Fasteners and Geometry for Casting Attachment

Disclosed is a retainer to couple a first component to a second component having a rib via a male fastener. The retainer includes a body portion, one or more tabs coupled to the body portion; and retention clips resiliently coupled to the body portion. The body portion includes or defines a female fastener to receive the male fastener. The one or more tabs and at least one of the plurality of retention clips cooperate to define a cavity to receive the rib. The plurality of retention clips is arranged to engage and retain the rib within the cavity. In some examples, the retainer is a stamped retainer clip.

BACKGROUND

Automotive components require fastening techniques that are simple to manufacture and assemble. Further, fastening techniques should above all be reliable and efficient. A retainer clip can be used to make a connection between components, such as automotive panels.

While the applications can vary greatly, such retainer clips are sometimes used to attach one component (e.g., a panel) to another component (e.g., a frame or other support structure). For example, in the context of automotive manufacturing, a frame is a structure that serves as a backbone of a vehicle or component thereof, providing support and a rigid structure to which other components, such as the engine, suspension, interior components, and body panels, are attached. Traditionally, such frames and other vehicular support structures were fabricated using metal tubing (e.g., square or rectangular tubing) and/or sheet metal that is bent, welded, and/or otherwise joined to one another to form a frame or other support structure. Often, these structures would include one or more openings configured to receive a retainer clip.

In recent years, however, there has been a shift from tubular and/or sheet metal based structures to structures to cast structures. A cast structure, in an automotive context, refers to a vehicle frame or chassis that is produced using a casting process. The choice of metal for casting can vary but often includes materials like iron or aluminum. Given the nature of cast structures, manufacturers are less inclined to cut, drill, or otherwise form openings configured to receive a retainer clip.

Therefore, despite advancements to date, it would be highly desirable to have a retainer clip that is configured to attach to a structure without requiring an opening formed therein.

SUMMARY

The present disclosure relates generally to a fastening system to form a connection between two components, such as vehicular components, using a retainer clip, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims.

DESCRIPTION

References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within and/or including the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. In the following description, it is understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” and the like are words of convenience and are not to be construed as limiting terms. For example, while in some examples a first side is located adjacent or near a second side, the terms “first side” and “second side” do not imply any specific order in which the sides are ordered.

The terms “about,” “approximately,” “substantially,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the disclosure. The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the disclosed examples and does not pose a limitation on the scope of the disclosure. The terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed examples.

Disclosed is a retainer clip configured to attach to a structure without requiring an opening formed therein. In some examples, the retainer clips can be captured at one end in an opening or doghouse structure of a first component and packaged as a part-in-assembly (PIA).

In one example, In one example, a retainer to couple a first component to a second component having a rib via a male fastener comprises: a body portion having formed therein a female fastener, wherein the female fastener is configured to receive the male fastener; one or more tabs coupled to the body portion; and a plurality of retention clips resiliently coupled to the body portion, wherein the one or more tabs and at least one of the plurality of retention clips cooperate to define a cavity configured to receive the rib, and wherein the plurality of retention clips is arranged to engage and retain the rib within the cavity.

In another example, a retainer assembly to couple a first component having an opening to a second component having a rib comprises: a male fastener configured to pass at least partially through the opening formed in the first component; and a retainer having a body portion, one or more tabs, and a plurality of retention clips, wherein a female fastener is formed in the body portion and is configured to receive the male fastener; wherein the plurality of retention clips is resiliently coupled to the body portion, wherein the one or more tabs and at least one of the plurality of retention clips cooperate to define a cavity configured to receive the rib, and wherein the plurality of retention clips is arranged to engage and retain the rib within the cavity.

In yet another example, a retainer to couple a first component to a second component having a rib via a male fastener comprises: a body portion having formed therein a female fastener, wherein the female fastener is shaped as a collar with a plurality of grooves formed on an inner sidewall surface thereof and configured to receive the male fastener; one or more tabs coupled to the body portion; and a first retention clip, a second retention clip, and a third retention clip resiliently coupled to the body portion, wherein the first retention clip and the third retention clip are configured to pinch, scrape, dig into, or otherwise grip the rib to mitigate pullout, and wherein the first retention clip and the second retention clip cooperate to define a flared opening to the cavity configured to guide a distal end of the rib into the cavity.

In some examples, the female fastener is shaped as a collar with a plurality of grooves formed on an inner sidewall surface thereof.

In some examples, the body portion defines a set of shoulders configured to engage a doghouse structure.

In some examples, the plurality of retention clips defines a set of clips guide members configured to guide a distal end of the rib into the cavity.

In some examples, the clip tab is canted into the cavity and configured to engage the rib. In some examples, the retainer is a stamped retainer clip.

In some examples, the plurality of retention clips comprises a first retention clip, a second retention clip, and a third retention clip. The first retention clip can comprise a clip tab formed therein. The first retention clip and the third retention clip can be configured to pinch, scrape, dig into, or otherwise grip the rib to mitigate pullout. The first retention clip and the second retention clip can cooperate to define a flared opening to the cavity configured to guide a distal end of the rib into the cavity.

FIGS.1athrough1dillustrate a fastening system100configured to couple a first component102relative to a second component104via a retainer clip106in accordance with an aspect of this disclosure. The first component102is omitted from Figures la and1bfor illustrative purposes, but is illustrated inFIGS.1cand1d. More specifically, Figure la illustrates an isometric assembly view of the fastening system100in accordance with an aspect of this disclosure, whileFIG.1billustrates an assembled isometric view of the fastening system100.FIG.1cillustrates an elevation assembly view of the fastening system100in accordance with an aspect of this disclosure, whileFIG.1dillustrates an elevation assembled view of the fastening system100.

The illustrated fastening system100includes the first component102, the second component104, and a retainer assembly110. The retainer assembly110is configured to join the first component102and the second component104. To facilitate attachment via the retainer assembly110, each of the first component102and the second component104can include one or more engagement features. For example, the first component102is illustrated as having an opening116formed therein and the second component104is illustrated as having one or more ribs108from on a surface thereof. For example, the one or more ribs108protrude perpendicularly from a surface of the second component104, which may be a cast structure.

The opening116can be formed in the first component102during manufacturing thereof or added post-manufacture through a mechanical process (e.g., drilling, cutting, carving, etc.). Each rib108(sometimes called a blade, tower or protrusion) may be shaped as a planar tab or continuous ridge. Depending on the material type, the one or more ribs108may be formed during casting, molding, or layup of the second panel104, or attached after fabrication (e.g., using adhesive or mechanical fasteners). After the first component102and the second component104are assembled, as best illustrated inFIGS.1band1d, the second component104is covered at least partially by the first component102.

The retainer assembly110is illustrated as a multi-component retainer clip assembly having a male fastener112(e.g., a fastener head112awith an externally-threaded shank112b, such as a bolt) and a retainer clip106(e.g., a metal retainer clip), The retainer clip106defines or otherwise comprise a female fastener122(e.g., an internally-threaded component, such as a threaded collar). The retainer clip106is configured to mechanically engage and couple with the first component102via the male fastener112passing through the opening116to engage the female fastener122. The retainer clip106is configured to mechanically engage and couple with the second component104via the rib108and, as will be discussed, engagement features formed on the retainer clip106.

It is contemplated that certain components of the retainer assembly110may be fabricated as a stamped-metal component using a metal-stamping technique. For example, the retainer clip106can be fabricated from a single sheet of metal and stamped/bent using a metal-stamping technique, while the male fastener112can be fabricated from metal via one or more metal-shaping techniques, such as cold forging. In another example, the retainer clip106can be fabricated as a stamped-metal component, whereas the male fastener112can be fabricated from a plastic material using a plastic injection technique, additive manufacturing, or otherwise. To is contemplated, however, that the retainer clip106could also be fabricated using material extrusion (e.g., fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), material jetting, binder jetting, powder bed fusion, directed energy deposition, VAT photopolymerisation, and/or any other suitable type of additive manufacturing/3D printing process.

The first component102and the second component104may be, for example, automotive panels or other automotive components. Depending on the application, one or both of the first component102and/or the second component104may be fabricated from, for example, metal (or a metal alloy), synthetic or semi-synthetic polymers (e.g., plastics, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials (e.g., fiber glass), or a combination thereof. In the automotive industry, example first components104include, without limitation, door trim panels, moldings, trim pieces, and other substrates (whether used as interior or exterior surfaces). The second component104may be, for example, a frame, an automotive panel, a structural component of a vehicle, such as doors, pillars (e.g., an A-pillar, B-pillar, C-pillar, etc.), dashboard components (e.g., a cross member, bracket, frame, etc.), seat frames, center consoles, fenders, sheet metal framework, or the like. Depending on the application, the first component102and/or the second component104may be fabricated from, for example, metal (or a metal alloy), synthetic or semi-synthetic polymers (e.g., plastics, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials (e.g., fiber glass), or a combination thereof. In some examples, one or both if the first component102and the second component104are formed using a casting process, which involves pouring molten metal into a mold to create the desired shape. In the case of a cast automotive frame, the metal is typically cast into a mold that represents the frame's structure.

The retainer106can be attached to the rib108vertically. During installation, as best illustrated inFIGS.1aand1c,the retainer clip106is slid over the rib108of the second component102as indicated by arrow114and to engage the rib108via an interference fit. Once the retainer clip106is installed, an end of the male fastener112is passed through both the opening116formed in the first component102and an opening120formed in the retainer clip106as indicated by arrow118to ultimately to access and engage the female fastener122.

The male fastener112can be rotated relative to the female fastener122about its axis of rotation124to join and compress the first component102relative to the retainer clip106. As will be described in greater detail, the retainer clip106includes one or more engagement features to attach or otherwise engage the first component102and/or second component104. During assembly/disassemble, the male fastener112and the female fastener122utilize the rib108for anti-rotation to achieve bolt or stud torque.

In the illustrated example, the male fastener112is a threaded bolt with a hex-shaped head, but other types of fasteners are contemplated. In some examples, the retainer clip106may comprise a seal when desirable to mitigate dust, dirt, and/or moisture penetration through the openings116,120. The seal may be embodied as a ring (e.g., an annulus) and fabricated from foam material, thermoplastic, rubber, etc. For example, a seal can be configured to surround a portion of the male fastener112(e.g., the shank112b) and positioned between the fastener head112aand the first component102and/or between the first component102and the retainer clip106.

FIGS.2aand2billustrate, respectively, first and second topside isometric views of the retainer clip106ofFIGS.1athrough1d,whileFIGS.2cthrough2fillustrate first, second, third, and fourth side elevation views of the retainer clip106.FIGS.2gand2hillustrate, respectively, top and bottom plan views of the retainer clip106.FIG.2iillustrates a cross-sectional view of an assembled fastening system100taken along cut line A-A (FIG.1b). Once advantage of the disclosed retainer106is that it provides a serviceable attachment between the first component102and the second component104that have one or more ribs108(such as plastic or cast materials). The retainer106may be fabricated in various sizes depending on the application.

The retainer106may be a stamped retainer clip. For example, a flat sheet of metal may be stamped (e.g., die stamped) to define the outer perimeter, profile, and cutouts to define the various features of the retainer106. After stamping, the flat sheet of metal may be bent along one or more lines or at one of more points through one or more steps to define the retainer106.

As illustrated, the retainer106generally comprises a body portion202, a pair of tabs204, and a plurality of resiliently-attached retention clips. As used herein, components or portions of the retainer clip106are said to be resiliently connected when the components or portions default (e.g., spring back) to a predetermined shape. For example, during assembly, the components or portions may be biased (e.g., pushed) inward and/or outward, but, in the absence of such external forces, return to the default shape.

In the illustrated example, the body portion202is generally planar and, upon assembly, configured to abut an underside of the first component102. The body portion202defines the opening120through which the male fastener112passes to engage the female fastener122. In the illustrated example, the female fastener122is shaped as a collar with a plurality of grooves formed on the inner sidewall surface206. The plurality of grooves correspond to the externally-threaded shank112b.A noted above, the retainer106can be fabricated from a single sheet of metal that is stamped, bent, and extruded to form the body portion202, a pair of tabs204, and a plurality of resiliently attached clips; therefore, while described as separate elements, the retainer106can remain a single, integrated structure.

In the illustrated example, the body portion202is coupled to a plurality of resiliently-attached retention clips, including a first retention clip208, a second retention clip210, and a third retention clip212. In operation, the first retention clip208, the second retention clip210, and the third retention clip212cooperate to engage and attach to the rib108. For example, one or more of the first retention clip208, the second retention clip210, and the third retention clip212can include one or more clip tabs to pinch, scrape, dig into, or otherwise grip the rib108. For example, as will be discussed, the retainer106can engage the rib108by one or more clip tabs digging into the rib108, or a through-window can be placed in the rib108for the one or more tabs to snap into or otherwise engage to yield an even higher retention. In addition, the retainer106has features for stabilizing it against the rib108in addition to one or more tabs digging in, such as a pair of tabs204. The illustrated pair of tabs204are substantially perpendicular to the body portion202.

The illustrated first retention clip208comprises a leg214and a guide member216. The leg214can be parallel to the pair of tabs204or, as illustrated, canted inward toward the pair of tabs204to help pinch the rib108. In some examples, the leg214can be canted inward toward the pair of tabs204by an angle that is 2 to 15 degrees, or about 5 to 10 degrees. As best illustrated inFIGS.2e,2f, and2i, the leg214and the pair of tabs204define a cavity218configured to receive and, ultimately, retain the rib108.

The leg214further comprises a clip tab220formed therein (e.g., via a die punch) that is canted inward (i.e., into the cavity218). The guide member216is angled to help guide a distal end of the rib108into the cavity218. During and post assembly, the clip tab220is configured to pinch, scrape, dig into, or otherwise grip the rib108to mitigate pullout.

The illustrated second retention clip210comprises a pair of legs222and a guide member224. In some examples, each of the pair of legs222is bent at one or more locations along its length to define a side profile that is generally J-shaped. In the illustrated example, each leg222defines a first linear segment222a,a second linear segment222b,and a third linear segment222c.Each of the pair of legs222is resiliently coupled to the body portion202at a first end (e.g., via the first linear segment222a) and to the guide member224at a second end (e.g., via the third linear segment222c). As illustrated, each end of the guide member224is coupled to a leg222via its third linear segment222c.The guide member224is substantially perpendicular to the third linear segments222c.The guide member224is angled to help guide a distal end of the rib108into the cavity218. As best illustrated inFIGS.2eand2f, the guide members216,224cooperate to define a flared opening to the cavity218, thus allowing for a degree of misalignment during assembly as the guide members216,224guide the distal end of the rib108into the cavity218. The flexible nature of the retainer106and angles of the guide members216,224permit a relatively low insertion force required to insert the rib108into the retainer106. In some example, the insertion force may be about two pounds. The second linear segment222bis substantially parallel to the body portion202and, in some examples, can serve as a base that contacts the second component104to increase stability.

The illustrated third retention clip212is bent at one or more locations along its length to define a first linear segment212a,a second linear segment212b,and a third linear segment212c,which serves as a clip tab. As best illustrated inFIG.2i, the third linear segment212ccooperates with the clip tab220to pinch, scrape, dig into, or otherwise grip the rib108to mitigate pullout. As illustrated inFIG.2b, the material use to form the third retention clip212can be punched from the second retention clip210(e.g., the area bounded by the material used to form the pair of legs222and the guide member224). In some examples, the third retention clip212comprises a fastener pass-through opening226to allow the distal end of the shank112bof the male fastener112to pass through the third retention clip212when tightened without interfering with or otherwise affecting the third retention clip212. In other examples, the fastener pass-through opening226can be omitted such that the male fastener112engages the third retention clip212to bias it in a desired manner.

In the illustrated example, the retainer106defines a clip tab220and a third linear segment212cthat engages the rib108; however, it is to be understood that the retainer106may comprise any number of components that engage the rib108. For example, two or more clip tabs220and/or two or more third linear segments212c.Further, in some examples, one or more features can be formed in or on the surface of the rib108to increase friction. For example, the rib108may comprise one or more bumps, recesses, apertures, or ledges to increase friction between the rib108and the clip tab220, the third linear segment212c,etc.

FIGS.3athrough3dillustrate a fastening system100configured to couple a first component102relative to a second component104via a retainer clip106using a doghouse structure in accordance with another aspect of this disclosure. More specifically,FIG.3aillustrates an isometric assembly view of the fastening system100in accordance with an aspect of this disclosure, whileFIG.3billustrates an assembled isometric view of the fastening system100.FIG.3cillustrates an elevation assembly view of the fastening system100in accordance with an aspect of this disclosure, whileFIG.3dillustrates an elevation assembled view of the fastening system100.

The fastening system100ofFIGS.3athrough3dis substantially the same as the fastening system100of Figures la through1dexcept that the retainer clip106ofFIGS.3athrough3dis configured to further engage the first component102via a doghouse structure302. Therefore, in this example, the retainer clip106defines a set of shoulders308, while the first component102may include or define, the doghouse structure302. A doghouse structure302allows for the first component102to be used with a wide variety of fasteners, including the retainer clip106. In addition, the retainer clip106can be preinstalled on the first component102via the doghouse structure304to be packaged and shipped as a part-in-assembly (PIA), thus reducing time and effort needed during assembly by an end-user.

As illustrated, the doghouse structure302is composed of a set of doghouse sidewalls304defining the receptacle306therebetween. The receptacle306is size and shaped to receive a portion of the retainer clip106. The doghouse sidewalls304may include one or more features shaped to increase engagement with the retainer clip106and/or serve as stops for the retainer clip106, such as interference features310that engage the set of shoulders308. In some examples, the interference features310may exhibit a soft click as the retainer clip106is secured in the receptacle306. The doghouse structure302may be molded during molding of the first component102; however, in some examples, they may be fabricated separately and later joined to one another (e.g., using adhesive, mechanical fasteners, etc.). The doghouse structure302is contemplated to be modified in size and shape to suit individual applications. For example, while illustrated with two opposing doghouse sidewalls304, in some examples, the doghouse structure302may further include a doghouse end wall formed to bridge the gap between the set of doghouse sidewalls304.

FIGS.4aand4billustrate, respectively, first and second topside isometric views of the retainer clip106ofFIGS.3athrough3d,whileFIGS.4cthrough4fillustrate first, second, third, and fourth side elevation views of the retainer clip106.FIGS.4gand4hillustrate, respectively, top and bottom plan views of the retainer clip106.FIG.4iillustrates a cross-sectional view of an assembled fastening system100taken along cut line B-B (FIG.3b).

The retainer clip106ofFIGS.4athrough4iis substantially the same as the retainer clip106ofFIGS.2athrough2iexcept that the retainer clip106ofFIGS.4athrough4icomprises the set of shoulders308configured to engage the doghouse structure302once the retainer clip106is position in the receptacle306. In addition, a portion of each of the pair of tabs204is bent (e.g., by90degrees in the illustrated example) to define a flange402that is configured to mitigate rattling, scraping, and/or damage to the first component102and/or doghouse structure302when inserted and/or housed within the doghouse structure302.

FIG.5illustrates a topside isometric view of a retainer clip106in accordance with yet another aspect of this disclosure. The retainer clip106ofFIG.5is substantially the same as the retainer clip106ofFIGS.4athrough4iexcept that the retainer clip106ofFIG.5comprises one or more barbs502in addition to or in lieu of the flat edges of the above-described clip tab220and the third linear segment212c.The one or more barbs502enable the first retention clip208and the second retention clip210to pinch, scrape, dig into, or otherwise grip the rib108more aggressively. The retainer clip106further comprises one or more alignment features504to serve as, for example, a poke-yoke feature to prevent or mitigate human error during assembly. For example, the one or more alignment features504can be configured to engage a corresponding slot or depression in or on the rib108, which could be useful in instances where the retainer clip106is installed onto rib108prior to installation of the first component102. In the illustrated example, the alignment features504ensures that the retainer clip106is installed in the correct orientation, and not 180° from the intended orientation.

In some examples, a method of manufacturing a retainer106to couple a first panel102to a second panel104would start with stamping a sheet of metal to form a die cutout for the retainer106. The die cutout is generally planar and resides in a plane (e.g., a single plane) and is shaped to define portions that correspond to the various components of the retainer106, such as the body portion202, the pair of tabs204, and the plurality of resiliently-attached retention clips. The sheet of metal may be stamped via a press and die. In other examples, the die cutout may be cut from sheet of metal using lasers, water jets, jigsaw, etc. Next, the various features are bent along multiple fold lines during multiple steps to produce the retainer106.