Abstract:
A resilient clip for engaging a structure and having a body portion ( 22 ) with a pair of top flanges ( 24 ), a pair of fastening fingers ( 26 ) and a pair of abutting coupling flanges (28). Each of the fastening fingers ( 26 ) are coupled to the body portion ( 22 ) that is coupled to an associated top flange ( 24 ). Each of the abutting flanges ( 26 ) has a concave surface, which engages the mounting structure. The fastening finger ( 26 ) portions are configured to engage a first side of a mounting flange on an interior trim component.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates generally to resilient clip fasteners and more particularly to a resilient clip fastener that employs a particular surface geometry to secure the body portion of the resilient clip to a structure. More specifically, the present invention relates to a resilient clip fastener having a construction that utilizes abutment flanges to permit the clip to be inserted into an aperture with a relatively low insertion force while resisting relatively high withdrawal forces. The invention also relates to a resilient clip fastener having a construction that accounts in several manners for part-to-part variation between the structures that are to be fastened together.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many current vehicles employ resilient clips to secure various components to the vehicle body. One such application concerns interior panels that mount to the interior of the vehicle such as on the doors. Such panels serve not only to provide occupants with a convenient point to grasp during ingress to and egress from the vehicle, but also provide energy absorption during a crash event.  
           [0003]    During assembly of the vehicle, it is conventional procedure of the entire panel assembly to be installed onto the interior of the vehicle in a single operation. In other words, the panel assembly is passed through either the windshield or backlight opening of the vehicle body on the assembly line and then the panel assembly is secured by line operators to the interior of the vehicle.  
           [0004]    In order to accomplish this assembly task, the panel assembly is typically equipped with numerous fasteners, located around the periphery of the panel assembly as well as at predetermined locations around the interior area of the panel, that are adapted to penetrate through corresponding holes located in the reinforcing sheet metal members of the vehicle interior. It is the responsibility of the line operators to properly orient the panel assembly adjacent the interior of the vehicle and press the fasteners into the various mounting holes in the reinforcing sheet metal members to secure the panel assembly to the interior of the vehicle.  
           [0005]    For aesthetic reasons, the panel fasteners are typically secured in some fashion to the backside of the panel so that they are not visible from the interior of the vehicle after the panel assembly is installed. Consequently, it is often incumbent upon the line operators to blindly “feel” for the location of the mounting holes with their fingers before pressing the fasteners into the holes from the opposite show-surface side of the panel.  
           [0006]    Due to slight misalignments, which can occur between the fasteners and their corresponding mounting holes, some of the fasteners may not be properly seated and secured to the sheet metal.  
           [0007]    Accordingly, there remains a need in the art for an improved fastener having a relatively low installation force and a relatively high removal force that is relatively more tolerant of misalignment problems. Ideally, the fastener should be inexpensive to manufacture, reliable and simple to install. Furthermore, the fastener should be particularly adapted for securing structures to one another in a manner, which minimizes vibration, and the concomitant noise problems that are often associated with such fasteners.  
         SUMMARY OF THE INVENTION  
         [0008]    In one preferred form, the present invention provides a resilient clip for engaging a structure. The resilient clip includes a body portion having a pair of top flanges, a pair of fastening members and a pair of abutting flanges. Each of the fastening members has a base portion that is coupled to an associated top flange. Each of the abutting flanges has a concave surface that engages the mounting structure. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:  
         [0010]    [0010]FIG. 1 is a perspective view of a fastener constructed in accordance with the teachings of the present invention;  
         [0011]    [0011]FIG. 2 is a lower perspective view of the fastener of FIG. 1;  
         [0012]    [0012]FIG. 3 a  is a side view of a portion of the fastener of FIG. 1 illustrating the spacing of the structures in greater detail;  
         [0013]    [0013]FIGS. 3 b  and  3   c  depict cross-sectional views of the fastener depicted in FIG. 3 a;    
         [0014]    [0014]FIG. 4 is a side view of a fastener constructed in accordance with the teachings of the preferred embodiment of the present invention;  
         [0015]    [0015]FIG. 5 a  is a top view of a portion of the fastener of FIG. 1, illustrating the clip structure in greater detail;  
         [0016]    [0016]FIGS. 5 b  and  5   c  depict cross-sectional views of the fastener depicted in FIG. 5 a;    
         [0017]    [0017]FIG. 6 is a lower perspective view of the fastener of FIG. 1;  
         [0018]    [0018]FIG. 7 is a bottom view of the fastener of FIG. 1;  
         [0019]    [0019]FIG. 8 is a perspective view of the fastener of FIG. 1;  
         [0020]    [0020]FIG. 9 is an exploded perspective view showing the fastener being used to mount an interior trim component;  
         [0021]    [0021]FIGS. 10 a  and  10   b  show the insertion of the fastener;  
         [0022]    [0022]FIG. 11 is a cross-sectional view of the fastener of FIG. 10 with corresponding trim component  
         [0023]    [0023]FIG. 12 is a perspective view of a fastener constructed in accordance with the teachings of a second embodiment of the present invention;  
         [0024]    [0024]FIG. 13 is a lower perspective view of the fastener of FIG. 12;  
         [0025]    [0025]FIG. 14 a  is a side view of a portion of the fastener of FIG. 13 illustrating the spacing of the structures in greater detail;  
         [0026]    [0026]FIGS. 15 b  and  15   c  depict cross-sectional views of the fastener depicted in FIG. 14 a;    
         [0027]    [0027]FIG. 16 is a side view of a fastener constructed in accordance with the teachings of the preferred embodiment of the present invention;  
         [0028]    [0028]FIG. 17 a  is a top view of a portion of the fastener of FIG. 12, illustrating the clip structure in greater detail;  
         [0029]    [0029]FIGS. 5 b  and  5   c  depict cross-sectional views of the fastener depicted in FIG. 5 a;    
         [0030]    [0030]FIG. 16 is a lower perspective view of the fastener of FIG. 12;  
         [0031]    [0031]FIG. 17 is a bottom view of the fastener of FIG. 12;  
         [0032]    [0032]FIG. 18 is a perspective view of the fastener of FIG. 12;  
         [0033]    [0033]FIG. 19 is an exploded perspective view showing the fastener being used to mount an interior trim component;  
         [0034]    [0034]FIGS. 20 a  and  20   b  show the insertion of the fastener; and  
         [0035]    [0035]FIG. 21 is a cross-sectional view of the fastener of FIG. 20 with corresponding trim component 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0036]    Referring to FIGS. 1 through 8, a generally U-shaped fastener  20  in accordance with the present invention is disclosed. The generally U-shaped fastener  20  is defined by a body portion  22  and a pair of top flanges  24 . Integral with the top flanges  24  are two pair of finger members  26  which are used to couple the generally U-shaped fastener  20  to a mounting flange (shown in FIG. 11). Additionally, the body portion  22  has a pair of abutting flanges  28  which generally lie outside side members  29  and  30  of the body portion  22 . The side members, which are coupled by a bottom curved member  29  and  30 , define a pair of apertures  32  and  33 , which allow for the inward compression of the abutting flanges  28 .  
         [0037]    Generally, the abutting flanges  28  are defined by three portions. The first portion  36  is defined by an exterior concave engaging surface  50 . The second portion  37 , which acts as a transition to the third portion  38 , is defined by a convex surface. The third portion  38  functions to couple the abutting flange  28  to the base portion  40  of the body  22  of the generally U-shaped fastener  20 .  
         [0038]    [0038]FIG. 3 a  depicts a side view of the generally U-shaped fastener  20  of the current invention. Shown is the relationship of the finger members  26  to the abutting flanges  28 , which are formed within the aperture  32 . As best seen in FIGS. 3b and 4, the tips  42  of the finger members  26  are angled to frictionally engage a flange member  54  of a trim component  60 . FIG. 3 b  shows the relationship of the third portion  38  to the base member  40  of the body portion  22 .  
         [0039]    [0039]FIG. 4 is a side view of the U-shaped fastener  20  and shows the relationship of the abutting flanges  28  to the body portion  22 . As can be seen, the top flanges  24  defines an upper keyhole slot  46  which allow the movement of the abutting flanges  28  when they are compressed. Further depicted is the angular relationship of the side members  29  and  30  of the body portion with respect to the base  40  and the top flanges  24 . It must be noted that while the finger member  26  are shown, any suitable fastener is usable. This includes but is not limited to a hole, threaded hole, slots or flanges.  
         [0040]    [0040]FIG. 5 a  depicts a top view of the generally U-shaped fastener  20 . Defined by the side members  29  and  30  is a slot  48  which is used to engage the coupling flange  54  (see FIGS. 9 and 11) of a trim component  60 . The exterior concave surface  50  of the abutting flanges  28  are used to engage sheet metal to hold the fastener in place. Also depicted is the interior surface  52  of the finger members  26 , which engage the surfaces of the coupling flange  54 .  
         [0041]    [0041]FIG. 5 b  is a cross-section of the fastener as shown in FIG. 5 a.  Depicted is the relationship of the abutting flanges  28  with the base member  40 . Further, the cross-section details the radius of the exterior concave surface  50 . The radius of the concave surface  50  generally can be between 3.5 to 6.0 millimeters and preferably 4.75 millimeters. The center of curvature for the radius R is between 2 and 4 millimeters from the top of the fastener and preferably 2.3 millimeters. FIG. 5 c  best details the relationship of the finger members  26  to the top flanges  24  and the first and second flange members  43  and  44 .  
         [0042]    [0042]FIGS. 6 through 8 are depictions of the U-shaped fastener  20  of the current invention with hidden components shown in phantom. Depicted is the relationship of the fastener components with various surfaces of the fastener.  
         [0043]    [0043]FIG. 9 depicts the use of the U-shaped fastener  20  of the current invention. Shown is a sheet metal structure  56 , which defines a pair of apertures  58 . The apertures  58  are designed to accept the U-shaped fastener  20  to allow for the mating of a trim component  60  to the sheet metal  56 . The trim component  60  has a pair of flanges  54 , which are inserted, into the slot  48  of the U-shaped fastener  20 .  
         [0044]    As best seen in FIG. 10, the U-shaped fastener  20  is inserted into the aperture  58  of the sheet metal structure  56 . As the fastener  20  is depressed into the aperture  58 , the abutting flanges  28  are compressed toward each other and the centerline of the U-shaped fastener  20 . This compression of the abutting flanges  28  continues until the sheet metal  56  of the aperture  58  reaches the second portion  37  of the abutting flanges. At this point, a transition occurs and the sheet metal  56  is allowed to engage with the concave surface  56  of the first portion  36  of the abutting flanges  28 .  
         [0045]    [0045]FIG. 11 depicts the coupling of the trim component  60  to the U-shaped fastener  20 . Shown is the coupling flange  54  inserted between the finger members  26  of the U-shaped fastener  20 .  
         [0046]    It has been shown that the current fastener  20  is significantly more easy to insert into a sheet metal structure  56  than it is to remove. For example, the fastener as depicted has a required insertion force of about 10 pounds and a removal force of greater than 20 pounds.  
         [0047]    Referring to FIGS. 12 through 20, a generally U-shaped fastener  20  in accordance with a second embodiment of the present invention is disclosed. The generally U-shaped fastener  120  is defined by a body portion  122  and a pair of top flanges  124 . Integral with the top flanges  124  are two pair of first finger member  126  and a pair of second finger member  127  which are used to couple the generally U-shaped fastener  120  to a mounting flange (shown in FIG. 20). Additionally, the body portion  122  has a pair of abutting flanges  128  which generally lie outside the side members  129  and  130  of the body portion  122 . The side members  129  and  130  define a pair of apertures,  132  and  133 , which allow for the inward compression of the abutting flanges  128 .  
         [0048]    Generally, the abutting flanges  128  are defined by three portions. The first portion  136  is defined by an exterior concave engaging surface  150 . The second portion  137 , which acts as a transition to the third portion  138 , is defined by a convex surface. The third portion  138  functions to couple the abutting flange  128  to the base portion  140  of the body  122  of the generally U-shaped fastener  120 .  
         [0049]    [0049]FIG. 14 a  depicts a side view of the generally U-shaped fastener  120  of the second embodiment of the current invention. Shown is the relationship of the first finger member  126  and second finger member  127  to the abutting flanges  128 , which are formed within the aperture  132 . As best seen in FIGS. 14 b  and  15 , the tips  142  of the first finger member  126  and the tips  143  of the second finger member  127  are angled to frictionally engage a flange member  154  of a trim component  160 . The angle of the first finger member  126  can be between about 15° to 25° and preferably about 20°, while the angle of the second finger member  127  can be between about 50° to 60° and preferably about 55°. FIG. 14 b  shows the relationship of the third portion  138  to the base member  140  of the body portion  122 .  
         [0050]    [0050]FIG. 15 is a side view of the U-shaped fastener  120  and shows the relationship of the abutting flanges  128  to the body portion  122 . As can be seen, the top flanges  124  defines an upper keyhole slot  146  which allow the movement of the abutting flanges  128  when they are compressed. Further depicted is the angular relationship of the side members  129  and  130  of the body portion with respect to the base  140  and the top flanges  124 . It must be noted that while the finger members  126  and  127  are shown, any suitable fastener is usable. This includes but is not limited to a hole, threaded hole, slots or flanges.  
         [0051]    [0051]FIG. 15 a  depicts a top view of the generally U-shaped fastener  120 . Defined by the side members  129  and  130  is a slot  148  which is used to engage the coupling flange  154  (see FIGS. 19 and 21) of a trim component  160 . The exterior concave surface  150  of the abutting flanges  128  are used to engage sheet metal to hold the fastener in place. Also depicted is the interior surface  152  of the first and second finger members  126  and  127 , which engage the surfaces of the coupling flange  154 .  
         [0052]    [0052]FIG. 15 b  is a cross-section of the fastener as shown in FIG. 15 a.  Depicted is the relationship of the abutting flanges  128  with the base member  140 . Further, the cross-section details the radius of the exterior concave surface  150 . The radius of the concave surface  150  generally can be between 3.5 to 6.0 millimeters and preferably 4.75 millimeters. The center of curvature for the radius R is between 2 and 4 millimeters from the top of the fastener and preferably 2.3 millimeters. FIG. 15 c  best details the relationship of the first finger member  126  to the top flanges  124  and the first and second flange members  143  and  144 .  
         [0053]    [0053]FIGS. 16 through 18 are depictions of the U-shaped fastener  120  of the current invention with hidden components shown in phantom. Depicted is the relationship of the fastener components with various surfaces of the fastener.  
         [0054]    [0054]FIG. 19 depicts the use of the U-shaped fastener  120  of the current invention. Shown is a sheet metal structure  156 , which defines a pair of apertures  158 . The apertures  158  are designed to accept the U-shaped fastener  120  to allow for the mating of a trim component  160  to the sheet metal  156 . The trim component  160  has a pair of flanges  154 , which are inserted, into the slot  148  of the U-shaped fastener  120 .  
         [0055]    As best seen in FIG. 20, the U-shaped fastener  120  is inserted into the aperture  158  of the sheet metal structure  156 . As the fastener  120  is depressed into the aperture  158 , the abutting flanges  128  are compressed toward each other and the centerline of the U-shaped fastener  120 . This compression of the abutting flanges  128  continues until the sheet metal  156  of the aperture  158  reaches the second portion  137  of the abutting flanges. At this point, a transition occurs and the sheet metal  156  is allowed to engage with the concave surface  156  of the first portion  136  of the abutting flanges  128 .  
         [0056]    [0056]FIG. 21 depicts the coupling of the trim component  160  to the U-shaped fastener  120 . Shown is the coupling flange  154  inserted between the first and second finger members  126  and  127  of the U-shaped fastener  120 .  
         [0057]    It has been shown that the current fastener  120  is significantly more easy to insert into a sheet metal structure  156  than it is to remove. For example, the fastener as depicted has a required insertion force of about  10  pounds and a removal force of greater than 20 pounds.  
         [0058]    The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such a discussion, and from the accompanying drawings and claims that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention.