Abstract: A method for manufacturing a one-way clutch includes forming an inner plate; forming first and second outer plate members having a common axis; forming at least one strut pocket in one of the group consisting of the inner plate and the second outer plate member; forming at least one notch in the other of the group consisting of the inner plate and the second outer plate member; assembling a strut in the at least one strut pocket; inserting the inner plate between the outer plate members; and securing the outer plate members together to form a unitary outer plate assembly such that the inner plate is rotatably retained within the outer plate assembly and the strut is engageable with the at least one notch to effect one-way torque transfer between the inner plate and the outer plate assembly. The method may also include forming the second outer plate member as two pieces having mating surfaces, and interlocking the mating surfaces together. A one-way clutch manufactured by the method is also disclosed.

Abstract: A strut for mechanically coupling a driving member to a driven member in a planar one-way clutch is formed in a progressive die from a length of cold-formed metallic stock material such that the strut's diametrical member-engaging end surfaces are coextensive with a pair of cold-formed surfaces of the stock material. A pair of oppositely-projecting "ears" are integrally formed on the strut proximate to one of its end surfaces at one station of the progressive die. The ears cooperate with a complementary recess or pocket formed in one member's planar clutch face to thereby nominally position and maintain the strut's first end surface within the pocket. A surface on each ear is preferably coined at another station of the progressive die to thereby provide a relief which prevents deleterious contact between the ears and the opposed clutch face of the other clutch member.