 and the base 14
could be one piece. Thus, the demarcation could be continuous in
whole, or part, and therefore might only be discernable after the
aligner 10 is used. In the case where the aligner 10 was formed it
two pieces, a housing 12 and a base 14, the base could be friction
fit or otherwise attached (e.g. adhered) within the housing. This
would mean that there is a high probability that the base 14 could
be visually identifiable from the housing 12, thus the point of
demarcation would be identifiable. Generally, a friction fit would
create a discontinuity between the housing 12 and the base 14.
Adhering the base 14 within the housing 12 may, or may not, create
a discernable demarcation.
[0028] The aligner 10 may also incorporate a flash trap 32. The
flash trap 32 accepts excess material that is generated because of
the staking operation of a staked fastener, such as a rivet
(generally referred to by reference number 34), which is explained
in greater detail below.
[0029] The base 14 of the aligner 10 also may incorporate a
depression 36. The depression 36, which is in the channel surface
30, may extend around the entire base 14. Referring to FIG. 2, the
depression 36 is placed to cooperate with the relevant parts of a
tip 38 of a staking tool 40 so that the base 14 may be more easily
disassociated from the housing 12 during a staking operation.
[0030] Further depending upon the type of staking method employed,
the depression's 36 placement and depth may also assist in energy
distribution from the tip 38 to a clinch portion 34c of the rivet
34, and base 14, if applicable. More specifically, where
ultrasonics is the staking method, the staking tool 40 employs a
horn. The energy that melts the clinch portion 34c and the base 14,
if applicable, is at the end of the horn. Thus, where the end of
the horn might otherwise contact the base 14 without contacting the
clinch portion 34c but for the depression 36, the depression
permits the end of the horn to simultaneously, or nearly
simultaneously, contact the base and the clinch portion.
[0031] Referring to FIG. 2, the depicted tip 38 is a standard
profile, but other tips, such as dome, knurled, flushed, hollow or
inverse, could be used. Where the tip 38 has an outer ridge, such
as with a standard profile, the depression 36 is proximate the
intersection of the channel surface 30 of the base 14 and the
interior surface 16 that defines the channel 18.
[0032] Continuing with FIGS. 1 and 2, the interior surface 16 of
the aligner 10 may also define a chamfer 42. The chamfer 42 is
located at an entrance 44 defined by the housing 12 of the aligner
10. As shown in FIG. 2, the chamfer 42 assists in guiding the tip
38 into the channel 18 during a staking operation.
[0033] Additionally, the aligner 10 may also incorporate a
hold-down 45, such as cooperating appendages 46 extending outwardly
from the housing 12. The hold-down 45 can be continuous around the
housing 12 or be formed of individual protrusions. The hold-down 45
may be employed by a user of the aligner 10 to assist in holding
the aligner against the exposed surface 22 during a staking
operation.
[0034] Referring to FIG. 1, the aligner 10 may also incorporate a
grasp 47 for assisting in holding on to the aligner. The grasp 47
is positioned on the exterior surface 15. The grasp 47 is
illustrated as knurling, but other structures such as protrusions
or indentations, or combinations of structures may be used. The
grasp 47 may be positioned proximate an opposing surface 48 of the
aligner 10.
[0035] In an exemplary use, a staked fastener such as the rivet 34,
which in addition to the clinch portion 34c includes a head 34a and
a grip portion 34b, is used to secure the material 26 to another
material 49. The material 26 defines a hole 50 and the other
material 49 defines another hole 51. The hole 50 and the other hole
51, which each have a cross-section suitable for the relevant
portions of the rivet 34 placed therein and therethrough, are
aligned and the rivet 34 is positioned therethrough. Positioning of
the rivet 34 in the holes 50, 51 results in the head 34a on one
side 52 of the material combination 26, 49, the grip portion 34b in
the material 26, 49, and the clinch portion 34c projecting
outwardly from the exposed surface 22.
[0036] The precise demarcation between the grip portion 34b and the
clinch portion 34c of the river 34 depends in large part upon how
the base 14 is finally incorporated into the completed staked
fastener. As discussed below, if the base 14 and clinch portion 34c
become unified to some degree as a result of the staking operation,
it might be argued that the grip portion 34c ends at the exposed
surface 22; if not at the channel surface 30. Generally, the grip
portion 34c is that portion of a rivet 34 that is not reshaped
during the staking operation. The precise demarcation point is
generally not an issue as rivets 34 are homogenous. Where this is
not the case, the precise demarcation point is application
dependent.
[0037] Continuing with FIGS. 1 and 2, the aligner 10 is positioned
about the clinch portion 34c. More specifically, the bore 28 in the
base 14 has a cross-section suitable for permitting at least some
of the grip portion 34c of the rivet 34 to enter into the channel
18. Ideally, the end 34d of the grip portion 34c will not extend
out of the channel 18. It should be appreciated that the aligner 10
and the rivet 34 each have a centerline. Depending upon the
application, the placing of the rivet 34 in the aligner 10 may
align these centerlines.
[0038] Referring to FIG. 2, to stake the clinch portion 34c, the
tip 38 of the staking tool 40 is positioned within the channel 18.
Positioning of the tip 38 in the channel 18 may be assisted by the
chamfer 42 defined by the housing 12 at the entrance 44. If it is
desired to have the tip 38 aligned with the clinch portion 34c
before the tip contacts the clinch portion, the chamfer 42 will
have to end at a point "A" within the channel 18, which is above
the end 34d of the rivet 34.
[0039] When the tip 38 enters the channel 18, the channel is
appropriately dimensioned to align eventually the tip with the grip
portion 34c of the rivet 34. Depending upon the application, this
alignment may involve aligning the tip's 38 centerline with the
centerline of the channel 18 and/or rivet 34. This embodiment shows
a tip 38, which is cylindrical, entering the channel 18 and
encountering after the chamfer 42 a complimentary cylindrical
portion. As the cylindrical portion of the interior surface 16 of
the aligner 10 extends down to the base 14, alignment of the tip 38
and the grip portion 34c of the rivet 34 is maintained throughout
the staking operation.
[0040] Continuing with FIG. 2, as should be readily appreciated,
the base 14, as a result of the staking of the clinch portion 34c,
will be trapped between a head 5'4 (shown in dotted lines) being
formed and the exposed surface 22 of the material 26. It should be
appreciated that if the centerlines of the aligner 10, rivet 34,
and tip 38 are all aligned, the head 54 should have a centerline
that is aligned with these centerlines. As a result, the base 14
will become a part of the finished rivet. During the staking
operation, the tip 38 will inevitably encounter the base 14 and the
base must be disassociated from the housing 12 to permit the
housing 12 to be removed to complete the staking operation.
[0041] How the base 14 ultimately is disassociated from the housing
12 is generally a function of the interaction of the base 14 with
the clinch portion 34c during the staking operation. The
interaction of the base 14 with the clinch portion 34c during a
staking operation is dependent upon the materials from which the
base and clinch portion are made and the staking method used.
[0042] For example and as illustrated in FIG. 2, if the base 14 and
the clinch portion 34c are made of the same, or compatible,
plastic, and an ultrasonic staking method is used, it might be
possible to melt both the clinch portion and the base together,
even to the point where after the staking operation they are
indistinguishable one from the other. Thus, the base 14 could be
disassociated from the housing 12 by the staking tool 40 as it
reaches the exposed surface 22, which would be part of the staking
operation. More specifically as to the use of ultrasonics, the horn
could cut the base 14 away from the housing 12 at the point of
demarcation.
[0043] In another example (not depicted), if the base 14 was made
from a metal unaffected by the staking operation (e.g., heat
staking), and the clinch portion 34c was made from a plastic, and
the staking operation relied on melting the clinch portion, the
head 54 would be formed when the staking tool 40 reaches the
channel surface 30 of the base 14. Thus, the base 14 effectively
would be unchanged and trapped in position by the head 54. The
housing 12 would be removed by pulling the housing from the base
14, which, depending upon the method of construction of the aligner
10, may be by breaking any connection between the housing and base.
These two examples represent extremes, and it should be appreciated
that other material combinations in conjunction with other staking
methods could produce an entire spectrum of outcomes.
[0044] The staking operation in all likelihood will generate flash
(not shown), excess material, generally from the clinch portion
34c, that is not part of the finished head. If a flash trap 32 is
present, some flash should enter the trap. In any event, it should
be contemplated that flash will be within the channel 18. Thus, the
cross-section of channel 18 relevant to the cross-section of the
tip 38 should have a tolerance suitable to permit the anticipated
flash so the tip will not bind in the channel throughout the
duration of the staking operation, including extraction of the
tip.
[0045] Referring to FIG. 2, as an option the staking tool 40 may
incorporate a stop 53. The stop 53 is located on the staking tool
40 such that the stop abuts the opposing surface 48 of the aligner
10 coincidentally with the tip 38 completing its maximum movement
in the channel 18 during the staking operation.
[0046] It is important that the cross-section of the housing 12 at
least generally maintain its shape during the staking operation.
Thus, the material for the housing 12 must be selected based on the
type of staking method (e.g., ultrasonic, or hot air/cold stake) to
be performed. The housing's 12 cross-section after the completion
of the staking operation has a considerable influence on the final
shape and location of the formed head 54.
[0047] As shown in FIG. 3A, the chamfer 42 on the interior surface
16 of the housing 12 of the aligner 10 may define a channel 18
having tapering sides, such as a frustum of a cone. The tapering
sides begin at the entrance 44 of the aligner 10 and extend to the
channel surface 30 of the base 14. The interior surface 16
proximate the base 14 should define a cross section that aligns the
tip 38 (see FIG. 2) with the clinch portion 34c of the rivet 34.
While the tapering sides of the interior surface 16 have been shown
as regular, this need not be the case.
[0048] As shown in FIGS. 3A and 3B during a staking operation, the
tip 38 of a staking tool 40 is inserted into the aligner 10 and
guided by the channel 18 into alignment with the clinch portion 34c
of the rivet 34. It should be appreciated that when the tip 38
initially contacts the clinch portion 34c (not shown), the tip may
not be properly aligned with the clinch portion. However, as the
staking operation proceeds with the tip 38 traversing the channel
18, alignment of the tip and clinch portion 34c will improve and
will be proper when the tip encounters the channel surface 30 of
the base 14. At this point, depending upon how the aligner 10 is
constructed, the tip 38 may progress through the base 14 and
eventually reach a final position on the exposed surface 22 of the
Material 26. If the tip 38 does not progress through the base 14,
the tip's final position will be on the channel surface 30 (not
shown).
[0049] After the tip 38 reaches its final position, the tapering
sides of the interior surface 16 permit the tip to be wobbled. If
during wobbling, the tip 38 remains in contact with the interior
surface 16, the tip will be at a constant angle (the angle as shown
is exaggerated for clarity) as to the head 54. When the tip 38 is
wobbled, the pressure the tip exerts is concentrated in a
rotational series of point contacts, thus aiding in cutting off any
flash. Therefore, wobbling tends to provide a more finished
appearance to the head 54.
[0050] Continuing with FIGS. 4A and 4B, the aligner 10 depicted
also permits the tip 38 of the staking tool 40 to be wobbled. As
shown in FIG. 4A, the bottom 20 of the housing 12 and a bottom 55
the hold-down 45, if present and desired, is at the angle .beta. to
the exposed surface 22 of the material 26. As previously discussed,
the tip 38 would enter the channel 18 and then reach a final
position. After reaching the final position, the tip 38 may be
wobbled, with the wobble being controlled by the bottom 20 of the
housing 12 and the opposing surface 48 of the hold-down 45, if
present. It should be appreciated, that, while the opposing surface
48 of the hold-down 45 has been shown cooperating with the bottom
20 during wobbling of the tip 38, this is not a requirement.
[0051] Referring to FIG. 5, the aligner 10 may have an observation
slit (general reference 57). The observation slit 57 may be of any
shape and there may be one or more. The observation slit 57 is
designed to permit viewing of tip 38 (not shown) as it moves down
the channel 18 to encounter the end 34d of the rivet 34. The
observation slit 57 may also be sufficient to permit viewing of the
tip 38 as it encounters the base 14. FIG. 5A shows an observation
slit 57a that is circular in cross-section. FIG. 5B, shows an
oblong observation slit 57b. FIG. 5C shows multiple oblong
observation slits 57c. FIG. 5D shows an oblong observation slit 57d
that is open at the opposing surface 48 of the aligner 10.
[0052] Referring to FIG. 6, the aligner 210 (similar features to
the basic invention use the same reference number preceded by a
"2") has a stop 58. The stop 58 may be continuous around the
interior surface 216, or it may be a series of individual
protrusions. The stop 58 is placed in the channel 218, and it
creates an abutment 60 for the base 214. This arrangement permits
an independent base 214 to be positioned in the channel 218 of the
aligner 210 at the proper depth such that the bottom 220 of the
housing 212 can still be placed on the exposed surface 222 of the
material 226.
[0053] This configuration works especially well when the housing
212 and the base 214 are made from different materials. It is also
a good configuration when reuse of the housing 212 by repeated
insertion of new bases 214 is contemplated. If reuse is
contemplated, the staking operation should not remove the stop 58.
In this configuration, this might be accomplished by designing the
tip (not shown) to not remove the stop 58 during the staking
operation.
[0054] In an alternative shown in Insert A of FIG. 6, if a flash
trap 232 is present, the stop 58 could be recessed therein, thus it
should not be in the path of a tip (not shown) as it travels
through the channel 218. Referring to FIGS. 2 and 4, the base 14,
214 still must have the proper cross-section so that when it is
positioned and held within the channel 18, 218 the alignment
function of the base, between the clinch portion 34c, 234c of the
rivet 34, 234 and the tip 38 (not shown in FIG. 6), is properly
achieved.
[0055] In an alternative shown in Insert B of FIG. 6, the stop 58
could be defined by the interior surface 216.
[0056] Continuing with FIG. 7, the aligner 310 (similar features to
basic invention use the same reference number preceded by the
number "3") has both a stop 62 and a keeper 64. The stop 62, and
similarly the keeper 64, may be continuous about the side 316 or a
cooperating set of protrusion. The stop 62 and keeper 64 cooperate
to trap the base 314 therebetween within the channel 318.
[0057] This arrangement is particularly desirable where the base
314 and the housing 312 are of different materials, and there is no
intention of reusing the housing. As part of the staking operation,
the keeper 64 must be removed to allow the base 314 to be released
from the housing 312.
[0058] As indicated above, the aligner 10 is particularly valuable
where the clinch portion 334c of the rivet 334 and the base 314 are
both melted during the staking operation, such as in the case of a
rivet having a plastic clinch portion and a plastic base that is
staked using an ultrasonic hand tool, which employs a horn. The
flowing plastic, which is located at the interface of the horn and
the rivet, can cause the tip to slip thereby causing the head to be
off center, or cause the tip to adopt an angle resulting from the
flowing plastic being forced from one side to the other.
[0059] The aligner 10 may be even more valuable in the creation of
a unified multi-part head. As explained in U.S. patent application
Ser. No. 10/955,174, (United States Patent Publication Number
20060067806), which is incorporated herein by reference in its
entirety, a unified multi-part head is created using a plastic
rivet and a plastic supplemental material wherein the clinch
portion and/or the supplemental material contains at least one
fiber. In the case of the present invention, the supplemental
material equates to the base 14. During the staking operation, the
clinch portion and the supplemental material are melted to such a
degree that a portion of a fiber in the clinch portion, and/or the
supplemental material, migrates into the other. Thus, the resulting
clinched rivet has in the head that as formed at least one fiber
that has a portion in the original clinch portion and another
portion in the original supplemental material.
[0060] Creating a unified multi-part head using ultrasonic staking
techniques, requires more energy than would otherwise be used if
such a result was not required. As those skilled in ultrasonic
staking methods will appreciate, the increase in energy increases
the time involved to stake a fastener and the fluidity of the
material. Both of these factors tend to increase the complexity of
the staking operation and lead to increased variations in its
outcome, such as heads not properly centered on the grip portion of
the rivet.
[0061] Referring to FIG. 8, the aligner 10 can used in conjunction
with a hold-down tool, generally referred to by reference number
65. The hold-down tool 65 has a handle 66 connected to a body 68.
The body 68 defines a cavity 70 with a surface 72 dimensioned and
shaped to accept the aligner 10 through an opening 74. The surface
72 may define a chamfer 76, which assists in the placement of the
aligner 10 in the cavity 70. The surface 72 also defines a stop 77
that positions the aligner 10 in the cavity 70, such that the
bottom 20 of the housing 12 is ideally at, but may extend outwardly
from, the cavity so that the bottom can contact the exposed surface
22 of the material 26.
[0062] The body 68 also defines a passage 78 positioned opposite
the opening 74. Referring to FIGS. 2 and 8, the passage 78 is
dimensioned to allow the tip 38 of a staking tool 40 to pass
through and enter the channel 18 of the aligner 10.
[0063] As shown in FIG. 9, where the aligner 10 has a hold-down 45
the stop 77 of the hold-down tool 65 may engage the hold-down
instead of the housing 12.
[0064] Referring to FIG. 10, the aligner 10 can be used in
conjunction with a staking tool (generally referred to by reference
number 80) having a hold-down unit 82 affixed thereto at a suitable
location. The hold-down unit 82 has a foot 84 that contacts the
aligner 10. The foot 84 has a mechanism, such as a spring, that
allows the foot to engage the aligner 10 and retract as the tip 38
is advanced down the channel 18 during a staking operation.
[0065] Continuing with FIG. 11, the aligner 10 may be used in
conjunction with a pry 86 that may assist in separating the base 14
(not shown) from the housing 12. The pry 86 interacts with the
hold-down 45, which is shown elevated above the exposed surface 22.
In operation, a force is exerted on the pry 86 that causes it to
pivot on the exposed surface 22 thereby forcing the hold-down 45,
thus the housing 12, away from the exposed surface 22.
[0066] Referring to FIGS. 12 and 13, a pry may be incorporated into
a hold-down tool (generally referred to by reference number 88). In
this configuration, the hold-down tool 88 both holds the aligner 10
in contact with the exposed surface 22 and assists in removing the
base 14 (not shown) from the housing 12.
[0067] As illustrated, the hold-down tool 88 has a pry 90 and a
handle 92 connected together by a receptacle 94. The receptacle 94
defines a hole 96 dimensioned to accept an aligner 10.
[0068] In use, an aligner 10, which has a hold-down 45 comprised of
a plurality of protrusions, is dropped downward (i.e., the bottom
20 of the aligner 10 entering the hole 96 first) into the hold-down
tool 88 (see FIG. 13 and dotted hold-down tool). The hold-down 45
rests on a surface 98 of the receptacle 94. The aligner 10 and/or
hold-down tool 88 are then moved, in this case rotated, relative
one to the other such that a portion of the hold-down 45 enters a
notch 100 defined by the handle 92 and another notch 102 defined by
the pry 90. The notches 100, 102 may have stops (not shown) therein
to assist is proper placement of the hold-down 45.
[0069] While the hold-down tool 88 has been illustrated as
accepting the aligner 10 by having the aligner dropped therein,
those skilled in the art would appreciate that this could be
reversed by merely inverting the receptacle 94.
[0070] Referring to FIG. 14, the aligner 10 may have a positioning
guide 104. The positioning guide 104 may have appendages 106, 108,
each having a protrusion 110, 112 extending outwardly therefrom
(i.e., a direction away from the bottom 20 of the aligner 10). In
operation, each protrusion 110, 112 may be placed within
corresponding holes 114, 116 through which another staked fastener
(not shown) will be placed. The protrusions 110, 112 are spaced one
from the other a distance, which may be a function of the pitch of
the holes into which rivets 34 will be placed, such that the bore
28 of the aligner 10 is aligned with the holes 50, 51 through which
a rivet will be placed. It should be appreciated that the holes
114, 116 could be replaced by appropriately placed depressions.
[0071] Materials for the aligner are selected based on the
application, as is the material for the rivet. The aligner permits
the base and the housing to be made of the same or different
materials to meet the needs of the fastener in the application.
[0072] Referring to the second and third embodiments, these
embodiments generally contemplate a method of manufacture for the
aligner 10 wherein the base 14 and the housing 12 are separately
made then assembled. Thus, the base 14 is inserted into the housing
12 to create the aligner 10 sometime before use of the aligner.
[0073] It should also be appreciated that the aligner is but one
part used in a staking operation. Thus, the aligner could be part
of a kit of some combination of the other items disclosed
herein.
[0074] While there has been illustrated and described what is at
present considered to be preferred and alternative embodiments of
the claimed invention, it will be appreciated that numerous changes
and modifications are likely to occur to those skilled in the art.
It is intended in the appended claims to cover all those changes
and modifications that fall within the spirit and scope of the
claimed invention. Additionally, while the aligner has been
depicted as round, this is not a requirement. In addition, while
the channel and staking tools have been depicted as cylindrical,
this is not a requirement. Additionally, the staked fastener has
been depicted as a rivet, it should be appreciated that the aligner
could be used with a post, which is similar to a rivet but lacks a
second head. Additionally, the rivet has only been depicted as
using the aligner to form the final head on the rivet. It is
certainly possible to use the aligner to form the initial head as
well, such as during the manufacturing of a rivet blank, i.e., the
state a rivet is in prior to having the second head created. Also,
the use of multiple reference numbers for an element, e.g., 10,
210, 310, is provided to assist the reader in understanding
differences in embodiments and should only be relied upon in that
context. Therefore, the absence of multiple reference numbers
should not be presumed as a limitation. This list should not be
considered exhaustive.
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