Abstract:
A clip cooperates with a fastener, such as a mounting screw, to hold the fastener securely in an object. The clip can be designed into the object or, for example, the objects designed to receive the clip. The construction of the clip not only allows an installer to “push” the fastener into the fastener-receiving hole a certain distance thereby obviating the need to screw all the threads to complete the installation, but also provides a greater holding force between the clip and the fastener, and thus the objects. The clip can also include one or more knife-edged tabs that engage the fastener.

Description:
RELATED APPLICATION DATA  
       [0001]     This application is related to copending Application Ser. No. 10/946,327 entitled “Quick Set Device For Mounting Electrical Devices,” filed on Sep. 22, 2004, which claims priority to U.S. Provisional Patent Application No. 60/504,203 entitled “Quick Set Device For Mounting Electrical Devices,” filed on Sep. 22, 2003, and U.S. Design Patent No. D,491,537, entitled “Quick Set Device For Mounting Electrical Devices,” issued on Jun. 15, 2004, all of which are incorporated herein by reference in their entirety. 
     
    
     BACKGROUND  
       [0002]     1. Field of the Invention  
         [0003]     This invention generally relates to securing mechanisms. In particular, an exemplary embodiment of this invention relates to securing mechanisms having at least one knife-edged surface that engages a portion of a fastener to thereby hold the fastener securely.  
         [0004]     2. Description of Related Art  
         [0005]     Electrical work boxes are known that receive one or more screws that secure one or more of an electrical receptacle, such as an outlet, and a faceplate to the electrical work box. Typically these screws are screwed directly into the plastic of the work box. Due to the configuration of the receiving hole for these mounting screws, the user is required to turn the screw numerous times before the screw head becomes flush with the surface of the item being affixed to the work box and therefore tight.  
       SUMMARY  
       [0006]     Exemplary aspects of the present invention are directed toward a clip that cooperates with a fastener, such as a mounting screw, to hold the fastener securely in an object. For example, and in accordance with a first exemplary embodiment, the clip is associated with the object. The clip can be designed into the object or, for example, the object designed to receive the clip. The construction of the clip not only allows an installer to “push” the fastener into the fastener-receiving hole a certain distance thereby obviating the need to screw all the threads to complete the installation, but also provides a greater holding force between the clip and the fastener, and thus the object.  
         [0007]     Another exemplary embodiment of the invention is directed toward a clip having a knife-edge on one or more engagement tabs that are associated with the clip. These engagement tabs contact the fastener, such as a mounting screw, thereby increasing the holding force there between.  
         [0008]     In accordance with yet another exemplary embodiment, the clips can be made by running a ribbon of material through a stamp that partially cuts a portion of the clip out of the material. The partially stamped clip can remain affixed to the ribbon that is, for example, placed on the reel. The reel may then be fed into an assembly machine for inserting the clips into, for example, plastic electrical work boxes or the assembly machine can break the clip off of the ribbon. The ribbon, and thus the clip, can be made of, for example, pre-plated or non-corrosive material such as stainless steel, Beryllium-copper, zinc-coated, heat treated, or any other type of material as appropriate.  
         [0009]     Another exemplary aspect of the invention relates to a clip that has a plurality of flexible engagement tabs that not only have a knife-edged nose, but also have a radius cut in the nose of the engagement tab wherein the radius can be designed, for example, to match a root diameter of a fastener.  
         [0010]     These and other features and advantages of this invention are described in, or are apparent from, the following description of the embodiments. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]     The embodiments of the invention will be described in detail, with reference to the following figures, wherein:  
         [0012]      FIG. 1  illustrates an environmental view of an exemplary clip mechanism according to this invention;  
         [0013]      FIG. 2  illustrates a back-side perspective view of the exemplary clip mechanism according to this invention;  
         [0014]      FIG. 3  illustrates a side view of the exemplary clip mechanism according to this invention;  
         [0015]      FIG. 4  illustrates a bottom view of the exemplary clip mechanism according to this invention;  
         [0016]      FIG. 5  illustrates a front-side view of the exemplary clip mechanism according to this invention;  
         [0017]      FIG. 6  illustrates a back-side view of the exemplary clip mechanism according to this invention;  
         [0018]      FIG. 7  illustrates a cross-sectional view of a screw partially engaged by the exemplary clip mechanism according to this invention;  
         [0019]      FIG. 8  illustrates a screw fully engaged by the exemplary clip mechanism according to this invention;  
         [0020]      FIG. 9  illustrates a second environmental view of an exemplary clip mechanism located in an electrical work box according to this invention;  
         [0021]      FIG. 10  is an enlarged view of portion A in  FIG. 9 ;  
         [0022]      FIG. 11  is a hidden-line view illustrating the exemplary clip secured in an electrical work box according to this invention;  
         [0023]      FIG. 12  is an enlarged view of portion B of  FIG. 11 ;  
         [0024]      FIG. 13  is an enlarged partial cross sectional view taken along plane A-A of  FIG. 1  of the exemplary clip secured in an electrical work box according to this invention; and  
         [0025]      FIG. 14  illustrates a partial cross-section of the clip taken along plane B-B of  FIG. 1 . 
     
    
     DETAILED DESCRIPTION  
       [0026]     The exemplary systems methods of this invention will be described in relation to a clip or securing mechanism. However, to avoid unnecessarily obscuring the present invention, the following description omits well-known structures and devices. For the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated, however, that the present invention may be practiced in a variety of ways beyond these specific details. For example, the clip mechanism is not limited to use in an electrical work box or to the number of engagement tabs as shown. In general, the clip mechanism can be used in conjunction with any device or object to assist with the securing of a fastener thereto. Furthermore, the number of engagement tabs can be varied to include any number of engagement tabs, the engagement tabs can be cut at a radius at the nose end, as well as knife-edged, or any combination thereof.  
         [0027]      FIG. 1  illustrates an exemplary electrical work box  200 . The exemplary electrical work box  200  comprises one or more fasteners, such as nails  210 , for securing the electrical work box  200  to, for example, a stud (not shown), a first screw-receiving portion  220 , a second screw-receiving portion  230 , a lip  240  designed to hold the clip mechanisms  100  in the electrical work box  200 , one or more punch-out portions  250 , for receiving cable therethrough, and a trough  260  that allows, for example, longer screws to extend past the clip mechanism  100  adjacent to the electrical work box  200 .  
         [0028]     As illustrated in  FIG. 1 , a fastener, such as a threaded machine or sheet metal type screw, can be inserted into the screw-receiving portion  220 . The screw-receiving portion  220  can be designed to be of slightly larger diameter than that of the screw, thereby holding the screw in contact with the clip mechanism  100 . Through this cooperation between the clip mechanism  100  and the screw-receiving portion, the fastener is held firmly in place within the electrical work box  200 .  
         [0029]      FIG. 2  illustrates the clip mechanism  100  from the backside or box engagement side. It should be appreciated that this backside not be limited to contacting an electrical box, but rather can come into contact and be modified as appropriate for cooperation with any structure to allow engagement and to provide the force opposing that of a fastener coming into contact with the engagement tab(s).  
         [0030]     The securing mechanism  100  illustrated in  FIG. 2  highlights the securing tab  110  extending at an angle of, for example, 90 degrees or less from the securing mechanism  100 . The securing tab  110  has a securing tab engagement surface  105  that comes into contact with the structure into which the securing mechanism  100  is placed. The securing tab  110  can be made of a spring-like material such that depression of the securing tab  110  is possible so that it can be pressed flush with the securing mechanism  100  to a allow, for example, insertion of or withdrawal from the structure into which it is inserted.  
         [0031]     The securing mechanism  100  also includes a bevel  160  that facilitates, for example, insertion of the securing mechanism  100  into a structure as well as a hip portion  150  that limits the insertion depth of the securing mechanism  100 .  
         [0032]      FIG. 3  illustrates a side view of the securing mechanism  100 . In particular, one or more engagement tabs, such as engagement tabs  120  and  130 , are on a first side of the securing mechanism  100 , while the securing tab  110  is on the opposite side of the securing mechanism  100 . It should be appreciated that the securing tab  110  could also be placed on the same side as the one or more engagement tabs with the corresponding configuration of the structure into which is inserted modified so as to hold the securing mechanism in place. The location of the securing tab  110  could also relocated to any position on the securing mechanism  100 .  
         [0033]     In this exemplary embodiment, the engagement tabs  120  and  130  also include a knife-edge portion  140  on the nose of the engagement tab that is “sharpened” to better engage the fastener. As discussed hereinafter, one or more of the noses of the engagement tabs in addition to, or in lieu of, being knife-edged, could also be cut on a radius at the tip end  145  to increase the contact area with a fastener.  
         [0034]     As with the securing tab  110 , the engagement tab(s) can also be flexible such that a ratcheting-type action is provided when a threaded fastener is inserted. This could allow, for example, a push-in-and-twist type motion for quickly securing a screw in a structure.  
         [0035]     It should be appreciated that the securing tab engagement surface  105  could also be knife-edged and/or radiused based on, for example, the type of structure into which the securing mechanism is intended for use.  
         [0036]      FIG. 4  illustrates a bottom view of the securing mechanism  100 . In particular, the securing tab  110  is illustrated on the opposite side of the engagement tab  130 . In this particular exemplary embodiment, the engagement tab  130  is tapered. It should be appreciated that the end  135  of the engagement tab  130  is not limited to being narrower than the base of the engagement tab  130 , but could also be larger and, as previously discussed, knife-edged and/or radiused.  
         [0037]      FIG. 5  illustrates a front-side view of the securing mechanism  100 . In this view, the hip structure  150  and bevel  160  are clearly seen. The securing mechanism  100  also includes a head portion  155 . As previously discussed, this head portion can be utilized, for example, to secure adjacent securing mechanisms to a ribbon or tape as well as allow, for example, as a surface that can be gripped to remove the securing mechanism  100  from a structure.  
         [0038]      FIG. 6  illustrates an alternative embodiment of the securing mechanism  100  where one or more of the engagement tabs  120 / 130  have a radiused tip  145 . The radiused tip(s) can be combined with the knife-edging as previously discussed. Furthermore, it should be appreciated that in the case where there is more than one engagement tab associated with the securing mechanism  100 , the tips of each engagement tab can vary such that, for example, one engagement tab may be knife-edged, another engagement tab may be radiused, and a third engagement tab may be knife-edged and radiused. In general, any number of engagement tabs with any type of tip or combination of tip can be utilized in conjunction with the disclosed embodiments of this invention.  
         [0039]      FIG. 7  is a cross-sectional view taken along plane B-B of  FIG. 1 . In particular,  FIG. 7  illustrates an intermediate operational position of a screw  700  being inserted into a structure, which in this case is a portion of an electrical work box  200 .  
         [0040]     The securing mechanism  100  is illustrated in its installed position with the securing tab  110 , and in particular the securing tab engagement surface  105  in contact with the work box securing mechanism engagement surface  202 . As will be illustrated in greater detail hereinafter, the securing tab  110  cooperates with the hip structure  150  to firmly “lock” the securing mechanism  100  into a structure. This “locking” type operation can occur, for example, as a securing mechanism  100  is pressed into a structure and the securing tab  110  springs from an insertion position into a secured position as shown in  FIG. 7 .  
         [0041]     In this partially inserted view, the screw  700  and, in particular, threads  710  are engaging the first engagement tab  120  and particularly the knife edge  140 . As previously discussed, the securing mechanism  100  can be used in conjunction with a fastener to provide a push-in-and-turn type operation. Thus, in this intermediate state as illustrated in  FIG. 7 , the screw  700  and threads  710  slide across the work box fastener engagement surface  204  as the one or more engagement tabs, in this case engagement tab  120  deflects and comes into contact with the threaded surface of the screw  700 .  
         [0042]      FIG. 8  illustrates the screw  700  flush with and snug against the work box  200 . After the screw  700  has been pushed in, the screw is turned in a tightening direction at which point the engagement tabs  120  and  130  create a force Q pushing the threaded portion  710  of the screw  700  into the work box fastener engagement surface  204 . At the same time, the knife edges  140  of the engagement tabs  120  and  130  securely engage the thread  710  thereby holding the screw  700  firmly in the work box  200 .  
         [0043]      FIG. 9  illustrates an environmental perspective view of a work box  200  with the exemplary securing mechanism  100  installed therein. In this view, the securing tab  110  can be seen in contact with the work box securing mechanism engagement surface  202 .  
         [0044]      FIG. 10  is an enlarged view of portion A of  FIG. 9 . In greater detail, the securing mechanism  100  can be seen inserted into receiving slot  212 (s) which thereby hold the securing mechanism  100  in the appropriate position relative to screw  700 .  
         [0045]      FIG. 11  illustrates a hidden-line view of the exemplary securing mechanism  100  installed in an electrical work box  200 . In greater detail,  FIG. 12  is an exploded view of portion B of  FIG. 11 . In this exploded view, the securing mechanism  100  is shown with a securing tab  110  abutting the work box securing mechanism engagement surface  202 . Furthermore, the head portion  155  and hip structure  150  can be seen as being recessed into the work box  200 . The work box is thus provided with a complementary structure adapted to receive the hip structure  150 .  
         [0046]      FIG. 13  is a cross-sectional view taken along plane C-C of  FIG. 8 . In particular, the securing mechanism  100  is illustrated with the hip structure  150  in contact with the hip engagement surface  222 . As previously discussed, cooperation between the hip structure  150 , hip engagement surface  222 , work box securing mechanism engagement surface  202 , and the securing tab  110  securely hold the securing mechanism  100  in the work box  200 .  
         [0047]      FIG. 14  illustrates an end view of the work box having an exemplary securing mechanism  100  installed therein. The engagement tab  120  extends into the hole  232  into which a fastener, such as a screw, is inserted. As the screw is inserted, the engagement tab  120  deflects with the knife-edge surface  140  ratcheting over the thread on the fastener thereby allowing the fastener to be pressed substantially into the work box  200 . The screw can then be tightened with minimal turns thereby affixing the screw securely to the work box  200 .  
         [0048]     It is therefore apparent that there has been provided, in accordance with the present invention, a securing mechanism. While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, it is intended to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention.