Patent Publication Number: US-2022228611-A1

Title: Ergonomic fastening clip

Description:
TECHNICAL FIELD 
     The present invention generally relates to the field of fasteners and in particular, to the field of fastening clips for attaching one or more components, such as airbag devices, to an external structure. More specifically, the present invention relates to an ergonomic fastening clip for attaching a side-impact airbag or curtain-type airbag to a vehicle structure. 
     INTRODUCTION 
     Airbags are safety devices that are increasingly being used in the motor industry and which, in combination with other safety components, such as seatbelts, help to reduce fatal accidents in the case of collisions. The tests to which the vehicles have been subjected, as well as, mortality statistics, have clearly demonstrated that the use of airbags can considerably improve the safety of automobile occupants and, when combined with other forms of passive safety, such as seat belts, significantly (by about 30%) reduce mortality in the case of serious accidents. 
     Today, manufacturers produce frontal airbags, which are designed to protect the driver and/or passenger in the event of a head-on collision and, considering their positions, lateral airbags that are installed behind the posts and/or in the sides of the vehicle seats, along with curtain airbags. 
     Airbags of the curtain type are usually located in the part close to the roof on the sides of the automobile, e.g. situated above the front and rear doors. Such airbags have very rigorous requirements with regards to the goals set for them and the technical challenges that have to be overcome. Typical challenges may be their location in the vehicle and the way they are fastened, required deployment time and the time that the airbag is required to remain inflated. Other challenges may come from the fact that there is only a short distance between the body and the occupant and that there is little vehicle material between the occupant and an impacting vehicle. For example, it is essential that airbags are deployed in a fraction of a second, giving rise to an enormous snatch force on their attachment components, which then suffer the consequences of that impact. 
     Further, when installing new or restore previously deployed airbags, it is well known in the industry that the installation or restoration is tedious work, comprising steps, such as, (i) dismantling all the attachments of the airbag, (ii) replacing the airbag and installing a new one, and then again (iii) fitting all its attachments. The work involved generally requires the installer to at least partly manually assemble and install the airbag to the vehicle. During the assembly, the installer may have to push numerous fastening clips into a vehicle panel or structure to attach or operably couple the airbag to the vehicle. Such work steps can be very repetitive and potentially cause injuries to the installer if the component parts are not adequately designed for manual installation. 
       FIG. 1 , for example, illustrates a typical clip  10  used for the attachment of airbags, such as, side-impact or curtain airbags, that is of the type formed by a body from which extend flexible elements  12  typically bearing against the surface of the clip entered into the attachment panel of the vehicle. The clip  10  comprises laterally protruding tangs  14  having upper surfaces  16  configured to bear against an inner surface of the attachment panel so as to “sandwich” the panel surface between the flexible elements  12  and the upper surfaces  16  of the tangs  14 . Clip  10  may be formed from a single folded and punched laminar surface, so as to form a three-dimensional body made from, for example, metal, such as, carbon steel. 
     However, clip  10  is designed in such a way that the top region (or head portion) does not provide sufficient area for the installer to safely and efficiently push the clip into the attachment panel. There are also exposed sharp edges on this top region which can lead to an uncomfortable insertion of the clip, or even potentially injure the installer during such insertion, i.e. when pushing the clip into an attachment panel opening. 
     Another fastener clip  20  typically used to attach airbags to a vehicle structure is illustrated in  FIG. 2 . Fastening clip  20  comprises laterally protruding tangs  22  adapted to fixingly engage with the panel&#39;s inner surface when entered through a mounting aperture of the panel. Clip  20  is designed so as to either provide an unloaded connection, where the tangs  22  simply prevent the clip  20  from sliding out of the mounting aperture once installed, or where the connection is loaded only if the dimensions of the panel surface (thickness) and aperture (rectangular cut-out) are suitably matched to the clip design. In the event of an unloaded connection (i.e. without resilient springs), the bias or spring load may be provided by a different component of the airbag module. Usually, this different component is made in plastic which, for a spring effect under mechanical loads (strength, fatigue) may not perform as good as metal. 
     Also, even though clip  20  has a flat upper surface, sharp edges are exposed at the upper surface making it uncomfortable and even risk injuries to the installer when pushing the fastening clip  20  into the mounting aperture. 
     Therefore, it is an object of the present invention to provide an improved and ergonomic fastening clip, suitable for attaching airbags, such as side-impact or curtain airbags, that robust and efficient, as well as, ergonomic and safe so as to minimise any potential risk to the user during assembly. 
     SUMMARY 
     According to a first aspect of the present invention, there is provided a fastening clip for mounting a component part, such as an airbag, to a support structure, comprising: 
     a body portion, extending between an upper end region and a lower end region along a longitudinal axis, comprising at least one elastically deflectable retaining member, projecting laterally from said lower end region of said body portion so as to fixingly engage when inserted into an orifice of the support structure; 
     a head portion, provided at said upper end region of said body portion, comprising a rectangularly shaped plate member, having a flat upper surface extending in a transverse plane relative to said longitudinal axis, and at least two opposing resilient spring members extending transversely away from opposing first and second edges of said plate member and folded towards said lower end region of said body portion. 
     The fastening clip of the present invention provides the advantage of an ergonomic pushing surface without any exposed sharp edges that may damage other components in the application or the user during assembly. Further, the fastening clip of the present invention provides the advantage of combining spring arms with an ergonomic pushing surface adapted, so as to prevent exposure of any sharp edges to the user or other components while the construction still allows the use of a single (uniaxial) folded (and punched) laminar sheet material (e.g. metal). 
     Advantageously, said plate member may be configured for push engagement by a digit of a user. 
     Advantageously, each one of the two opposing resilient spring members may be uniaxially folded about a respective first and second folding axis. Preferably, said first and second folding axis are perpendicular to said longitudinal axis. Even more preferably, said first and second folding axis are parallel to each other. 
     The plate member may further comprise a first fold extending from at least a centre portion of said first edge and folded towards said body portion. Preferably, said first fold may form a single fold about a first folding axis perpendicular to said longitudinal axis. 
     Advantageously, said plate member may further comprise a second fold extending from at least a centre portion of said second edge and folded towards said lower end region of said body portion. Preferably, said second fold may form a single fold about a second folding axis perpendicular to said longitudinal axis. Preferably, said second folding axis may be parallel to said first folding axis. 
     Advantageously, said plate member may further comprise at least one edge member extending from at least a central portion of each one of said first and second edges and folded towards said lower end region and said body portion. Preferably, said at least one edge member may extend from each one of said opposing first and second edges into forming said body portion. 
     Advantageously, at least one of said resilient spring members may be a flexion leg ending in a looped or folded end portion shaped, so as to minimise damage to the support structure and/or the user during assembly. 
     Advantageously, said resilient spring members may be provided at diagonally opposing corners of said plate member. 
     Advantageously, said body portion and said head portion may be formed from a single piece. 
     According to a second aspect of the present invention, there is provided a planar sheet material for forming a fastener clip, comprising a predetermined pattern of cut-outs, fold lines and apertures, configured to fold into a fastener clip according to the first aspect of the present invention. 
     Advantageously, said predetermined pattern of cut-outs, fold lines and apertures may be fabricated by any one of punching, stamping, cutting and bending. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Example embodiments of the description will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  (Prior Art) is a perspective illustrations of a typical fastening clip used for attaching components, such as airbags, to a vehicle chassis; 
         FIG. 2  (Prior Art) is a perspective illustration of another typical fastening clip used for attaching components, such as airbags, to a vehicle chassis; 
         FIGS. 3A-3C  show a perspective view of an example embodiment of the fastening clip of the present invention,  FIG. 3A  top-side view,  FIG. 3B  bottom-side view, and  FIG. 3C  perspective top view with hatched pushing surface; 
         FIGS. 4A-4C  are perspective views of the fastening clip shown in  FIGS. 3A  top view,  3 B front view and  3 C side view; 
         FIG. 5  is a side cross-sectional side-view of the fastening clip when installed with an attachment panel; 
         FIG. 6  is a perspective cross-sectional view of the fastening clip shown in  FIG. 5 , i.e. when installed in an attachment panel, and 
         FIGS. 7A-7B  illustrate examples of embodiment of the sheet metal blank cut, punched and bent for forming the fastening clip  FIG. 7A  top view and  FIG. 7B  bottom view. 
     
    
    
     DETAILED DESCRIPTION 
     The described example embodiment relates to a fastening clip suitable for securing paraphernalia and accessories. The embodiment(s) of the invention are normally applied in vehicles. Although the invention is described with respect to vehicles, the invention is not restricted to vehicles altogether, but may also be used in other structures requiring attachment of accessories or peripheral components to a structure. 
     Certain terminology is used in the following description for convenience only and is not limiting. The words ‘right’, ‘left’, ‘lower’, ‘upper’, ‘front’, ‘rear’, ‘upward’, ‘down’ and ‘downward’ designate directions in the drawings to which reference is made and are with respect to the described component when assembled and mounted. The words ‘inner’, ‘inwardly’ and ‘outer’, ‘outwardly’ refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description. 
     Further, as used herein, the terms ‘connected’, ‘attached’, ‘coupled’, ‘mounted’ are intended to include direct connections between two members without any other members interposed therebetween, as well as, indirect connections between members in which one or more other members are interposed therebetween. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import. 
     Further, unless otherwise specified, the use of ordinal adjectives, such as, “first”, “second”, “third” etc. merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking or in any other manner. 
     Referring now to  FIGS. 3A-3C, 4A-4C, 5 and 6 , an example embodiment of the fastening clip  100  is shown before it is used for assembly, i.e. when securing an airbag to an attachment panel. In particular, the clip  100  of the present invention comprises an improved airbag clip of the type of clips which are used for the attachment of airbags, such as, for example side-impact or curtain airbags, the air bag clips are of the type formed by a pre-cut 2D blank (patterned and cut for folding). The clip  100  has a head portion  102  from which extend flexible elements, such as spring elements  114 , that, during use, are adapted to bear against an outer surface of an attachment panel  500  when the clip  100  enters an aperture  502  of the panel  500 , and a body  104 , comprising descending tangs  110  which give rise to different structures for the clip  100 , such as, for example, side limbs  112  having surfaces configured to bear against an inner surface of the panel  500  in such a way that the supporting surfaces and those provided by the flexible spring elements  114  engage the attachment panel  500  on both sides, i.e. in the form of a sandwich, thus, enabling the clip  100  to be fixedly supported on the attachment panel  500 . The improvements of the clip  100  comprise a pushing surface with an improved ergonomic shape, as well as, a head portion configured to protect from potential injuries during assembly. Furthermore, the improved airbag clip  100  has been simplified to include spring elements  114  extending directly from the head portion  102  and formed by a single fold of the spring elements  114  toward the distal end of the body  104 . 
     Clips  100  for airbags such as those according to this invention are inserted into an opening made in the surface of the attachment panel  500 . This surface effectively divides the clip  100  into an upper outer part, i.e. the head portion  102 , which is not inserted into the opening and an inner lower part, i.e. the body portion  104 , which is inserted into the opening (see  FIGS. 5 and 6 ). The upper part or head portion  102  of the clip  100  corresponds to the outer part and the lower part or body portion  104  of the clip  100  corresponds to the inner part. Likewise, the ascending direction is from the inner part to the outer (lower to upper) and the descending part is from the outer part to the inner (upper to lower). The body portion  104  may be formed by a box  106  that is formed by the union of two surfaces which are approximately “U”-shaped in transverse cross-section, being attached by one of their ends, and the attachment being strengthened by respective tabs  108  produced by division of the portions of the connecting part forming opposite surfaces. As may be seen from the attached figures, tabs  108  which are located within box  106  may have nails (not shown) that are shaped so as to engage in the openings provide in box  106 . 
     Tangs  110  have an inclination towards the central axis  128  of the clip and extend downwards from box  106  towards the centre of clip  100  to then form a loop and extend away from the centre of the clip  100  in the opposite direction as ascending side limbs  112 . In the preferred construction of the invention and as illustrated in the drawings, the loops of tangs  110  may be in contact with each other. This contact provides strength to the clip against pull-out forces. 
     Tangs  110  may have an enlarged surface  116 , almost in the form of a triangle, which allows its base to extend beyond the walls forming box  106 . This obviously prevents box  106  from “descending” under pressure and passing beyond those stops represented by the enlarged surface  116 . 
     Side limbs  112  are configured to emerge from the inner part of box  106  towards the exterior of the same, through a hollow space, opening or window  118  made in its surface, creating a bearing surface  132  that is approximately parallel to the flat upper surface of the head portion  102  and which is configured to engage with the panel  500  (whin in use). 
     The sides of window  118  may have lateral tabs  120  which provide a support for the bearing surfaces  132  of box  106  against the inner surface of the panel  500  in response to forces which tend to extract clip  100 . 
     The upper part or head portion  102  of the clip  100  comprises a substantially rectangularly shaped plate  122  with a flat upper surface. The plate  122  is arranged transverse to a longitudinal axis  128  of the body portion  104 . Resilient spring elements  114  (i.e. flexion leg) extend transversely away from opposing edges at diagonally opposing corners of the plate  122 . Each spring element  114  is folded towards the body portion  104 , so as to form an obtuse angle with the flat upper surface of the plate  122 . Respective folds are uniaxial about a single axis  130  that is perpendicular to the longitudinal axis  128  of the clip  100 . The fold of the spring elements  114  forms a rounded side edge  134  of the plate  122 . Further, a distal end portion of each spring element  114  is looped back, so as to form a rounded spring element end (i.e. a tear-drop hem). 
     A central portion  124  of two opposing protruding side edges of the plate  122  is folded towards and merging into a respective side of the body portion  104  (i.e. forming the box  106 ), so as to form a rounded side edge (e.g. a closed or open hem). 
     In addition, the plate  122  may be provided with two centrally aligned apertures  126 , so as to allow access to the inner part of box  106 . 
     Referring now to  FIGS. 7A and 7B , the clip  100  may be formed from a single laminar surface  200  (i.e. a sheet material or blank) that is cut and punched in a unique way, so as to allow forming a three-dimensional embodiment of the clip  100  by simply folding respective cut or punched portions of the sheet material  200  at predetermined fold lines. In particular, the laminar surface (i.e. sheet material or blank) may be a sheet metal blank  200  comprising predetermined cuts, bends and apertures that when folded form the specific parts and portions of the three-dimensional clip  100 .  FIGS. 7A-7B  include the reference signs pointing to the 2D portion of the parts of the clip  100  once formed. The sheet metal material may be cut, punched, stamped or bent utilising suitable tooling (e.g. press, drills, laser cutting etc.). 
     It is understood by the person skilled in the art, that the unique cut-out pattern of the sheet metal allows for a clip with two spring elements  114  extending directly from the plate  122  of the head portion  102  and uniaxially bent about a single axis  130  that is perpendicular to the longitudinal centre axis  128  of the clip  100 , thus, minimising the material required to form the intended shape (and functionality) of the clip  100 . 
     The laminar surface or sheet metal blank may be made from a metal, such as, for example, carbon steel which has been heat treated to impart improved strength qualities to it. Further, clip  100  may undergo treatment to prevent corrosion and/or receive a suitable coating in order to improve its service life and wear in relation to dust, moisture and other elements which might attack the clip. 
     During assembly, the user simply pushes the fastening clip  100  into the mounting aperture  502  of the attachment panel  500  thus fixingly engaging the side limbs  112  with an inner surface of the attachment panel  500 . The flat surface and round edges of the plate  122  provide an ergonomic pushing surface adapted to minimise potential injuries to the user during assembly. 
     It will be appreciated by persons skilled in the art that the above embodiment(s) have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departing from the scope of the invention as defined by the appended claims. 
     REFERENCE LIST 
     
         
         
           
               100  fastening clip 
               102  head portion 
               104  body 
               106  box 
               108  body tabs 
               110  tang 
               112  Side limbs 
               114  Spring elements 
               116  enlarged surface 
               118  Window/body aperture 
               120  lateral tabs 
               122  Plate (head portion) 
               124  central edge of plate  134   
               126  apertures 
               128  longitudinal axis 
               130  single axis (fold) 
               132  bearing surface 
               134  rounded side edge 
               200  2D blank 
               500  attachment panel 
               502  mounting aperture