Extruded fastener and method for making same

An extruded integrated fastener assembly comprising a plurality of fasteners cut to length from an extruded length of material. Unwanted areas of material are cut away leaving the individual fasteners, which fasteners are also connected together by an expanse of material that remains. The fastener assembly can be single durometer or double durometer. A profile with retention members and/or leg features are formed in the fasteners for connecting to a predetermined component. The process for manufacturing the extruded integrated fastener assembly includes providing fabrication tooling suitable to cut away the unwanted area between the fasteners. The fasteners are thereby able to be cut to any desired length.

FIELD OF THE INVENTION

The present invention relates to an integrated fastener and process for manufacturing same.

BACKGROUND OF THE INVENTION

Current extruded fasteners, such as extruded push pins and attachment clips or attachment clip strips, are rather expensive to manufacture. The process for manufacturing can also be time consuming. One common method is molding push pins. In addition, the fasteners do not have adequate retention. There is also less capability for effectively and efficiently changing the fastener length, when desired. Typical fasteners are also individual pieces that may become lost easier or be undesirable for certain applications.

Therefore, it is desirable to have an integrated fastener and method for making same which incorporates fabrication tooling for the integrated fastener to be cut to any desired length.

SUMMARY OF THE INVENTION

The present invention is generally directed to an extruded integrated fastener with at least two fasteners, preferably, push pin fasteners. A continuous strip of predetermined profile is extruded. By way of non-limiting example, the extrusion includes a wider upper portion which is integrally formed with a lower depending portion having a plurality of grippers extending longitudinally along the lower depending portion of the continuous extrusion. Fabrication tooling is provided to form the integrated fastener. Preferably, to fabricate notches of predetermined width along the longitudinal length of the lower depending portion or “extending portion” to form a series of fasteners (most preferably, push pins) that are connected only to the wider upper portion, e.g., to gang parts together. The fabrication tooling cuts away the unwanted area on either side of each fastener. The fasteners can thereby be cut to any predetermined desired length depending on the application.

The process in accordance with the present invention provides improved costs in manufacturing, e.g., about ¼ the cost of conventional fabrication. The product also has improved retention. And the fasteners are ganged or linked together by a strip of the extruded material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-2depict an example of a conventional individual push pin. The larger head1is square, but other conventional push pins have round, C-shaped, etc heads. The body is a narrower shaft2with teeth3or other shaft retaining feature such as circumferential threads.

Referring toFIGS. 3-18generally, in accordance with the present invention there is provided an extruded integrated fastener assembly, e.g., most preferably, push pins, linked together by an expanse of material, and a process for manufacturing same. It is understood that the fastener comprises any predetermined profile suitable for retention and predetermined properties depending on the particular application without departure from the scope of the present invention. By way of non-limiting example, each extruded integrated fastener assembly incorporates one or more fastener types which are push pins, attachment clips, Christmas tree fasteners, pop rivets, push rivets, clip fasteners, or any other suitable fastener and profile, etc and any combination of fasteners.

Referring more particularly toFIGS. 3-9generally, in accordance with the present invention there is provided the extruded integrated fastener assembly shown generally at10including the at least two fasteners12(e.g., most preferably, push pins of predetermined width, depth, length and durometer(s) depending on the particular application) linked together by an expanse of material14. During fabrication, the extrusion is a continuous piece and the predetermined tooling cuts away the unwanted areas of the fasteners12, e.g., push pins, most preferably clip fasteners, forming at least an upper portion16and a lower portion, shown generally at18. The extruded continuous piece has a predetermined profile depending on the particular application. The fasteners can be any desired length “L” depending on the particular application. The lower portion18of the extrusion additionally has at least one retention member, preferably has a plurality of retention members20. Most preferably, the retention members20are grippers. These grippers20can be in parallel rows along the longitudinal length of the sides of the fasteners12(e.g., seeFIGS. 6-7), or, offset from each other (e.g., seeFIGS. 8-9).

After being extruded, the continuous strip is notched out or otherwise cut to define individual fasteners12. In particular, the lower depending portion of the strip is cut out at predetermined intervals to form gaps, shown generally at22, in the extrusion. These gaps have a predetermined width “W” that define the space between the lower portions18of adjacent fasteners12, and thereby the depth “D” of each fastener lower portion18. The predetermined width “W” of the gaps22between adjacent fasteners12,12depends on the particular application. The gaps22have a height “H” that defines height of the lower portions18from the underside of the upper portion16. The predetermined length L and predetermined depth D of the fasteners12depend on the particular application. The upper portion16of the continuous strip10is also cut away at predetermined intervals to define the distance between the top16of each fastener12and the width of each expanse of material14that chains adjacent fasteners12together.

Alternatively, the top portion16of the continuous strip is not cut, but rather links the plurality of fasteners18together without a narrower expanse of material providing the assembly10. Thus, the expanse of material14would be a seamless continuous portion of the upper portion16when viewed from a top plan view.

The assembly10is a single durometer or a dual durometer, depending on the application.

FIG. 6depicts the fastener12with exemplary single durometer fastener materials, e.g., hard material suitable for retention, and substantially parallel grippers20. An inner portion24or stem is the same durometer as the grippers20.

FIG. 7depicts the fastener12with exemplary dual durometer fastener materials. The grippers20aare preferably thicker than the single durometer fastener. The durometer of the grippers20ais different than the inner portion24. Most preferably, the inner panel24of the fastener is a harder durometer material than the grippers20a.

FIG. 8depicts the fastener12with exemplary single durometer fastener materials, e.g., harder material, which is identical toFIG. 6except that the fastener inner panel24ais longer, and the fastener12has offset grippers20b.

FIG. 9depicts the fastener12with exemplary dual durometer materials, which fastener is identical toFIG. 7except that the fastener inner panel24ais longer. The grippers20care preferably thicker than the single durometer fastener. The durometer of the grippers20cis different than the inner portion24a. Most preferably, the inner panel24aof the fastener is a harder durometer material than the grippers20c.

The process of the present invention provides the extruded integrated fastener with at least two push pins. A continuous strip of predetermined profile is extruded. By way of non-limiting example, the extrusion includes a wider upper portion integrally formed with a lower extending portion with a plurality of grippers along the longitudinal axis of the continuous extrusion. Fabrication tooling is provided to form the integrated fastener. In particular, to fabricate notches of predetermined width along the longitudinal axis of the lower extending portion to form fasteners that are connected only at the upper portion, e.g., to gang parts together. The fabrication tooling cuts away the unwanted area on either side of each push pin. The pins can thereby be cut to any predetermined desired length depending on the application.

The process in accordance with the present invention provides improved costs in manufacturing, e.g., at least about ¼ the cost of conventional fabrication. The product also has improved retention properties. In addition, there are no loose pieces since the fasteners are ganged together. Another significant advantage is the incorporation of single or multiple durometers and various retention features.

In use, a final assembly10of predetermined length, depending on the application, is used, e.g., cut to length suitable for attachment to a vehicle part. Each final assembly has at least one fastener, preferably, at least two fasteners, most preferably, more than two fasteners.

FIG. 10illustrates another prior art fastener50that has a depressible part52that compresses to a closed position for retention.

FIG. 11illustrates legs compressible legs102,102of an extruded integrated fastener assembly, according to the present invention, overlaid over the conventional fastener50, for illustration.

Referring now more particularly toFIGS. 12-18generally, the extruded integrated fastener assembly indicated generally at100includes at least two fasteners shown generally at104, e.g., preferably, attachment clips, forming the lower portion of the assembly100. The legs102of each include a step portion106. After the legs102are pushed from one side of a part101through a slot108, sheet metal slot formed in the part, the legs102expand outward and each step portion106retains the legs102on the within the slot108. An upper portion110of the assembly is a continuous piece that links the fasteners104together. The upper portion110includes opposing side legs112,114that contact the top of the sheet, e.g., metal sheet in which the slot is formed108. Each fastener104is cut to a predetermined width, length and depth.

Generally, the process of manufacturing is substantially identical as described previously, except that the fastener has legs102that are operably formed (or operably cut out) and have no grippers. The process for forming the assembly100is identical as set forth previously, wherein, in general, the continuous strip with predetermined profile is extruded and then cut out in the lower portion to define the distance between each individual fastener104(and the length of each fastener104in the longitudinal direction).

Referring more particularly toFIGS. 13-14generally, the assembly100is substantially identical as shown and described previously, except that the opposing legs212,214are longer legs for built-in interference, and, a hinge216, preferably, a small longitudinal recess or channel or notch, is also formed in the lower surface of the upper portion110between the legs102,102. This hinge216predicts the flex point. The upper portion110of the assembly is a continuous piece that links the fasteners104together. The legs102,102are preferably longer to coordinate with the longer212,214. The opposing side legs212,214contact the top of the sheet, e.g., metal sheet in which a slot is formed108. The opposing legs212,214are longer legs (e.g., longer thanFIG. 12, for example) for built-in interference. The fastener104is pushed through the slot108and a downward force “F” on the upper surface of the upper portion110opposite the hinge216causes the legs to push out further in an engagement direction. Each step portion106retains the legs102within the slot108. Each fastener104is cut to a predetermined width. The process for forming the assembly is identical as set forth previously, wherein, in general, the continuous strip with predetermined profile is extruded and then cut out in the lower portion to define the distance between each individual fastener104(and the length of each fastener104in the longitudinal direction).

Referring toFIGS. 15-16generally, the extruded integrated fastener assembly indicated generally at100includes at least two fasteners shown generally at104, e.g., attachment clips, forming the lower portion of the assembly100. Legs102of each include a step portion106. A hinge216, preferably, a small longitudinal axis recess or channel or notch, is formed in the lower surface of an upper portion310between the legs212,214. This hinge216predicts the flex point. The upper portion310has a reverse blow to assist the fastener104to insert easier. The upper portion310of the assembly is a continuous piece that links the fasteners104together. The upper portion310also includes opposing side legs212,214that contact the top of the sheet, e.g., metal sheet in which a slot is formed108. The opposing legs312,314are longer legs for built-in interference. Each fastener104is pushed through a respective slot108and a downward force “F” on the upper surface of the upper portion310opposite the hinge216causes the legs to push out further in an engagement direction.FIG. 15depicts the legs102,102compressed as the fastener104is pushed through the slot108. Each step portion106retains the legs102,102within the slot108. Each fastener104is cut to a predetermined width. Preferably, the legs102,102to accommodate the reverse bow, than the substantially flat upper portion. The process for forming the assembly is identical as set forth previously, wherein, in general, the continuous strip with predetermined profile is extruded and then cut out in the lower portion to define the distance between each individual fastener104(and the length of each fastener304in the longitudinal direction).

In use, a final assembly10,100of predetermined length, depending on the application, is used, e.g., cut to length suitable for attachment to a vehicle part. Each final assembly has at least one fastener, preferably, at least two fasteners, most preferably, more than two fasteners (e.g., seeFIG. 18broken along the length indicating that the final assembly can be any predetermined length suitable for the application.

It is understood that the legs112,114,212,214,102,104described or shown throughout the application can be any predetermined lengths and combinations of lengths depending on the particular applications without departure from the scope of the present invention. By way of non-limiting example, when the opposing legs212,214of the upper portion are longer, the corresponding legs102,102of the fastener are operably longer.