Patent Description:
A push-on fastener may be disposed to distribute load of an inner member, e.g., a shaft in an assembly or mechanism. Specific types of push-on fasteners may be used to axially fix itself to an inner member and interact with another component of the assembly.

In a number of assemblies, the inner member may be rotating during usage where the push-on fastener may move against the side of other components of the assembly, such as an outer member, which may cause friction, vibration, and noise. There continues to be a need for push-on fasteners for use in applications to fix to inner members and provide decreased friction, vibration, and noise while simplifying assemblies, increasing assembly lifetimes.

<CIT> discloses a retainer clip and shaft combination for axially securing an apertured mechanical element on the shaft.

<FIG> includes a perspective view of a push-on fastener in accordance with an embodiment.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.

Subject matter of the present invention is a push-on fastener as defined in claim <NUM>, and an assembly as defined in claim <NUM>, which assembly comprises the push-on fastener according to the present invention. The dependent claims relate to particular embodiments thereof.

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other embodiments can be used based on the teachings as disclosed in this application.

For example, when a single embodiment is described herein, more than one embodiment may be used in place of a single embodiment. Similarly, where more than one embodiment is described herein, a single embodiment may be substituted for that more than one embodiment.

The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in textbooks and other sources within the push-on fastener and push-on fastener assembly arts.

Embodiments described herein are generally directed to a push-on fastener and methods of creating and using a push-on fastener within an assembly. According to the present invention, the push-on fastener has an annular base and a plurality of radial tabs extending from the annular base. The radial tabs provide at least one peripheral surface that is free of low friction layer.

For purposes of illustration, <FIG> includes a diagram showing a forming process <NUM> for forming a push-on fastener. The forming process <NUM> may include a first step <NUM> of providing a base material, a second step <NUM> of coating the base material with a low friction coating to form a composite material and a third step <NUM> of forming the composite material into a push-on fastener.

Referring to the first step <NUM>, the base material may be a substrate. In an embodiment, the substrate can at least partially include a metal. According to certain embodiments, the metal may include iron, copper, titanium, tin, aluminum, alloys thereof, or may be another type of material. More particularly, the substrate can at least partially include a steel, such as, a stainless steel, carbon steel, or spring steel. For example, the substrate can at least partially include a <NUM> stainless steel. The <NUM> stainless steel may be annealed, ¼ hard, ½ hard, ¾ hard, or full hard. The substrate may include a woven mesh or an expanded metal grid. Alternatively, the woven mesh can be a woven polymer mesh. In an alternate embodiment, the substrate may not include a mesh or grid.

<FIG> includes an illustration of the composite material <NUM> that may be formed according to first step <NUM> and second step <NUM> of the forming process <NUM>. For purposes of illustration, <FIG> shows the layer by layer configuration of a composite material <NUM> after second step <NUM>. In a number of embodiments, the composite material <NUM> may include a substrate <NUM> (i.e., the base material provided in the first step <NUM>) and a low friction layer <NUM> (i.e., the low friction coating applied in second step <NUM>). As shown in <FIG>, the low friction layer <NUM> can be coupled to at least a portion of the substrate <NUM>. In a particular embodiment, the low friction layer <NUM> can be coupled to a surface of the substrate <NUM> so as to form a low friction interface with another surface of another component. The low friction layer <NUM> can be coupled to the radially inner surface of the substrate <NUM> so as to form a low friction interface with another surface of another component. The low friction layer <NUM> can be coupled to the radially outer surface of the substrate <NUM> so as to form a low friction interface with another surface of another component.

In a number of embodiments, the low friction layer <NUM> can include a low friction material. Low friction materials may include, for example, for example, a polymer, such as a polyketone, a polyaramid, a polyimide, a polytherimide, a polyphenylene sulfide, a polyetherslfone, a polysulfone, a polypheylene sulfone, a polyamideimide, ultra high molecular weight polyethylene, a fluoropolymer, a polyamide, a polybenzimidazole, or any combination thereof. In an example, the low friction layer <NUM> includes a polyketone, a polyaramid, a polyimide, a polyetherimide, a polyamideimide, a polyphenylene sulfide, a polyphenylene sulfone, a fluoropolymer, a polybenzimidazole, a derivation thereof, or a combination thereof. In a particular example, the low friction/wear resistant layer includes a polymer, such as a polyketone, a thermoplastic polyimide, a polyetherimide, a polyphenylene sulfide, a polyether sulfone, a polysulfone, a polyamideimide, a derivative thereof, or a combination thereof. In a further example, the low friction/wear resistant layer includes polyketone, such as polyether ether ketone (PEEK), polyether ketone, polyether ketone ketone, polyether ketone ether ketone, a derivative thereof, or a combination thereof. In an additional example, the low friction/wear resistant layer may be an ultra high molecular weight polyethylene. An example fluoropolymer includes fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyphenylene oxide, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymers (LCP), or any combination thereof. The low friction layer <NUM> may include a solid based material including lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide, or diamond like carbon, a metal (such as aluminum, zinc, copper, magnesium, tin, platinum, titanium, tungsten, lead, iron, bronze, steel, spring steel, stainless steel), a metal alloy (including the metals listed), an anodized metal (including the metals listed) or any combination thereof. Fluoropolymers may be used according to particular embodiments. As used herein, a "low friction material" can be a material having a dry static coefficient of friction as measured against steel of less than <NUM>, such as less than <NUM>, less than <NUM>, or even less than <NUM>. A "high friction material" can be a material having a dry static coefficient of friction as measured against steel of greater than <NUM>, such as greater than <NUM>, greater than <NUM>, greater than <NUM>, or even greater than <NUM>.

In a number of embodiments, the low friction layer <NUM> may further include fillers, including glass fibers, carbon fibers, silicon, PEEK, aromatic polyester, carbon particles, bronze, fluoropolymers, thermoplastic fillers, aluminum oxide, polyamidimide (PAI), PPS, polyphenylene sulfone (PPSO2), LCP, aromatic polyesters, molybdenum disulfide, tungsten disulfide, graphite, grapheme, expanded graphite, boron nitride, talc, calcium fluoride, or any combination thereof. Additionally, the filler can include alumina, silica, titanium dioxide, calcium fluoride, boron nitride, mica, Wollastonite, silicon carbide, silicon nitride, zirconia, carbon black, pigments, or any combination thereof. Fillers can be in the form of beads, fibers, powder, mesh, or any combination thereof.

The low friction layer <NUM> can have an axial height TFL in a range of <NUM> and <NUM>, such as in a range of <NUM> and <NUM>, or even in a range of <NUM> and <NUM>. The axial height of the low friction <NUM> may be uniform, i.e., an axial height at a first location of the low friction layer <NUM> can be equal to an axial height at a second location therealong. The low friction layer <NUM> may overlie one major surface of the substrate <NUM>, shown, or overlie both major surfaces. The substrate <NUM> may extend at least partially along a length of the composite material <NUM>. The substrate <NUM> may be at least partially encapsulated by the low friction layer <NUM>. That is, the low friction layer <NUM> may cover at least a portion of the substrate <NUM>. Axial surfaces of the substrate <NUM> may or may not be exposed from the low friction <NUM>. The composite material <NUM> can have an axial height TSW in a range of <NUM> and <NUM>, such as in a range of <NUM> and <NUM>, or even in a range of <NUM> and <NUM>.

<FIG> includes an illustration of an alternative composite material that may be formed according to first step <NUM> and second step <NUM> of the forming process <NUM>. For purposes of illustration, <FIG> shows the layer by layer configuration of a composite material <NUM> after second step <NUM>. According to this particular example, the composite material <NUM> may be similar to the composite material <NUM> of <FIG>, except this composite material <NUM> may also include at least one adhesive layer <NUM> that may couple the low friction layer <NUM> to the substrate <NUM> (i.e., the base material provided in the first step <NUM>) and a low friction layer <NUM> (i.e., the low friction coating applied in second step <NUM>). In another alternate example, the substrate <NUM>, as a solid component, woven mesh or expanded metal grid, may be embedded between at least one adhesive layer <NUM> included between the low friction layer <NUM> and the substrate <NUM>.

The adhesive layer <NUM> may include any known adhesive material common to the fastener arts including, but not limited to, fluoropolymers, epoxy resins, polyimide resins, polyether/polyamide copolymers, ethylene vinyl acetates, ethylene tetrafluoroethylene (ETFE), ETFE copolymer, perfluoroalkoxy (PFA), or any combination thereof. Additionally, the adhesive can include at least one functional group selected from -C=O, -C-O-R, -COH, - COOH, -COOR, -CF<NUM>=CF-OR, or any combination thereof, where R is a cyclic or linear organic group containing between <NUM> and <NUM> carbon atoms. Additionally, the adhesive can include a copolymer. The hot melt adhesive can have a melting temperature of not greater than <NUM>, such as not greater than <NUM>. In another example, the adhesive may break down above <NUM>, such as above <NUM>. In further examples, the melting temperature of the hot melt adhesive can be higher than <NUM> or even higher than <NUM>. The adhesive layer <NUM> can have an axial height of about <NUM> to <NUM> microns, such as about <NUM> to <NUM> microns.

<FIG> includes an illustration of an alternative composite material that may be formed according to first step <NUM> and second step <NUM> of the forming process <NUM>. For purposes of illustration, <FIG> shows the layer by layer configuration of a composite material <NUM> after second step <NUM>. According to this particular example, the composite material <NUM> may be similar to the composite material <NUM> of <FIG>, except this composite material <NUM> may also include at least one corrosion protection layer <NUM>, <NUM>, and <NUM>, and a corrosion resistant coating <NUM> that can include an adhesion promoter layer <NUM> and an epoxy layer <NUM> that may couple to the substrate <NUM> (i.e., the base material provided in the first step <NUM>) and a low friction layer <NUM> (i.e., the low friction coating applied in second step <NUM>).

The substrate <NUM> may be coated with corrosion protection layers <NUM> and <NUM> to prevent corrosion of the composite material <NUM> prior to processing. Additionally, a corrosion protection layer <NUM> can be applied over layer <NUM>. Each of layers <NUM>, <NUM>, and <NUM> can have an axial height of about <NUM> to <NUM> microns, such as about <NUM> to <NUM> microns. Layers <NUM> and <NUM> can include a phosphate of zinc, iron, manganese, or any combination thereof, or a nano-ceramic layer. Further, layers <NUM> and <NUM> can include functional silanes, nano-scaled silane based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers, chlorinated polyolefins, passivated surfaces, commercially available zinc (mechanical/galvanic) or zinc-nickel coatings, or any combination thereof. Layer <NUM> can include functional silanes, nano-scaled silane based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers. Corrosion protection layers <NUM>, <NUM>, and <NUM> can be removed or retained during processing.

The composite material <NUM> may further include a corrosion resistant coating <NUM>. The corrosion resistant coating <NUM> can have a axial height of about <NUM> to <NUM> microns, such as about <NUM> to <NUM> microns, and such as about <NUM> to <NUM> microns. The corrosion resistant coating <NUM> can include an adhesion promoter layer <NUM> and an epoxy layer <NUM>. The adhesion promoter layer <NUM> can include a phosphate of zinc, iron, manganese, tin, or any combination thereof, or a nano-ceramic layer. The adhesion promoter layer <NUM> can include functional silanes, nano-scaled silane based layers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers, chlorinated polyolefins, passivated surfaces, commercially available zinc (mechanical / galvanic) or Zinc-Nickel coatings, or any combination thereof. The epoxy layer <NUM> can be a thermal cured epoxy, a UV cured epoxy, an IR cured epoxy, an electron beam cured epoxy, a radiation cured epoxy, or an air cured epoxy. Further, the epoxy layer <NUM> can include polyglycidylether, diglycidylether, bisphenol A, bisphenol F, oxirane, oxacyclopropane, ethylenoxide, <NUM>,<NUM>-epoxypropane, <NUM>-methyloxirane, <NUM>,<NUM>-epoxy-<NUM>,<NUM>-dihydroanthracene, or any combination thereof. The epoxy layer <NUM> can further include a hardening agent. The hardening agent can include amines, acid anhydrides, phenol novolac hardeners such as phenol novolac poly[N-(<NUM>-hydroxyphenyl)maleimide] (PHPMI), resole phenol formaldehydes, fatty amine compounds, polycarbonic anhydrides, polyacrylate, isocyanates, encapsulated polyisocyanates, boron trifluoride amine complexes, chromic-based hardeners, polyamides, or any combination thereof. Generally, acid anhydrides can conform to the formula R-C=O-O-C=O-R' where R can be CXHYXZAU as described above. Amines can include aliphatic amines such as monoethylamine, diethylenetriamine, triethylenetetraamine, and the like, alicyclic amines, aromatic amines such as cyclic aliphatic amines, cyclo aliphatic amines, amidoamines, polyamides, dicyandiamides, imidazole derivatives, and the like, or any combination thereof.

For example, under step <NUM> of <FIG>, any of the layers on the composite material <NUM>, <NUM>, <NUM>, as described above, can each be disposed in a roll and peeled therefrom to join together under pressure, at elevated temperatures (hot or cold pressed or rolled), by an adhesive, or by any combination thereof. Any of the layers of the composite material <NUM>, as described above, may be laminated together such that they at least partially overlap one another. Any of the layers on the composite material <NUM>, <NUM>, <NUM>, as described above, may be applied together using coating technique, such as, for example, physical or vapor deposition, spraying, plating, powder coating, or through other chemical or electrochemical techniques. For example, the low friction layer <NUM> may be applied by a roll-to-roll coating process, including for example, extrusion coating. The low friction layer <NUM> may be heated to a molten or semi-molten state and extruded through a slot die onto a major surface of the substrate <NUM>. For example, the low friction layer <NUM> may be cast or molded.

Under step <NUM> of <FIG>, any of the layers on the composite material <NUM>, <NUM>, <NUM>, as described above, may be applied by a coating technique, such as, for example, physical or vapor deposition, spraying, plating, powder coating, or through other chemical or electrochemical techniques. For example, the low friction layer <NUM> may be applied by a roll-to-roll coating process, including for example, extrusion coating. The low friction layer <NUM> may be heated to a molten or semi-molten state and extruded through a slot die onto a major surface of the substrate <NUM>. For example, the low friction layer <NUM> may be cast or molded.

Referring now to the third step <NUM> of the forming process <NUM> as shown in <FIG>, forming the composite material <NUM>, <NUM>, <NUM> into a push-on fastener may include a cutting operation. The cutting operation may include use of a stamp, press, punch, saw, or may be machined in a different way. The cutting operation may form a peripheral surface on the push-on fastener. The cutting operation may define a cutting direction initiated from a first major surface to a second major surface, opposite the first major surface, to form the peripheral surfaces or edges. Alternatively, the cutting operation may define a cutting direction initiated from the second major surface to the first major surface to form the peripheral surfaces or edges.

For purposes of illustration, <FIG> include an illustration showing a cutting operation to form a push on fastener <NUM>. The push on fastener <NUM> has a first major surface <NUM> and a second major surface <NUM>. The push-on fastener <NUM> further has an annular base <NUM>. The push-on fastener <NUM> further includes at least one radial tab <NUM>. As shown in <FIG>, the at least one radial tab <NUM> may include an inner radial edge <NUM>. The at least one radial tab <NUM> may define a peripheral surface 112a. As shown in <FIG>, the at least one radial tab <NUM> may include an outer radial edge <NUM>. The at least one radial tab <NUM> may define a peripheral surface 112b. As shown in <FIG>, the push-on fastener <NUM> may be cut by a cutting operation to form one of the peripheral surfaces 112a, 112b after the low friction layer <NUM>, <NUM>' is formed on the substrate <NUM>. Two low friction layers <NUM>, <NUM>' may be coupled to the substrate <NUM>. <FIG> shows an upward cutting direction against an angle α on a push-on fastener <NUM> with inwardly facing radial tabs <NUM>. <FIG> shows a downward cutting direction toward the angle α on a push-on fastener <NUM> with inwardly facing radial tabs <NUM>. <FIG> shows an upward cutting direction against the angle α on a push-on fastener <NUM> with outwardly facing radial tabs <NUM>. <FIG> shows a downward cutting direction toward the angle α on a push-on fastener <NUM> with outwardly facing radial tabs <NUM>. The cut may form an exposed surface <NUM> free of low friction layer <NUM> on the push-on fastener <NUM>. As shown in <FIG>, the cut may form an exposed surface <NUM> free of low friction layer <NUM> on the inner radial edge <NUM> of the at least one radial tab <NUM> of the push-on fastener <NUM>. As shown in <FIG>, the cut may form an exposed surface <NUM> free of low friction layer <NUM> on the outer radial edge <NUM> of the at least one radial tab <NUM> of the push-on fastener <NUM>. As shown in <FIG>, the first major surface <NUM> may intersect at least one peripheral surface 112a, 112b to form a sharp corner <NUM> while the second major surface <NUM> may intersect the peripheral surface 112a, 112b to form a radiused corner <NUM>. The sharp corner <NUM> may have burr <NUM> or have an extreme slope to otherwise form a sharp edge. The sharp corner <NUM> has a radius of curvature in the range of <NUM> to <NUM>. The radiused corner <NUM> may have a more gradual slope to otherwise form a smooth edge. The radiused corner <NUM> has a radius of curvature in the range of <NUM> to <NUM>.

Turning now to the push-on fastener formed according to examples described herein, <FIG> includes a top view illustration of a push-on fastener <NUM>. For purposes of illustration, <FIG> shows a top view of a push-on fastener <NUM> described herein, which can include a push-on fastener body <NUM> oriented about a central axis A. The push-on fastener <NUM> further has an annular base <NUM>. The annular base <NUM> may include an inner radial edge <NUM> and an outer radial edge <NUM>. The inner radial edge <NUM> may at least partially define an aperture <NUM> in the push-on fastener <NUM>. The push-on fastener <NUM> further includes at least one radial tab <NUM> disposed along at least one of the inner radial edge <NUM> of the annular base <NUM>.

The annular base <NUM> may have a particular outer radius ORAB. For purposes of examples described herein and as shown in <FIG>, the outer radius ORAB of the annular base <NUM> is the distance from the central axis A to the outer radial edge <NUM>. For example, the outer radius ORAB of the annular base <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to other examples, the outer radius ORAB of the annular base <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the outer radius ORAB of the annular base <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the outer radius ORAB of the annular base <NUM> may be any value between any of the minimum and maximum values noted above. For example, the outer radius ORAB of the annular base <NUM> may be <NUM>.

In a number of examples, the annular base <NUM> may have a particular inner radius IRAB. For purposes of examples described herein and as shown in <FIG>, the inner radius, IRAB of the annular base <NUM> is the distance from the central axis A to the inner radial edge <NUM>. According to certain examples, the inner radius IRAB of the annular base <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the inner radius IRAB of the annular base <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the inner radius IRAB of the annular base <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the inner radius IRAB of the annular base <NUM> may be any value between any of the minimum and maximum values noted above. For example, the inner radius IRAB of the annular base <NUM> may be <NUM>.

For purposes of illustration, <FIG> includes a cross-sectional view of a push-on fastener <NUM>, as shown in <FIG>, in accordance with embodiments described herein. As shown in <FIG>, the annular base <NUM> can include a first axial surface <NUM> and a second axial surface <NUM> opposite the first axial surface <NUM> oriented down the central axis A and spaced apart by a axial height TAB. The annular base <NUM> may have a polygonal, oval, circular, semi-circular, or substantially circular cross-section when viewed in a plane perpendicular to the central axis A.

For example, the annular base <NUM> may have a particular axial height TAB. For purposes of examples described herein and as shown in <FIG>, the axial height TAB of the annular base <NUM> is the distance from the first axial surface <NUM> to the second axial surface <NUM>. For example, the axial height TAB of the annular base <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the axial height TAB of the annular base <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the axial height TAB of the annular base <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the axial height TAB of the annular base <NUM> may be any value between any of the minimum and maximum values noted above. For example, the axial height TAB of the annular base <NUM> may be <NUM>.

Referring back to <FIG>, the push-on fastener <NUM> includes at least one radial tab <NUM>. As disclosed herein, the at least one radial tab <NUM> may run the entire circumference of the push-on fastener <NUM>. According to the present invention, the push-on fastener <NUM> includes a plurality of radial tabs <NUM>, each extending from the annular base <NUM>. According to the present invention, the plurality of radial tabs <NUM> project radially inwardly from the annular base <NUM>, providing the inner peripheral surface (112a), wherein the outer peripheral surface (112b) is free of the low friction layer (<NUM>), or the radial tabs (<NUM>) terminate radially outwardly, providing the outer peripheral surface (112b), wherein the inner peripheral surface (112a) is free of the low friction layer (<NUM>).

According to still other examples, the at least one radial tab <NUM> may include an inner radial edge <NUM> and an outer radial edge <NUM>. The outer radial edge <NUM> may be contiguous with the inner radial edge <NUM> of the annular base <NUM>. The at least one radial tab <NUM> may include a first circumferential edge <NUM> and a second circumferential edge <NUM> along an arc length measured as an angle Θ with respect to the central axis A, as shown best in <FIG>. The inner radial edge <NUM> may at least partially define the aperture <NUM> in the push-on fastener <NUM> and/or annular base <NUM>. As shown in <FIG>, the at least one radial tab <NUM> can include a first axial surface <NUM> and a second axial surface <NUM> opposite the first axial surface <NUM>.

As shown in both <FIG>, the radial tabs <NUM> can be circumferentially offset from one another. The plurality of radial tabs 110can be circumferentially offset from one another by a plurality of radial slots <NUM>. The radial slots <NUM> may be gaps defining the first circumferential edge <NUM>, and the second circumferential edge <NUM> of neighboring radial tabs <NUM>. The at least one radial tab <NUM> may have a polygonal, oval, circular, semi-circular, or substantially circular cross-section when viewed in a plane generally perpendicular to the central axis A.

In a number of examples, as shown in <FIG>, the at least one radial tab <NUM> may have a width WRT, as measured in an arc length from the first circumferential edge <NUM> to the second circumferential edge <NUM>. Width WRT can be calculated by the formula <MAT>, where Θ is the angle formed between the first circumferential edge <NUM> and the second circumferential edge <NUM> with respect to the central axis A, and C is the circumference of the push-on fastener <NUM> along a best fit circle formed by inner radial edges <NUM> of the radial tabs <NUM> of the push-on fastener <NUM>. According to certain examples, the width WRT of the at least one radial tab <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the width WRT of the at least one radial tab <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the width WRT of the at least one radial tab <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the width WRT of the at least one radial tab <NUM> may be any value between any of the minimum and maximum values noted above. For example, the width WRT of the at least one radial tab <NUM> may be <NUM>.

In a number of examples, as shown in <FIG>, the at least one radial tab <NUM> can have an axial height TRT. As described herein, the axial height TRT of the at least one radial tab <NUM> is the distance from the first axial surface <NUM> to the second axial surface <NUM>. According to certain examples, the axial height TRT of the at least one radial tab <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the axial height TRT of the at least one radial tab <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the axial height TRT of the at least one radial tab <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the axial height TRT of the at least one radial tab <NUM> may be any value between any of the minimum and maximum values noted above. For example, the axial height TRT of the at least one radial tab <NUM> may be <NUM>.

In a number of examples, as shown in <FIG>, the at least one radial tab <NUM> can have a length LRT. As described herein, the length LRT of the at least one radial tab <NUM> is the distance from the inner radial edge <NUM> to the outer radial edge <NUM>. According to certain examples, the length LRT of the at least one radial tab <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the length LRT of the at least one radial tab <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the length LRT of the at least one radial tab <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the length LRT of the at least one radial tab <NUM> may be any value between any of the minimum and maximum values noted above. For example, the length LRT of the at least one radial tab <NUM> may be <NUM>.

In an example, as shown in <FIG>, the at least one radial tab <NUM> can include a bridge portion <NUM> connecting the inner radial edge <NUM> of the at least one radial tab <NUM> to the annular base <NUM>. In certain examples, the bridge portion <NUM> can cant relative to the central axis A. As stated above and now shown in <FIG>, the bridge portion <NUM> can form an angle α with respect to the plane parallel to the annular base <NUM> and perpendicular to the central axis A. By way of a non-limiting example, the angle α between the bridge portion <NUM> and the annular base <NUM> in the unloaded state can be at least <NUM>°, such as at least <NUM>°, at least <NUM>°, at least <NUM>°, or even at least <NUM>°. In another example, the angle α can be no greater than <NUM>°, such as no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, or even no greater than <NUM>°. In still another example, the angle α can be no less than or equal to <NUM>°. It will be appreciated that the angle α may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the angle α may be any value between any of the minimum and maximum values noted above. For example, the angle α may be <NUM>°.

In a number of examples, the angles α of the radial tabs <NUM> can all be uniform. In another example, an angle α of at least one radial tab <NUM> may differ. In a particular example, each angle α can be no less than <NUM>°, such as no less than <NUM>°, no less than <NUM>°, or even no less than <NUM>°. In a further example, each angle α can be less than <NUM>°, such as no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, or even no greater than <NUM>°. In a particular example, the angles α can all lie along straight lines that extend in a substantially parallel direction. As used herein, "substantially parallel direction" refers to a deviation of no greater than <NUM>° between the measured directions of two lines, such as no greater than <NUM>°, no greater than <NUM>°, or even no greater than <NUM>°. In a more particular example, the angles α can all lie along lines that extend in parallel. As used herein, "extend in parallel" refers to a deviation of no greater than <NUM>° between the measured directions of two lines.

Per <FIG>, and as now shown in more detail in <FIG>, the at least one radial tab <NUM> may define an inner peripheral surface 112a. For example, the inner radial edge <NUM> of at least one radial tab <NUM> may define the inner peripheral surface 112a. In this way, the radial tabs <NUM> project radially inwardly and forms the inner peripheral surface 112a. For example, at least one of the radial tabs <NUM> may have an exposed surface <NUM> defined as being free of the low friction layer <NUM>. As shown in <FIG>, this exposed surface <NUM> may be the inner peripheral surface 112a at the inner radial end <NUM> of the radial tab <NUM>.

As stated previously, and as shown in <FIG>, the inner radial edge <NUM> of the annular body <NUM>, and the inner radial edge <NUM> of the at least one radial tab <NUM> may at least partially define an aperture <NUM> in the push-on fastener <NUM>. The aperture <NUM> may have a polygonal, oval, circular, semi-circular, or substantially circular cross-section when viewed in a plane generally perpendicular to the central axis A. The aperture <NUM> may be non-uniform in shape.

As shown in <FIG>, the aperture <NUM> may have a radius, RA. As described herein, the aperture radius RA is the distance from the central axis A to the outermost point of either the inner radial edge <NUM> of the annular base <NUM>, or the inner radial edge <NUM> of the at least one radial tab <NUM>. For example, the aperture radius RA may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. For example, aperture radius RA may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the aperture radius RA may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the aperture radius RA may be any value between any of the minimum and maximum values noted above. For example, the aperture radius RA may be <NUM>.

As shown in <FIG>, the push-on fastener <NUM> can have an axial height TW. As described herein, the axial height TW of the push-on fastener <NUM> is the distance from the more axially distant of either the first axial surface <NUM> of the annular base <NUM> or the second axial surface <NUM> of the axial flange <NUM>, and second axial surface <NUM> of the innermost radial tab <NUM>. According to certain examples, the axial height TW of the push-on fastener <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. For example, the axial height TW of the push-on fastener <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the axial height TW of the push-on fastener <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the axial height TW of the push-on fastener <NUM> may be any value between any of the minimum and maximum values noted above. For example, the axial the axial height TW of the push-on fastener <NUM> may be <NUM>.

As shown in <FIG>, the push-on fastener <NUM> may have an overall outer radius ORW. As described herein, the outer radius ORW of the push-on fastener <NUM> is the distance from the central axis A to the radially outermost periphery of the push-on fastener <NUM>, which may be either the outer radial edge <NUM> of the axial flange <NUM>, the outer radial edge <NUM> of the annular base <NUM>, or the outer radial edge <NUM> of the at least one radial tab <NUM>. For example, the outer radius ORW of the push-on fastener <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. For example, the outer radius ORW of the push-on fastener <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the outer radius ORW of the push-on fastener <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the outer radius ORW of the push-on fastener <NUM> may be any value between any of the minimum and maximum values noted above. For example, the outer radius ORW of the push-on fastener <NUM> may be <NUM>.

As shown in <FIG>, the push-on fastener <NUM> may have an overall inner radius IRW. As described herein, the inner radius IRW of the push-on fastener <NUM> is the distance from the central axis A to the radially innermost periphery of the push-on fastener <NUM>, which may be either the inner radial edge <NUM> of the innermost radial tab <NUM>, the inner radial edge <NUM> of the axial flange <NUM>, or the inner radial edge <NUM> of the annular base <NUM>. According to certain examples, the inner radius IRW of the push-on fastener <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. According to still other examples, the inner radius IRW of the push-on fastener <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the inner radius IRW of the push-on fastener <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the inner radius IRW of the push-on fastener <NUM> may be any value between any of the minimum and maximum values noted above. For example, the inner radius IRW of the push-on fastener <NUM> may be <NUM>.

For purposes of illustration, <FIG> includes a perspective top view of a push-on fastener <NUM>. It will be appreciated that corresponding components between <FIG> (i.e., components having the same reference number) may be described as having any of the characteristics or features described in reference to <FIG>.

Referring now to <FIG>, the push-on fastener <NUM> can include a push-on fastener body <NUM> oriented about a central axis A. The push-on fastener <NUM> may further have an annular base <NUM>. The push-on fastener <NUM> may further include at least one radial tab <NUM> disposed along at least one of the inner radial edge <NUM> of the annular base <NUM>. As shown, the push-on fastener <NUM> and/or annular base <NUM> may include an axial flange <NUM>. The axial flange <NUM> may have a first axial surface <NUM> and a second axial surface <NUM> opposite the first axial surface <NUM>. The axial flange <NUM> may have a polygonal, oval, circular, semi-circular, or substantially circular cross-section when viewed in a plane perpendicular to the central axis A. For example, the axial flange <NUM> can cant relative to a line parallel to the central axis A.

For example, as shown in <FIG>, the axial flange <NUM> can have an axial height TAF. As described herein, the axial height TAF of the axial flange <NUM> is the distance from the first axial surface <NUM> to the second axial surface <NUM>. For example, the axial height TRT of the axial flange <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. For example, the axial height TRT of the axial flange <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the axial height TRT of the axial flange <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the axial height TRT of the axial flange <NUM> may be any value between any of the minimum and maximum values noted above. For example, the axial the axial height TRT of the axial flange <NUM> may be <NUM>.

For purposes of illustration, <FIG> includes a top view, a cross-sectional view, and a perspective view respectively of a push-on fastener <NUM>. It will be appreciated that corresponding components between <FIG> and <FIG> (i.e., components having the same reference number) may be described as having any of the characteristics or features described in reference to <FIG>.

Referring now to <FIG>, the push-on fastener <NUM> can include a push-on fastener body <NUM> oriented about a central axis A. The push-on fastener <NUM> may further have an annular base <NUM>. The push-on fastener <NUM> may further include at least one radial tab <NUM> disposed along the outer radial edge <NUM> of the annular base <NUM>. As shown, the at least one radial tab <NUM> may project radially outward from the annular base <NUM>. The at least one radial tab <NUM> may include an inner radial edge <NUM> and an outer radial edge <NUM>. In this example, the inner radial edge <NUM> of the radial tab <NUM> may coincide with the outer radial edge <NUM> of the annular base <NUM>. In this example the at least one radial tab <NUM> can define an outer radial edge <NUM> and a bridge portion <NUM> connecting the outer radial edge <NUM> to the annular base <NUM>.

Per <FIG> and as now shown in more detail in <FIG>, the at least one radial tab <NUM> may define an outer peripheral surface 112b. In this alternative example, the outer radial edge <NUM> of at least one radial tab <NUM> may define the outer peripheral surface 112b. In this way, the radial tabs <NUM> project radially outwardly and forms the outer peripheral surface 112b. In a particular example, at least one of the radial tabs <NUM> may have an exposed surface <NUM> defined as being free of the low friction layer <NUM>.

As shown in <FIG>, the axial flange <NUM> may include an inner radial edge <NUM> and an outer radial edge <NUM>. The axial flange <NUM> can have a length LAF. As described herein, the length LAF of the axial flange <NUM> is the distance from the inner radial edge <NUM> to the outer radial edge <NUM>. For example, the length LAF of the axial flange <NUM> may be at least about <NUM>, such as, at least about <NUM> or at least about <NUM> or at least about <NUM> or at least about <NUM> or even at least about <NUM>. For example, the length LAF of the axial flange <NUM> may be not greater than about <NUM>, such as, not greater than about <NUM> or even not greater than about <NUM>. It will be appreciated that the length LAF of the axial flange <NUM> may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the length LAF of the axial flange <NUM> may be any value between any of the minimum and maximum values noted above. For example, the length the length LAF of the axial flange <NUM> may be <NUM>.

For purposes of illustration, <FIG> includes a top view, a side view, a side view, a top cutout view, and a cross-sectional view respectively of a push-on fastener <NUM> within an assembly <NUM> in accordance with embodiments described herein. It will be appreciated that corresponding components between <FIG> (i.e., components having the same reference number) may be described as having any of the characteristics or features described in reference to <FIG>. The push-on fastener <NUM> can be disposed adjacent to, or contacting, an inner member <NUM> (such as a shaft) in an assembly <NUM>. The assembly <NUM> may also include an outer member <NUM> (such as a bearing, housing, a side member, or other structural member) fitted on the inner member <NUM>. According to the present invention, the outer member <NUM> is adapted to rotate relative to the inner member <NUM>, or alternatively the inner member <NUM> is adapted to rotate relative to the outer member <NUM>. The push-on fastener <NUM> can be disposed adjacent to, or contacting, an inner member <NUM> in an assembly <NUM>. In a number of embodiments, the push-on fastener <NUM> may be installed on the inner member <NUM> in the assembly <NUM>. In a number of embodiments, the at least one radial tab <NUM> of the push-on fastener <NUM> may fix the push-on fastener <NUM> to the inner member <NUM> in the assembly <NUM>.

During and after installation, the at least one radial tab <NUM> may be adapted to radially deform. The at least one radial tab <NUM> can operate in an elastic zone of deformation, i.e., the at least one radial tab <NUM> can be capable of deforming upon application of a force and returning to its original shape after removal of the force. In a further example, at least one at least one radial tab <NUM> can operate in a plastic zone of deformation, i.e., the at least one radial tab <NUM> can be incapable of fully returning to its original shape after removal the force. It may be possible, by including at least one radial tab <NUM> of different deformation characteristics on the annular base <NUM>, to yet further alter the characteristics of the push-on fastener <NUM>, e.g., stiffness, sliding capability, or tolerance absorption.

Referring to <FIG>, a non-limiting embodiment of an assembly <NUM> is shown. In an embodiment, the assembly <NUM> may be a seat assembly <NUM> for a vehicle. The seat assembly <NUM> generally includes a seat <NUM> having a bottom portion <NUM> and a seat back <NUM>. The seat back <NUM> may be pivotally connected with the bottom portion <NUM>. The bottom portion <NUM> may include a frame <NUM>, a cover <NUM>, and a cushion or support disposed therebetween. The seat back <NUM> may include an internal support <NUM>. The seat assembly <NUM> may provide a location whereby a vehicle passenger may sit. The seat assembly <NUM> may include at least one sliding assembly <NUM>, <NUM>'. The seat assembly <NUM> can include at least one inner member <NUM>, <NUM>', <NUM>''. The seat assembly can include at least one outer member <NUM>. The seat assembly can include at least one push-on fastener <NUM>. <FIG> shows a side view of a push-on fastener <NUM> within an assembly <NUM> as shown in <FIG>. In a number of embodiments, the inner member <NUM> may be a cross-tube of the seat assembly <NUM> and part of the frame <NUM> of the bottom portion <NUM> of the seat assembly <NUM>. <FIG> shows a side view of a plurality of push-on fasteners <NUM>, <NUM>' within an assembly having multiple inner members <NUM>, <NUM>'. <FIG> shows a cut-out top view of a push-on fastener <NUM> within an assembly. <FIG> show the inner member <NUM>, as it may be coupled to a side plate <NUM>, <NUM>' of the frame <NUM> of the bottom portion <NUM>.

Referring now to <FIG>, in a number of embodiments, a push-on fastener <NUM> in accordance with one or more of the embodiments described herein can be disposed onto an inner member <NUM> (such as a shaft) to form an assembly <NUM> with the push-on fastener <NUM> in an installed state. The inner member <NUM> may be a cross-tube for a seat assembly <NUM> for a vehicle. In a number of embodiments, the assembly <NUM> may further include a side seat member <NUM>. In a number of embodiments, the assembly <NUM> may further include a bearing <NUM>. As shown in <FIG>, in a number of embodiments, at least one of the radial tabs <NUM> of the push-on fastener <NUM> may engage and/or contact at least one of the inner member <NUM> or the outer member <NUM>. In another embodiment, the first major surface <NUM> of the push-on fastener <NUM> may define an axially interior surface and the second major surface <NUM> of the push-on fastener <NUM> may define an axially exterior surface while the plurality of radial tabs <NUM> project axially outwardly along the central axis A of the assembly <NUM>. In an embodiment, the annular base <NUM> may include a bearing surface <NUM> that the outer member <NUM> contacts.

As shown in <FIG>, the axial flange <NUM> can form an angle β with respect to the plane parallel to the annular base <NUM> and perpendicular to the central axis A. By way of a non-limiting embodiment, the angle β between the axial flange <NUM> and the annular base <NUM> in the unloaded state can be at least <NUM>°, such as at least <NUM>°, at least <NUM>°, at least <NUM>°, or even at least <NUM>°. In another embodiment, the angle β can be no greater than <NUM>°, such as no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, no greater than <NUM>°, or even no greater than <NUM>°. It will be appreciated that the angle β may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the angle β may be any value between any of the minimum and maximum values noted above. For example, the angle β may be <NUM>°.

For purposes of illustration, <FIG> show a top side, cross-sectional, and perspective view of a push-on fastener <NUM> within an assembly <NUM> respectively. In a number of embodiments, as shown in <FIG>, at least one of the inner radial edges <NUM> of the radial tabs <NUM> of the push-on fastener <NUM> may be keyed to the inner member <NUM> through matching or otherwise corresponding grooves <NUM> found in the inner member <NUM>. In a number of variations, the grooves <NUM> may have a polygonal, oval, circular, semi-circular, or substantially circular cross-section and may coincide with the shape of at least one of the radial tabs <NUM> to form an interference fit preventing or restricting the relative movement of the push-on fastener <NUM> with at least one of the inner member <NUM>.

In a number of embodiments, at least one of the first major surface <NUM> or a second major surface <NUM> of the push-on fastener <NUM> may be engaged with the outer member <NUM> so as to prevent or restrict relative movement between the push-on fastener <NUM> and the inner member <NUM>. The movement may be prevented or restricted in a rotational, axial, or radial direction with respect to the central axis A. According to a particular embodiment, relative axial movement may be prevented. In a number of embodiments, at least one of the peripheral surfaces 112a, 112b of the push-on fastener <NUM> may form an interlock with at least one of the inner member <NUM> or the outer member <NUM>. In a number of embodiments, the interlock may be a corner <NUM>, <NUM> of at least one of the peripheral surfaces 112a, 112b contacting at least one of the inner member <NUM> or the outer member <NUM>. In a number of embodiments, the sharp corner <NUM> may be adapted to contact at least one of the inner member <NUM> or the outer member <NUM> in an assembly <NUM>.

In an embodiment, the push-on fastener <NUM> can provide a retention force on the inner member <NUM> of at least <NUM> N under a strain of less than <NUM>.

In an embodiment, the metal substrate <NUM> and the low friction layer <NUM> on the push-on fastener exhibit a peel strength (measured according to Standard ISO <NUM> of greater than <NUM> N/cm, such as greater than <NUM> N/cm, greater than <NUM> N/cm, greater than <NUM> N/cm. In an embodiment, the metal substrate <NUM> and the low friction layer <NUM> on the push-on fastener exhibit a peel strength (measured according to Standard ISO <NUM> of less than <NUM> N/cm, such as less than <NUM> N/cm, less than <NUM> N/cm, or less than <NUM> N/cm.

In an embodiment, the assembly <NUM> can be installed or assembled by an assembly force of at least <NUM> N a longitudinal direction relative to the inner member <NUM>, such as at least <NUM> N, at least <NUM> N, at least <NUM> N, at least <NUM> N, at least <NUM> N, or even at least <NUM> N. In a further embodiment, the assembly <NUM> can be installed or assembled by an assembly force of at least <NUM> kgf in a longitudinal direction relative to the inner member <NUM>, such as no greater than <NUM> N, no greater than <NUM> N, no greater than <NUM> N, or even no greater than <NUM> N.

Use of the push-on fastener <NUM> or assembly <NUM> may provide increased benefits in several applications such as, but not limited to, vehicle tail gates, door frames, seat assemblies, or other types of applications. Notably, the use of the push-on fastener <NUM> may provide a simplification of the assembly <NUM> by eliminating components. Further, use of the push-on fastener <NUM> may improve assembly forces required, compensate for axial tolerances between the inner and outer members <NUM>, <NUM>, and provide noise reduction and vibration decoupling within the assembly <NUM> by preventing undesired movement between the inner and outer members <NUM>, <NUM>. Further, the push-on fastener <NUM> may be a simple installation and be retrofit and cost effective across several possible assemblies of varying complexity. Further, the low friction layer <NUM> on the push-on fastener 100may provide low friction properties and act as an axial bearing while still being a fixation element against a component of the assembly <NUM>. This can improve the friction performance between the push-on fastener <NUM> and other components of the assembly <NUM>. Lastly, the use of the push-on fastener <NUM> may maintain the improved stiffness and tensile strength between the inner and outer members <NUM>, <NUM>, increasing the lifetime of the assembly <NUM>.

Note that not all of the features described above are required, that a portion of a specific feature may not be required, and that one or more features may be provided in addition to those described. Still further, the order in which features are described is not necessarily the order in which the features are installed.

Certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombinations.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments, however, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

Claim 1:
A push-on fastener (<NUM>) comprising:
a push-on fastener body (<NUM>) comprising an annular base (<NUM>) defining an aperture (<NUM>), first and second opposing major surfaces (<NUM>, <NUM>), a plurality of radial tabs (<NUM>) extending from the annular base (<NUM>), the radial tabs (<NUM>) terminating radially inwardly or radially outwardly; and a low friction layer (<NUM>) overlying the first major surface (<NUM>) of the push-on fastener body (<NUM>), the annular base (<NUM>) further defining an inner peripheral surface (112a) and an outer peripheral surface (112b) opposite the inner peripheral surface (112a), characterized in that
the radial tabs (<NUM>) terminate radially inwardly, providing the inner peripheral surface (112a), wherein the outer peripheral surface (112b) is free of the low friction layer (<NUM>), or
the radial tabs (<NUM>) terminate radially outwardly, providing the outer peripheral surface (112b), wherein the inner peripheral surface (112a) is free of the low friction layer (<NUM>).