Hinged clip having a retainer

A clip retention system includes first and second body members. A first body member pin is joined by a living hinge to the second body member which permits an angular range of body member rotation. Retention elements partially enclose the pin. Upon living hinge failure the retention elements prevent body member disassociation for any angle within the angular range of rotation.

FIELD

The present disclosure relates in general to clip fasteners and more specifically to a device and method for creating and using a clip fastener having members joined by a living hinge, the clip fastener used for joining items such as cables or tubing to automobile vehicles.

BACKGROUND

Clips for attaching elongated articles such as fuel lines, brake fluid lines, wires or wiring harnesses to the body or panels of an automobile vehicle commonly have two major component members which can be joined by a living hinge. A first member normally includes one or more generally U-shaped receiving areas which are adapted to receive one or more of the elongated articles. The second member is further adapted to snap or fixedly connect to the first member, engaging the elongated articles between the first and second members. A living hinge is commonly used to join the two members and allow rotation to close the two members together. One or more male members commonly extend from one of the parts which are operable to engage a body panel of the automobile vehicle.

Several drawbacks are notable for common clip designs. A first drawback is due to the flexibility requirements of the living hinge. The living hinge must be thin enough to allow flexibility for rotation of the second member about the elongated articles during installation of the clip. Manufacturing defects, overextension of the clip before assembly, and/or damage during shipment can occur. This frequently results in failure of the living hinge, in some cases following manufacture of the clip but before the clip is installed or during installation of the clip. Living hinge failure prior to clip installation often results in lost parts or the inability to install the clip, particularly if automated installation equipment is used. Living hinge failure following clip installation can allow the elongated article(s) to displace which can result in further vehicle system or component failure. Any of the above failures can result in increased costs to the manufacturer, the clip installer or to a replacement service to replace the broken clip or failed systems while in service.

Clips having a retention feature to prevent dislocation of the first and second members upon failure of the living hinge during use may include a retainer element. Common retainer elements employ or are functional only when the two clip members are joined or after the two clip members are rotated toward each other beyond a predetermined angle. Some retainer elements are themselves frangible and break when rotation is initiated. Even with these retainer elements, if the living hinge or retainer element fails during clip transfer from the clip manufacturer to the installer, or at the facility of the installer before or during installation, the clip is generally discarded.

SUMMARY

A hinged clip having a retainer according to a preferred embodiment of the present disclosure includes first and second clip portions. A living hinge integrally connecting the first and second clip portions is operable to permit rotation of the first and second clip portions relative to each other throughout an angular range of rotation. A retention device connects the first and second clip portions. Upon failure of the living hinge the retention device is operable to prevent disassociation of the first and second clip portions for any angle within the angular range of rotation and up to a maximum rotation angle.

In another aspect of the disclosure, a clip retention system includes first and second integrally connected body members. A connection joint connects the second body member to the first body member. The connection joint includes a pin integrally connected to the first body member and a living hinge integrally connecting the pin to the second body member. The living hinge permits rotation of the first and second body members relative to each other throughout an angular range of rotation. At least one curved element integrally connected to the second body member partially encloses the pin. Upon failure of the living hinge the curved element prevents separation of the first and second clip members for any angle of rotation within an angular range of rotation and up to a maximum rotation angle.

In a further aspect of the disclosure, the living hinge includes a first end and a second end. A thickness of the living hinge is variable from the first end to the second end.

In a still further aspect of the disclosure, a method is provided for preventing disassociation of a first member of a clip having a pin from a second member of the clip normally joined by a living hinge upon failure of the living hinge, the living hinge operable to provide an angular range of rotation between the first and second members. The method includes integrally connecting the pin to the first body member. The method also includes integrally coupling the pin to the second member with the living hinge. The method further includes molding oppositely directed extension members integrally with the second member operable to at least partially enclose the pin. The method still further includes rotatably engaging the oppositely directed extension members with the pin to operably prevent disassociation of the first and second clip members upon failure of the living hinge for any angle of rotation between the first and second body members within the angular range of rotation.

A hinged clip having a retainer of the present disclosure offers several advantages. The retainer of the present disclosure is functional for any orientation of the first and second clip members. The retainer is therefore functional to provide for engagement of the two clip members even if the living hinge fails during shipment or before installation of the clip as well as after installation. The retainer of the present disclosure also maintains the necessary clamping force between the two clip members and the elongated article(s) if the living hinge fails after the clip is installed. The hinged clip of the present disclosure also accommodates installation tolerances of the elongated articles.

DETAILED DESCRIPTION

According to a preferred embodiment of the present disclosure and referring generally toFIG. 1, a clip10includes a clip receiving portion12and a clip retention portion14. Clip receiving portion12includes a first channel16and a second channel18. Each channel further includes a necked-down region20. First and second channels16,18are adapted to each receive an elongated element21such as a wire, a wiring harness, or a tubular member such as a fuel or break line for an automobile vehicle.

Clip receiving portion12further includes a first mounting post22and a second mounting post23which are slidably received within each of a first receiving aperture24and a second receiving aperture25of a body member26such as a body panel of an automobile vehicle. Each of first and second mounting posts22,23extend through first and second receiving apertures24,25until an engagement surface27of clip receiving portion12contacts body member26. At this position, a first deflecting wing28of first mounting post22and a second deflecting wing30of second mounting post23deflect outwardly to prevent disengagement of clip receiving portion12from body member26.

Clip receiving portion12further includes an abutment face32positioned between each of first and second channels16,18. A deflectable post34and a deflectable post36are positioned on either side of abutment face32and extend upwardly as viewed inFIG. 1. A projecting member38of clip retention portion14is engaged between deflectable posts34,36when clip retention portion14is rotated from the open position shown to a closed position in contact with clip receiving portion12. A distal end40of clip receiving portion12further includes an engagement aperture42which receives a hooked engagement device44having a deflectable hook member45of clip retention portion14. Hooked engagement device44is positioned at a retention portion distal end46. Deflectable hook member45engages within engagement aperture42to also assist in retaining clip retention portion14in contact with clip receiving portion12when clip10is in the closed position. Also in the closed position, a first positive engagement member48and a second positive engagement member50of clip retention portion14are positionable proximate to each of first and second channels16,18to further engage each of the elongated elements21positioned within first and second channels16,18. The rounded concave shape of each of first and second positive engagement members48,50is exemplary of a plurality of shapes that can be used depending upon the geometry of elongated elements21.

As further shown inFIG. 1, clip10includes a living hinge52integrally and homogenously joining clip receiving portion12to clip retention portion14. An angle α represents an angular range of rotation for clip retention portion14relative to clip receiving portion12when living hinge52remains intact. Angle α is measurable from a longitudinal axis53defining a center line of living hinge52and a center line of clip retention portion14. In the embodiment shown, angle α is at a maximum when a surface54of an end wall55of clip receiving portion12is contacted by a pin member56of clip retention portion14. It will be evident that angle α can range from 0° up to approximately 135°, or greater than approximately 135° depending upon the geometry and clearance provided between surface54and pin member56, as well as a length of living hinge52.

If living hinge52fails for any reason, pin member56is retained between a curved retaining element58and each of a pair of first and second retaining posts60,62(only first retaining post60is visible in this view). Each of curved retaining element58and first and second retaining posts60,62are integrally provided with clip receiving portion12. If living hinge52fails, clip receiving portion12can rotate relative to clip retention portion14up to a maximum rotation angle β. According to one aspect of the disclosure, maximum rotation angle β is at least 180 degrees and can range up to approximately 270 degrees. Maximum rotation angle β is functionally limited only by the geometry of pin member56within the channel defined by curved retaining element58and each of the pair of first and second retaining posts60,62, and can therefore exceed 270 degrees in alternate embodiments of the disclosure. Curved retaining element58and first and second retaining posts60,62are capable of retaining pin member56for any angle of rotation within the angular range of rotation of angle α and for any angle up to maximum rotation angle β.

Referring now toFIG. 2, an outer face64of clip retention portion14includes one or more raised stiles66and one or more raised rails68created during the forming process which define each of a plurality of partial cavities70. Partial cavities70are provided to eliminate “sink marks” during part cooling and to limit the weight and material costs of clip10while stiles66and rails68provide rigidity for clip retention portion14. A first connecting column72and a second connecting column74extend outwardly from a mating end76of clip retention portion14. Pin member56is integrally joined to each of first and second connecting columns72,74. Pin member56is positioned substantially perpendicular to a longitudinal axis75of clip retention portion14. A cavity78is created between each of first and second connecting columns72,74. Cavity78receives curved retaining element58of clip receiving portion12. Pin member56is therefore rounded to rotatably and slidably receive curved retaining element58.

In the as-molded condition of clip10, clip receiving portion12can be further connected to clip retention portion14by each of a first frangible element80and a second frangible element82. First frangible element80joins a distal end of first retaining post60to clip retention portion14. Similarly, second frangible element82connects a distal end of second retaining post62to clip retention portion14. Each of first and second frangible elements80,82are thin walled elements which break when clip retention portion14is rotated toward clip receiving portion12to close clip10. First and second frangible elements80,82provide a nominal angle α of approximately 90° which is suitable for automated machinery used to install clip10. Before first and second frangible elements80,82are broken, a first pin end84extends outwardly of first retaining post60and a second pin end86extends outwardly of second retaining post62. Each of first and second pin ends84,86extend past their respective retaining post by a dimension “A”. Also in this condition, a clearance “B” is provided between each of the first and second retaining posts60,62and the respective one of the first or second connecting column72,74. Extension dimension “A” and clearance dimension “B” permit relative displacement between clip receiving portion12and clip retention portion14in either of directions “C” or “D” after first and second frangible elements80,82and if living hinge52are broken. This allows for some degree of alignment to permit curved retaining element58to rotatably engage pin member56within cavity78and provides clearance for the various tooling elements that are used to mold clip10. A total clearance dimension “E” is provided between first and second retaining posts60,62. By maintaining extension dimension “A” at least equal to or greater than each clearance dimension “B”, either first or second connecting column72,74will contact first or second retaining posts60,62without losing the retention capability of first or second pin ends84,86with respect to first and second retaining posts60,62.

As best seen in reference toFIG. 3, curved retaining element58extends radially outward from end wall55. In the as-formed condition shown, a portion of curved retaining element58is positioned within cavity78. A connecting leg88integrally joins second retaining post62to a member outer wall90of clip receiving portion12. A channel wall92of first channel16is spatially separated from member outer wall90by a plurality of cavities94. Cavities94are provided to eliminate “sink marks”, and reduce an overall weight and material costs of clip10. Each of cavities94end approximately at a central location of clip receiving portion12at a central wall95positioned therein. Pin member56is provided with a curved outer face96which closely matches a curvature of curved retaining element58and a curvature of each of first and second retaining posts60,62. After first and second frangible elements80,82break, curved outer face96can smoothly contact curved retaining element58during rotation of clip retention portion14and clip receiving portion12about living hinge52. Because each of first and second retaining posts60,62extend to first and second frangible elements80,82and curved retaining element58extends beyond each of first and second connecting columns72,74, pin member56is enclosed. If living hinge52breaks in addition to first and second frangible elements80,82, pin member56is retained by first and second retaining posts60,62and curved retaining element58for any angle α and up to maximum rotation angle β.

Referring now toFIG. 4, curved outer face96of pin member56is more readily visible with respect to each of a curved post face98of first retaining post60and a curved post face99of second retaining post62. Pin member56also includes a smooth arc surface100proximate to a sliding engagement area with curved retaining element58. A retention device101is therefore created from each of the components of pin member56, curved retaining element58, first and second connecting columns72,74, and first and second retaining posts60,62. Retention device101functions to prevent disassociation of clip receiving portion12from clip retention portion14when first and second frangible elements80,82and/or living hinge52break.

Referring now generally toFIG. 5, living hinge52is integrally joined to pin member56with a first hinge end102and to member outer wall90with a second hinge end104. In the embodiment shown, first hinge end102is radiused at its intersection with pin member56, which provides a greater cross-section of first hinge end102compared to second hinge end104(which can include a small radii at pin member56), this greater cross-section is adjustable by the designer to control the rotation point of living hinge52between pin member56and member outer wall90. The geometry of living hinge52can also be varied from that shown to alter the rotation point of living hinge52at the discretion of the designer. To further reduce the overall weight of clip10, portions of each of first and second pin ends84,86can be eliminated. In the embodiment shown, a flattened face106which is substantially coplanar with an edge face108of clip receiving portion12is recessed from first pin end84. A similar flattened face is provided proximate to second pin end86to reduce the amount of material of first and second pin ends84,86. As further evident fromFIG. 5, in the event that both first and second frangible elements80,82and living hinge52are broken, pin member56is retained between curved retaining element58and a shelf or bracket110positioned substantially perpendicular to member outer wall90.

Referring next toFIG. 6, clip10is shown in the closed condition having living hinge52still intact. To reach the closed condition, first and second frangible elements80,82(if provided) are broken upon initiation of rotation of clip retention portion14relative to clip receiving portion12. Remaining portions80′,82′ of broken first and second frangible elements80,82are shown. Projecting member38is frictionally engaged between deflectable posts34,36. First and second positive engagement members48,50are operable in the closed condition to engage elongated elements21. In alternate embodiments, additional projecting member(s)38are positionable between any two proximate channels such as first and second channels16,18to provide additional engagement force for additional positive engagement members. Deflectable hook member45of hooked engagement device44latches with a shoulder created in engagement aperture42. Should living hinge52fail in the closed condition, curved outer face96of pin member56remains in contact with curved retaining element58to positively retain elongated elements21.

According to a preferred embodiment of the present disclosure, clip10is preferably formed using an injection molding process using a polymeric material such as Acetal (for example DELRIN® 100P) (polyoxymethylene acetal) available from the DuPont Corporation. In addition to Acetal, nylon material such as ZYTEL® (thermoplastic polyamide) can also be used. A thickness of living hinge52can vary from approximately 0.4 mm to approximately 0.55 mm in one aspect of the disclosure, however, the disclosure is not limited to specific dimensions for living hinge52. In one preferred embodiment of the present disclosure, a quantity of two retaining posts such as first and second retaining posts60,62are provided. The disclosure can also include only one retaining post or more than two retaining posts (not shown). The embodiment shown inFIG. 1having two channels, i.e. first and second channels16,18is exemplary of a plurality of possible clip embodiments. The quantity of channels can vary from one to greater than 5 at the discretion of the designer. The quantity of mounting posts22,23can also be varied from that shown herein. A minimum of zero and a maximum of greater than 2 mounting posts can be used and the mounting post(s) can also be mounted to clip retention portion14without departing from the gist of the disclosure. The embodiment of the disclosure depicted in the Figures herein is therefore exemplary of multiple embodiments of the present disclosure which each can benefit from a retention device of the present disclosure. Although the injection molding process is identified for use in a preferred embodiment of the present disclosure, other processes suitable for molding polymeric materials can be used.

Referring now toFIG. 7, a clip112is similar to clip10and therefore the differences will be further discussed. Clip112can be made from the same materials as clip10and also defines a homogenous molded part. Clip112includes a clip receiving portion114and a clip retention portion116. Clip receiving portion114includes a first channel118and a second channel120. Each channel further includes a necked-down region122. First and second raised elements124(124′) and126(126′) are provided in first and second channels118,120to assist in gripping elongated element21(not shown in this view) such as a wire, a wiring harness, or a tubular member such as a fuel or break line for an automobile vehicle. Clip112is modified from clip10to include only a single mounting post128extending from a surface130opposed to first and second channels118,120. Mounting post128is similar in design and function to first and second mounting posts22,23of clip10.

Clip receiving portion114further includes an abutment feature132positioned between each of first and second channels118,120which is modified from abutment face32of clip10by eliminating deflectable posts34and36. A receiving channel134of clip retention portion116receives abutment feature132when clip retention portion116is rotated from the open position shown to a closed position in contact with clip receiving portion114. An engagement end136of clip receiving portion114is similar to distal end40of clip10and further includes an engagement aperture138which receives a hooked engagement device140having a deflectable hook member142of clip retention portion116. Hooked engagement device144is positioned at a retention portion distal end144. Deflectable hook member142engages within engagement aperture138to also assist in retaining clip retention portion116in contact with clip receiving portion114when clip112is in the closed position. Also in the closed position, a first positive engagement member146and a second positive engagement member148of clip retention portion116are positionable proximate to each of first and second channels120,118respectively to further engage each of the elongated elements positioned within first and second channels118,120.

As further shown inFIG. 7, clip112includes a living hinge150integrally and homogenously joining clip receiving portion114to clip retention portion116. A curved retaining element152is provided similar to curved retaining element58of clip10. Clip112is further modified from clip10by eliminating the pair of first and second retaining posts60,62and first and second frangible elements80,82.

Application of clips10and112of the present disclosure is also not limited to the examples given herein. For example, clips10and112can be used in addition to automotive applications in multiple applications including but not limited to aircraft, ships, trains, computer systems, etc. The shape of first and second channels16,18is not limited to the generally circular shape described herein. Other shapes such as rectangular, oval, triangular, etc. can also be used. The embodiment shown herein having an angle α of approximately 90° for the as-formed condition is particularly beneficial for applications where automated machinery is used to install clips10or112. This angle can also be varied at the discretion of the designer depending upon the intended application, the type of automated installation equipment used, or if manual assembly of clip10is anticipated. Angle α and maximum rotation angle β can also be controlled at the discretion of the designer for a specific application of clips10or112by varying the geometry of the various components of retention device101.

A hinged clip having a retainer of the present disclosure offers several advantages. The retainer of the present disclosure is functional for any orientation of the first and second clip members. The retainer is therefore functional to provide for engagement of the two clip members even if the living hinge fails during shipment or before installation of the clip as well as after installation. The retainer of the present disclosure also maintains the necessary clamping force between the two clip members and the elongated article(s) if the living hinge fails after the clip is installed. The hinged clip of the present disclosure also accommodates installation tolerances of the elongated articles.