A clip has a head portion and a locking leg. The locking leg includes a shaft portion vertically extending from the head portion and a plurality of elastic locking legs which are arranged at given intervals at the outer periphery of the shaft portion. Upper ends of the elastic locking legs are connected to the lower surface of the head portion, and each of the elastic locking legs has two portions on two sides, respectively, of a lower end connected to connection ribs extending from the shaft portion. The outer periphery of the shaft portion except for the connection ribs is arranged within an inner side of an inner periphery of the elastic locking members, such that the locking leg can pass through a mounting hole of a panel without the outer periphery of the shaft portion contacting the inner periphery of the elastic locking members.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a clip used to fix a component, such as an automotive interior component, to a mounting hole of a vehicle body panel or the like.

2. Description of the Related Art

Conventionally, a clip of this type has been used which has a head portion to be fixed to a component and a locking leg extending from the head portion, with the locking leg being inserted into a mounting hole of a vehicle body panel or the like for fixation.

For example, Japanese Utility Model Application Laid-Open No. Hei 4-105615 discloses a clip which is equipped with a head portion and a leg portion. The leg portion is to be inserted into a hole of a panel of a vehicle body or the like to be thereby locked thereto, and includes four legs which independently extend from the head portion. Each leg is integrally molded so as to have an intermediate portion expanding radially outwards and to form a tapered leg portion at its end. Further, the legs are of the same sectional configuration around the intermediate portions thereof and are symmetrically arranged at equal intervals with respect to the central axis of the leg portion.

JP 3560061 B discloses a synthetic resin fastener which has a head portion and a locking leg extending from the lower surface of the head portion and which is to be immovably mounted to a panel by forcing the locking leg into a through-hole of the panel. The locking leg includes a shaft core portion and a plurality of elastic locking members. The shaft core portion extends straight from the lower surface of the head portion and has three or four protrusions protruding outwardly from the center thereof, the protrusions being arranged at requisite intervals. An imaginary shaft diameter as defined by the outermost peripheral portions of the protrusions does not exceed the diameter of the through-hole of the panel. The plurality of elastic locking members are arranged between the protrusions of the shaft core portion and maintain requisite intervals between themselves and the protrusions. The elastic locking members have upper end portions which are bonded to a base portion of the shaft core portion or the lower surface of the head portion, lower end portions which are bonded to the leg end of the shaft core portion, and intermediate portions which are separated from the shaft core portion to provide gaps and have on the outer side thereof swelling portions of a size exceeding the diameter of the through-hole of the panel. When locking the fastener to the through-hole of the panel, the elastic locking members are reduced in diameter as the shaft core portion is forced into the through-hole to thereby hook the swelling portions onto the edge of the through-hole of the panel.

Further, JP 2005-315369 A discloses a resin clip which has a head portion to be held in contact with the peripheral edge of a mounting hole of a mounting panel and a leg portion extending from the head portion to be inserted into the mounting hole and adapted to be engaged with the peripheral edge on the back side of the mounting hole. The leg portion has a shaft portion vertically extending from the center of the lower surface of the head portion, at least three protrusions which extend radially from the shaft portion and whose upper ends are connected to the lower surface of the head portion, and engagement members which extend circumferentially from the protrusions to be arranged between the protrusions. The engagement members have upper ends which are connected to the head portion, end portions in the circumferential extending direction which define predetermined slits between themselves and opposing protrusions, and exclusively lower end portions which are connected to the opposing protrusions. The outer diameter of the engagement members is larger than the inner diameter of the mounting hole.

In the clip disclosed in Japanese Utility Model Application Laid-Open No. Hei 4-105615, the leg portion includes four legs (elastic locking members) independently extending from the head portion, so no shaft portion exists at the center of the elastic locking members. When the position of the mounting hole is deviated due to dimensional deviation between components, and the leg portion has to be obliquely inserted into the mounting hole, buckling may be caused to make the insertion impossible or breakage may be caused.

In the clip disclosed in JP 3560061 B, the protrusions outwardly protruding from the center of the shaft core portion are situated between the elastic locking members, and, while the locking leg is being inserted into the mounting hole, the protrusions abut the inner periphery of the mounting hole to perform positioning on the center of the locking leg with respect to the mounting hole. However, when there is a considerable dimensional deviation between the mounting holes, and the leg portion has to be inserted into the mounting hole obliquely at a considerably large angle with respect thereto, the insertion is effected with the protrusions being scraped by the inner periphery of the mounting hole. Thus, there arises a problem in that the insertion resistance for the locking leg increases.

Further, in the clip disclosed in JP 2005-315369 A, one side of each engagement member is connected to a protrusion radially extending from the shaft portion, so there is a difference in deflection rigidity, toward the inside, between the side edge connected to the protrusion of the engagement member and the side edge spaced apart from the shaft portion. Thus, it is difficult to obtain a deflection rigidity uniform over the entire periphery, and when a large lateral external force is applied to the leg portion in the mounted state, the engagement members undergo great deformation depending upon the direction and the clip may become subject to detachment.

SUMMARY OF THE INVENTION

It is accordingly an object of the present invention to provide a clip which involves no buckling when the position of a mounting hole is deviated at the time of insertion of the locking leg into the mounting hole, and which allows insertion locking without involving a great increase in insertion resistance, which makes it possible to obtain a substantially uniform deflection rigidity over the entire periphery if a lateral external force is applied to the leg portion in the mounted state.

In order to attain the above object, a first aspect of the present invention provides a clip formed of synthetic resin including: a head portion; and a locking leg vertically extending from a lower surface of the head portion, the clip being capable of being immovably mounted to a panel by inserting the locking leg into a mounting hole of the panel, in which the locking leg includes: a shaft portion vertically extending from the center of the lower surface of the head portion; and at least three elastic locking members arranged at given intervals in an outer periphery of the shaft portion, each having an upper end thereof connected to the lower surface of the head portion and two portions on both sides of a lower end thereof connected to the shaft portion, and in which the outer periphery of the shaft portion excepting portions connected to the elastic locking members is situated on an inner side of an inner periphery of the elastic locking members, such that the locking leg can pass through the mounting hole of the panel without coming into contact at the inner periphery of the elastic locking members with the outer periphery of the shaft portion.

According to the above aspect of the present invention, the locking leg has the shaft portion vertically extending from the center of the lower surface of the head portion, and at least three elastic locking members arranged in the outer periphery of this shaft portion at given intervals, so even when the position of the mounting hole is deviated due to dimensional deviation between components, and the locking leg has to be obliquely inserted into the mounting hole, it is possible to avoid buckling or breakage of the elastic locking members due to the shaft portion. Further, the outer periphery of the shaft portion excepting connection ribs are situated on the inner side of the inner periphery of the elastic locking members, and when the locking leg is inserted into the mounting hole, the inner periphery of the elastic locking members does not abut the outer periphery of the shaft portion, so the shaft portion as well as the elastic locking members are not scraped by the inner periphery of the mounting hole, and there is involved no excessive increase in insertion resistance. Further, the upper ends of the elastic locking members are connected to the lower surface of the head portion, and two portions on both sides of the lower end of each elastic locking member are connected to the shaft portion, so it is possible to obtain a substantially uniform deflection rigidity over the entire periphery.

A second aspect of the present invention provides a clip according to the first aspect, in which the two portions on both sides of the lower end of each of the elastic locking members are connected to the shaft portion via connection ribs extending from the shaft portion.

According to the above aspect of the present invention, the two portions on both sides of the lower end of each elastic locking member are connected to the shaft portion via the connection ribs extending from the shaft portion, so no deterioration in flexibility is involved, while an appropriate rigidity is maintained, making it possible to achieve a relatively small insertion resistance at the time of insertion of the locking leg into the mounting hole and attain a satisfactory insertion workability.

A third aspect of the present invention provides a clip according to the second aspect, in which the shaft portion has protrusions extending along an axial direction, the protrusions being situated on the position substantially between the elastic locking members, in which upper ends of the protrusions are connected to the lower surface of the head portion, in which lower ends of the protrusions constitute the connection ribs, and in which an outer periphery of the protrusions excepting the connection ribs is situated on the inner side of the inner periphery of the elastic locking members.

According to the above aspect of the present invention, the shaft portion is equipped with protrusions extending along an axial direction, whereby it is possible to enhance the rigidity of the shaft portion and to enhance the insertion guiding property for the insertion into the mounting hole. Further, the outer periphery of the protrusions excepting the connection ribs is situated on the inner side of the inner periphery of the elastic locking members, so even when it is necessary to obliquely insert the locking leg into the mounting hole, the protrusions do not abut the inner periphery of the mounting hole to thereby be scraped, and no excessive increase in insertion resistance is involved.

A fourth aspect of the present invention provides a clip according to the third aspect, in which the elastic locking members include four elastic locking members arranged at an interval of approximately 90 degrees with respect to the shaft portion, in which, of the four elastic locking members, a pair of the elastic locking members opposed to each other are wider and thinner than another pair of the elastic locking members opposed to each other, and in which each pair of the protrusions extending toward both sides of each of the wider elastic locking members make an acute angle.

According to the above aspect of the present invention, the pair of protrusions extending toward both sides of the wider elastic locking member make an acute angle, so when the elastic locking member is deflected greatly inwards, the elastic locking member would reach the forward ends of the protrusions. However, since the wider elastic locking member is formed thin, it is possible to secure a sufficient margin for the deflection. On the other hand, when it is greatly deflected inwards, the wider elastic locking member actually abuts the forward ends of the protrusions. Therefore, in the mounted state, even when there is exerted to the locking leg a large external force to deflect the wider elastic locking member, the inner periphery of the elastic locking member abuts the protrusions, and further deflection thereof is restrained, whereby it is possible to prevent the situation such as a damage of the elastic locking member, a detachment of the clip due to extreme deformation, and the like.

On the other hand, the narrower elastic locking member is formed relatively thick, so it is rather difficult to secure a margin for deflection toward the inside. However, the pair of protrusions extending toward both sides of the narrower elastic locking member make an obtuse angle, so when the narrower elastic locking member is deflected inwardly, it does not interfere with the protrusions, and can be deflected greatly, thus making it possible to secure a sufficient margin for deflection. Further, since it is formed thicker as compared with the wider elastic locking member, it is possible to substantially equalize the rigidity of the wider elastic locking member with that of the narrower elastic locking member, thereby making it possible to provide a substantially uniform deflection rigidity over the entire periphery of the clip.

A fifth aspect of the present invention provides a clip according to the fourth aspect, in which an outer periphery of a lower end portion of the locking leg includes four cavities defined by the elastic locking members, the connection ribs, and the shaft portion, and in which, of the four cavities, cavities situated in the lower side of the wider elastic locking members are narrower and more elongated upwardly than cavities situated in the lower side of the narrower elastic locking members.

According to the above aspect of the present invention, of the four cavities formed in the outer periphery of the lower end portion of the locking leg and defined by the elastic locking members, the connection ribs, and the shaft portion, the cavities situated in the lower side of the wider elastic locking members are narrower and extend farther upwards than those situated in the lower side of the narrower elastic locking members, whereby the flexibility of the portion between the connecting portions on both sides of the lower ends of the narrower elastic locking members and the flexibility of the portion between the connecting portions on both sides of the lower ends of the wider elastic locking members are balanced to make even, thereby attaining a more uniform deflection rigidity over the entire periphery of the locking leg at the connection portions.

A sixth aspect of the present invention provides a clip according to the fourth aspect or the fifth aspect, in which the shaft portion includes a rib-like protrusion to restrain excessive deflection of the protrusions, the rib-like protrusion being situated between the pair of the protrusions of the shaft portion extending toward the narrower elastic locking members.

According to the above aspects of the present invention, even when, in the mounted state, there is exerted on the locking leg a large external force to deflect the narrower elastic locking members, the inner periphery of the elastic locking members abut the rib-like protrusion, and further deflection thereof is restrained, so it is possible to avoid the situation such as a damage of the elastic locking members, a detachment of the clip due to excessive deformation, and the like.

A seventh aspect of the present invention provides a clip according to any one of the first aspect through the sixth aspect, in which each of the elastic locking members includes an upper end portion gradually reduced in width and connected to the lower surface of the head portion.

According to the above aspects of the present invention, the upper end portions of the elastic locking members are gradually reduced in width and connected to the lower surface of the head portion. Therefore, when an external force is exerted on the elastic locking members, not only are the elastic locking members deflected inwardly, but the elastic locking members tend to be twisted at their narrowed upper end portions, so that the elastic locking members can be deflected in conformity with the inner periphery of the mounting hole, making it possible to maintain the requisite engagement force with respect to the mounting hole.

According to the clip of the present invention, even when the position of the mounting hole is deviated due to inter-component dimensional deviation, and the locking leg has to be inserted obliquely into the mounting hole, buckling or damage of the elastic locking members is prevented due to the shaft portion. Further, the shaft portion as well as the elastic locking members are not scraped by the inner periphery of the mounting hole, and no excessive increase in insertion resistance is involved. Further, the upper ends of the elastic locking members are connected to the lower surface of the head portion, and two portions on both sides of the lower end portion of each of the elastic locking members are connected to the connection ribs extending from the shaft portion, so the clip exhibits an appropriate rigidity without impairing its flexibility. Thus, it is possible to maintain a relatively low insertion resistance when inserting the locking leg into the mounting hole, thus attaining a satisfactory insertion workability.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Next, a clip according to an embodiment of the present invention will be described with reference toFIGS. 1 through 14.

As shown inFIG. 1, this clip, indicated by reference numeral10, includes a head portion11and a locking leg12. The head portion11has a base portion13formed as a bottomed cylinder, a first flange portion14formed in the outer periphery of the upper end of the base portion13, a second flange portion15formed in the outer periphery of an intermediate portion of the base portion13, and a seal flange portion16formed in the outer periphery of the lower end portion of the base portion13. As shown inFIG. 6, the second flange portion15has an annular protrusion15awhich is upwardly curved.

As shown inFIG. 11, the clip10is previously fixed to amounting member17by being fit-engaged with an engagement groove18of the mounting member17, with the peripheral edge of the engagement groove18being held between the first flange portion14and the second flange portion15.

The peripheral edge of the seal flange portion16extends obliquely downwards in a skirt-like fashion, and is held in contact with the upper surface of a mounting panel19, thus also serving to seal a mounting hole20. The mounting member17may include, for example, an automotive door trim, and the mounting panel19may include, for example, a body panel.

Referring toFIGS. 6,7, and8, the locking leg12has a shaft portion21vertically extending from the center of the lower surface of the head portion11. Four protrusions22extend radially outwards from the shaft portion21. The protrusions22extend in the axial direction of the shaft portion21. Their upper ends are connected to the lower surface of the head portion11, and their lower end portions constitute connection ribs23connected to elastic locking members24aand24b, which are described below.

In the outer periphery of the shaft portion21, four elastic locking members24aand24bare arranged at a predetermined angular interval of approximately 90 degrees. Of those, a pair of opposing elastic locking members24aare wide in width, and the remaining pair of opposing elastic locking members24bare narrow in width. Upper end portions25of the elastic locking members24aand24bare connected to the head portion11. The protrusions22are substantially situated between the elastic locking members24aand24b(seeFIG. 8); two portions on both sides of the lower end portion of each of the elastic locking members24aand24bare connected to the connection ribs23extending as the lower edge portions of the protrusions22. Slits32are defined between the elastic locking members24aand24b.

The upper end portions25of the elastic locking members24aand24bare gradually reduced in width toward the head portion11, whereby when an external force is applied to any one of the elastic locking members24aand24b, not only is it deflected inwardly but also it can be twisted at the upper end portion25thereof, which is reduced in width.

Referring also toFIGS. 1,2, and3, somewhat below the upper end portions of the elastic locking members24aand24b, there are formed engagement step portions26, and diverging portions27are provided below the engagement step portions26. Further, the portions below the diverging portions27are formed as tapered portions28gradually reduced in diameter. Below the tapered portions28, the end edges of the connection ribs23extend to a lower end portion30of the locking leg12via connecting portions29.

In the outer periphery of the lower end portion30of the locking leg12, there are formed four cavities33and34defined by the elastic locking members24aand24b, the connection ribs23, and the shaft portion21. Of those, as compared with second cavities34situated below the narrower elastic locking members24b, first cavities33situated below the wider elastic locking members24aare narrower in width and more elongated upwards.

FIG. 10schematically shows the construction of a mold for producing the clip10. This mold has a pair of dies35and36adapted to slide in the directions indicated by the arrows A, and a plurality of dies37and38adapted to be opened and closed in the directions indicated by the arrows B. The pair of dies35and36have shapes to shape the outer peripheral configuration of the clip10and have insertion portions39to be inserted to make the gaps between the wider elastic locking members24a, the shaft portion21, and the protrusions22. Of the dies37and38, a pair of opposing dies37are inserted to make the inner periphery of the wider elastic locking members24a, and the remaining pair of opposing dies38are inserted to make the inner periphery of the narrower elastic locking members24b.

Referring also toFIG. 8, it is necessary to provide predetermined gaps S1between the wider elastic locking members24aand the protrusions22in order to allow insertion of the insertion portions39of the dies35and36and to secure margins sufficient for the elastic locking members24ato deflect toward the inside. Thus, the thickness t1of the elastic locking members24ais required to be relatively small, whereas their width W1can be made relatively large. On the other hand, the width W2of the elastic locking members24bis restricted by the insertion portions39, so they must be rather narrow. In view of this, in this embodiment, the width W1of the elastic locking members24ais made large, the thickness t1thereof is made small, the width W2of the elastic locking members24bis made small, and the thickness t2thereof is made large. Therefore, their sectional areas are as equal to each other as possible, thus obtaining a substantially uniform deflection rigidity over the entire periphery.

On the other hand, the thickness t2of the elastic locking members24bbeing made large, in order to secure margins sufficient for them to deflect toward the inside, a structure must be provided, that prevents interference with the protrusions22as far as possible when the elastic locking members24bare inwardly deflected. In view of this, in this embodiment, the angle θ1of the pair of protrusions22extending toward each wider elastic locking member24ais made acute, and the angle θ2of the pair of protrusions22extending toward each narrower elastic locking member24bis made obtuse. Thus, gaps S2are secured between the elastic locking members24band the protrusions22, which allows the elastic locking members24bto be deflected greatly inwards without interfering with the protrusions22.

Further, to make the above-mentioned different angles depending upon the orientations of the protrusions22, the dies37, which are inserted to make the spaces exhibiting the acute angle θ1, have a radially thin and long sectional configuration. The dies38, which are inserted to make the spaces exhibiting the obtuse angle θ2, have a circumferentially wide sectional configuration. As a result, as shown inFIGS. 2,3, and5, the first cavities33, into which the dies37are inserted, are narrow and vertically elongated, and the second cavities34, into which the dies38are inserted, are wide and of a relatively small vertical dimension. This provides the following effect. Due to the large interval between the connection ribs23, the deflection rigidity of the connection ribs23situated on both sides of each wide, second cavity34can be made relatively low, whereas, due to the small interval between the connection ribs23, the deflection rigidity of the connection ribs23situated on both sides of each narrow, first cavity33usually tends to be high. However, in this embodiment, described above, the first cavities33are vertically elongated. Therefore, despite the small interval, the deflection rigidity is reduced, which, as a result, contributes to making the deflection rigidity at the connecting portions29relatively uniform over the entire periphery.

FIG. 9shows the clip10in sections as taken at various heights and angles; portions A through K of the drawing show sectional configurations obtained at positions indicated by corresponding arrows. As shown in portions A through D of the drawing, the connection ribs23extend radially outwards as the locking leg12extends upwardly from the lower end portion30. And, as shown in portions D, E, and F of the drawing, the connection ribs23are connected to both side portions of each of the elastic locking members24aand24b, and both side portions of each of the elastic locking members24aand24bare supported by corresponding connection ribs23. Further, as shown in portions G, H, and I of the drawing, the outer peripheral diameter of the elastic locking members24aand24bincreases gradually to form the tapered portions28and the diverging portions27. Further, as shown in portions J and K of the drawing, the elastic locking members24aand24bare gradually reduced in diameter to form the engagement step portions26, and are gradually narrowed toward the head portion11, with their upper end portions being connected to the lower surface of the head portion11.

As shown in portions G through K ofFIG. 9, the outer periphery of the protrusions22of the shaft portion21is situated on the inner side of the inner periphery of the elastic locking members24aand24b. And, as shown inFIG. 12, if the elastic locking members24aand24bare deflected inwardly in order that the locking leg12can be inserted into the mounting hole20of the mounting panel19(seeFIG. 11), the elastic locking members24aand24bdo not come into contact with the protrusions22of the shaft portion21.

Next, the effects of the clip10will be described.

As shown inFIG. 11, the base portion13between the first flange portion14and the second flange portion15of the clip10is inserted into the engagement groove18formed in the mounting member17which is formed of an automotive door trim or the like, and the peripheral edge of the engagement groove18is held between the first flange portion14and the second flange portion15, thus previously fixing the clip10to the mounting member17.

In this state, the locking leg12of the clip10is inserted into the mounting hole20of the mounting panel19which is formed of a body panel or the like. Then, the elastic locking members24aand24bare inwardly deflected, and the diverging portions27of the locking leg12pass through the mounting hole20; the engagement step portions26are engaged with the peripheral edge of the back side of the mounting hole20to fix the clip10in position, thereby fixing the mounting member17to the mounting panel19.

When passing the locking leg12through the mounting hole20, and if the locking leg12has to be inserted obliquely with respect to the mounting hole20due to positional deviation between the mounting panel19and the mounting member17, in this clip10, the presence of the shaft portion21prevents the locking leg12from buckling, making it possible to insert the locking leg12into the mounting hole20.

As shown inFIG. 12, the elastic locking members24aand24bare deflected until their outer periphery reaches the inner periphery of the mounting hole20; in this state, there are provided gaps large enough to prevent the inner periphery of the elastic locking members24aand24bfrom coming into contact with the protrusions22of the shaft portion21. Thus, if the locking leg12has to be inserted obliquely into the mounting hole20as stated above, the protrusions22do not come into contact with the inner periphery of the mounting hole20. Therefore, the insertion process does not involve scraping of the protrusions22, so that the insertion of the locking leg12can be effected smoothly.

FIGS. 13 and 14show states in which a lateral load due to, for example, a difference in thermal expansion between the mounting member17and the mounting panel19is applied to the locking leg12of the clip10, with the mounting member17being fixed to the mounting panel19via the clip10.FIG. 13shows a state in which a load is applied in the direction of the wider elastic locking members24a, andFIG. 14shows a state in which a load is applied in the direction of the narrower elastic locking members24b.

If, inFIG. 13, a still larger load is applied, the protrusions22of the shaft portion21abut the inner periphery of one elastic locking member24a, and further deformation of the elastic locking member24ais prevented, thereby avoiding breakage of the clip10.

In each of the states shown inFIGS. 13 and 14, the inner periphery of the mounting hole20obliquely abuts adjacent elastic locking members, and an oblique pressurizing force may be applied thereto; however, in this embodiment, the upper end portions25of the elastic locking members24aand24bare gradually reduced in width toward the head portion11, so that the elastic locking members24aand24bcan be twisted to some degree, thereby enabling being deformed so as to be adapted to the inner periphery of the mounting hole20.

And, in the clip10, though the elastic locking members24aand24bdiffer in width, their thickness is adjusted so as to exhibit substantially the same cross-sectional area, whereby it is possible to obtain a substantially uniform deflection rigidity over the entire periphery of the locking leg12. Further, as described above, also regarding the connecting portions29of the elastic locking members24aand24b, the first cavities33are narrower and more elongated in the height direction than the second cavities34, whereby it is possible to obtain a substantially uniform deflection rigidity over the entire periphery.

FIGS. 15 and 16show a clip according to another embodiment of the present invention. The portions that are substantially the same as those of the above-described embodiment are indicated by the same reference numerals, and a description thereof will be omitted.

In a clip10aaccording to this embodiment, rib-like protrusions22aeach protrude between each of the pairs of the protrusions22of the shaft portion21facing toward the narrower elastic locking members24b. Referring also toFIG. 15, the rib-like protrusions22aextend in the axial direction from the lower surface of the head portion11in a predetermined height. Starting from an intermediate position in the axial direction of the shaft portion21, there are formed tapered surfaces22bgradually reduced in height toward the distal end of the shaft portion21.

And, in this embodiment, even if a large external force to deflect the narrower elastic locking members24bis applied to the locking leg12in the state in which the clip10ahas been mounted to the mounting hole20of the mounting panel19, the inner periphery of the elastic locking members24babuts the rib-like protrusions22a. Therefore, further deflection thereof is restrained, so it is possible to prevent the situation such as a damage of the elastic locking members24b, a detachment of the clip10from the mounting hole20due to extreme deformation, and the like.