Abstract:
A magnet fastener includes a carrier connectable to a first component and a magnet for attachment to a second, metal component. The carrier includes structures for holding a magnet assembly including the magnet in a manner that reduces rattle caused by vibration but provides flex so the magnet can articulate and adjust to a surface of the metal component.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present regular United States patent application claims the benefits of U.S. Provisional Application Ser. No. 61/031,275, filed on Feb. 25, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to blind fasteners adapted to secure one panel or structure to another panel or structure, and, more specifically to blind fasteners that employ magnets fastened to one structure and secured to a metal structure. 
       BACKGROUND OF THE INVENTION 
       [0003]    Different types of fasteners are used in structures and assemblies to secure one panel or covering to another component of the structure or assembly. Fasteners of various types are particularly useful in automobile assemblies to secure headliners, interior panels, trim pieces and the like to roofs, door structures and other components. In some instances, one or more of the structures is relatively thin, and connecting a fastener thereto can be difficult, time-consuming or otherwise costly. 
         [0004]    A problem with some known types of fasteners is that the fastener must be secured in a hole, slot, doghouse or other mating structure after the fastener has been secured to one of the components being connected together. Often, this results in a blind installation because the assembler is not able to view either the fastener or the mating structure in the component to which the fastener is being attached. To facilitate installation of fasteners in blind fastening situations, when one of the structures is a suitable metal, it is known to use magnetic fasteners, thereby eliminating the difficulty of a blind fastener application. The magnet is attached to one component of any material and will connect to a metal second component whenever the magnet fastener is brought in close proximity to the underlying metal structure. Known magnet fasteners are an assembly of a plastic base and a magnet assembly retained therein, with the plastic base secured to a nonmetallic component in typical fashion, such as by adhesive, and the magnet held to the metal component. With magnet fasteners, the assembler is not required to align a fastener with a mating hole and attach the fastener to the hole. The assembler need only bring the first component with the magnet fastener attached thereto into the desired final position relative to a metallic second component and the magnet fastener attaches thereto magnetically. 
         [0005]    While magnetic fasteners of the type generally described have facilitated installations in many blind fastening situations, there is a continuing need for improved structures and arrangements for such fasteners. It is desirable for the fastener to have some yield or flexibility incorporated therein. During installation some fabric components can be moved, stretched or twisted inconsistently. Once installed, during use of an automobile, for example, the headliner is sometimes contacted or pushed by passengers. The components being connected together can have irregular or curved surfaces. Accordingly, it is desirable for the magnet to move as necessary to establish and maintain the magnet connection to the metallic component. However, since magnet fasteners can be used in vehicle interiors, for example, any rattling sound from vibration of the fastener can be objectionable. It is known to provide a compliant washer of foam or the like between the magnet assembly and the plastic base to minimize rattles. While such structures have been effective, the additional part of the foam washer adds cost to the fastener and can complicate assembly and installation of the fastener. Further, if the washer deteriorates over time the effectiveness in minimizing rattle is reduced. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides a fastener having a carrier that attaches to a first structure and holds a magnet assembly for connection to a metallic structure. The carrier holds the magnet assembly in a non-rattling yet yielding position. 
         [0007]    In one aspect of one form thereof, the present invention provides a fastener with a carrier having a receiver including a floor and a holder. A magnet assembly is disposed in the receiver and is held therein between the floor and a portion of the holder engaging a first side of the magnet assembly. A biasing element of the floor is engaged against a side of the magnet assembly opposite the first side. 
         [0008]    In another aspect of another form thereof, the present invention provides a carrier for a magnet fastener, for retaining a magnet assembly, the carrier having a floor, a wall at least partly surround the floor at the perimeter thereof and a post extending from the floor. A deflectable portion of the post extends outwardly from the post. A biasing element of the floor is configured for biasing a magnet assembly toward the deflectable portion of the post. 
         [0009]    In a still further aspect of a still further form thereof, the present invention provides a magnet fastener with a fastener carrier including a receiver having a floor, a wall at least partly surrounding the floor, and a post extending away from the floor. Securing mounts extend away from the receiver and are adapted for attaching the fastener carrier to a component. The post is hollow and defines openings therein. The post has outwardly angled tabs aligned with the openings, the tabs being deflectable toward the openings. A magnet assembly includes a cup disposed on the post and a magnet disposed in the cup, the cup having a bottom encircling the post between the floor and the tabs. Biasing elements of the floor urge the bottom of the cup against the tabs. 
         [0010]    An advantage of the present invention in one form is providing a magnet fastener that includes a yielding magnet assemble to conform and align to a surface to which it connects. 
         [0011]    Another advantage of the present invention in another form is providing a magnet fastener that facilitates blind connections and that is simple and easy to assemble and install. 
         [0012]    A further advantage of the present invention in a further form is providing a magnet fastener that reduces relative vibration between parts thereof and minimizes rattle and sounds that could result from vibration. 
         [0013]    Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a perspective view of a magnet fastener having a magnet assembly retained by a carrier in accordance with the present invention; 
           [0015]      FIG. 2  is a cross sectional view of the fastener shown in  FIG. 1 , illustrating the fastener installed in an assembly of first and second components held by the fastener; 
           [0016]      FIG. 3  is a perspective view of the carrier portion of the fastener shown in  FIGS. 1 and 2 ; 
           [0017]      FIG. 4  is a perspective view of the bottom of the carrier; 
           [0018]      FIG. 5  is a side elevational view of the carrier; and 
           [0019]      FIG. 6  is top plan view of the carrier. 
       
    
    
       [0020]    Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including”, “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0021]    Referring now more specifically to the drawings and to  FIG. 1  in particular, numeral  10  designates a magnet fastener having a carrier  12  in accordance with the present invention. Fastener  10  further includes a magnet assembly  14  held by carrier  12 , the magnet assembly having a cup  16  and a magnet  18  held in cup  16 . Carrier  12  can be made of plastic by injection molding or other suitable processes. In a preferred embodiment, cup  16  is made of metal so that magnet  18  can be carried and retained therein without independent attachment means, although for added security adhesive can be used. Magnet assembly  14  is connected to carrier  12  by attaching structure on carrier  12  to be explained subsequently herein. 
         [0022]    Carrier  12  includes a receiver  20  in which magnet assembly  14  is held and outwardly extending securing mounts  22 ,  24  by which carrier  12  can be attached to a component for which fastener  10  is to be used. In the exemplary embodiment shown, mounts  22 ,  24  are substantially rectangular extensions and may define holes or openings  26  for insertion of fasteners, or for receiving adhesive, or the like. By way of example and not limitation,  FIG. 2  illustrates fastener  10  securing a first component  28 , which may be an automobile headliner, for example, to a metallic second component  30 , which may be an automobile roof. Securing mounts  22 ,  24  can be attached to the first component  28  by various methods, including, for example, gluing, welding, heat staking, pins or fasteners inserted through holes  26 , or by an arrangement in which mounts  22 ,  24  are inserted into mating features or pockets (not shown) in the component. It should be understood that the principles of the present invention can be used in fasteners of other types and for many different purposes. 
         [0023]    Accordingly, the shape and construction of the securing mounts  22 ,  24  can be other than the rectangular panels shown. With fastener  10  physically attached or connected to first component  28 , the first component is then held to second component  30  by magnet  18 . 
         [0024]    Receiver  20  of the exemplary embodiment is a generally rounded structure, although other shapes and configurations also can be used. As seen most clearly in  FIG. 3 , receiver  20  includes a floor  32  and walls  34 ,  36 . In the exemplary embodiment, walls  34 ,  36  are on opposite sides of floor  32  and define spaces  38 ,  40  there between on opposite ends. However, it should be understood that a single continuous wall around floor  32  also can be used, as well as more than two wall segments. Further, in some situations it may be advantageous to provide carrier  12  without mounts  22 ,  24  and without a sidewall around the floor. 
         [0025]    Floor  32  can be attached directly to the first component by other types of attaching structures or by adhesive or other bonding techniques including welding or the like. While the exemplary structure shown for floor  32  and walls  34 ,  36  define a generally circular structure flattened on opposite sides, other shapes and configurations also can be used. 
         [0026]    Receiver  20  is provided with a holder  42  by which magnet assembly  14  is retained. In the exemplary embodiment, holder  42  is a post  42  extending from floor  32  substantially centrally located in receiver  20 . Magnet assembly  14 , of generally annular shape, is received on post  42  between walls  34 ,  36  and against floor  32 . 
         [0027]    Floor  32  defines a plurality of curved slots  44 ,  46 ,  48 ,  50  there through, and in the exemplary embodiment four slots  44 ,  46 ,  48 ,  50  are shown arranged in closely associated spaced pairs on opposite sides of post  42 . Accordingly, slots  44 ,  46  define therebetween a relatively narrow, curved region of the floor forming a spring support  52  on one side of post  42 ; and slots  48 ,  50  define therebetween a relatively narrow, curved region of the floor forming a spring support  54  on an opposite side of post  42  from spring support  52 . Protuberances  56 ,  58  on spring supports  52 ,  54 , respectively, project above an inner surface  59  of floor  32 . With the presence of protuberances  56 ,  58  spring supports  52 ,  54  are thicker than regions of floor  32  immediately adjacent spring supports  52 ,  54 . Accordingly, spring supports  52 ,  54  are the areas of first contact by floor  32  against magnet assembly  14  during installation of magnet assembly  14  in receiver  20 . 
         [0028]    Post  42  is hollow and includes openings  60 ,  62  on diametrically opposite sides thereof. Deflectable tabs  64 ,  66  aligned with openings  60 ,  62 , respectively, are united with the main cylindrical body of post  42  near the distal end of post  42 . Tabs  64 ,  66  angle outwardly to form the widest portion of post  42  at the free ends of tabs  64 ,  66 . Inwardly directed force against tabs  64 ,  66  can deflect the tabs inwardly in the openings  60 ,  62  to narrow the effective diameter of post  42 . When inwardly directed force is relieved, tabs  64 ,  66  can rebound outwardly to again form a wider diameter of post  42 . 
         [0029]    Magnet assembly  14  includes both cup  16  and a magnet  18 . Cup  16  is a circular structure having a bottom  70  and an annular sidewall  72 . A hole  74  is defined in bottom  70 . Hole  74  has a diameter sufficient to receive post  42  therein. The diameter of hole  74  is smaller than the maximum diameter of post  42  at the widest thereof, near the free ends of tabs  64 ,  66 , when tabs  64 ,  66  are not deflected inwardly. The thickness of bottom  70  and the lengths and the positions of tabs  64 ,  66  are selected so that bottom  70  is held snuggly between the free ends of tabs  64 ,  66  which contact one surface of bottom  70 , and protuberances  56 ,  58  which contact an opposite surface of bottom  70 . Accordingly, once installed on post  42 , cup  16  is restrained against axial movement along post  42 . In one preferred arrangement, the distance between the free ends of tabs  64 ,  66  and a plane defined by the uppermost ridges of protuberances  56 ,  58  is somewhat less than the thickness of bottom  70  so that spring supports  52 ,  54  are pushed downwardly by magnet assembly  14  upon installation, and provide biasing force to urge magnet assembly  14  against the free ends of tabs  64 ,  66 . 
         [0030]    Magnet  18  is an annular or doughnut-like magnetic body of a size to fit within cup  16 . Magnet  18  has a central hole  76  larger than hole  74 , whereby tabs  64 ,  66  can freely fit therein and overlap bottom  70  adjacent hole  74 . 
         [0031]    Spring supports  52 ,  54  in a preferred arrangement are relatively long and narrow to provide sufficient flexibility so that uneven force exerted on magnet assembly  14  allows magnet assembly  14  to move angularly relative to receiver  20 . The articulation of magnet assembly  14  relative to receiver  20  allows magnet assembly  14  to conform to and align with the surface of second component  32  to which it magnetically connects. Articulation of magnet assembly  14  relative to receiver  20  and post  42  is further facilitated by protuberances  56 ,  58  which hold bottom  70  spaced from the major expanse of surface  59  of floor  32 . Cup  16  can tilt on protuberances  56 ,  58  with or without an additional deflection of spring supports  52 ,  54 . 
         [0032]    Carrier  12  of fastener  10  is secured to first component  28  by any suitable means, such as, for example, the aforementioned gluing, welding, heat staking, pins, fasteners, pocket-like receivers or the like (not shown) by placing base  20  against a substrate (not shown) of the headliner and attaching it with glue or the like. 
         [0033]    Cup  16  is attached to carrier  12  by inserting the distal end of post  42  into central hole  74 , and pushing bottom  70  of cup  16  along post  42  and over tabs  64 ,  66 . Since hole  70  is of a narrower diameter than the widest diameter of post  42  as defined by tabs  64 ,  66 , the edge of bottom  70  defining hole  74  engages the outer surface of tabs  64 ,  66 . Continued force exerted on cup  16  to slide the cup axially along post  42  causes tabs  64 ,  66  to deflect inwardly in openings  60 ,  62  and allow bottom  70  to pass there over. Upon tabs  64 ,  66  passing through and emerging from hole  74 , tabs  64 ,  66  rebound outwardly and overlap bottom  70  adjacent hole  74 . Accordingly, cup  16  is locked in position on post  42 , between the free ends of tabs  64 ,  66  and protuberances  56 ,  58  against which bottom  70  rests. Cup  16  can be attached to carrier  12  before or after carrier  12  is attached to the first component. 
         [0034]    Magnet  18  is placed in cup  16 , and if cup  16  is metal can be retained therein without adhesive. Magnet  18  can be placed within cup  16  at various times during the assembly process, either before carrier  12  is attached to first component  28 , or at some time thereafter. Magnet  18  can be placed within cup  16  before or after cup  16  is connected to carrier  12 . 
         [0035]    Carrier  12  provides a flexible, yet snug connection between magnet assembly  14  and receiver  20 . The snug fit of bottom  70  between spring supports  52 ,  54  and the free ends of tabs  64 ,  66  resists vibration and prevents rattle from occurring between the carrier and the magnet assembly. The flexibility provided by the narrow spring supports  52 ,  54 , and the ability of cup  16  to tilt on post  42  enable magnet assembly  14  to articulate as necessary to accommodate angular variations in the surface of the second component to which it attaches. 
         [0036]    It should be understood that the various components of the present invention can be provided in different shapes, sizes and configurations. The components shown and described as being round, annular or cylindrical can be of other shapes as well. 
         [0037]    Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art. 
         [0038]    Various features of the invention are set forth in the following claims.