A method of installing an overhead panel to another panel is provided. The method includes connecting a base of a positioning structure to a surface of the overhead panel. The positioning structure includes the base, a stem that extends outwardly from the base and an enlarged head that extends outwardly from the stem and overhangs the base. The enlarged head of the positioning structure is moved against a ledge of the another panel. The ledge contacts the enlarged head and moves the enlarged head from a catch configuration to an insertion configuration where the enlarged head reduces in dimension. The enlarged head is passed by the ledge such that the enlarged head moves from the insertion configuration to the catch configuration of increased dimension. The enlarged head is hung on the ledge such that the positioning structure supports the overhead panel in a pre-installation position that is different from an installed position.

Apparatuses, systems, and methods are disclosed for non-planar features for a fastened connection. A forming die is shaped to be disposed between at least two members of a fastened connection. One or more non-planar features are integrally formed from a continuous material of the forming die to at least partially deform the at least two members at an interface between the at least two members.

A mechanical assembly for securing a first sheet to a second sheet includes a first projection having a first sidewall and a first top wall. The first sidewall extends from the first top wall at a first acute angle. The first sidewall includes a first top end and a first bottom end. A first discontinuity is defined in the first sidewall between the first top end and the first bottom end. A first base wall extends from the first bottom end. The first base wall extends generally parallel to the first top wall.

A method for manufacturing metal parts with split ends joined. An end of a metal plate or solid metal rod is split. The length of the incision is adjusted and a smooth split face is formed. A metal plate is secured by pinching both sides with a clamping device, or a solid metal rod is pinched on opposite portions on the periphery with a clamping device. The plate/rod is split longitudinally by slitting or cleaving the plate/rod by pressing a slitting or cleaving punch against the face of one end of the plate/rod. The splitting is advanced by repeating the operation of pressing the punch against the cleft of the splitting. In each splitting operation, the position of the clamping device is moved in advance of the next pressing by a stroke corresponding to the distance from one end of the plate/rod, to the distal end of a split-desired portion.

The present invention is a part positioning mechanism configured to insert a protruding portion constituting a part of a second sheet metal part into an opening formed in a first sheet metal part. The first contact portion which contacts the first convex portion of the first sheet metal and the second contact portion which contacts the second convex portion of the first sheet metal are disposed to be shifted in an orthogonal direction which intersects orthogonally with the plate thickness direction and an insertion direction for the protruding portion. The edge of the opening of the first sheet metal part has a first edge which is distant from the protruding portion increases from the first convex portion to the second convex portion, and a second edge which is distant from the protruding portion increases from the second convex portion to the first convex portion.

A profile assembly having a first profile and having a second profile connected on its long side to the first profile, which two profiles each have a hook strip integrally formed on the long side, wherein the hook projection of the hook strip of the first profile points in the one direction, and the hook projection of the hook strip of the second profile points in the opposite direction, the hook strips brought into engagement with one another in a claw-like manner. The first profile has an anchoring channel following its longitudinal extent, and the hook strip of the second profile has a clamping strip which is integrally formed thereon, which hook strip is secured by its hook projection and its clamping strip in the anchoring channel of the other profile by a cold joining connection. In order to produce the cold joining connection, one of the two hook strips comprises an adjusting strip which is formed by the cold joining process and which is supported in the produced profile assembly by its free end face while being under prestress. The hook strip secured in the anchoring channel is placed under prestress within the anchoring channel, at two points situated opposite one another in the direction of the height of the profile assembly, with respect to the adjoining portions of the first profile as a result of the cold joining connection.

A mechanical assembly for securing a first sheet to a second sheet includes a first projection having a first sidewall and a first top wall. The first sidewall extends from the first top wall at a first acute angle. The first sidewall includes a first top end and a first bottom end. A first discontinuity is defined in the first sidewall between the first top end and the first bottom end. A first base wall extends from the first bottom end. The first base wall extends generally parallel to the first top wall.

A self-piercing rivet (SPR) joint includes a top layer including at least one steel material or at least one aluminum material, a middle layer including at least one magnesium material, and a bottom artificial aluminum layer including at least one aluminum material.

A doghouse retainer includes a body having an end wall incorporating a clip receiver and a sidewall having an ultrasonic heating concentration feature. A door assembly is provided including a door inner and a door trim panel incorporating such a doghouse retainer. A method of adjusting a gap between two components is also provided.

A method of installing an overhead panel to another panel is provided. The method includes connecting a base of a positioning structure to a surface of the overhead panel. The positioning structure includes the base, a stem that extends outwardly from the base and an enlarged head that extends outwardly from the stem and overhangs the base. The enlarged head of the positioning structure is moved against a ledge of the another panel. The ledge contacts the enlarged head and moves the enlarged head from a catch configuration to an insertion configuration where the enlarged head reduces in dimension. The enlarged head is passed by the ledge such that the enlarged head moves from the insertion configuration to the catch configuration of increased dimension. The enlarged head is hung on the ledge such that the positioning structure supports the overhead panel in a pre-installation position that is different from an installed position.