Abstract:
A receptacle for a fastener is provided that may be relatively light weight and compact, may reduce the number of parts required for mounting an object to a surface, and may allow for greater flexibility in positioning the fastener. Additionally, a corresponding method for installing a receptacle and mounting an object is provided. The receptacle has an outer housing and a floating insert, and the floating insert is positioned within an internal cavity of the outer housing. A fastener may be inserted into an internal cavity of the floating insert through apertures in the outer housing and the floating insert. The floating insert is configured such that it is movable within the outer housing. As a result, the location of the aperture of the floating insert is adjustable, providing greater tolerances during the installation process.

Description:
FIELD OF THE INVENTION 
       [0001]    Embodiments of the present invention are related to a receptacle for mounting objects on a surface and a method for installing the receptacle and mounting objects. In particular, embodiments of the present invention are directed to a receptacle for mounting objects on an aircraft interior surface using fasteners and an associated method. 
       BACKGROUND OF THE INVENTION 
       [0002]    In aircraft and other structures, it is often desirable to mount objects, such as magazine display racks or control panels, to various surfaces. One common method of mounting objects is by using Nylatch® or other expandable fasteners. Nylatch® fasteners are designed to attach a removable member, such as a magazine display rack, to a fixed member, such as the interior wall or other interior surface of an aircraft, by expanding latching members of a fastener, such as a grommet end of a Nylatch® fastener, to lock the two members together. 
         [0003]    Another common method of mounting objects is by using pegs or other fasteners having a head portion and a shank portion, the head being wider than the shank. With these types of fasteners, the shank portion of the fastener is attached or integral to the object to be mounted, such as the magazine rack. The object is mounted by hooking the head of the fastener into an appropriately shaped aperture in the fixed member, such as the interior surface of the aircraft. 
         [0004]    In at least some instances, the construction of a wall or other surface to which an object is to be mounted makes it difficult or impossible to mount a fastener directly to the wall or other surface, at least with the surety that is desired. For example, some interior surfaces of aircraft consist of honeycomb panels. As a result, mounting an object to the honeycomb panel with a Nylatch® or other expandable fastener currently requires the use of a sheet metal plate which defines a hole to receive the grommet end of the fastener. The metal plate is attached to the honeycomb panel using one or more potted inserts that, in turn, are mounted within the honeycomb panel. The object to be mounted is attached to the metal plate by inserting the fastener into the hole defined by the metal plate and expanding the grommet end. 
         [0005]    Mounting an object with a fastener such as a peg to a honeycomb panel similarly requires supplemental parts to prepare the mounting surface. A sheet metal plate with a keyhole-shaped aperture is required to receive the head portion of the fastener. The keyhole aperture consists of two intersecting apertures, one larger than the other. The larger portion of the keyhole is configured to receive the wider head portion of the fastener, and the smaller portion of the keyhole is configured to retain the head in the installed position and is thus smaller than the width of the head. The object is installed by inserting the head into the larger portion of the keyhole and sliding the peg into the smaller portion. However, this requires that the honeycomb panel be cut behind both portions of the keyhole before installing the metal plate to allow enough clearance for the head to slide from one portion of the keyhole to the other. 
         [0006]    The current method of mounting objects to such interior surfaces has several disadvantages. It requires the manufacture of multiple parts, such as the metal plates and the potted inserts. The use of multiple parts increases the manufacturing and shipping costs, the cost of labor for installing the metal plates and mounting the objects, as well as the overall weight of the structure, which is a particularly acute concern for aircraft and other vehicles. Aesthetic concerns also factor in when the object to be mounted is smaller than the metal plate used for mounting, and the choice of location of the fasteners on the object to be mounted becomes limited. These disadvantages are further magnified by the large quantities of fasteners commonly utilized on board aircraft and other structures. In addition, the fixed nature of the holes in the metal plates provides small tolerances and does not allow for minor changes in the position of the fasteners, making small miscalculations in the mounting process costly. 
         [0007]    Thus, there is a need for a simpler, more cost effective way of mounting objects using Nylatch® or other fasteners that requires fewer, lighter parts, allows greater flexibility in placement, and provides greater mounting tolerances. 
       SUMMARY OF THE INVENTION 
       [0008]    Embodiments of the present invention are directed to a receptacle for a fastener that is relatively light weight and compact, reduces the number of parts required for mounting an object to a surface, and allows greater flexibility in the placement of the object to be mounted. Additionally, a corresponding method for installing a receptacle and mounting an object is provided. As a result, embodiments of the present invention address at least some of the concerns with the use of expandable fasteners. 
         [0009]    A receptacle of one embodiment of the present invention has an outer housing forming an internal cavity and an aperture opening into the internal cavity. The internal cavity is configured to receive at least part of a fastener, such as the latching members of a Nylatch® fastener. The outer housing has a rim extending circumferentially out from the internal cavity. In some embodiments, the rim forms one or more openings to allow the application of adhesive when installing the receptacle in or on a surface. The rim of one embodiment serves as an integral spacer having increased thickness to allow for the installation of fasteners in certain types of surfaces where the depth of the mounting surface is less than the length of the shank or latching members of the fastener, such as with shallow panels. 
         [0010]    In another embodiment, the outer housing has two rims. The first rim may extend circumferentially out from an end of the outer housing that defines the aperture, and the second rim may extend circumferentially out from an end of the outer housing opposite the first rim. In one embodiment, the second rim is larger than and extends beyond the first rim. The larger, second rim may define one or more openings to allow for the application of adhesive during installation of the receptacle directly onto a surface. The second rim may also have a plurality of pins extending away from the aperture. These pins may be used to locate the proper positioning of the receptacle with respect to holes configured to receive the pins in the mounting surface. 
         [0011]    In another embodiment of the present invention, the aperture of the receptacle is configured to receive and hold in place the head portion of a fastener. In this case, the aperture has a keyhole shape formed by two intersecting aperture portions in the outer housing. The first aperture portion is sized to receive the head portion of a fastener. The second aperture portion is smaller than the first aperture portion and is sized to allow the fastener, e.g., a shaft of the fastener, to be moved from the first aperture portion to the second aperture portion. As a result, the head portion of a fastener may be inserted into the first aperture portion and moved into the second aperture portion of the keyhole aperture. Positioned in the second aperture portion, the head portion of the fastener is held in place by the outer housing. To facilitate the orientation of receptacles with respect to the mounting surface and the object to be mounted, the outer housing may be marked or notched, such as by forming a flat portion in a generally circular outer housing to mark the top of the receptacle for installation purposes. 
         [0012]    A receptacle of another embodiment of the present invention has an outer housing and a floating insert. The outer housing defines an internal cavity and forms an aperture that opens into the internal cavity. The floating insert also defines an internal cavity and forms an aperture that opens into the internal cavity of the floating insert. The floating insert is sized to be smaller than the internal cavity of the outer housing and is configured to fit within the outer housing, such that the floating insert is movable within the internal cavity of the outer housing. 
         [0013]    The aperture of the floating insert is configured to receive at least part of a fastener, such as the latching member of a Nylatch® fastener. In one embodiment, the aperture of the floating insert is smaller than the aperture of the outer housing. However, the floating insert of one embodiment is configured such that the aperture of the floating insert is within the aperture of the outer housing in all positions. The mobility of the floating insert within the outer housing provides the ability to make minor adjustments in the position of the fastener, thereby increasing mounting tolerances. 
         [0014]    In some embodiments of the present invention, the receptacle may include a cap which mates with the outer housing to at least partially close the internal cavity of the outer housing. The cap may be configured to be press fit around the outer wall of the outer housing, it may be configured to fit inside the internal cavity of the outer housing, or it may be bonded to a surface of the outer housing, among other options. 
         [0015]    Another embodiment of the present invention is directed to a method of mounting an object using a receptacle. As described above, the receptacle may include an outer housing and a floating insert fitting within an internal cavity of the outer housing such that the floating insert is movable within the outer housing. The receptacle is configured to receive a fastener and may be installed on a surface, such as the interior surface of an aircraft, for mounting an object. In one embodiment, the receptacle may be installed by forming a hole in the surface, inserting the receptacle into the hole, and bonding the receptacle within the hole. In another embodiment, the receptacle may be installed by forming a hole in the surface, inserting the receptacle at least partially into the hole, bonding the receptacle within the hole, and bonding the rim to the surface, such that the receptacle in the installed position is not flush with the surface but rather extends in part beyond the surface. In yet another embodiment, the receptacle may be bonded directly to the surface. 
         [0016]    The fastener with the object to be mounted may then be at least partially inserted into the internal cavity of the outer housing or, if the receptacle includes a floating insert, into the internal cavity of the floating insert within the outer housing. In the case of a receptacle having a floating insert, if the fastener is not aligned exactly with the internal cavity of the floating insert, the floating insert may be moved within the outer housing to allow a better fit between the fastener and the receptacle. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
           [0018]      FIG. 1  is an exploded view of a receptacle with a cap in accordance with one embodiment of the present invention; 
           [0019]      FIG. 2  is a side view with partial cross-section of a receptacle in accordance with one embodiment of the present invention that is installed in a shallow panel; 
           [0020]      FIG. 3  is a top perspective view of a receptacle in accordance with one embodiment of the present invention with first and second rims and openings for bonding the receptacle to a surface; 
           [0021]      FIG. 4  is a bottom perspective view of a receptacle in accordance with one embodiment of the present invention with first and second rims and pins for orienting the receptacle; 
           [0022]      FIG. 5  is a top perspective view of a receptacle with a keyhole aperture and notch in accordance with another embodiment of the present invention, as well as a fastener with a head portion and a shank portion; 
           [0023]      FIG. 6A  is a cross-sectional view of an assembled receptacle having an outer housing and a floating insert with a cap in accordance with one embodiment of the present invention, with the floating insert centrally located within the outer housing; 
           [0024]      FIG. 6B  is a cross-sectional view of an assembled receptacle having an outer housing and a floating insert with a cap in accordance with one embodiment of the present invention, with the floating insert moved to one side of the outer housing; 
           [0025]      FIG. 6C  is a cross-sectional view of an assembled receptacle having an outer housing and a floating insert with a cap in accordance with one embodiment of the present invention, with the floating insert moved to another side of the outer housing; 
           [0026]      FIG. 7  is an exploded view of a receptacle having a floating insert with a cap in accordance with one embodiment of the present invention; 
           [0027]      FIG. 8  is a cross-sectional view of a receptacle in accordance with one embodiment of the present invention that has a floating insert installed in a surface with a fastener and a mounted object; 
           [0028]      FIG. 9A  is a top plan view of a receptacle having a floating insert in accordance with one embodiment of the present invention, with the floating insert moved to one side of the outer housing; and 
           [0029]      FIG. 9B  is a top plan view of a receptacle having a floating insert in accordance with one embodiment of the present invention, with the floating insert moved to another side of the outer housing. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    Embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. 
         [0031]    The receptacle  10  of one embodiment of the present invention is shown in  FIG. 1 . The receptacle  10  comprises an outer housing  12  defining an internal cavity  14  and an aperture  16  that opens through a first end  11  of the outer housing  12  into the internal cavity  14 . Although the receptacle  10  and correspondingly the internal cavity  14  can have various shapes, the receptacle  10  and the internal cavity  14  of one embodiment are generally cylindrical as shown in the figures. The internal cavity  14  of the outer housing  12  is configured, e.g., sized and shaped, to partially receive a fastener  40 , such as a plurality of latching members  42  of a fastener  40 , shown in  FIG. 8 . Referring again to  FIG. 1 , the outer housing  12  has a first rim  18  extending circumferentially about the internal cavity  14  and disposed at the first end  11  of the outer housing  12  so as to define the aperture  16 . The first rim  18  generally extends inwardly from a sidewall  23  of the outer housing  12  at or proximate the first end  11  so as to define the aperture  16 . In some embodiments, the first rim  18  may also extend outwardly from the sidewall  23  of the outer housing  12 . In these embodiments, the first rim  18  may define one or more openings  20 ,  21  which facilitate the application of adhesive during the installation of the receptacle  10  in a surface  60 , as described hereinbelow. 
         [0032]    Referring to  FIGS. 4 and 7 , at least in those embodiments discussed below in which a floating insert  34  is to be disposed within the internal cavity  14 , the receptacle  10  may be constructed such that the internal cavity  14  is accessible via an aperture  17  defined in a second end  13  that is larger than the aperture  16  defined by the first rim  18 . The receptacle  10  of one embodiment defines an aperture  17  in the second end  13  of the outer housing  12 , opposite the first end  11 . The aperture  17  defined in the second end  13  of the outer housing  12  also opens into the internal cavity  14  and is larger than the aperture  16  defined by the first end  11  of the outer housing  12 . In this regard, the aperture  17  defined in the second end  13  of the outer housing  12  may have the same or nearly the same cross-sectional dimensions, e.g., diameter, as the internal cavity  14 . In this embodiment, the receptacle  10  may further comprise a cap  22  that snugly fits within the aperture  17  defined in the second end  13  of the outer housing  12  and mates with the outer housing  12 . In some embodiments, the outer housing  12  includes a groove in the inner wall  24  of the outer housing  12 , not shown in the figures. The cap  22  may be press fit or bonded to the groove of the outer housing  12 , thereby partially closing the internal cavity  14  of the outer housing  12 , such as following the insertion of the floating insert  34  as noted below. 
         [0033]    In another embodiment of the present invention, shown in  FIG. 2 , the first rim  18  has a predefined thickness X such that the first rim  18  can serve as a spacer for mounting objects  62  on certain surfaces  60 . For example, a surface  60  may be too shallow to fully receive the length of a fastener  40 . In this case, the predefined thickness X of the first rim  18  supplements the thickness of the surface  60  and allows for the latching members  42  to be fully received within the internal cavity  14  of the receptacle  10  even though the latching members  42  are otherwise longer than the surface is thick. 
         [0034]    The receptacle  10  of another embodiment of the present invention is shown in  FIGS. 3 and 4 . The outer housing  12  of this embodiment includes a first rim  18  and a second rim  19 . The first rim  18  extends circumferentially about the internal cavity  14  and is disposed at the first end  11  of the outer housing  12  closest to the aperture  16  as described above. The second rim  19  extends circumferentially about the internal cavity  14  in a plane that is parallel to the plane in which the first rim  18  lies. The second rim  19  is spaced apart from the first rim  18 , however, and is typically disposed at the second end  13  of the outer housing  12  opposite the aperture  16 . The second rim  19  may extend outwardly from a sidewall  23  of the receptacle by a greater distance than the first rim  18 . The second rim  19  may also define a plurality of openings  25  to facilitate in the bonding of the receptacle  10  to a surface  60  as described below. 
         [0035]    Referring to  FIG. 4 , which shows a bottom view of the receptacle  10 , the second rim  19  may have one or more pins  26  extending outwardly from the receptacle  10 , such as in a direction orthogonal to the respective planes defined by the first and second rims  18 ,  19 . The pins  26  may be used to orient the receptacle  10  with respect to the surface  60  by inserting the pins  26  into pre-formed holes in the surface  60 . 
         [0036]    Another embodiment of the receptacle  10  of the present invention is shown in  FIG. 5 . In this embodiment, the aperture  16  of the outer housing  12  has a keyhole shape. The keyhole aperture  16  may consist of a first portion  30  and a second portion  31  wherein the first and second portions  30 ,  31  intersect and the first portion  30  is larger than the second portion  31 . A fastener  40  having a head portion  44  and a shank portion  46 , also shown in  FIG. 5 , may be used to hold an object  62  to the surface  60  by inserting the head portion  44  into the first portion  30  of the aperture  16  and moving it into the second portion  46 . The first portion  30  of the aperture  16  and the head portion  44  of the fastener  40  are configured such that the head portion  44  is smaller than the first portion  30  and, therefore, can be inserted through the first portion  30  and into the internal cavity  14 . The second portion  31  of the aperture  16  is configured to be smaller than the head portion  44  such that the head portion  44  will be retained within the internal cavity  14  once the fastener  40  has been translated as described above. As will be apparent, the shank portion  46  is smaller or at least no larger in cross-section than the second portion  31  of the aperture  16  such that the shank portion  46  can freely move between the first and second portions  30 ,  31 . Once the fastener is moved into alignment with the second portion  31  of the aperture  16 , the head portion  44  of the fastener  40  is held in place by the outer housing  12 , and mounting of the object  62  affixed to the fastener  40  is thus accomplished. As illustrated in  FIG. 5 , the receptacle  10  may include a notch  32  in the first rim  18  of the outer housing  12 . This notch  32  facilitates installation of the receptacle  10  in a surface  60  by providing a reference orientation for the aperture  16  with respect to the object  62  to be mounted. 
         [0037]      FIGS. 6-9  show a receptacle  10  of another embodiment of the present invention. The receptacle  10  of this embodiment comprises an outer housing  12  and a floating insert  34 . Referring to  FIGS. 7 and 8 , the outer housing  12  defines an internal cavity  14  and an aperture  16  that opens into the internal cavity  14 . A first rim  18  extends circumferentially about the internal cavity  14  of the outer housing  12  and is disposed at the first end  11  of the outer housing  12  closest to the aperture  16 . 
         [0038]    As indicated above, the floating insert  34  is configured to fit within the internal cavity  14  of the outer housing  12  and is therefore sized to be smaller than the internal cavity  14  of the outer housing  12 . For example, in an embodiment including a cylindrical receptacle  10  and a cylindrical floating insert  34 , the circumference (or diameter) of the outer wall  36  of the floating insert  34  is smaller that the circumference (or diameter) of the inner wall  24  of the outer housing  12 . In this way, the floating insert  34  is movable within the outer housing  12 , providing a maximum tolerance of 2Y for mounting objects  62 . This characteristic is illustrated in  FIGS. 6A ,  6 B, and  6 C. The floating insert  34  is larger, however, than the aperture  16  defined by the outer housing  12  such that the floating insert  34  is retained within the internal cavity  14  of the receptacle  10  by its first rim  18 . 
         [0039]    Referring again to  FIGS. 6 and 7 , the floating insert  34  also defines an internal cavity  35  and an aperture  37  that opens into the internal cavity  35  of the floating insert  34 . The aperture  37  is typically defined by a lip  38  proximate one end of the floating insert  34  that extends inwardly from the outer wall  36  of the floating insert  34  and circumferentially about the aperture  37 . The internal cavity  35  of the floating insert  34  is configured to partially receive a fastener  40 . For example, the internal cavity  35  may be configured, e.g., sized and shaped, to receive a plurality of latching members  42  of a fastener  40 , shown in  FIG. 8 , through the aperture  16  of the outer housing  12  and the aperture  37  of the floating insert  34 . In one embodiment, the aperture  37  of the floating insert  34  is smaller than the aperture  16  of the outer housing  12 . In this embodiment, the outer housing  12  and the floating insert  34  are advantageously configured such that the aperture  37  of the floating insert  34  is, in all positions, fully within the aperture  16  of the outer housing  12 , as illustrated in  FIGS. 9A and 9B . 
         [0040]    As noted above, in some embodiments of the present invention, the receptacle  10  includes a cap  22  that mates with the outer housing  12 , as shown in  FIG. 6 . The cap  22  may be press fit or bonded to the inner wall  24  of the internal cavity  14  of the outer housing  12 , thereby partially closing the internal cavity  14  of the outer housing  12 . Similarly, the outer housing  12  may include a groove in the inner wall  24  of the outer housing  12 , not shown, into which the cap  22  may be press fit or bonded. As such, prior to mating the cap  22  with the outer housing  12 , the floating insert  34  may be inserted into the internal cavity  14 . The cap  22  may then be mated with the outer housing  12  to at least partially close the internal cavities  14 ,  35  and to retain the floating insert  34  therewithin. 
         [0041]    Methods of installing a receptacle  10  in accordance with another aspect of the claimed invention will now be described. In embodiments that utilize a receptacle  10  that includes a floating insert  34 , the floating insert  34  is initially positioned within the internal cavity  14  and the cap  22  is attached to the outer housing  12 , partially closing the internal cavity  14  of the outer housing  12 , to retain the floating insert  34  within the internal cavity  14 . See, for example,  FIGS. 6 and 7 . 
         [0042]    An assembled receptacle  10  may be mounted to a surface  60  in several ways. Referring to  FIG. 8 , for example, a hole may be formed in a surface  60 , such as a wall, partition or the like, to receive the receptacle  10 . The receptacle  10  may then be inserted into the hole and secured within the hole, such as by bonding. In this regard, adhesive or another bonding agent may be injected within the hole about the exterior of the receptacle  10 . In order to facilitate the injection of the adhesive, the first rim  18  may define a first opening  20  through which the adhesive is injected, shown in  FIG. 7 . The first rim  18  may also define a second opening  21 , typically located about 180° from the first opening  20 . As such, adhesive may be injected through the first opening  20  defined by the first rim  18  until adhesive begins to emerge from the second opening  21 , at which time the injection of the adhesive may be terminated. 
         [0043]    Although the receptacle  10  may be flush mounted in some situations, in other situations, such as when the surface  60  is a shallow panel, the receptacle  10  may be only be partially inserted into the hole, as shown in  FIG. 2 . In this case, a receptacle  10  with a first rim  18  having a predefined thickness X is used. The receptacle  10  is bonded partially within the hole, and the first rim  18  of the outer housing  12  is bonded to the surface  60  by application of adhesive to the surface of the first rim  18  that faces the surface  60 . As such, the receptacle  10  of this embodiment is not installed flush with the surface  60 . Similarly, a receptacle  10  may be attached directly to a surface  60 , such as by bonding the second rim  19  of the receptacle  10  to the surface  60 . To facilitate the application of adhesive about the second rim  19 , the second rim  19  can also define one or more openings  25 , shown in  FIGS. 3 and 4 , through which adhesive may engage the second rim  19 . 
         [0044]    An object  62  to be mounted onto a surface  60  may then be attached to the receptacle  10  using a fastener  40 . In embodiments having a floating insert  34 , the fastener  40  may be partially inserted into the internal cavity  35  of the floating insert  34  through the aperture  16  of the outer housing  12  and the aperture  37  of the floating insert  34 . If necessary, the location of the aperture  37  of the floating insert  34  may be adjusted relative to the outer housing  12  to obtain better alignment with the location of the fastener  40  being used to mount the object  62  to the surface  60 , as shown in  FIG. 9 . As such, the relative movement permitted between the floating insert  34  and the outer housing  12  serves to increase the permissible tolerance Y between the fastener  40  and the receptacle  10 , as illustrated in  FIG. 6 . 
         [0045]    For example, a fastener  40 , such as a Nylatch® fastener, may have a plurality of latching members  42 . The latching members  42  of the fastener  40  may first be inserted through an opening defined by the object  62  to be mounted to the surface  60 . The latching members  42  of the fastener  40  are then inserted into the internal cavity  35  of the floating insert  34  through the apertures  16 ,  37  of the outer housing  12  and the floating insert  34 , respectively. In a fastener  40  in which the latching members  42  are expandable, the latching members  42  may be compressed while being fit through the aligned apertures  16 ,  37  and then expanded within the internal cavity  35  of the floating insert  34  to secure the fastener  40  and the object  62  in place. An installed receptacle  10  having a floating insert  34  and a mounted object  62  are shown in  FIG. 8 . 
         [0046]    In an embodiment wherein the receptacle  10  does not include a floating insert  34  and wherein the aperture  16  is in the shape of a keyhole, a fastener  40  such as the one shown in  FIG. 5  may be used to mount an object  62 . In this case, the head portion  44  of the fastener  40  is inserted into the first portion  30  of the aperture  16  and moved into the second portion  31 . As a result of the relative sizes of the first and second portions  30 ,  31 , the head portion  44  of the fastener  40  is retained within the internal cavity  14  as described above. 
         [0047]    The receptacle  10  of embodiments of the present invention may be utilized to mount a variety of objects  62  to various surfaces  60 . For example, the receptacle  10  may be employed onboard an aircraft or other vehicle in which an object  62 , such as a magazine rack, is desirably mounted to an interior surface  60 , such as a wall, a partition or the like. 
         [0048]    It is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.