Apparatus and method for manufacturing weld nuts

Claim 3

The method of manufacturing a weld nut as defined in claim 1 wherein said supported end surface of said blank is disposed within a portion of said cutting die aperture during said first-mentioned application of axial pressure to said blank end surfaces whereby a portion of the lateral deformation of said blank engages the walls of said cutting die aperture to lock said blank nut within said cutting die aperture.

Claim 4

A press for manufacturing weld nuts by the application of pressure to a standard nut blank of the type having substantially parallel flat end surfaces and generally flat side surfaces intersecting each other to foRm corners and wherein said side surfaces are normal to said end surfaces; said press comprising: a pair of die members movable relative to each other; a cutting die disposed between said die members, said cutting die having an aperture shaped complementary to said blank side surfaces and aligned with said die members such that one of said die members is relatively reciprocally movable therethrough, said one die member having a blank support surface for supporting thereon one of said end surfaces of said nut blank, said support surface having localized recesses in areas adjacent and under the corners of said one supported blank end surface; means for moving said die members toward each other with said one die member moving in one direction into said cutting die aperture for applying an axial pressure on said end surfaces to axially deform the corners of said blank into said recessed areas of said one die member to form axially disposed welding projections at the periphery of said nut blank and laterally displacing a portion of said side wall corners with a portion thereof engaging the walls of said aperture; means separating said die members with said one die member moving in an opposite direction for withdrawal from said cutting die aperture while said blank remains in engagement with said cutting die aperture walls; and means engaging the other of said blank end surfaces for displacing said blank through said cutting die aperture to effect a cutting operation thereon to remove said lateral deformations such that the resulting weld nut ejected from said cutting die aperture has side surfaces that are normal to the original planes of said end surfaces and without substantial lateral deformation from the original dimensions of said side surfaces of said blank.

Claim 5

A press for manufacturing weld nuts by the application of pressure to a standard nut blank of the type having substantially parallel flat end surfaces and generally flat side surfaces intersecting each other to foRm corners and wherein said side surfaces are normal to said end surfaces; said press comprising: a pair of die members movable relative to each other; a cutting die disposed between said die members, said cutting die having an aperture shaped complementary to said blank side surfaces and aligned with said die members such that one of said die members is relatively reciprocally movable therethrough, said one die member having a blank support surface for supporting thereon one of said end surfaces of said nut blank, said support surface having localized recesses in areas adjacent and under the corners of said one supported blank end surface; means for moving said die members toward each other with said one die member moving in one direction into said cutting die aperture for applying an axial pressure on said end surfaces to axially deform the corners of said blank into said recessed areas of said one die member to form axially disposed welding projections at the periphery of said nut blank and laterally displacing a portion of said side wall corners with a portion thereof engaging the walls of said aperture; means separating said die members with said one die member moving in an opposite direction for withdrawal from said cutting die aperture while said blank remains in engagement with said cutting die aperture walls; and means engaging the other of said blank end surfaces for displacing said blank through said cutting die aperture to effect a cutting operation thereon to remove said lateral deformations such that the resulting weld nut ejected from said cutting die aperture has side surfaces that are normal to the original planes of said end surfaces and without substantial lateral deformation from the original dimensions of said side surfaces of said blank.

Claim 6

The press for manufacturing weld nuts as defined in claim 3 wherein said cutting die is carried by said other die member and movable therewith toward said one die member.

Claim 7

The press for manufacturing weld nuts as defined in claim 3 wherein said blank is supported on said one die member and carried thereby through said aperture into engagement with said other die member.

Claim 8

A press for manufacturing weld nuts by the application of pressure to a standard nut blank of the type having substantially parallel flat end surfaces and side surfaces intersecting each other to form corners and wherein said side surfaces are normal to said end surfaces, said press comprising: a lower die member having a nut blank supporting surface with localized areas of the supporting surface being recessed and disposed under the corners of said nut blank when the same is supported on said lower die member; an upper die member reciprocally movable to and from said lower die member and adapted to engage the other end surface of said blank for applying an axial pressure on said blank to axially displace the corners of said blank into said recessed areas on said lower die member and laterally displace portions of said side wall corners; an intermediate die member having a cutting aperture and disposed between said upper and lower die members in axial alignment therewith, said intermediate die member being carried by and movable with said upper die member, said cutting die aperture being complementary to the side surfaces of said blank such that said blank and lower die member pass therethrough as said upper die member moves toward said lower die member to apply said aforementioned axial pressure, said laterally displaced portions of said blank corners partially engaging said aperture such that upon separation of said upper and lower die members said blank is maintained within the upper portion of said aperture; and means operable upon separation of said upper and lower die members for engaging the upper end surface of said blank to drive said blank through said cutting aperture to remove said laterally displaced portions from said blank such that the resulting weld nut has side surfaces that Are normal to the original planes of said end surfaces and without substantial lateral deformation from the original dimensions of said blank side walls.

Claim 9

A press for manufacturing weld nuts by the application of pressure to a standard nut blank of the type having substantially parallel flat end surfaces and side surfaces intersecting each other to form corners and wherein said side surfaces are normal to said end surfaces, said press comprising: a lower die member having a nut blank supporting surface with localized areas of the supporting surface being recessed and disposed under the corners of said nut blank when the same is supported on said lower die member; an upper die member reciprocally movable to and from said lower die member and adapted to engage the other end surface of said blank for applying an axial pressure on said blank to axially displace the corners of said blank into said recessed areas on said lower die member and laterally displace portions of said side wall corners; an intermediate die member having a cutting aperture and disposed between said upper and lower die members in axial alignment therewith, said intermediate die member being carried by and movable with said upper die member, said cutting die aperture being complementary to the side surfaces of said blank such that said blank and lower die member pass therethrough as said upper die member moves toward said lower die member to apply said aforementioned axial pressure, said laterally displaced portions of said blank corners partially engaging said aperture such that upon separation of said upper and lower die members said blank is maintained within the upper portion of said aperture; and means operable upon separation of said upper and lower die members for engaging the upper end surface of said blank to drive said blank through said cutting aperture to remove said laterally displaced portions from said blank such that the resulting weld nut has side surfaces that Are normal to the original planes of said end surfaces and without substantial lateral deformation from the original dimensions of said blank side walls.

Claim 10

The press for manufacturing weld nuts as defined in claim 6 further comprising: an upper die member support on which said upper member is reciprocally carried for movement to and away from said lower die member; a tubular member carried by said upper die member and circumscribing said upper die member, said tubular member extending beyond said upper die member and carrying said intermediate die members, said tubular member having a bore with a surface complementary to the outer peripheral surface of said intermediate die member for supporting same, said intermediate die member being removably attached thereto, whereby said intermediate die member may be replaced by other intermediate die members having varying sized cutting apertures to accommodate the manufacture of weld nuts of different dimensions.

Claim 11

The press for manufacturing weld nuts as defined in claim 6 further comprising a lower die member support, said lower die member support fixedly mounting said lower die member in axial alignment with said die cutter aperture, said lower die member comprising: a post member for having an englarged lower end; a mounting base having a step bore through which said post member is insertable, said step bore engaging said enlarged end of said post member; and means engageable between said enlarged end and said base bore for preventing relative rotation between said post member and said base, said post member being supported directly on the surface of said lower die support member to transmit forces from said upper die member directly to said lower die member.