Patent Description:
Fastener clips are known, for example, from <CIT> and <CIT>. Further, a number of devices and fasteners are currently available for fastening panels, such as body panels and automobile interior trim piece panels, to the chassis of a vehicle. As used herein, a body panel refers to, for example, any interior or exterior body panel on a vehicle, a plastic interior trim piece, door panel, headliner or any interior trim piece. Additionally, the panel may be any suitable exterior body panel, such as a fender, bumper, quarter panel or door panel. The chassis of the vehicle may include any substrate, plate, body panel, structural framework, chassis component or subcomponent, wall or any suitable object.

These conventional fastener devices provide approximately relatively equal levels of insertion and extraction force. These body panels often attach to the chassis of an automobile with a relatively high level of insertion force while providing a relatively low level of extraction force.

Fastener clips, such as two-piece fasteners (multi-piece), are known for attaching body panels to an automobile chassis. Two-piece fasteners are used so that if the panels are removed after original installation, such as to service the components in the door, they may be pulled apart so that one portion remains attached to the sheet metal while the other remains attached to the trim panel. The two pieces may also be reattached after separation. However, two-piece fasteners require manufacturing of multiple pieces and labor-intensive assembly of the two pieces and thus are relatively expensive.

One-piece fasteners are typically less expensive than two or multi piece fasteners. One-piece fasteners have a base to attach to a body panel and a blade attached to the base and wings attached at least to the top of the blade at a tip of the fastener for fastening to a frame slot. However, if the frame slot and the fastener are misaligned then the forces on the wings are unequal since the wing closest to the slot edge will experience higher wing compression while the other wing will have insufficient springing force to engage the slot. As the clip is forced into the slot, such high forces on one wing may cause the wing to break off thus rendering the fastener incapable of fastening the body panel to the frame. Worse, the broken, damaged or weakened wing can cause detachment of the body panel or contribute to rattles.

The wings of conventional fasteners have a sharp, unsmooth groove to engage the edge of the frame slot. When the clip is removed however, the sharp edges of the frame slot cut into the softer plastic and cut the groove. During manufacture, the slots are typically formed in the frame of the vehicle, such as in an inner roof or door sheet metal structure, by punching the sheet metal. As the punch enters the sheet metal, the outer part of the sheet metal is pushed toward the inside and a metal puncture or ridge is formed on the inside of the sheet metal. The resulting slot edge on the outer part of the slot is relatively smooth; however, the inner part of the slot edge is sharp and rough. Upon removal of the fastener clip, the sharp edges of the frame cut off the groove so that the clip may not be reinserted and reusable.

If the slot is off-center or if the sheet metal varies in thickness or if tolerances in production of the slot in the vehicle chassis or in the trim-piece exist, for example, then engagement of one portion of the slot in the chassis with one of the wings may not provide suitable frictional engagement. Twisting of the body panel will be likely more prevalent because less than all contact points are actually made with the slot of the vehicle chassis. As a result, conventional single piece fasteners do not self-align themselves when the fastener and the body panel are misaligned and are prone to wing breakage such that the fastener cannot be re-attached.

Conventional fasteners typically do not adequately secure the panel to the vehicle chassis having variations in slot size and location or sheet metal with different curvature or thicknesses throughout. Conventional single piece fasteners do not self-align themselves when the fastener and the body panel are misaligned and are prone to wing breakage such that the fastener cannot be re-attached. Also, conventional fasteners are not suitable when subjected to a variety of environmental conditions, such as in the presence of vibration at various levels of amplitude and frequency. For example, conventional fasteners of this type typically do not prevent or minimize the amount of buzzing, rattling or any other type of noise that may cause attention to the occupants of the vehicle or otherwise weaken the attachment. Conventional fasteners do not adequately accommodate various levels of production tolerances, such as various dimensions amongst, for example, the body panels as well as the vehicle chassis. Thus, conventional fastener devices typically do not self-align nor adequately fasten to a range of sheet metal thicknesses and do not minimize or eliminate buzzing and rattling and do not sufficiently accommodate variations in production tolerances. As a result, wear, squeaks, rattles, buzzing, corrosion and loss of elasticity and loss of sealing may result, especially after years of vehicle operation and exposure to vibration, heat, humidity, and other environmental conditions.

Other objects and advantages of the invention may become apparent upon reading the detailed description and upon reference to the accompanying drawings.

While the invention is subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and the accompanying detailed description. It should be understood, however, that the drawings and detailed description are not intended to limit the invention to the particular embodiments. This disclosure is instead intended to cover all modifications and alternatives falling within the scope of the present invention as defined by the appended claims.

<FIG> is a perspective view of a fastener clip assembly, in accordance with some embodiments.

In some embodiments, fastener clip <NUM> is configured to fasten together top surface <NUM> and bottom surface <NUM>. Blade <NUM>, which extends from surface <NUM>, is configured to receive and be secured to fastener clip <NUM>. In some embodiments, blade <NUM> may be molded onto surface <NUM>. In other embodiments, blade <NUM> may be attached to surface <NUM> using various other means.

In some embodiments, fastener clip <NUM> may be configured to be inserted through slot <NUM> of top surface <NUM> and to secure itself to the top surface <NUM>. In some embodiments, the fastener clip assembly is configured to fasten together top surface <NUM> and bottom surface <NUM> based at least upon the fastener clip being secured to slot <NUM> of surface <NUM> and to blade <NUM> of surface <NUM>.

In some embodiments, surface <NUM> may be part of a panel and surface <NUM> may be part of the chassis/frame of an automobile. Accordingly, the fastener clip assembly may be configured to fasten together a panel to the chassis/frame of an automobile.

<FIG> is a perspective view of two pieces of a fastener clip, in accordance with some embodiments.

<FIG> is another perspective view of two pieces of a fastener clip, in accordance with some embodiments.

<FIG> is yet another perspective view of two pieces of a fastener clip, in accordance with some embodiments.

In some embodiments, fastener clip <NUM> may be made of at least two different materials. The first material may be one with high elasticity/springiness (such as metal, for example) to allow the clip to spring between at least two positions to facilitate insertion and engagement. The second material may be a softer material (such as plastic, for example) to allow the clip to form better and/or safer contact with the surfaces with which the clip is to engage. Such softer material may prevent, for example, early wear of either the clip or the surfaces engaged by the clip.

In some embodiments, fastener clip <NUM> may be made with a combination of metal and an injection moldable plastic. In some embodiments, the metal portion may be made first, using sheet metal made of steel and a stamping process, for example. The plastic may be then injected around the metal. In some embodiments, the plastic may be injected both to the inside and to the outside of the metal clip as will be described further elsewhere.

In some embodiments, fastener clip <NUM> comprises first piece <NUM> and a second piece <NUM> that are combined to form the fastener clip <NUM>. In some embodiments, first piece <NUM> may be made of an elastic/springy material such as metal, and second piece <NUM> may be made of a softer material such as plastic.

In some embodiments, first piece <NUM> includes a pair of legs <NUM> joined at a head portion <NUM>. The pair of legs <NUM> form a clip opening <NUM> at an opposite end of the head portion <NUM> to allow entry of a blade <NUM> to which clip <NUM> is configured to attach. In some embodiments, each of legs <NUM> terminate at the end opposite to head portion <NUM> to feet <NUM>.

In some embodiments, first piece <NUM> may also include, on each leg <NUM>, windows <NUM> and <NUM> that may be configured to permit the molded material of piece <NUM> to flow between the inside and the outside of piece <NUM>. In some embodiments, molding the material of second piece <NUM> between the inside and the outside of first piece <NUM> significantly strengthens the coupling between first piece <NUM> and second piece <NUM>. Additionally, first piece <NUM> may include protrusions, such as protrusion <NUM>, to further enhance the coupling between first piece <NUM> and second piece <NUM>.

In some embodiments, first piece <NUM> may also include a pair of barbs on each of the legs <NUM> (four barbs, in one embodiment). In some embodiments, barbs <NUM> are each attached to the sides of the legs <NUM>. Based at least on barbs <NUM> being sharp at their ends and of greater hardness than the material of blade <NUM>, the barbs are configured to dig into and attach the first piece <NUM> to the blade <NUM> upon inserting the fastener clip <NUM> over the blade <NUM>.

In some embodiment, upon inserting fastener clip <NUM> over blade <NUM>, the blade <NUM> is configured to bend barbs <NUM> apart, and the barbs <NUM> are configured to spring back against the blade <NUM>. During insertion, blade <NUM> slides upwards towards barbs <NUM>, which are also pushed apart by blade <NUM>. Upon inserting the clip <NUM> over blade <NUM>, barbs <NUM> are configured to dig into the material of blade <NUM> to further increase the removal effort required to separate the clip from the blade. Furthermore, barbs <NUM> provide additional support for the coupling between the fastener clip <NUM> and the blade <NUM>.

In some embodiments, second piece <NUM> includes a pair of legs <NUM> joined at a head portion <NUM>. The pair of legs <NUM> form a clip opening <NUM> at an opposite end of the head portion <NUM> to allow entry of a blade <NUM> to which clip <NUM> is configured to attach. In some embodiments, each of legs <NUM> terminate at the end opposite to head portion <NUM> to feet <NUM>.

In some embodiments, second piece <NUM> may be injection molded around first piece <NUM>. In some embodiments, portions of second piece <NUM> may be molded to the outside of the first piece <NUM> while other portions of second piece <NUM> may be molded to the inside of the first piece <NUM>.

In some embodiments, the second piece <NUM> may be molded as one continuous piece and may be weaved inside and outside of first piece <NUM> through windows <NUM> and <NUM>, for example. In some embodiments, legs <NUM> and feet <NUM> may be to the outside of first piece <NUM> while head portion <NUM> and inner pieces <NUM> may be to the inside of first piece <NUM>. In some embodiments, weaving the second piece in such a manner significantly enhances the coupling between the first and second pieces. For example, by having the strength and elasticity of the first piece behind the second piece where the second piece is configured to engage the slot <NUM> (as will be described more later) significantly enhances the coupling between the clip <NUM> and the surface <NUM>. In addition, the head portion <NUM> being on the inside of head portion <NUM> is configured to engage blade <NUM> tightly to enhance the coupling between the clip <NUM> and blade <NUM>.

In some embodiments, each leg <NUM> may include a sloping portion such that, while engaging slot <NUM>, legs <NUM> are configured to spring in and then spring back when clip <NUM> engages the slot <NUM>. In some embodiments, each leg <NUM> may include at least one depressed portion <NUM>. The depressed portion <NUM> is formed and is configured to engage a portion of the slot <NUM> of surface <NUM>. In some embodiments, slot <NUM> may have any shape such as a circle, a square, a rectangle, a pentagon, a hexagon, a polygon, an n-sided polygon where n is a whole number, an ellipse, an oval, etc..

In some embodiments, the depressed portion <NUM> may include, for example, an abrupt edge, a gradual angled edge, such as a curve, a single angled edge, a discrete multiangled edge or a pointed edge. The depressed portion <NUM> may be formed on the depressed part of each leg <NUM> so as to engage the slot <NUM> to increase an extraction force for the fastener clip <NUM> from the slot <NUM>. The depressed portion <NUM> may be sized to suitably engage slot <NUM> of the surface <NUM> in order to obtain the desired level of extraction force. According to one embodiment, the depressed portion <NUM> may be a depression formed on legs <NUM>. The size and shape of the depressed portion <NUM> may be formed in any suitable manner in order to permit relatively easy insertion of the fastener clip <NUM> into the slot <NUM> while increasing the extraction force.

<FIG> is a perspective view of a blade configured to receive a fastener clip, in accordance with some embodiments.

In some embodiments, blade <NUM> is configured to receive and attach to fastener clip <NUM>. Blade <NUM> may be either attached to or be part of surface <NUM>. In embodiments where surface <NUM> is made of plastic, for example, the structure of blade <NUM> may be molded as part of surface/structure <NUM>. In some embodiments, surface/structure <NUM> may be an automobile panel that is to be attached to the automobile chassis.

In some embodiments, guiding structures <NUM>, positioned on either side of blade <NUM>, are configured to guide fastener clip <NUM> over blade <NUM> as the fastener clip is being inserted over the blade. In addition, guiding structures <NUM> are configured to provide additional stability to the coupling between blade <NUM> and fastener clip <NUM> after installation.

<FIG> is a perspective view of a fastener clip attached to a chassis, in accordance with some embodiments.

In some embodiments, the fastener clip assembly is configured to join together two surfaces such as surfaces <NUM> and <NUM>. Fastener clip <NUM> is configured to fit over and attach to blade <NUM> that is attached to surface <NUM>, and in addition fastener clip <NUM> is configured to removably attach to the slot in surface <NUM>. For example, the fastener clip system may be used to fasten together a body panel to the chassis of an automobile.

It is understood that the implementation of other variations and modifications of the present invention in its various aspects will be apparent to those of ordinary skill in the art and that the invention is not limited by the specific embodiments described. It is therefore contemplated to cover by the present invention any and all modifications or variations that fall within the scope of the basic underlying principles disclosed and claimed herein.

One or more embodiments of the invention are described above. It should be noted that these and any other embodiments are exemplary and are intended to be illustrative of the invention rather than limiting. While the invention is widely applicable to various types of systems, a skilled person will recognize that it is impossible to include all of the possible embodiments and contexts of the invention in this disclosure. Upon reading this disclosure, many alternative embodiments of the present invention will be apparent to persons of ordinary skill in the art.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the scope of the invention as defined by the appended claims. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed and claimed herein.

The benefits and advantages that may be provided by the present invention have been described above with regard to specific embodiments. These benefits and advantages, and any elements or limitations that may cause them to occur or to become more pronounced are not to be construed as critical, required, or essential features of any or all of the claims. As used herein, the terms "comprises," "comprising," or any other variations thereof, are intended to be interpreted as non-exclusively including the elements or limitations that follow those terms. Accordingly, a system, method, or other embodiment that comprises a set of elements is not limited to only those elements and may include other elements not expressly listed or inherent to the claimed embodiment.

Claim 1:
A fastener clip (<NUM>) comprising:
a first piece (<NUM>) made of a first material, wherein the first material is elastic, wherein the first piece (<NUM>) comprises:
a pair of legs (<NUM>) joined at a head portion (<NUM>), wherein the legs (<NUM>) form a clip opening (<NUM>) at an opposite end of the head portion (<NUM>);
one or more pairs of barbs (<NUM>) coupled to the pair of legs (<NUM>),
wherein the barbs (<NUM>) are configured to dig into a blade (<NUM>), wherein the blade (<NUM>) is configured to be coupled to a panel, wherein the fastener clip (<NUM>) is configured to be secured over the blade (<NUM>) based at least upon the barbs (<NUM>) being configured to dig into the blade (<NUM>) upon the fastener clip (<NUM>) being pushed over the blade (<NUM>);
a second piece (<NUM>) made of a second material coupled to the first piece (<NUM>), wherein the second material is softer than the first material, wherein the second material comprises inside portions to the inside of the first piece (<NUM>) and outside portions to the outside of the first piece (<NUM>), wherein the outside piece portions are configured to engage a slot (<NUM>) in a chassis and to secure the fastener clip (<NUM>) to the chassis.