Abstract: A clinch fastener includes a shaft defining a central axis and a head having an outer periphery cooperating with the shaft. A plurality of ribs disposed under the head to engage a workpiece. The plurality of ribs extending radially outward in a direction from a displacement collar positioned proximate the central axis of the clinch fastener to the outer periphery of the head. Each of the plurality of ribs includes multiple sections forming at least a sidewall and a parametric profile for each rib. The clinch fastener includes a retaining ring cooperating with the shaft and a retaining groove cooperating with the shaft positioned between the displacement collar and retaining ring. The plurality of ribs and displacement collar are configured to radially displace workplace material into the retaining groove and diffuse stress within the workpiece material when the fastener is secured to the workpiece.

Abstract: A clinch fastener that includes a plurality of ribs disposed under a head of the clinch fastener, wherein the ribs are specifically configured to displace host material more evenly than conventional clinch fasteners. To that end, in cross section, along a line, arc, or combination, going from a central axis of the clinch fastener to an outer periphery of the head of the clinch fastener, each rib preferably provides a curved surface that is formed of multiple sections, wherein different radii define at least two of the sections. The configuration of the ribs allows for a vented escape of host material beyond the rib outside diameter and provides for radially focused material displacement, thereby releasing stress within the host material and reducing warping during clinching.

Abstract: A ball stud assembly includes a ball stud for engaging a component with a stepped bore extending along a bore axis and a reaction surface orthogonal to the bore axis. The stud includes a ball first end, a threaded second end, and a flange. The stud additionally includes a shank extending along a stud axis between the first and second ends, having a stepped shank shape, and configured to extend through the stepped bore and leave a gap between the bore and the shank. The stud also includes a flange between the first end and the shank with a flange surface orthogonal to the stud axis for engaging and abutting the reaction surface. The stud additionally includes a sleeve positioned on the shank and a threaded nut configured to tighten the stud on the component and deform the sleeve such that the sleeve fills at least part of the gap.

Abstract: A bolted joint providing a “zero-clearance” fit formed from a bolt including a shoulder that works during installation to cold form a deformable sleeve. The bolted joint joins a bolt receiving member to a clamped component. One or more bolted joints may be used and as the bolts are installed, shoulders on each of the bolts dilate deformable sleeves until the outer diameters of the sleeves contact internal walls of through holes in the clamped component. Each of the deformable sleeves includes at least one groove or flute on its interior surface that results in: reduced radial load on internal walls of the clamped component and the bolt receiving members, and less friction between the sleeve and both the clamped component and a counter bore disposed within the bolt receiving member, thereby allowing for smaller percentage of the bolt's tensile strength capability required to deform the sleeve.

Abstract: A fastener system that includes a fastener, a compression-limiting sleeve, and a retainer which generally retains the compression-limiting sleeve on the fastener. By providing that the compression-limiting sleeve is not staked to the fastener, existing technology can be used, and no extra staking processing step needs to be performed. The fastener may comprise a conventional metal threaded screw or bolt, possibly having a recess in its head for receiving a driver. Preferably, the compression-limiting sleeve is cold headed as opposed to being stamped, and preferably includes a counter bore which assures that an end of the retainer is below an end surface of the compression-limiting sleeve. Preferably, the retainer is formed of a thermoplastic elastomer or another suitable material.

Abstract: A drive system with full surface drive contact. The drive system tends to maximize the surface contact pattern or area at typical bit-recess reaction (drive) torque values, thereby tending to minimize bit-recess surface contact stresses, coating damage, recess ream and premature bit fatigue failure. The drive system comprises a fastener and/or bit having drive surfaces formed of either polygon involutes or a single arc construction. A punch is also provided for forming a recess in either the fastener or the bit, wherein the punch has corresponding surfaces.

Abstract: A drive system with full surface drive contact. The drive system tends to maximize the surface contact pattern or area at typical bit-recess reaction (drive) torque values, thereby tending to minimize bit-recess surface contact stresses, coating damage, recess ream and premature bit fatigue failure.

Abstract: A fastener system that includes a fastener, a compression-limiting sleeve, and a retainer which generally retains the compression-limiting sleeve on the fastener. By providing that the compression-limiting sleeve is not staked to the fastener, existing technology can be used, and no extra staking processing step needs to be performed. The fastener may comprise a conventional metal threaded screw or bolt, possibly having a recess in its head for receiving a driver. Preferably, the compression-limiting sleeve is cold headed as opposed to being stamped, and preferably includes a counter bore which assures that an end of the retainer is below an end surface of the compression-limiting sleeve. Preferably, the retainer is formed of a thermoplastic elastomer or another suitable material.

Abstract: Punch pins which have further extending lobes, and which are designed to punch sockets that have deeper flutes while not having lobes which extend further toward a center axis of the fastener. Using such a punch pin to form a socket in a fastener provides that the resulting socket has flutes which are deeper than they otherwise would be, without having to provide corresponding lobes which extend further toward the center axis of the socket. This extra deepness in the flutes helps to provide extra room for a coating to deposit.

Abstract: A die case extractor and method for extracting a die case from a die bed. The die case extractor is engaged with the die case which is disposed in the die bed. The die case extractor is engaged by a pulling device, such as a ram. When the pulling device is retracted from the die bed, the die case extractor pulls on the die case, thereby extracting the die case from the die bed. Preferably, the die case extractor includes a bracing piece that is engaged with the die case. The die case extractor also preferably includes a member, such as a screw, which is engaged with the bracing piece. A holder is retained on the member and is engaged by the ram. The ram is then retracted generally away from the die bed, thereby pulling on the die case and extracting the die case from the die bed. Preferably, multiple die case extractors can be used simultaneously to extract a plurality of die cases in a single pulling action of the ram.

Abstract: In a preferred embodiment, a driver socket is configured to provide a visual indicator on a portion of a locknut upon application of a predetermined torque to the driver socket relative to the locknut. The driver socket has a member which is positioned proximate to the first end, with a portion thereof protruding into an aperture of the driver socket. The member is configured to engage a drive configuration of a locknut in order to apply nut torque to the locknut upon rotation of the drive socket and to form a mark on the drive configuration of the locknut in order to provide a visual indicator on the locknut that the locknut has been subjected to the desired torque during initial assembly. The driver socket is preferably attached to a ratchet arm of a fastening tool which provides a mechanical advantage in applying the desired torque.

Abstract: A die case extractor and method for extracting a die case from a die bed. The die case extractor is engaged with the die case which is disposed in the die bed. The die case extractor is engaged by a pulling device, such as a ram. When the pulling device is retracted from the die bed, the die case extractor pulls on the die case, thereby extracting the die case from the die bed. Preferably, the die case extractor includes a bracing piece that is engaged with the die case. The die case extractor also preferably includes a member, such as a screw, which is engaged with the bracing piece. A holder is retained on the member and is engaged by the ram. The ram is then retracted generally away from the die bed, thereby pulling on the die case and extracting the die case from the die bed. Preferably, multiple die case extractors can be used simultaneously to extract a plurality of die cases in a single pulling action of the ram.

Abstract: A fastener system that includes a fastener, a compression-limiting sleeve, and a retainer which generally retains the compression-limiting sleeve on the fastener. By providing that the compression-limiting sleeve is not staked to the fastener, existing technology can be used, and no extra staking processing step needs to be performed. The fastener may comprise a conventional metal threaded screw or bolt, possibly having a recess in its head for receiving a driver. Preferably, the compression-limiting sleeve is cold headed as opposed to being stamped, and preferably includes a counter bore which assures that an end of the retainer is below an end surface of the compression-limiting sleeve. Preferably, the retainer is formed of a thermoplastic elastomer or another suitable material.

Abstract: In a preferred embodiment, a driver socket is configured to provide a visual indicator on a portion of a locknut upon application of a predetermined torque to the driver socket relative to the locknut. The driver socket has a member which is positioned proximate to the first end, with a portion thereof protruding into an aperture of the driver socket. The member is configured to engage a drive configuration of a locknut in order to apply nut torque to the locknut upon rotation of the drive socket and to form a mark on the drive configuration of the locknut in order to provide a visual indicator on the locknut that the locknut has been subjected to the desired torque during initial assembly. The driver socket is preferably attached to a ratchet arm of a fastening tool which provides a mechanical advantage in applying the desired torque.

Abstract: A drive tool that includes a drive socket. The drive socket includes alternating flutes and lobes and has a conical portion. The lobes, rather than being tapered in the conical portion of the socket, are each uniform in width as they progress to an end of the socket. The fact that the lobes are uniform in width in the conical portion of the drive socket provides for better engagement with the flutes of a conical section of a fastener.

Abstract: An adjustable strap handle that can be used in connection with a packaging frame. The strap handle provides not only that the effective length of the strap is adjustable, but also provides that no tool needs to be used to install the strap. Additionally, a dual head self-pierce rivet is described that can be used in connection with a packaging frame, specifically to secure cardboard edge pieces to thin sheet metal or cardboard corner pieces and provide structure with which strap handles can engage. The dual head self-pierce rivet has a shank and a poke at its end. The poke is configured to pierce through the cardboard edge pieces of a cube frame, advance into the edge pieces, and flare into a profiled anvil. While a lower head of the rivet seats against the cardboard, an upper head contains and holds a strap handle in a ring groove.

Abstract: A thread forming screw having a minimum surface hardness of HRC 56. The screw can form threads in a workpiece having a surface hardness which exceeds HRC 23. A method of surface hardening a screw includes carbon enriching the screw to at least a 0.48 carbon level, and then quenching the screw. Then, the screw is tempered such that the surface hardness does not exceed the core hardness by more than 3 Rockwell C points, and both the surface and core are at a Rockwell C33-C39 hardness. Subsequently, the point is induction hardened, and the screw is quenched again. The screw is again tempered such that the lead threads and the first 3-4 full threads are at a Rockwell C56 minimum hardness, preferably to a depth of at least 0.008 inches, and the core of the fastener is at Rockwell C33-C39 hardness. Finally, a finish is applied.

Abstract: A lock nut having a plurality of sides having a radius crimp which is consistent with the radius of the threaded bore in the lock nut. Preferably, the lock nut is crimped using a three sided die, each die having a radius crimp with relief angles. The relief angles are provided at a desired angle to result in the desired amount of contact area between the lock nut and the die. The device includes a housing, and the housing includes at one end a threaded bore which is configured to mount on a ram. An opposite end of the housing provides a tapered die section in which the three sided die is disposed. The three sided die is engaged with a locking die base which is movable within the housing.

Abstract: In a preferred embodiment, a driver socket is configured to provide a visual indicator on a portion of a locknut upon application of a predetermined torque to the driver socket relative to the locknut. The driver socket has a member which is positioned proximate to the first end, with a portion thereof protruding into an aperture of the driver socket. The member is configured to engage a drive configuration of a locknut in order to apply nut torque to the locknut upon rotation of the drive socket and to form a mark on the drive configuration of the locknut in order to provide a visual indicator on the locknut that the locknut has been subjected to the desired torque during initial assembly. The driver socket is preferably attached to a ratchet arm of a fastening tool which provides a mechanical advantage in applying the desired torque.

Abstract: An isolator assembly which may be used, for example, to secure a fuel rail to a cylinder head. The isolator assembly includes a bolt, washer and compressive elements. When using the isolator assembly to mount a fuel rail, preferably initially the washer and a first compressive element are retained on the bolt. A shaft end of the bolt is then inserted into a mounting boss of the fuel rail, and a second compressive element is engaged with both the fuel rail and a threaded portion of the bolt. The bolt is then threaded into the cylinder head, causing the second compressive element to come into contact with the cylinder head and compress, along with the first compressive element. When fully installed, the first compressive element isolates the fuel rail from the bolt itself (and the washer), and the second compressive element isolates the cylinder head from the fuel rail.