Patent Description:
Many variations of clips and nut, or other fasteners, are widely used in the automobile industry to fasten specific parts, panels or other accessories in a vehicle. Attachment clips may be used to attach car components, such as a heat shield plate for insulating heat of a muffler underside the vehicle, that are apt to be affected by heat. <FIG> show examples of two different clips <NUM>, <NUM> commonly used to attach a heat shield plate to a suitable bolt projecting through the heat shield plate to mountably engage with the clip <NUM>, <NUM>. Here, when fitting the clip <NUM>, <NUM>, the installer simply pushes the slanted teeth or claws <NUM>, 22over the shank of the bolt or screw so as to funnel the clip into a centralised position and aligning the bolt or screw with the clip <NUM>, <NUM>. Subsequently, the claws or teeth <NUM>, <NUM> are pushed over the thread ridges t of the shank until the clip is attached to the heat shield panel. In this engaged position, the claws or teeth <NUM>, <NUM> axially urge the clip <NUM>, <NUM> toward the heat shield panel by the elastic forces of the biased claws or teeth <NUM>, <NUM>. Additional retention members <NUM> further engage with the threaded shank portion to lock the clip into position, though, the leading edge of the retention members <NUM> tangentially engages with the thread portion of the shank only providing a single point of contact between he retention members <NUM> and the threaded shank of the bolt or screw making it a relatively unstable and insecure connection.

The example clip of <FIG> simply relies on the relatively insubstantial claws or teeth <NUM> to lock the clip <NUM> into position and bias the clip <NUM> onto the heat shield panel potentially accepting the loosening or even loss of the clip <NUM> because of the relatively weak connection.

Thus, currently available fastening clips, such as the clips <NUM>, <NUM> illustrated in <FIG>, tend to fail when used for high-speed automated assembly, because such clips are difficult to consistently centre and securely lock on a respective bolt or screw at really fast mounting speed (e.g. due to inaccuracies of the automated system and or installation tool when moved at high speed) causing potential misalignment and even incomplete connections. Another fastening clip is known from <CIT>.

Therefore, it is an object of the present invention to provide an improved fastening clip, suitable for automated assembly (especially at high-speed settings), that allows for a more reliable central alignment with the bolt or screw during installation and provides a stronger but demountable connection.

According to a first embodiment of the invention there is provided a fastening clip for attachment to a threaded elongate fastener, in accordance with claim <NUM>.

This provides the advantage of a fastener suitable for automated installation (e.g. push-in action) that may also be removed without damaging the fastener or attachment bolt. In particular, the unique design of the fastener of the present invention ensures that the part (e.g. heat shield) is not dented or otherwise damaged during installation or disassembly. The resilient retention arms and cooperating end portions provide for a strong connection with the stud or attachment bolt (or screw), while maintaining pressure on the part via the biased retention arms, therefore, mitigating the potentially damaging effect of vibrations. In addition, the frustoconical aperture of the base plate allows for easy and accurate positioning of the fastener on the stud or bolt, especially when mounted automatically in a high-speed action. Apertures have been provided to the retention arms to allow for a temporary attachment to the installation tool (i.e. when moved into position by the tool) via a friction fit between the resilient retention arms and the installation tool which is achieved by the resilient deformability of the retention arms.

Advantageously, each one of said end portions of said resilient retention arms may comprise an engagement member at a distal end adapted to matingly engage with a corresponding thread section of the threaded elongate fastener. Preferably, said engagement member may be formed by an extruded lip formed in line with the orientation of the corresponding thread of the threaded elongate fastener.

This provides the advantage of a considerably improved contact area between the threaded bolt or screw and the retention arm provided by an engagement member that is matingly shaped to a respective thread of the bolt or screw, therefore, providing a stronger and more secure mount.

One of said two cooperating end portions comprises at least one ramp member extending from said distal end in a direction nonparallel to a central longitudinal axis of said end portion of said retention arms, so as to slidingly engage with said distal end of the other one of said two cooperating end portions during movement between said first position and said second position.

This provides the advantage of preventing entanglement between the cooperating retention arms during assembly, especially during high-speed assembly utilising an automated installation system. In particular, the one or two (arranged in parallel, depending on the design of the end portion) ramp member(s) are arranged so as to abuttingly engage with an underside of the end portion of the other retention arm, when in the first position, and slidingly engage with (i.e. slidingly move the end portion of the other retention arm up and over) the other end portion, when moving between the first position and the second position.

Advantageously, each one of said retention arms may comprise at least one reinforcing rib member at least partially extending along said central longitudinal axis of respective said end portions.

This provides an improved stiffness at the end portion of the retention arm, so as to optimise the movement of the engagement members of the end portions along the threaded bolt or screw and strengthen the locking engagement between the engagement members of the end portions and the threaded bolt or screw.

Preferably, said reinforcing rib member may be provided by a stiffening emboss.

Advantageously, each one of said at least one recessed portion may be provided on a lateral edge of a respective one of said two cooperating end portions. Preferably, said recessed portion may be adapted to form an interference fit with a corresponding portion of the installation tool.

Advantageously, a proximal rim of said frustoconical sleeve may be configured to abuttingly engage with said two cooperating end portions when in said second position.

Advantageously, said proximal face may comprise a protruding rim extending at least partially along a peripheral edge of said base plate.

Advantageously, each one of said at least two diametrically opposing resilient retention arms may comprise at least one aperture adapted to receive a corresponding tool for dismounting said fastening clip from the threaded elongate fastener. The aperture(s) provide the advantage of a suitable point of contact for disassembling the fastening clip from the threaded bolt or screw, e.g. by either prying the retention arms out of engagement with the threaded bolt or screw, or by providing a turning handle to unscrew the fastening clip of the threaded bolt or screw, utilising, for example, a screw driver or similar hand tool.

Alternatively, or additionally, said at least two diametrically opposing resilient retention arms may be adapted to operably engage with a socket tool during disassembly of said fastening element from the shaft member of the vehicle part.

Advantageously, said at least two diametrically opposing resilient retention arms may be integral to said base plate. Preferably, said base plate and said at least two diametrically opposing resilient retention arms may be formed from a single piece of material.

Advantageously, said single piece of material is a resilient material.

Embodiment(s) of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:.

The described example embodiment relates to a fastening clip suitable for securing paraphernalia and accessories, and especially heat shield panels. The embodiment(s) of the invention is(are) normally applied in vehicles. Although the invention is described with respect to vehicles, the invention is not restricted to vehicles altogether, but may also be used in other structures requiring attachment of accessories or peripheral components to a structure.

Certain terminology is used in the following description for convenience only and is not limiting. The words 'right', 'left', 'lower', 'upper', 'front', 'rear', 'upward', 'down' and 'downward', 'top' and 'bottom' designate directions in the drawings to which reference is made and are with respect to the described component when assembled and mounted. The words 'inner', 'inwardly' and 'outer', 'outwardly' refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description.

Further, relative positional terms, such as, 'distal', 'proximal', 'lateral' and 'medial' are understood in their normal meaning and in relation to a specific element being described. In particular, these terms designate directions in relation to the tool or user end, e.g. proximal is in a direction towards the installation tool or user, wherein distal refers to the direction away from the installation tool or user.

Referring now to <FIG>, a preferred embodiment of the fastening clip <NUM> of the present invention is manufactured from a single sheet material, such as, for example, a sheet metal and in particular a spring steel that is formed using, inter alia, a punch and stamping press. The sheet metal may be heat treated after the punching and/or stamping process so as to form at least resilient retention arms 106a, 106b. However, it is understood by the person skilled in the art that any other suitable material or manufacturing process may be used, such as, for example, a resilient polymer or polymer compound using suitable polymer manufacturing processes (thermoforming, injection moulding, extrusion), but also 3D printing manufacturing processes.

The fastening clip <NUM> comprises a substantially circular base plate <NUM> having a frustoconical aperture <NUM> projecting towards an upper or proximal end (i.e. into the direction of the installation tool <NUM> or user). Two diametrically opposing retention arms 106a, 106b extend from a peripheral edge of the base plate <NUM> first radially and proximally outward to then invertingly fold back towards a centre axis <NUM> of the aperture <NUM> such that the distal end portions 110a, 110b are positioned proximally spaced apart (i.e. on top of) from the frustoconical aperture <NUM>. In this position, the resilient retention arms 106a, 106b are in an unbiased first position with the space between the end portions 110a, 110b defining the axial freedom of movement of the retention arms 106a, 106b between respective first (unlocked) position and second (locked) position. The frustoconical aperture <NUM> may be provided with a rim <NUM> adapted to abuttingly engage with any one of the end portions 110a, 110b when in the second position.

Each one of the end portions 110a, 110b is provided with an engagement member 112a, 112b on its distal end (i.e. the distal edge of the retention arms 106a, 106b) comprising of an extruded lip portion 114a, 114b forming a clamping collar adapted to matingly interlock with a corresponding thread section of the connecting stud, bolt or screw <NUM>, i.e. at least an upper edge of the extruded lip portion 114a, 114b or clamping collar is inclined in line with the thread angle of the threaded stud, bolt or screw <NUM> so as to match the corresponding thread space. Furthermore, the lip portion 114a, 114b is extruded into a frustoconically shaped collar with the narrower edge at the proximal side (i.e. top) of the end portion 110a, 110b, therefore allowing the engagement member 112a to slidingly move over a corresponding thread of the stud, bolt or screw <NUM> when moving from the first position towards the second position, but block or jam with the thread of the stud, bolt or screw <NUM> when moved from the second position towards the first position.

Each one of the resilient retention arms 106a, 106b may further comprise a reinforcing rib 116a, 116b configured to structurally stiffen at least a portion of the retention arms 106a, 106b. The reinforcing rib 116a, 116b may be provided along a longitudinal central axis of the end portion 110a, 110b, so as to stiffen that portion of the retention arm 106a, 106b (i.e. only allowing resilient flexure at the bent portion of the retention arms 106a, 106b). Preferably, the reinforcing rib 116a, 116b is provided by stamping a central portion of the end portion 110a, 110b so that the material is protruding on its distal side. However, the stiffening and reinforcement of at least a portion of the retention arms 106a, 106b may be provided by any other suitable structure.

Apertures 118a, 118b may further be provided on each of the retention arms 106a, 106b so as to allow as suitable engagement with at least a hand tool for dismounting the fastening clip <NUM> from the stud, bolt or screw <NUM>. Any suitable number of apertures 118a, 118b may be used.

In a preferred embodiment of the fastening clip <NUM> of the present invention, one of the end portions 110a, 110b may comprise at least one ramp member <NUM> extending from the distal edge of the retention arm 106a, 106b so as to abuttingly engage with an underside of the other retention arm 106a, 106b, when in the first unbiased position. In this particular embodiment, the at least one ramp member <NUM> is nonparallel with respect to the longitudinal axis of the end portion 110a, 110b such that the distal edge of the other retention arm 106a, 106b slides up and over when the cooperating retention arms 106a, 106b are moved between the first position and the second position (without jamming). It is understood by the person skilled in the art that the at least one ramp member <NUM> may be at any angle (including an extension parallel to the longitudinal axis of the end portion 110a, 110b) suitable to prevent jamming of the cooperating retention arms 106a, 106b during use.

Each one of the retention arms 106a, 106b further comprises at least one recess portion 122a, 122b adapted to attachingly engage with a corresponding installation tool <NUM>. The recess portion(s) 122a, 122b may be provided on a lateral edge of the end portion 110a, 110b and may be in the form of a simple cut-out or a stepped end section.

The proximal face of the base plate <NUM> may further comprise a protruding rim <NUM> along at least a portion of its peripheral edge configured to retainingly position and to centre a corresponding installation tool when attachingly coupled to the fastening clip <NUM>.

Referring now to <FIG>, the function of the fastening clip <NUM> is described when used with a suitable installation tool <NUM>. Here, the installation tool <NUM> is suitable for high-speed automatic assembly, such as, for example, a system using assembly line robots. However, the basic operation of the fastening clip <NUM> is the same when assembled manually (e.g. using fingers or any other suitable tool).

<FIG> shows an illustration of the fastening clip <NUM> when attached to a suitable installation tool <NUM>, i.e. before the fastening clip <NUM> is mounted to the stud, bolt or screw <NUM>. Here, the installation tool <NUM> comprises suitable recesses <NUM> forming a chamfered edge (or bevel) <NUM> configured to engage with a respective edge portion of the recess portion 122a, 122b of the retention arm 106a, 106b. When the installation tool <NUM> is pushed onto the proximal portion of the fastening clip <NUM>, the resilient retention arms 106a, 106b flex just enough for the edge portion of the recess portion(s) 122a, 122b and the chamfered edge(s) <NUM> to form a friction or interference fit that is strong enough to attach the fastening clip <NUM> to the installation tool <NUM>. In this configuration, the installation tool <NUM> can move with the attached fastening clip <NUM> to the respective stud, bolt or screw <NUM>.

<FIG> shows the fastening clip <NUM> when moved into a mounting position on the vehicle part (e.g. heat shield panel <NUM>), where the stud, bolt or screw <NUM> is guided by and pushed through the frustoconical aperture <NUM> and the engagement members 112a, 112b abuttingly engage with an end portion of the stud, bolt or screw <NUM>. Once the installation tool <NUM> has moved the fastening clip <NUM> onto the stud, bolt or screw <NUM> a plunger <NUM> axially pushes the retention arms 106a, 106b from the first unbiased position towards the second biased position by sliding the engagement members 112a, 112b over the thread of the stud, bolt or screw <NUM>. Due to the frustoconical design of the two cooperating engagement members (i.e. the formed clamping claw) 112a, 112b and the bias provided by the resilient retention arms 106a, 106b, the inclined edge of the lip portion 114a, 114b will matingly latch into corresponding thread sections of the stud, bolt or screw <NUM>, when moved towards the second position (see <FIG>) and released by the plunger <NUM> (see <FIG>), locking the fastening clip <NUM> onto the stud, bolt or screw <NUM>. The bias provided by the locked retention arms 106a, 106b maintains a consistent axial pressure of the fastening clip <NUM> onto the heat shield panel <NUM> mitigating any adverse effects caused by vibrations or any other external forces.

<FIG> illustrates the assembly setup between the installation tool <NUM>, the fastening clip <NUM> and the heat shield panel <NUM>, and Figure (b) provides a more detailed view of the installation tool <NUM>, the recesses <NUM>, chamfered edges <NUM> and plunger <NUM>.

In order to disassemble or remove the fastening clip <NUM> from the stud, bolt or screw <NUM> of the heat shield <NUM>, a user may simple pry the retention arms 106a, 106b away from the threaded stud, bolt or screw <NUM> using, for example, a screw driver or any other tool that fits into the apertures 118a, 118b, so that the biased retention arms 106a, 106b snap back into a respective unbiased position. Alternatively, another suitable tool may be used to push through both apertures 118a and 118b so as to provide a rotary handle (or rotary lever) in order to unscrew the fastening clip <NUM> from the threaded stud, bolt or screw <NUM>. This allows the removal of the fastening clip <NUM> without causing damage to the stud, bolt or screw, heat shield panel or the fastening clip <NUM> itself, therefore, providing for a fasting clip <NUM> that can be reused.

Referring now to <FIG>, an unclaimed alternative embodiment of the fastening clip <NUM> is shown comprising all the features of the first embodiment of the fastening clip <NUM> but without the ramp member(s) <NUM>.

<FIG> illustrates an embodiment of the fastening clip <NUM>, a panel portion <NUM> having a threaded bolt <NUM> and an installation tool <NUM> with a removed plunger <NUM> made from a polymer.

Referring now to <FIG> an unclaimed, alternative embodiment of the fastening clip <NUM> comprises a substantially circular frustoconical clamping disk, having an annular plate member <NUM> with a plurality of radially outwardly extending circumferentially segmented resilient fold members <NUM> folded axially downward from a peripheral edge of the annular plate member <NUM>, and a central aperture <NUM>, having a plurality of circumferentially segmented conically upwardly extending teeth <NUM> adapted to couplingly engage with a shaft member <NUM> (stud, bolt or screw) of the vehicle part during use. The alternative embodiment of the fastening clip <NUM> is characterised by at least three resilient circumferentially equidistantly spaced apart disassembly members <NUM> protruding axially upwards from the peripheral edge of the annular plate member <NUM>, which are adapted to operably engage with a socket tool <NUM> during disassembly of the fastening element <NUM> from the shaft member <NUM> of the vehicle part.

The at least three circumferentially equidistantly spaced apart disassembly members provide the advantage that the fastening clip <NUM> can be easily removed from its locking engagement with the shaft member <NUM> (e.g. threaded stud, bolt or screw) of the vehicle part or structure, by simply operably engaging with a suitable socket tool <NUM>, i.e. a hexagonal socket tool, where the disassembly members <NUM> are pressed into the hexagonal space of the socket tool <NUM> so as to form a resilient friction fit and allowing a torque force provided via the socket tool <NUM> to be imparted to the fastening clip <NUM> to then be unscrewed from the threaded bolt <NUM> during disassembly (manually or automatically). Thus, the alternative fastening clip <NUM> allows repeated use, as well as, a minimised risk of damaging the fastener and/or threaded bolt <NUM> during disassembly.

During use, the fastening clip <NUM> can be easily mounted according to known assembly procedures, e.g. with an automated push-in movement via a suitable tool or manually. In order to remove (disassemble) the fastening clip <NUM> from the locking engagement with the threaded bolt <NUM>, a suitable standard socket tool <NUM> is pushed into engagement with the at least three disassembly members <NUM>, such that a torque force provided to the socket tool <NUM> can be applied to the fastening clip <NUM> and unscrew it from the threaded bolt or shaft <NUM>.

As shown particularly in <FIG>, as well as, in a close-up view of the disassembly members <NUM> in <FIG>, the disassembly members are "lodged" into the hexagonal socket <NUM>, so that lateral edges of each one of the disassembly members <NUM> is abuttingly engaged with an inner surface of the hexagonal socket tool <NUM> (i.e. fit across the corners), allowing torque to be imparted from the tool <NUM> onto the disassembly members <NUM> and fastening clip <NUM>.

<FIG> illustrates a cross-section of the fastening clip <NUM> mounted to the heat shield panel <NUM> and attached to the socket tool <NUM> via the disassembly members <NUM>.

Claim 1:
A fastening clip (<NUM>) for attachment to a threaded elongate fastener (<NUM>), comprising:
a base plate (<NUM>), having a proximal face and a distal face, comprising a central through hole (<NUM>) defining a centre axis (<NUM>) and forming a frustoconical sleeve extending away from said proximal face along said centre axis (<NUM>) and which is configured to guidingly receive the threaded elongate fastener (<NUM>);
at least two diametrically opposing resilient retention arms, each one extending from a peripheral edge of said base plate (<NUM>) radially outward and invertingly folding back towards said centre axis (<NUM>), so as to provide two cooperating end portions (110a, 110b) operable to resiliently move substantially parallel to said centre axis (<NUM>) between an unbiased position, where said end portions (110a, 110b) are positioned proximally spaced apart from said frustoconical sleeve, and wherein said resilient retention arms have a space between said two cooperating end portions (110a, 110b) defining an axial freedom of movement of said resilient retentions arms, and a biased position, where the end portions (110a, 110b) are configured to retainingly and biasingly engage with a threaded elongate fastener when inserted through said central through hole, and
wherein each one of said two cooperating end portions (110a, 110b) further comprises at least one recessed portion (122a, 122b) adapted to receivingly and attachingly engage with a corresponding installation tool (<NUM>),
characterised in that one of said two cooperating end portions (110a, 110b) comprises at least one ramp member (<NUM>) extending from a distal end in a direction nonparallel to a central longitudinal axis of said end portion (110a, 110b) of said retention arms so as to slidingly engage with a distal end of the other one of said two cooperating end portions (110a, 110b) during movement between said unbiased position and said biased position.