Fastener clip and method of fabricating the same

A fastener clip includes a body having an opening extending therethrough, and a rigid retaining pin inserted through the opening, the rigid retaining pin having a first end secured within the body and a second end disposed outside the body, the retaining pin configured to limit the movement of a vehicle trim piece with respect to the vehicle chassis when an airbag is deployed. The fastener clip also includes a plurality of molding gates formed at an intersection between the body and the rigid retaining pin, the rigid retaining pin being subsequently movable with respect to the body after the molding gates are broken. The fastener clip further includes a pair of flexible retention legs adapted to secure the fastener clip to a vehicle chassis and a pair of flexible retention legs adapted to secure the trim piece to a vehicle chassis.

BACKGROUND OF THE INVENTION

The present invention relates generally to fasteners, and more particularly to side airbag retention systems and fasteners therefore.

Supplemental restraint systems or airbags have become an important safety feature in today's automobiles. At least one known supplemental restraint system includes a driver's side airbag that is mounted in the steering column and a passenger side airbag that is mounted in the vehicle dashboard. To further increase passenger safety, at least some known vehicles include a side airbag inflatable curtain system (SABIC). The SABIC system is installed within the vehicle using a side airbag retention system.

At least one known side airbag retention system includes a panel member having several openings therethrough. Prior to the airbag being deployed, the panel member covers and protects the side airbag. The panel member is generally attached to the vehicle chassis using a plurality of known fasteners that are inserted through the panel member to secure the panel member to the vehicle chassis. During operation, when the side airbag is deployed, the panel member separates from the vehicle chassis and may become a projectile. To enable the panel member to separate from the chassis and thus allow the airbag to deploy, at least one known fastener includes a tether.

More specifically, the known fastener includes a housing having a hollow interior to receive the tether. The known tether is fabricated using a flexible fiber material. The tether also has a predetermined length that is based on the amount of separation desired between the vehicle chassis and the panel member. For example, assuming the tether has a length of one one-half inch, when the airbag is deployed, the tether will limit the movement between the chassis and the panel member to one-half inch. Since, the size of the opening in the fastener housing is less than the length of the tether, the tether is bent or coiled to fit within the fastener housing.

However, assuming that a customer desires that the panel member be displaced by one inch during deployment, the length of the tether must also be increased. As a result, either the height of the fastener housing must be increased to accept the tether having the increased length or the tether must be more tightly stored within the known fastener housing. Increasing the height of the fastener housing may cause the fastener housing to extend into the passenger area causing the passenger to inadvertently strike the fastener. However, maintaining the size of the known fastener housing results in a tether, having an increased length, being stored in the fastener housing. In either configuration, the known tether is deformed in the stowed position, causing increase stress to the tether that may weaken the tether causing the tether to break when the airbag is deployed. Additionally, increased force may be applied to the fastener housing by the tether in the stowed position causing the fastener housing to separate from the chassis when the airbag is not deployed.

A need remains for a fastener clip that performs the intended function of holding the panel member to the vehicle chassis and while allowing the panel member to separate but not completely detach from the vehicle chassis, while also eliminating the need for a tether to secure the panel member when the airbag is deployed.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a fastener clip adapted to secure a trim piece to a vehicle chassis is provided. The fastener clip includes a body having an opening extending therethrough, and a rigid retaining pin inserted through the opening. The rigid retaining pin has a first end secured within the body and a second end disposed outside the body. The rigid retaining pin is configured to limit the movement of a vehicle trim piece with respect to the vehicle chassis when an airbag is deployed. The fastener clip also includes a plurality of molding gates formed at an intersection between the body and the rigid retaining pin, the rigid retaining pin being subsequently movable with respect to the body after the molding gates are broken. The fastener clip further includes a pair of flexible retention legs adapted to secure the fastener clip to a vehicle chassis and a pair of flexible retention legs adapted to secure the trim piece to a vehicle chassis.

In another embodiment, a method of fabricating a fastener clip assembly is provided. The method includes injecting a molding material into a mold assembly to form the fastener clip assembly including a body member and a rigid retaining pin that is formed unitarily with the body member. The method also includes removing the fastener clip from the mold, and applying pressure to at least one of the body member and the rigid retaining pin to break a plurality of molding gates formed at an intersection between the body member and the rigid retaining pin to separate the body member from the rigid retaining pin and to cause the rigid retaining pin to be inserted at least partially into the body member.

In a further embodiment, a side airbag retention system for use in conjunction with a vehicle is provided. The vehicle includes a vehicle chassis, an airbag coupled to the vehicle chassis, and a trim piece adapted to cover the airbag. The airbag retention system also includes a fastener clip adapted to secure a trim piece to a vehicle chassis is provided. The fastener clip includes a body having an opening extending therethrough, and a rigid retaining pin inserted through the opening. The rigid retaining pin has a first end secured within the body and a second end disposed outside the body. The rigid retaining pin is configured to limit the movement of a vehicle trim piece with respect to the vehicle chassis when an airbag is deployed. The fastener clip also includes a plurality of molding gates formed at an intersection between the body and the rigid retaining pin, the rigid retaining pin being subsequently movable with respect to the body after the molding gates are broken. The fastener clip further includes a pair of flexible retention legs adapted to secure the fastener clip to a vehicle chassis and a pair of flexible retention legs adapted to secure the trim piece to a vehicle chassis.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a cut-away view of an exemplary airbag retention assembly10that includes a plurality of exemplary fastener clips12in accordance with an embodiment of the present invention. Although the fastener clips have been described in connection with an airbag retention system, the fastener clips12described herein are capable of use in other applications, and the airbag retention assembly10is merely shown and described as an example of one such application.

The airbag retention assembly10includes an airbag20, an airbag tether22, and a trim piece24. As shown inFIG. 1, a portion of the trim piece24has been removed to illustrate the airbag20and the airbag tether22installed beneath the trim piece24. In the exemplary embodiment, the airbag20is secured to a vehicle chassis26via the airbag tether22. The airbag retention assembly10also includes the plurality of fastener clips12. In the exemplary embodiment, the vehicle chassis26includes a plurality of openings28and29that are each sized to receive a single fastener clip12therethrough. In one mode of operation, referred to herein as the airbag stowed mode, the fastener clips12restrain the trim piece24against the vehicle chassis26as shown inFIG. 1. In another mode of operation, the fastener clips12enable the trim piece24to separate but not completely detach from the vehicle chassis26, when the airbag is deployed as shown below inFIGS. 8 and 14.

FIG. 2is an exploded view of a portion of the airbag retention assembly10shown inFIG. 1that includes the exemplary fastener clip12in accordance with an embodiment of the present invention. The fastener clip12includes a body member102and a rigid retaining pin104. In the exemplary embodiment, the body member102and the retaining pin104are each fabricated from a plastic material as a unitary structure and then separated to form the fastener clip12as discussed below. As such, both the body member102and the retaining pin104, and all components included in each, are fabricated as part of a unitary structure to form fastener clip12. Optionally, the body member102and the retaining pin104may be fabricated as separate components that are coupled together to form fastener clip12.

In the exemplary embodiment, the body member102has a rectangular cross-sectional profile to enable the fastener clip12to be at least partially inserted into the opening28in the vehicle chassis26and an opening30in the trim piece24which will be discussed below. It should be realized that the body member102may have any shape that enables the fastener clip12to be inserted into the opening28. The body member102has a first side110, a second side112disposed approximately parallel to the first side110. The body member102also has a third side114and a fourth side116that is approximately parallel to the third side114. Both third and fourth sides114and116are disposed approximately perpendicular to first and second sides110and112. As such, body member102has a substantially rectangular cross-sectional profile having length118and a width120that is less than the length118. Moreover, opening28is substantially rectangular and has a length122and a width124.

As shown inFIG. 2, the length118and width120of the body member102is slightly less than the length122and width124of opening28to enable the fastener clip12to be at least partially inserted into the opening28in the vehicle chassis26. The sides110,112,114, and116that form body member102also define an opening130that extends through the fastener body member102. The fastener body opening130is configured to receive the retaining pin104therein. As such, the fastener body opening130extends from an upper surface132to a lower surface134of the body member102.

FIG. 3is a side section view of the exemplary fastener clip12shown inFIG. 2in accordance with an embodiment of the present invention. The body member102also includes a flange member136that is disposed approximately midpoint between the upper and lower surfaces132,134of the body member102. As shown inFIG. 3, the flange member136extends radially outwardly from the body member102. In use, the flange member136increases the strength and rigidity of the fastener clip12and also functions as a stop device when inserted into the trim opening28. More specifically, since the flange member136has a dimension that is larger than the size of the opening28, the flange member136limits the travel of the fastener clip12when the fastener clip12is installed into opening28which will be discussed below. The body member102may also includes a flexible member138that is formed between the flange member136and the lower surface134. In the exemplary embodiment, the flexible member138is concave and has a circular cross-sectional profile. The flexible member138is configured to deform when the fastener clip12is installed into the opening28. This deformation results in a slight pressure being exerted between the vehicle chassis26and the fastener clip12to limit movement of the fastener clip12when installed in the opening28.

The fastener clip12also includes a first pair of flexible retention legs140that are formed between the flexible member138and the lower surface134. More specifically, the fastener clip12includes a first retention leg142that is formed in the first side110of body member102and a second retention leg144that is formed in the second side112of body member102. As shown inFIG. 3, the pair of retention legs140each have a triangular shape to enable the fastener clip12to be inserted within the opening28while also retaining the fastener clip12within opening28. It should be realized that the pair of retention legs140may have any shape that enables the fastener clip12to be inserted and retained within the opening28. More specifically, the pair of retention legs140deform inwardly towards body member102to enable the fastener clip12to be inserted into opening28. After the fastener clip12is inserted into opening28, the pair of retention legs140deform outwardly from body member102to enable the fastener clip12to be retained within opening28.

The fastener clip12also includes a second pair of flexible retention legs150that are formed between the flange member136and the upper surface132of body member102. More specifically, the fastener clip12includes a third retention leg152that is formed in the first side110of body member102and a fourth retention leg154that is formed in the second side112of body member102. As shown inFIG. 3, the pair of retention legs150each have a triangular shape to enable the fastener clip12to be inserted within the trim piece opening30while also securing the trim piece24to the fastener clip12and thus securing the trim piece24to the vehicle chassis26. It should be realized that the pair of retention legs150may have any shape that enables the fastener clip12to be inserted and retained within the opening30. During operation, the pair of retention legs150deform inwardly towards body member102to enable the fastener clip12to be inserted into the trim piece opening30. After the fastener clip12is inserted into the trim piece opening30, the pair of retention legs150deform outwardly from body member102to securely couple the trim piece24to the vehicle chassis26via the fastener clip12.

FIGS. 4A and 4Bare side section views of the exemplary fastener clip12in a molding position in accordance with an embodiment of the invention. Specifically, the molding position illustrates the position of fastener clip12after completion of the molding process. As discussed above, the fastener clip12is fabricated from a plastic material as a unitary structure, as such, both the body member102and the retaining pin104, and all components included in each, are fabricated as part of the unitary structure of fastener clip12.

In the molding position, the body member102is aligned with the retaining pin104along a common axis, shown inFIGS. 4A and 4Bas the Z-axis. During the molding process, common molding gates are formed at an intersection between the body member102and the retaining pin104. This initially results in vestiges156being formed at the intersection between the body member102and the retaining pin104. After the molding process is completed, the molding gates or vestiges156are broken by moving the retaining pin104along the Z-axis with respect to the body member102. Specifically, the retaining pin104is forced into the fastener body opening130.

The retaining pin104includes a rectangular body160having a first end162and a second end164. The retaining pin body160is substantially rectangular to enable the retaining pin104to be inserted into the rectangular fastener body opening130. During operation, the rectangular shape of both the fastener body opening130and the retaining pin body160substantially limit the rotational movement of the retaining pin104with respect to the body member102. Thus the retaining pin104is configured to move only along a Z-axis as shown inFIG. 4.

The retaining pin104also includes a pair of catch members170that are disposed proximate to the retaining pin second end164. In the exemplary embodiment, the combination of the retaining pin second end164and the catch members170form a substantially arrow-shaped member. The catch members170each have a first end172that is formed unitarily with the retaining pin second end164and a second end174that extends outwardly from the retaining pin body160. In operation, the catch members170enable the retaining pin104to be inserted into the fastener body opening130while also securing the retaining pin104within the body member102.

For example, after the molding process is completed, a portion of the retaining pin104that includes the pair of catch members170, is forced through the fastener body opening130until the pair of catch members170are positioned past a pair of stops176. The pair of stops176then prohibit the retaining pin104from being removed from the body member102after the retaining pin104has been inserted therein. The catch members170deform inwardly towards body member102to enable the retaining pin104to be inserted into the body member102. After the retaining pin104is inserted into the body member102, the retaining pin104passes by the pair of stops176and catches on a pair of ledges or stops188shown inFIG. 4A. Optionally, the retaining pin104passes by a pair of ramps190(shown inFIG. 4B. Upon deployment, the retaining pin104slides outwardly from the retaining pin body160and catches the pair of stops176formed on an inner surface of the body member102.

FIG. 5is a side section view of the exemplary fastener clip12in a pre-installation position. Specifically,FIG. 5illustrates the fastener clip12after the molding vestiges156have been broken as discussed inFIG. 4. As shown inFIG. 5, the retaining pin104also includes a shoulder180that is formed between the catch members170and the retaining pin first end162. In the exemplary embodiment, the shoulder180is positioned a predetermined distance from the catch member second ends174. For example, assuming that it is desired that the trim piece24separate from the vehicle chassis26by approximately one inch when the airbag is deployed, the shoulder180is positioned approximately one inch from the catch member second ends174. Optionally, retaining pin104does not include the shoulder180. The shoulder180may be formed anywhere along the retaining pin104between the catch members170and the retaining pin first end162. For example, to increase the distance that the trim piece24separates from the chassis26, the shoulder180may be formed nearer the retaining pin first end162. Optionally, to decrease the distance that the trim piece24separates from the chassis26, the shoulder180may be formed nearer the catch members170.

The retaining pin104also includes a trim stop182that is disposed on the retaining pin first end162. As shown inFIG. 2, the trim stop182is disposed approximately perpendicular to the shoulder180, the body member102, and thus the fastener body opening130. The trim stop182is substantially rectangular and includes a length184and a width186as shown inFIG. 4. Optionally, the trim stop182may be any shape. In the exemplary embodiment, the length184and width186of the trim stop182is slightly less than the length and width of the trim piece opening30to enable the trim stop182to be inserted through the trim piece opening30during installation.

For example,FIG. 6Aillustrates a portion of the fastener clip12inserted through the trim piece opening30.FIG. 6Billustrates the fastener clip12coupled to trim piece24. As shown inFIG. 6A, and in the exemplary embodiment, the trim stop182is inserted through the trim piece opening30. The fastener clip12, including trim stop182is then rotated approximately 90 degrees until the fastener member body102is aligned with the opening30. The fastener clip12is then fully inserted into the trim piece opening30until the pair of retention legs150pass through the trim piece opening30and thus couple the fastener clip12to the trim piece24as shown inFIG. 6B. The trim piece assembly, i.e. the trim piece24and fastener clip12may then be coupled to the vehicle chassis26using the pair of retention legs140, as shown inFIG. 7. Optionally, the fastener clip12may first be coupled to the chassis26. The trim piece24may then be coupled to the fastener clip12as described above.

FIG. 7illustrates the fastener clip12in a non-deployed or standby position.FIG. 8illustrates the fastener clip12in a deployed position. As shown inFIG. 7, in the standby position, the retaining pin104is fully inserted into the fastener body opening130. More specifically, the retaining pin104is inserted into the fastener body opening130until the retaining pin shoulder180contacts the upper surface132of the fastener body as shown inFIG. 7. As discussed above, the shoulder180provides a positive stop for the retaining pin104when the retaining pin is inserted into the fastener body opening130. When the airbag20is deployed, i.e. a predetermined force is applied to the trim piece24, the trim piece24moves away from the vehicle chassis26as shown inFIG. 8. More specifically, the trim piece24disengages or detaches from the pair of retention legs150and moves outwardly from the chassis26. As shown inFIG. 8, the trim piece24moves away from the vehicle chassis26until the trim piece24contacts the trim stop182. At this point, both the trim piece24and the retaining pin104move away from the chassis. This movement continues, until the pair of catch members170make contact with the pair of stops176. The pair of stops176then prohibit the retaining pin104, and thus the trim piece24from moving further from the chassis. As a result, the retaining pin104prevents the trim piece24from moving a distance from the vehicle chassis26that is greater than the predefined distance as discussed above. At this time, the trim piece24is prevented from moving away from the chassis by a distance that exceeds a predetermined value by the trim stop182of the fastener clip12.

FIG. 9is a method200for fabricating a fastener clip assembly. The method200includes injecting202a molding material into a mold assembly to form the fastener clip assembly including a body member and a rigid retaining pin that is formed unitarily with the body member. This initially results in an integral piece. The fastener clip12is then removed204from the mold. The method also includes applying pressure206to at least one of the body member and the rigid retaining pin to break a plurality of molding gates formed at an intersection between the body member and the rigid retaining pin to separate the body member from the rigid retaining pin and to cause the rigid retaining pin to be inserted at least partially into the body member.

For example, during fabrication, the fastener clip12is molded as a unitary assembly that can achieve movement after breaking its molding gates or vestiges156in such a way that once it leaves its molding position, the body member102is separated from the retaining pin104. More specifically, pressure is applied along the Z-axis of the fastener clip12, to at least one of the body member102and the rigid retaining pin104to break the molding gates156. The pressure not only breaks the molding gates but forces the retaining pin104to be inserted into the body member102. A portion of the retaining pin104is then locked within the fastener body opening130using a combination of the catch members170and the stops188or ramps190. The assembled fastener clip12may then be coupled to both the vehicle chassis26and the trim piece24as discussed above.

FIG. 10is perspective view of another exemplary fastener clip300in accordance with an embodiment of the present invention. Fastener clip300is substantially similar to fastener clip12shown above. Fastener clip300includes a body member302and a rigid retaining pin304. In the exemplary embodiment, the body member302and the retaining pin304are each fabricated from a plastic material as a unitary structure and then separated to form the fastener clip300as discussed below. As such, both the body member302and the retaining pin304, and all components included in each, are fabricated as part of a unitary structure to form fastener clip300. Optionally, the body member302and the retaining pin304may be fabricated as separate components that are coupled together to form fastener clip300.

In the exemplary embodiment, the body member302is substantially cylindrical to enable the substantially cylindrical fastener clip300to be at least partially inserted into a cylindrical opening29(shown inFIG. 1) in the vehicle chassis26and an opening331in trim piece24which will be discussed below.

FIG. 11is a section view of the exemplary fastener clip300shown inFIG. 10in accordance with an embodiment of the present invention.FIG. 12is another section view of the exemplary fastener clip300shown inFIG. 10. As shown inFIGS. 11 and 12, the body member302has a first end314and a second end316. The first end314is disposed approximately perpendicular to a side310of the body member302. Body member302has a diameter318that is substantially similar to a diameter319of the cylindrical opening29in the vehicle chassis26.

The side310of the body member302defines an opening330that extends therethrough. The body member opening330is configured to receive the retaining pin304therein. As such, the body member opening330extends from the first end314to the second end316of the body member302.

The body member302also includes a flange member336that is disposed proximate to the first end314of the body member302. As shown inFIGS. 11 and 12, the flange member336extends outwardly from the body member302. Optionally, the flange member336may have any shape. In use, the flange member336increases the strength and rigidity of the fastener clip300and also functions as a stop device. More specifically, since the flange member336has a dimension337that is larger than the dimension319of the opening29in the vehicle chassis26, the flange member336limits the travel of the fastener clip300when the fastener clip300is installed into the opening29which will be discussed below. In the exemplary embodiment, the flange member336is flexible and concave and has a circular cross-sectional profile. The flange member336is configured to deform when the fastener clip300is installed into the opening29. This deformation results in a slight pressure being exerted between the vehicle chassis26and the fastener clip300to limit movement of the fastener clip300when installed in the opening29.

As shown inFIG. 11, the fastener clip300also includes a pair of flexible retention legs340that are formed between the flange member336and the second end316. The pair of retention legs340each have a triangular shape to enable the fastener clip300to be inserted within the opening29while also retaining the fastener clip300within opening29. More specifically, the pair of retention legs340are configured to deform inwardly towards body member302to enable the fastener clip300to be inserted into opening29. After the fastener clip300is inserted into opening29, the pair of retention legs340are configured to deform outwardly from body member302to enable the fastener clip300to be retained within opening29.

As discussed above, the fastener clip300is fabricated from a plastic material as a unitary structure, as such, both the body member302and the retaining pin304, and all components included in each, are fabricated as part of the unitary structure of fastener clip300. For example, in the molding process, the body member302is aligned with the retaining pin304along a common axis, shown inFIG. 11as the Z-axis. Molding material is then injected into a mold such that molding gates are formed at an intersection between the body member302and the retaining pin304. This initially results in vestiges being formed at the intersection between the body member302and the retaining pin304as discussed above in the previous embodiment. After the molding process is completed, the molding gates or vestiges are broken by moving the retaining pin304along the Z-axis with respect to the body member302. Specifically, the retaining pin304is forced into the body member opening330.

Referring again toFIG. 12, the retaining pin304includes a cylindrical body360having a first end362and a second end364. The retaining pin body360is substantially cylindrical to enable the retaining pin304to be inserted into the body member opening330. Thus the retaining pin304is configured to move only along a Z-axis as shown inFIG. 11.

As shown inFIG. 12, the retaining pin304also includes a pair of catch members370that are disposed proximate to the retaining pin second end364. In the exemplary embodiment, the combination of the retaining pin second end364and the catch members370form a substantially arrow-shaped member. More specifically, the catch members370each have a first end372that is formed unitarily with the retaining pin second end364. The catch members370also have a second end374that extends outwardly form the retaining pin body360. The retaining pin304also includes a plurality of flexible catch members371that radially outwardly from the retaining pin body360.

In operation, the catch members370and371enable the retaining pin304to be inserted within the body member opening330while also securing the retaining pin304within the body member302. More specifically, after the molding process is completed, a portion of the retaining pin304that includes the pair of catch members370and371, are forced through the body member opening330until the pair of catch members370catch members371are positioned past a pair of stops376. The pair of stops376then prohibit the retaining pin304from being removed from the body member302after the retaining pin304has been inserted therein.

During installation, the catch members370and371are each configured to deform inwardly towards body member302to enable the retaining pin304to be inserted into the body member302. After the retaining pin304is inserted into the body member302, the catch members370and371are configured to deform outwardly from the retaining pin body360and contact the inner surface of the retaining pin body360.

As shown inFIGS. 11 and 12, the retaining pin304also includes a shoulder380that is formed between the catch members370and the retaining pin first end362. In the exemplary embodiment, the shoulder380is positioned a predetermined distance from the catch member second ends374. For example, assuming that it is desired that the trim piece24separate from the vehicle chassis26by approximately one inch when the airbag is deployed, the shoulder380is positioned approximately one inch from the catch member second ends374. Optionally, retaining pin304does not include the shoulder380. The shoulder380may be formed anywhere along the retaining pin304between the catch members370and the retaining pin first end362. For example, to increase the distance that the trim piece24separates from the chassis26, the shoulder380may be formed nearer the retaining pin first end362. Optionally, to decrease the distance that the trim piece24separates from the chassis26, the shoulder380may be formed nearer the catch members370.

The retaining pin304also includes a trim stop382that is disposed on the retaining pin first end362. As shown inFIGS. 11 and 12, the trim stop382is disposed approximately parallel to the shoulder380and approximately perpendicular to the body member302, and thus the body member opening330. The trim stop382is substantially circular and includes a diameter384. Optionally, the trim stop382may have any shape. The trim piece opening331includes a first opening332and a second opening333that is coextensive with the first opening332. In the exemplary embodiment, the diameter of trim stop382is less than a diameter383of the first opening332to enable the trim stop382to be inserted through the opening331in the trim piece24during installation.

For example,FIG. 13Aillustrates a portion of the fastener clip300inserted through the opening331of the trim piece24.FIG. 13Billustrates the fastener clip300coupled to trim piece24. As shown inFIG. 13A, and in the exemplary embodiment, the trim stop382is inserted through the first opening332in the trim piece24. The fastener clip300, including trim stop382is then moved laterally to engage the second opening333that is coextensive with the first opening332. Since a diameter387of the second opening333is less than the diameter384of the trim stop382, the trim stop is friction fit into the second opening333. The trim piece assembly, i.e. the trim piece24and fastener clip300may then be coupled to the vehicle chassis26using the pair of retention legs340, as shown inFIG. 11. Optionally, the fastener clip300may first be coupled to the chassis26. The trim piece24may then be coupled to the fastener clip300as described above.

FIG. 14illustrates the fastener clip300in a deployed position. As shown inFIG. 12, in the standby position, the retaining pin304is fully inserted into the body member opening330. More specifically, the retaining pin304is inserted into the body member opening330until the retaining pin shoulder380contacts the first end314of the fastener body302as shown inFIG. 12. As discussed above, the shoulder380provides a positive stop for the retaining pin304when the retaining pin is inserted into the body member opening330. When the airbag20is deployed, i.e. a predetermined force is applied to the trim piece24, the trim piece24moves away from the vehicle chassis26as shown inFIG. 14. As shown inFIGS. 13A and 13B, since the diameter of the trim stop382is larger than the diameter of the opening in the trim piece24, the trim piece24remains coupled to the fastener clip300. As such, when the airbag is deployed, both the trim piece24and the retaining pin304move away from the chassis. This movement continues, until the pair of Catch members370make contact with the pair of stops376. The pair of stops376then prohibit the retaining pin304, and thus the trim piece24from moving further from the chassis. As a result, the retaining pin304prevents the trim piece24from moving a distance from the vehicle chassis26that is greater than the predefined distance as discussed above. At this time, the trim piece24is prevented from moving away from the chassis by a distance that exceeds a predetermined value by the trim stop382of the fastener clip300.

FIG. 15is a perspective view of another exemplary fastener clip400in accordance with an embodiment of the present invention. The fastener clip400includes a body member402and a rigid retaining pin404. In the exemplary embodiment, the body member402and the retaining pin404are each fabricated from a plastic material as a unitary structure and then separated to form the fastener clip400as discussed below. As such, both the body member402and the retaining pin404, and all components included in each, are fabricated as part of a unitary structure to form fastener clip400. Optionally, the body member402and the retaining pin404may be fabricated as separate components that are coupled together to form fastener clip400.

FIG. 16is a side section view of the exemplary fastener clip400shown inFIG. 15in accordance with an embodiment of the present invention.FIG. 17is another side section view of the exemplary fastener clip400shown inFIG. 15in accordance with an embodiment of the present invention. In the exemplary embodiment, the body member402has a rectangular cross-sectional profile to enable the fastener clip400to be at least partially inserted into the rectangular opening28in the vehicle chassis26and the rectangular opening30in the trim piece24(shown inFIG. 2) which will be discussed below. The body member402has a length418and a width420that is less than the length418. In the exemplary embodiment, the length418and width420of the body member402is slightly less than the length122and width124of opening28to enable the fastener clip400to be at least partially inserted into the opening28in the vehicle chassis26. The sides that form body member402also define an opening430that extends through the fastener body member402. The fastener body opening430is configured to receive the retaining pin404therein.

The body member402also includes a flange member436that is disposed approximately midpoint between the upper and lower surfaces of the body member402. As shown inFIGS. 16 and 17, the flange member436extends outwardly from the body member402. Optionally, the flange member436may have any shape. In use, the flange member436increases the strength and rigidity of the fastener clip400and also functions as a stop device. More specifically, since the flange member436has a diameter that is larger than the size of the opening28, the flange member436limits the travel of the fastener clip400when the fastener clip400is installed into opening28which will be discussed below. The body member402may also include a flexible member438that is formed between the flange member436and a lower surface434. In the exemplary embodiment, the flexible member438is concave and has a circular cross-sectional profile. The flexible member438is configured to deform when the fastener clip400is installed into the opening28. This deformation results in a slight pressure being exerted between the vehicle chassis26and the fastener clip400to limit movement of the fastener clip400when installed in the opening28.

The fastener clip400also includes a pair of flexible retention legs440that are formed between the flexible member438and the lower surface434. More specifically, the fastener clip400includes a first retention leg442that is formed in a first side410of body member402and a second retention leg444that is formed in a second side412of body member402. As shown inFIG. 17, the pair of retention legs440each has a triangular shape to enable the fastener clip400to be inserted within the opening28while also retaining the fastener clip400within opening28. Optionally, the retention legs440may have a shape other than triangular. More specifically, the pair of retention legs440deform inwardly towards body member402to enable the fastener clip400to be inserted into opening28. After the fastener clip400is inserted into opening28, the pair of retention legs440deform outwardly from body member402to enable the fastener clip400to be retained within opening28.

Similar to the fastener clips described above, the fastener clip400is fabricated from a plastic material as a unitary structure, as such, both the body member402and the retaining pin404, and all components included in each, are fabricated as part of the unitary structure of fastener clip400. In the molding position, the body member402is aligned with the retaining pin404along a common axis, shown inFIG. 16as the Z-axis. During the molding process, common molding gates are formed at an intersection between the body member402and the retaining pin404. This initially results in vestiges being formed at the intersection between the body member402and the retaining pin404. After the molding process is completed, the molding gates or vestiges are broken by moving the retaining pin404along the Z-axis with respect to the body member402. Specifically, the retaining pin404is forced into the fastener body opening430.

FIG. 18is a side section view of the exemplary fastener clip400shown inFIG. 15in the installed position in accordance with an embodiment of the present invention. As shown inFIG. 18, the retaining pin body402is substantially rectangular to enable the retaining pin404to be inserted into the body member opening430and the retaining pin trim stop482is substantially circular. Optionally, the trim stop482may have any shape.

The retaining pin404also includes a pair of catch members470that are disposed proximate to a retaining pin second end464. In the exemplary embodiment, the combination of the retaining pin second end464and the catch members470form a substantially arrow-shaped member. More specifically, the catch members470each have a first end472that is formed unitarily with the retaining pin second end464and a second end474that extends outwardly from the retaining pin body460.

In operation, the catch members470enable the retaining pin404to be inserted within the body member opening430while also securing the retaining pin404within the body member402. More specifically, after the molding process is completed, a portion of the retaining pin404that includes the pair of catch members470, are forced through the body member opening430until the pair of catch members470are positioned past a pair of stops476. The pair of stops476then prohibit the retaining pin404from being removed from the body member402after the retaining pin404has been inserted therein. Optionally, the retaining pin404may also include a pair of catch members473that extend outwardly from a shoulder480and are configured to “snap” to the flange member436. During operation, when the airbag is deployed, both the trim piece24and the retaining pin404move away from the chassis. This movement causes the pair of catch members473to disengage from the flange member436thus allowing the retaining pin404to move away from the body member402as is discussed below.

During installation, the catch members470are each configured to deform inwardly towards body member402to enable the retaining pin404to be inserted into the body member402. After the retaining pin404is inserted into the body member402, the catch members470are configured to deform outwardly from the retaining pin body460and contact the inner surface of the retaining pin body460.

As shown inFIG. 18, the retaining pin404also includes a shoulder480. In the exemplary embodiment, the shoulder480is positioned a predetermined distance from the catch member second ends474. For example, assuming that it is desired that the trim piece24separate from the vehicle chassis26by approximately one inch when the airbag is deployed, the shoulder480is positioned approximately one inch from the catch member second ends474. Optionally, retaining pin404does not include the shoulder480. The shoulder480may be formed anywhere along the retaining pin404between the catch members470and a retaining pin first end462. For example, to increase the distance that the trim piece24separates from the chassis26, the shoulder480may be formed nearer the retaining pin first end462. Optionally, to decrease the distance that the trim piece24separates from the chassis26, the shoulder480may be formed nearer the catch members470.

The retaining pin404also includes a trim stop482that is disposed on the retaining pin first end462. As shown inFIG. 18, the trim stop482is disposed approximately parallel to the shoulder480and approximately perpendicular to the body member402, and thus the body member opening430. The trim stop482is substantially circular and includes a diameter484. Optionally, the trim stop482has a shape other than circular. In the exemplary embodiment, the fastener clip400is configured to be installed into the exemplary trim piece24shown inFIGS. 13A and 13B. Referring toFIGS. 13A and 13B, the trim piece24includes the trim piece opening331includes a first opening332and a second opening333that is coextensive with the first opening332. In the exemplary embodiment, the diameter of trim stop482is less than a diameter383of the first opening332to enable the trim stop482to be inserted through the opening331in the trim piece24during installation.

For example, as shown inFIG. 13A, and in the exemplary embodiment, the trim stop482is inserted through the first opening332in the trim piece24. The fastener clip400, including trim stop482is then moved laterally to engage the second opening333that is coextensive with the first opening332. Since a diameter387of the second opening333is less than the diameter484of the trim stop482, the trim stop is either friction fit into the second opening333or may be secured in the second opening333using a mechanical lock formed as part of the trim piece itself. The trim piece assembly, i.e. the trim piece24and fastener clip400may then be coupled to the vehicle chassis26using the pair of retention legs440, as shown inFIG. 17. Optionally, the fastener clip400may first be coupled to the chassis26. The trim piece24may then be coupled to the fastener clip400as described above.

FIG. 19illustrates the fastener clip400in a deployed position. As shown inFIG. 18, in the standby position, the retaining pin404is fully inserted into the body member opening430. More specifically, the retaining pin404is inserted into the body member opening430until the retaining pin shoulder480contacts the flange member436. As discussed above, the flange member436provides a positive stop for the retaining pin404when the retaining pin404is inserted into the body member opening430. When the airbag20is deployed, i.e. a predetermined force is applied to the trim piece24, the trim piece24moves away from the vehicle chassis26as shown inFIG. 19. As shown inFIGS. 13A and 13B, since the dimension of the trim stop482is larger than the dimension of the opening in the trim piece24, the trim piece24remains coupled to the fastener clip400. As such, when the airbag is deployed, both the trim piece24and the retaining pin404move away from the chassis. This movement continues, until the pair of catch members470make contact with the pair of stops476. The pair of stops476then prohibit the retaining pin404, and thus the trim piece24, from moving further from the chassis. As a result, the retaining pin404prevents the trim piece24from moving a distance from the vehicle chassis26that is greater than the predefined distance as discussed above. At this time, the trim piece24is prevented from moving away from the chassis by a distance that exceeds a predetermined value by the trim stop482of the fastener clip300.

FIG. 20is perspective view of another exemplary fastener clip500in accordance with an embodiment of the present invention. Fastener clip500includes a body member502and a rigid retaining pin504. In the exemplary embodiment, the body member502and the retaining pin504are each fabricated from a plastic material as separate unitary structures and then coupled together to form the fastener clip500as discussed below. In the exemplary embodiment, the body member502is substantially cylindrical to enable the substantially cylindrical fastener clip500to be at least partially inserted into a cylindrical opening29(shown inFIG. 1) in the vehicle chassis26and an opening331in trim piece24which will be discussed below.

FIG. 21is a side view of the exemplary body member502shown inFIG. 20in accordance with an embodiment of the present invention. As shown inFIG. 21, the body member502has a first end514and an opposite second end516. The first end514is disposed approximately perpendicular to a side510of the body member502. Body member502has a diameter518that is substantially similar to a diameter319of the cylindrical opening29in the vehicle chassis26.

The side510of the body member502defines an opening530that extends therethrough. The body member opening530is configured to receive the retaining pin504therein. As such, the body member opening530extends from the first end514to the second end516of the body member502.

The body member502also includes a flange member536that is disposed proximate to the first end514of the body member502. As shown inFIGS. 20 and 21, the flange member536extends outwardly from the body member side510. In use, the flange member536increases the strength and rigidity of the fastener clip500and also functions as a stop device. More specifically, since the flange member536has a diameter537that is larger than the diameter319of the opening29in the vehicle chassis26, the flange member536limits the travel of the fastener clip500when the fastener clip500is installed into the opening29which will be discussed below. In the exemplary embodiment, the flange member536is circular, flexible and concave. The flange member536is configured to deform when the fastener clip500is installed into the opening29. This deformation results in a slight pressure being exerted between the vehicle chassis26and the fastener clip500to limit movement of the fastener clip500when installed in the opening29.

As shown inFIG. 21, the fastener clip500also includes a plurality of flexible retention legs540that are formed between the flange member536and the second end516. In the exemplary embodiment, the fastener clip500includes three retention legs540that are each spaced apart by approximately 120 degrees. It should be realized that fastener clip500may have two or more retention legs540. The plurality of retention legs540each have a triangular shape to enable the fastener clip500to be inserted within the opening29while also retaining the fastener clip500within opening29. More specifically, the plurality of retention legs540are configured to deform inwardly towards body member502to enable the fastener clip500to be inserted into opening29. After the fastener clip500is inserted into opening29, the retention legs540are configured to deform outwardly from body member502to enable the fastener clip500to be retained within opening29.

FIG. 22is a bottom view of the body member502shown inFIGS. 20 and 21. As shown inFIG. 22, the body member502includes a first set of channels542, referred to herein as installation channels542and a second set of channels544, that are referred to herein as operational channels544. As shown inFIG. 22, and in the exemplary embodiment, body member502includes N installation channels542and N operational channels544that are parallel to the N installation channels542. In the exemplary embodiment, N is equal to the quantity of catch members570(shown inFIG. 23) installed on the retaining pin504. For example, in the exemplary embodiment, the retaining pin504includes three catch members570, therefore the body member502includes three installation channels542and three operational channels544. As shown inFIG. 22, each of the respective operational channels544is disposed between an adjacent pair of installation channels542. Accordingly, each respective installation channel542is disposed between a pair of operation channels544.

Each operational channel544includes a channel surface546and a pair of channel walls548that are disposed on opposite sides of the channel surface546. During operation, a single catch member570is disposed between and maintained within the respective operational channel544via the pair of channel walls548. In the exemplary embodiment, the fastener clip500includes three operational channels544and thus includes three pairs of channel walls548, or one pair per operational channel544. As shown inFIG. 22, the channel walls548extend axially along the inner surface of the body member502. The channel walls548extend from the fastener first end514towards the fastener second end516. In the exemplary embodiment, the channel walls548have a length550that is slightly less than a length552of the body member502to enable sufficient clearance for the fastener pin504to be rotated within the body member502as will be discussed below. Each installation channel542also includes a depth554and each operational channel544has a depth556that is greater than the installation channel depth554.

The body member502also includes a plurality of fastener pin stops576. In the exemplary embodiment, the body member502includes N pin stops576that are adapted to prohibit the retaining pin504from being removed from the body member502after the retaining pin504has been inserted therein. In the exemplary embodiment, the body member502includes three pin stops576, wherein each respective pin stop576is disposed within a respective operation channel544proximate to the first end514. As shown inFIG. 22, the combination of the pair of channel walls548and a single pin stop576form a substantially three-sided operational channel544, wherein the pair of channel walls548substantially limit the movement of the retaining pin504in a radial direction and the pin stop576limits the movement of the retaining pin504in an axial direction towards the first end514.

FIG. 23is a side view of the exemplary retaining pin504. The retaining pin504includes a cylindrical body560having a first end562and a second end564. The retaining pin body560is substantially cylindrical to enable the retaining pin504to be inserted into the body member opening530. As shown inFIG. 23, the retaining pin504also includes N catch members570that are disposed proximate to the retaining pin second end564. More specifically, the body member includes N=3 operational channels and the retaining pin504includes N=3 catch members570that are each adapted to move within a respective operational channel544. In the exemplary embodiment, the combination of the retaining pin second end564and the catch members570form a substantially arrow-shaped member. More specifically, the catch members570each have a first end572that is formed unitarily with the retaining pin second end564and a second end574that extends outwardly form the retaining pin body560.

In operation, the catch members570enable the retaining pin504to be inserted within the body member opening530while also securing the retaining pin504within the body member502which will be discussed in more detail below. The retaining pin504also includes a shoulder580that is formed between the catch members570and the retaining pin first end562. In the exemplary embodiment, the shoulder580is positioned a predetermined distance from the catch member second ends574. For example, assuming that it is desired that the trim piece24separate from the vehicle chassis26by approximately one inch when the airbag is deployed, the shoulder580is positioned approximately one inch from the catch member second ends574. Optionally, retaining pin504does not include the shoulder580. The shoulder580may be formed anywhere along the retaining pin504between the catch members570and the retaining pin first end562. For example, to increase the distance that the trim piece24separates from the chassis26, the shoulder580may be formed nearer the retaining pin first end562. Optionally, to decrease the distance that the trim piece24separates from the chassis26, the shoulder580may be formed nearer the catch members570.

The retaining pin504also includes a trim stop582that is disposed on the retaining pin first end562. As shown inFIG. 23, the trim stop582is disposed approximately parallel to the shoulder580and approximately perpendicular to the body member502, and thus the body member opening530. The trim stop582is substantially hexagonal and includes a plurality of “flats”583that enable an operator to grasp and operate the retaining pin504. Optionally, the trim stop582may have any shape that facilitates allowing an operator to turn or move the retaining pin504. The trim stop582also has a diameter584. The trim piece opening331(shown inFIGS. 13A and 13B) includes a first opening332and a second opening333that is coextensive with the first opening332. In the exemplary embodiment, the diameter584of trim stop582is less than a diameter383of the first opening332to enable the trim stop582to be inserted through the opening331in the trim piece24during installation.

The retaining pin504also includes a channel or groove590that is formed in a radial direction around an outer surface592of the retaining pin body. In the exemplary embodiment, the groove590is adapted to receive a plurality of flexible tabs594that are shown inFIGS. 20 and 22. During operation, the flexible tabs594that are formed with or coupled to the body member502cooperate with the groove590to resist the retaining pin504from being removed from the body member502after installation.

To assemble the fastener device500, the second end564of retainer pin504is positioned proximate to and axially aligned with the first end514of the body member502and such that retaining pin catch members570are axially aligned with the installation channels542. More specifically, each pin catch member570is axially aligned with a respective installation channel542. During installation, the retaining pin catch members570are retained within the installation channels542via the channel walls548. The retaining pin504is inserted into the body member502until the shoulder580of the retaining pin504contacts the first end514of the body member502as shown inFIG. 24. At this point, the plurality of flexible tabs594deflect radially inwardly and seat within the groove590. During operation, the plurality of flexible tabs594provide some resistance to inhibit the retaining pin504from being removed from the body member502during normal operation, i.e. when the airbag is not deployed. However, it should be realized that the resistance or pressure exerted on the groove590by the flexible tabs594is less than the pressure exerted by the airbag during deployment such that during airbag deployment, the flexible tabs594disengage from the groove590to enable the trim piece24to separate from the vehicle chassis26.

Once the retaining pin504is inserted into the body member502until the shoulder580of the retaining pin504contacts the first end514of the body member502, the retaining pin504is rotated until the catch members570are disposed within the operational channels544. More specifically, as shown inFIG. 22, the body member502includes a small gap that is formed in the channel walls548to enable the retaining pin catch members570to be repositioned or moved from the installation channels542to the operational channels544. As discussed above, the operational channels544have a depth556that is greater than the depth554of the installation channels. Accordingly, when the retaining pin504is rotated, via the flats583, and the catch members570move radially from the installation channels542into the operational channels544, the flexible catch members570deform or deflect radially outwardly until they contact the channel surface546. At this point, the retaining pin504is inhibited from rotating within the body member502because the catch members570are each radially securing within a respective operational channel544. Moreover, when the flexible catch members570deform or deflect radially outwardly within the operational channel544, the deflection of the catch members570causes an audible and tactile indication to the operator, thus allowing an operator to know when the retaining pin504is correctly installed within the body member502. The exemplary fastener clip may then be installed within the vehicle.

For example, referring again toFIG. 13A, the trim stop portion582of the fastener clip500is inserted through the opening331of the trim piece24. The fastener clip500, including trim stop582is then moved laterally to engage the second opening333that is coextensive with the first opening332. Since a diameter387of the second opening333is less than the diameter584of the trim stop582, the trim stop582is friction fit into the second opening333. The trim piece assembly, i.e. the trim piece24and fastener clip500may then be coupled to the vehicle chassis26using the pair of retention legs540, as shown inFIG. 21. Optionally, the fastener clip500may first be coupled to the chassis26. The trim piece24may then be coupled to the fastener clip500as described above.

FIG. 24illustrates the fastener clip500in a standby or non-deployed position. As shown inFIG. 24, in the standby position, the retaining pin504is fully inserted into the body member opening530. When the airbag20is deployed, i.e. a predetermined force is applied to the trim piece24, the trim piece24moves away from the vehicle chassis26. As shown inFIGS. 13A and 13B, since the dimension of the trim stop582is larger than the dimension of the opening332in the trim piece24, the trim piece24remains coupled to the fastener clip500. As such, when the airbag is deployed, both the trim piece24and the retaining pin504move away from the vehicle chassis26. This movement causes the flexible tabs594to disengage from the groove590since the pressure exerted on the groove590by the flexible tabs594is less than the pressure exerted by the airbag during deployment. The retaining pin504continues to move away from the body member502until the plurality of catch members570make contact with the plurality of stops576(shown inFIGS. 22 and 24). The plurality of stops576then prohibit the retaining pin504, and thus the trim piece24from moving further from the chassis. As a result, the retaining pin504prevents the trim piece24from moving a distance from the vehicle chassis26that is greater than the predefined distance as discussed above. At this time, the trim piece24is prevented from moving away from the chassis by a distance that exceeds a predetermined value by the trim stop582of the fastener clip500.

Described herein are fastener clips utilized to secure a trim piece to a vehicle chassis when the airbag is deployed. The fastener clips include a body fixedly coupled to a vehicle chassis and having an opening extending therethrough. In one embodiment, the opening is rectangular to receive a rectangular fastener clip body. Optionally, the opening is circular to receive a cylindrically shaped body. A rigid retaining pin is inserted through an opening in the fastener clip body. The rigid retaining pin has a first end that is secured within the body and a second end that is disposed outside the body. The rigid retaining pin includes an integral trim stop that limits the movement of a vehicle trim piece with respect to the vehicle chassis when the airbag is deployed.