Patent Description:
Wire tray assemblies are typically formed of a single, relatively inexpensive, polymeric material which may not provide sufficient stud-mount retention strength.

Publication <CIT> discloses a fastener for securing an undercover panel to an underside of a vehicle. The fastener includes a body having a bore for receiving a threaded bolt extending from the underside of the vehicle, a flange for engaging a first side of the undercover panel, a plurality of resiliently deformable engaging fingers for allowing insertion of the bolt into the bore and to resist removal of the bolt from the bore, and a plurality of resilient engaging members for enabling the engaging members to pass in a first direction through an aperture in the undercover panel, and to resist removal of the fastener from the panel. A plurality of reinforcing members extend from the body to engage a respective engaging member, as a result of forces urging said undercover panel towards the underside of the vehicle, to resist flexing of the engaging members away from the body. Further examples of fasteners are disclosed in publications <CIT>, <CIT>, <CIT>, and <CIT>. Publication <CIT> discloses a clip that is provided with a pin and a main body having an opening for inserting the pin. The pin has a flange and a shaft extending down from the flange. The outer circumference of the flange curves downward. The main body has a bottom, a pair of latching claws downward from the bottom through the opening, support legs extending downward from the bottom between the latching claws, an annular loop element on the top side of the bottom, a sloping element of gradually lowering height from the outside annular element and annular thin-walled flange from the underside of the bottom. In the primary joined state, the latching claws pushing on the pin shaft spread apart, and the claw tips engage the pin latching convex element of the pin shaft. The attached member is held between the base elements of the latching claws and contact element on the underside of the bottom of the main body. The edge of the outer circumference of the pin flange is in contact with the inclined element of the main body, improving water tightness.

The present invention proposes to solve the above mentioned problem by providing a system comprising a system according to claim <NUM>. Embodiments are subject of the dependent claims.

The present invention is now described by way of example with reference to the accompanying drawings in which:.

Hereinafter, a system comprising a stud-mount insert 12A for a wire tray assembly <NUM> according to the present invention will be described with reference to the figures. <FIG> illustrates a wire tray assembly <NUM>, hereafter referred to as the assembly <NUM>, configured to route a wiring harness (not shown) for a vehicle. As will be described in more detail below, the assembly <NUM> is an improvement over other wire tray assemblies because the assembly <NUM> includes removable stud-mount inserts <NUM> that may be formed of a different material than that of a wire tray <NUM>.

The assembly <NUM> includes the wire tray <NUM> that is preferably formed of a polymeric dielectric material, such as a polypropylene, that may be molded to fit a contour of a substrate <NUM>, such as a panel of an automobile. The assembly <NUM> also includes a system comprising a mounting tab <NUM> defining an aperture <NUM>, a threaded mounting stud <NUM> and a stud-mount insert 12A according to the invention, and a second system comprising a second mounting tab <NUM> defining a second aperture <NUM>, a second threaded mounting stud <NUM> and a second stud-mount insert 12B not covered by claims.

In the example illustrated in <FIG> the mounting tab <NUM> of the system according to the invention and the second mounting tab <NUM> of the second system are formed integral to the wire tray <NUM>. It will be appreciated that the assembly <NUM> may include a plurality of systems according to the invention and/or a plurality of second systems depending on a configuration of the substrate <NUM>. In the example illustrated in <FIG>, the assembly <NUM> includes one system according to the invention comprising a mounting tab <NUM> and two second systems comprising second mounting tabs <NUM>, the benefit of which will be explained below. The first aperture <NUM> may be characterized as having a circular shape and connects a top surface <NUM> of the wire tray <NUM> with a bottom surface <NUM> of the wire tray <NUM>. The second aperture <NUM> may be characterized as having a rectilinear shape and also connects the top surface <NUM> of the wire tray <NUM> with the bottom surface <NUM> of the wire tray <NUM>.

<FIG> illustrates the system according to the present invention, isolated from the assembly <NUM>. The system includes a mounting tab <NUM>, a stud-mount insert 12A releasably retained by the mounting tab <NUM> and overlaying the aperture <NUM> such that a mounting stud <NUM> extends through the first aperture <NUM> into the stud-mount insert 12A. The stud-mount insert 12A may be formed of any material and is preferably formed of a polyamide (NYLON) material that has a greater strength and wear resistance that the material of the wire tray <NUM>.

The mounting stud <NUM> is fixed to the substrate <NUM> and is configured to anchor the assembly <NUM> to the substrate <NUM>. The mounting stud <NUM> may be formed of any material, such as a steel alloy, and in the example illustrated in <FIG> includes helical threads <NUM> formed into an outer surface. The stud-mount insert 12A has a flange <NUM> and a body <NUM> (see <FIG>) and is rotatable about a longitudinal axis <NUM> of the mounting stud <NUM>. That is, the sutd-mount insert 12A may be threaded on and off the mounting stud <NUM> similar to a nut and bolt combination. The flange <NUM> engages a top surface <NUM> of the mounting tab <NUM> proximate a perimeter <NUM> of the aperture <NUM>. It will be appreciated that the flange <NUM> inhibits the stud-mount insert 12A from passing through the aperture <NUM> and transfers a retention force from the mounting stud <NUM> to the mounting tab <NUM> when the assembly <NUM> is installed in the vehicle.

<FIG> illustrates the stud-mount insert 12A isolated from the assembly <NUM>. The body <NUM> has a generally cylindrical shape extending beyond the flange <NUM> and aligned with the longitudinal axis <NUM> of the mounting stud <NUM>. The body <NUM> defines a cavity <NUM> into which are disposed a plurality of pawls <NUM> (see <FIG> configured to releasably engage the threads <NUM> of the mounting stud <NUM>. The stud-mount insert 12A also includes opposed locking tabs <NUM> extending along the longitudinal axis <NUM> from an end <NUM> opposite the flange <NUM> and terminating beyond the flange <NUM>. That is, the opposed locking tabs <NUM> extend beyond the top surface <NUM> of the mounting tab <NUM> when the stud-mount insert 12A is retained by the mounting tab <NUM>. The opposed locking tabs <NUM> include locking ramps <NUM> configured to releasably engage a bottom surface <NUM> of the mounting tab <NUM> proximate the perimeter <NUM> of the aperture <NUM>, as illustrated in <FIG>. The opposed locking tabs <NUM> are configured to inwardly deflect toward the longitudinal axis <NUM> enabling an assembler to both install and uninstall the stud-mount insert 12A by depressing the opposed locking tabs <NUM> toward the mounting stud <NUM>. The body <NUM> may include a means to retract and hold the opposed locking tabs <NUM> in a retracted position (not shown), thereby disengaging the opposed locking tabs <NUM> from the bottom surface <NUM> of the mounting tab <NUM>.

The body <NUM> is configured to accept a tool to rotate the stud-insert insert 12A about the longitudinal axis <NUM> of the mounting stud <NUM>. In the example illustrated in <FIG>, a flat blade screw driver, or similar tool, may be inserted into the cavity <NUM> to either tighten or loosen the stud-mount insert 12A on the mounting stud <NUM>. In another embodiment, not covered by claims, of the stud-mount insert 212A illustrated in <FIG>, the body <NUM> includes a hex head <NUM> extending beyond the flange <NUM> in a direction opposite the end <NUM>. The hex head <NUM> is configured to receive a hex socket (not shown) to either tighten or loosen the stud-mount insert 212A on the mounting stud <NUM>. It will be appreciated that the hex socket releases the first opposed locking tabs <NUM> from engaging the bottom surface <NUM> enabling a removal of the stud-mount insert 212A from the mounting tab <NUM>.

<FIG> illustrates the second system, not covered by claims, isolated from the assembly <NUM>. The second system includes a second mounting tab (<NUM>) and a second stud-mount insert 12B releasably retained by the second mounting tab <NUM> and overlaying the second aperture <NUM> such that a second mounting stud <NUM> extends through the second aperture <NUM> into the second stud-mount insert 12B. The second stud-mount insert 12B is preferably formed of the same polymeric material as that of the stud-mount insert 12A. The second mounting stud <NUM> is also fixed to the substrate <NUM> and is also configured to anchor the assembly <NUM> to the substrate <NUM>. The second mounting stud <NUM> may be identical to the mounting stud <NUM>, or may have different design features (e.g., diameter, thread size, length, material, etc.) depending on the application requirements. In the example illustrated in <FIG>, not covered by claims, the second body <NUM> may move a total of <NUM> along the lateral axis <NUM> relative to the second mounting stud <NUM>. This range of movement provides the technical benefit of enabling the mounting the assembly <NUM> to the mounting studs having true positions that exceed the designed positional tolerances.

<FIG>, not covered by claims, illustrate the second stud-mount insert 12B isolated from the assembly <NUM>. The second stud-mount insert 12B has a second flange <NUM> and a second body <NUM> and is moveable along the lateral axis <NUM> of the second mounting stud <NUM> as described above. The second flange <NUM> engages the top surface <NUM> of the second mounting tab <NUM> proximate the perimeter <NUM> of the second aperture <NUM> (see <FIG>). It will be appreciated that the second flange <NUM> inhibits the second stud-mount insert 12B from passing through the second aperture <NUM> and transfers the retention force from the second mounting stud <NUM> to the second mounting tab <NUM> when the assembly <NUM> is installed in the vehicle.

The second body <NUM> has intersecting walls <NUM> forming a generally rectilinear shape extending beyond the second flange <NUM>. The intersecting walls <NUM> are aligned with (i.e., parallel with) the longitudinal axis <NUM> of the second mounting stud <NUM>. The intersecting walls <NUM> define a second cavity <NUM> into which are disposed a plurality of second pawls <NUM> (see <FIG>) configured to releasably engage the threads <NUM> of the second mounting stud <NUM> as illustrated in <FIG>. The second body <NUM> is further configured to accept a tool, such as a blade of a screw driver, to disengage the plurality of second pawls <NUM> from the second mounting stud <NUM>, thereby enabling the removal of the second stud-mount insert 12B from the second mounting stud <NUM>.

<FIG>, not covered by claims, illustrates the second mounting tab <NUM> isolated from the assembly <NUM>, with the second stud-mount insert 12B removed. The second mounting tab <NUM> further defines a second retention cavity <NUM> configured to retain the second stud-mount insert 12B. The second retention cavity <NUM> has the generally rectilinear shape and the second aperture <NUM> is located within a floor <NUM> of the second retention cavity <NUM>. The second mounting tab <NUM> further defines a pair of first opposed notches <NUM> located at a midsection of each of two opposing sides of the second aperture <NUM>. In the example illustrated in <FIG>, the a pair of first opposed notches <NUM> are located on a first side <NUM> and a second side <NUM> of the second mounting tab <NUM>. The first side <NUM> and the second side <NUM> are configured to limit the movement of the second stud-mount insert 12B along a transverse axis <NUM> that is orthogonal to both the longitudinal axis <NUM> and the lateral axis <NUM>. The second mounting tab <NUM> further includes a first stop <NUM> and a second stop <NUM> configured to limit a movement of the second stud-mount insert 12B along the lateral axis <NUM> within the second aperture <NUM>. The second stud-mount insert 12B may further include an extension <NUM> (see <FIG>) of the second body <NUM> configured to be disposed within the second aperture <NUM> and engage both the first stop <NUM> and the second stop <NUM> when the second stud-mount insert 12B moves along the lateral axis <NUM>. In the example illustrated in <FIG>, the second stud-mount insert 12B may move a total of <NUM> along the lateral axis <NUM> within the second aperture <NUM>. This provides the technical benefit of the assembly <NUM> having a self adjusting property during the installation process that does not require the assembler to physically adjust the second stud-mount insert 12B along the lateral axis <NUM>. The first side <NUM> and the second side <NUM> also include opposing guide beams <NUM> that overlay a portion of the second aperture <NUM> and are aligned with the lateral axis <NUM>. The opposing guide beams <NUM> define a first surface <NUM> and a second surface <NUM>, the function of which will be explained below.

Referring back to <FIG>, not covered by claims, the second stud-mount insert 12B includes a pair of opposing brackets <NUM> extending from a midsection of two opposing walls along the transverse axis <NUM>. The pair of opposing brackets <NUM> overlay a portion of the pair of first opposed notches <NUM> of the second mounting tab <NUM> when the second stud-mount insert 12B is installed in the second mounting tab <NUM>. The pair of opposing brackets <NUM> are configured to slideably engage the first surface <NUM> of the opposing guide beams <NUM> and also transfer the retention force from the second mounting stud <NUM> to the second mounting tab <NUM>.

The second flange <NUM> defines a pair of second opposed notches <NUM> located at a midsection of each of two opposing walls of the second body <NUM> that underlay the pair of opposing brackets <NUM>. That is, the second flange <NUM> is discontinuous along the lateral axis <NUM>, defining the pair of second opposed notches <NUM>. The pair of second opposed notches <NUM> provide a clearance for a fastener, such as a wire tie <NUM> (see <FIG> <FIG>, not covered by claims), to be inserted through the pair of opposing brackets <NUM> and around the second body <NUM> (not shown). The pair of opposing brackets <NUM> may also include a detent feature <NUM> configured to retain the wire tie <NUM>, as illustrated in <FIG>. <FIG> <FIG> illustrate the wire tie <NUM> retained by one of the pair of opposing brackets <NUM> used to fasten a wire cable (not specifically shown) to the second stud-mount insert 12B.

<FIG> is a section view of the second stud-mount insert 12B retained in the second mounting tab <NUM> and engaging the second mounting stud <NUM>. The second flange <NUM> slideably engages the second surface <NUM> of the opposing guide beams <NUM> and also inhibits the second stud-mount insert 12B from being separated from the second mounting tab <NUM> when an installation force <NUM> is applied to the second stud-mount insert 12B.

The following description applies to both the stud-mount insert 12A, according to the invention, and the stud-mount insert 12B, not covered by claims. <FIG> will be used and it will be understood that <FIG> will apply to the internal components of both the stud-mount insert 12A and the second stud-mount insert 12B. The plurality of pawls <NUM> and the plurality of second pawls <NUM> are attached to inner surfaces <NUM> of both the cavity <NUM> and the second cavity <NUM> by webs <NUM> that define pivot points <NUM>. The pivot points <NUM> enable the plurality of pawls <NUM> and the plurality of second pawls <NUM> to outwardly deflect <NUM> when engaging the threads <NUM> of both the mounting stud <NUM> and the second mounting stud <NUM> during installation. The webs <NUM> provide a spring force such that the pawls <NUM> and the second pawls <NUM> form a ratchet mechanism with the threads <NUM> of the mounting stud <NUM> and the second mounting stud <NUM>, thereby enabling the installation over the studs with the installation force <NUM>.

The plurality of pawls <NUM> and the plurality of second pawls <NUM> also include second stops <NUM> positioned proximate the webs <NUM> such that the plurality of pawls <NUM> and the plurality of second pawls <NUM> are inhibited from inwardly deflecting when a removal force <NUM> is applied along the longitudinal axis <NUM> to both the stud-mount insert 12A and the second stud-mount insert 12B, thereby resisting the removal force <NUM>. That is, the plurality of pawls <NUM> engage the threads <NUM> of the mounting stud <NUM>, and the plurality of second pawls <NUM> engage the threads <NUM> of the second mounting stud <NUM>, when the installation force <NUM> is applied to both the stud-mount insert 2A and the second stud-mount insert 12B along the longitudinal axis <NUM> of both the mounting stud <NUM> and the second mounting stud <NUM>.

The plurality of pawls <NUM> and the plurality of second pawls <NUM> may include pairs of opposing pawls, wherein each pair of opposing pawls is configured to have a different pawl spacing (see <FIG>) from other pairs of opposing pawls. This has the technical benefit of enabling the stud-mount inserts <NUM> to be attached to mounting studs with different thread dimensions. Alternatively, each individual pawl may have a unique pawl spacing so that a common stud-mount-insert <NUM> may be attached to a variety of mounting studs with varying thread dimensions. For example, the opposing pawls may be configured to be spaced for an M6 threaded mounting stud, but will still retain the thread <NUM> of an M5 threaded mounting stud. An M5 threaded pawl spacing still allows ergonomic installation over the threaded mounting stud and will still retain the threads <NUM> of a M6 threaded mounting stud. Other thread sizes are envisioned, but are not illustrated herein.

<FIG> <FIG> illustrate another embodiment, not covered by claims, of the first mounting tab <NUM>. The first mounting tab <NUM> defines a first retention cavity <NUM> configured to retain another embodiment of the first insert 312A. The first retention cavity <NUM> has a generally truncated conical shape with a base <NUM> and a cap <NUM>, with a base diameter greater than a cap diameter. The first aperture <NUM> is positioned coaxial with a center of the cap <NUM>, as illustrated in <FIG> <FIG>. Interior walls <NUM> of the first retention cavity <NUM> include locking features <NUM> configured to releasably lock the first flange <NUM> within the first retention cavity <NUM>. The first insert 312A is also configured to receive a hex socket (not shown) to either tighten or loosen the first insert 312A on the first mounting stud <NUM>. It will be appreciated that the hex socket releases the locking features <NUM> from engaging the first flange <NUM>, thereby enabling a removal of the first insert 312A from the first retention cavity <NUM>. The first insert 312A may also include a first blocking rib <NUM> formed integral to the first body <NUM> and configured to inhibit the first mounting stud <NUM> from extending beyond the first body <NUM>. It will be appreciated that the first inserts 12A and 212A may also include the first blocking rib <NUM>.

<FIG> illustrate another embodiment, not covered by claims, of the second insert 212B and the second mounting tab <NUM>. The second insert 212B includes second opposed locking tabs <NUM> extending from a midsection of each of the two opposing walls and are aligned with the longitudinal axis <NUM>. The second opposed locking tabs <NUM> are configured to be disposed within the pair of first opposed notches <NUM> (see <FIG>) and engage a bottom surface <NUM> of the second mounting tab <NUM> thereby inhibiting a removal of the second insert 212B from the second mounting tab <NUM>. The second insert 212B may also include a second blocking rib <NUM> formed integral to the second body <NUM> and configured to inhibit the second mounting stud <NUM> from extending beyond the second body <NUM>. It will be appreciated that the second insert 12B may also include the second blocking rib <NUM>.

Accordingly, a wire tray assembly <NUM> (the assembly <NUM>) is provided. The assembly <NUM> is an improvement over prior art wire tray assemblies because the assembly <NUM> includes removable stud-mount inserts <NUM> that may be formed of a different material than that of the wire tray <NUM>.

Claim 1:
A system comprising:
a mounting tab (<NUM>) having an aperture (<NUM>) defined therethrough;
a threaded mounting stud (<NUM>), the threaded mounting stud (<NUM>) comprising threads (<NUM>), the threaded mounting stud (<NUM>) extending through the aperture (<NUM>); and
a stud-mount insert (12A) configured to be releasably retained by the mounting tab (<NUM>), the stud-mount insert (12A) further comprising:
a body (<NUM>) comprising a bottom end opposite an upper end,
the bottom end configured for insertion into the aperture (<NUM>),
the upper end comprising a flange (<NUM>) configured to engage a top surface (<NUM>) of the mounting tab (<NUM>) proximate a perimeter (<NUM>) of the aperture (<NUM>) and prevent the upper end from passing through the aperture (<NUM>),
the body (<NUM>) configured for rotation about a longitudinal axis (<NUM>) of the threaded mounting stud (<NUM>) such that the threaded mounting stud (<NUM>) is received into the body (<NUM>),
the body (<NUM>) further configured to align with the longitudinal axis (<NUM>) of the threaded mounting stud (<NUM>), and
the body (<NUM>) defining a cavity (<NUM>) including a plurality of pawls (<NUM>) that are configured to releasably engage the threads (<NUM>) of the threaded mounting stud (<NUM>), the plurality of pawls (<NUM>) attached to inner surfaces (<NUM>) of the cavity (<NUM>) by webs (<NUM>) that define pivot points (<NUM>) that enable the plurality of pawls (<NUM>) to outwardly deflect when engaging the threads (<NUM>) of the threaded mounting stud (<NUM>), and the plurality of pawls (<NUM>) further comprising stops (<NUM>) positioned proximate the webs (<NUM>) such that the plurality of pawls (<NUM>) is inhibited from inwardly deflecting when a removal force is applied along the longitudinal axis (<NUM>) to the stud-mount insert (12A).