Abstract: A method for forming a saddle for a U-bolt clamp assembly which is suitable for clamping together the components of an automotive exhaust system. The method is capable of forming a saddle which exhibits sufficient strength and rigidity in order to generate a clamping load which can reliably join the exhaust components, while also being sufficiently resilient to accommodate variations in pipe size and hardness so as to reliably seal the joint formed by the components. The method of this invention produces a saddle structure which is relatively uncomplicated, and can be manufactured from a one-piece blank utilizing a series of conventional forming operations that offer a relatively low cost manufacturing process suitable for use in mass production.

Abstract: An improved fastener and method of attachment to sheet material providing attachment of a tubular fastener to sheet material by extruding, without severing, portions of the sheet material completely through openings on the base portion of the fastener. The extruded material is clinched on the top surface of the base portion by clinch members integrally formed with the base portion. The fastener is internally threaded, lightweight and preferably heat-treated prior to attachment to the sheet material to provide fastener strength equivalent to or greater than that of much heavier nuts. Two types of such fasteners may be attached by a method which opens up a hole in the sheet material of a larger diameter than the major diameter of the threads in the fasteners while simultaneously clinching the fastener in place. This eliminates the need to use thread-cutting bolts. The fasteners may be connected together to form a strip to be fed into an automated assembly unit from a dispenser.

Abstract: A fastener and method of attachment of such fastener to sheet material to provide attachment of a tubular fastener to the sheet material by extruding, without severing, portions of the sheet material completely through openings on the base portion of the fastener. In one embodiment of the invention, the extruded material is clinched on the top surface of the base portion by clinch members integrally formed with the base portion. The fastener is internally threaded, lightweight and preferably heat-treated prior to attachment to the sheet material to provide fastener strength equivalent to or greater than that of much heavier nuts. Two types of such fasteners may be attached by a method which opens up a hole in the sheet material of a larger diameter than the major diameter of the threads in the fasteners while simultaneously clinching the fastener in place. This eliminates the need to use thread-cutting bolts.

Abstract: A die assembly for clinching a fastener such as a pierce nut to a panel. In the clinching operation, a pilot portion of the fastener is driven through the panel and into an aperture in a die body. Step portions of the die body deform the fastener pilot and interlock or clinch the fastener and panel together. After the clinching operation, the fastener and panel are stripped from the die assembly. In order to facilitate release of the fastener pilot from the die aperture, the die body is segmented so that its segments can separate in a radial direction to enlarge the aperture. The die body segments have sloping outer surfaces received in a complementary die holder so that the segments are cammed together during the clinching operation and are separable during the stripping operation.