Patent Description:
Airbags are safety devices that are increasingly being used in the motor industry and which, in combination with other safety components, such as seatbelts, help to reduce fatal accidents in the case of collisions. The tests to which the vehicles have been subjected, as well as, mortality statistics, have clearly demonstrated that the use of airbags can considerably improve the safety of automobile occupants and, when combined with other forms of passive safety, such as seat belts, significantly (by about <NUM>%) reduce mortality in the case of serious accidents.

Today, manufacturers produce frontal airbags, which are designed to protect the driver and/ or passenger in the event of a head-on collision and, considering their positions, lateral airbags that are installed behind the posts and/or in the sides of the vehicle seats, along with curtain airbags.

Airbags of the curtain type are usually located in the part close to the roof on the sides of the automobile, e.g. situated above the front and rear doors. Such airbags have very rigorous requirements with regards to the goals set for them and the technical challenges that have to be overcome. Typical challenges may be their location in the vehicle and the way they are fastened, required deployment time and the time that the airbag is required to remain inflated. Other challenges may come from the fact that there is only a short distance between the body and the occupant and that there is little vehicle material between the occupant and an impacting vehicle. For example, it is essential that airbags are deployed in a fraction of a second, giving rise to an enormous snatch force on their attachment components, which then suffer the consequences of that impact.

Further, when installing new or restore previously deployed airbags, it is well known in the industry that the installation or restoration is tedious work, comprising steps, such as, (i) dismantling all the attachments of the airbag, (ii) replacing the airbag and installing a new one, and then again (iii) fitting all its attachments. The work involved generally requires the installer to at least partly manually assemble and install the airbag to the vehicle. During the assembly, the installer may have to push numerous fastening clips into a vehicle panel or structure to attach or operably couple the airbag to the vehicle. Such work steps can be very repetitive and potentially cause injuries to the installer if the component parts are not adequately designed for manual installation.

<FIG>, for example, illustrates a typical clip <NUM> used for the attachment of airbags, such as, side-impact or curtain airbags, that is of the type formed by a body from which extend flexible elements <NUM> typically bearing against the surface of the clip entered into the attachment panel of the vehicle. The clip <NUM> comprises laterally protruding tangs <NUM> having upper surfaces <NUM> configured to bear against an inner surface of the attachment panel so as to "sandwich" the panel surface between the flexible elements <NUM> and the upper surfaces <NUM> of the tangs <NUM>. Clip <NUM> may be formed from a single folded and punched laminar surface, so as to form a three-dimensional body made from, for example, metal, such as, carbon steel.

However, clip <NUM> is designed in such a way that the top region (or head portion) does not provide sufficient area for the installer to safely and efficiently push the clip into the attachment panel. There are also exposed sharp edges on this top region which can lead to an uncomfortable insertion of the clip, or even potentially injure the installer during such insertion, i.e. when pushing the clip into an attachment panel opening.

Another fastener clip <NUM> typically used to attach airbags to a vehicle structure is illustrated in <FIG>. Fastening clip <NUM> comprises laterally protruding tangs <NUM> adapted to fixingly engage with the panel's inner surface when entered through a mounting aperture of the panel. Clip <NUM> is designed so as to either provide an unloaded connection, where the tangs <NUM> simply prevent the clip <NUM> from sliding out of the mounting aperture once installed, or where the connection is loaded only if the dimensions of the panel surface (thickness) and aperture (rectangular cut-out) are suitably matched to the clip design. In the event of an unloaded connection (i.e. without resilient springs), the bias or spring load may be provided by a different component of the airbag module. Usually, this different component is made in plastic which, for a spring effect under mechanical loads (strength, fatigue) may not perform as good as metal.

Also, even though clip <NUM> has a flat upper surface, sharp edges are exposed at the upper surface making it uncomfortable and even risk injuries to the installer when pushing the fastening clip <NUM> into the mounting aperture.

Fastening clips are also disclosed in the following documents: <CIT>, <CIT>, <CIT>, <CIT>, <CIT>.

Therefore, it is an object of the present invention to provide an improved and ergonomic fastening clip, suitable for attaching airbags, such as side-impact or curtain airbags, that robust and efficient, as well as, ergonomic and safe so as to minimise any potential risk to the user during assembly.

According to a first aspect of the present invention, there is provided a fastening clip for mounting a component part, such as an airbag, to a support structure, comprising:.

The fastening clip of the present invention provides the advantage of an ergonomic pushing surface without any exposed sharp edges that may damage other components in the application or the user during assembly. Further, the fastening clip of the present invention provides the advantage of combining spring arms with an ergonomic pushing surface adapted, so as to prevent exposure of any sharp edges to the user or other components while the construction still allows the use of a single (uniaxial) folded (and punched) laminar sheet material (e.g. metal).

Advantageously, said plate member may be configured for push engagement by a digit of a user.

According to the invention, each one of the two opposing resilient spring members is uniaxially folded about a respective first and second folding axis. Preferably, said first and second folding axis are perpendicular to said longitudinal axis. Even more preferably, said first and second folding axis are parallel to each other. said plate member may further comprise a first fold extending from at least a centre portion of said first edge and folded towards said body portion. Preferably, said first fold may form a single fold about a first folding axis perpendicular to said longitudinal axis.

Advantageously, said plate member may further comprise a second fold extending from at least a centre portion of said second edge and folded towards said lower end region of said body portion. Preferably, said second fold may form a single fold about a second folding axis perpendicular to said longitudinal axis. Preferably, said second folding axis may be parallel to said first folding axis.

Advantageously, said plate member may further comprise at least one edge member extending from at least a central portion of each one of said first and second edges and folded towards said lower end region and said body portion. Preferably, said at least one edge member may extend from each one of said opposing first and second edges into forming said body portion.

Advantageously, at least one of said resilient spring members may be a flexion leg ending in a looped or folded end portion shaped, so as to minimise damage to the support structure and/or the user during assembly.

Advantageously, said resilient spring members may be provided at diagonally opposing corners of said plate member.

Advantageously, said body portion and said head portion may be formed from a single piece.

According to a second aspect of the present invention, there is provided a planar sheet material for forming a fastener clip, comprising a predetermined pattern of cut-outs, fold lines and apertures, configured to fold into a fastener clip according to the first aspect of the present invention.

Advantageously, said predetermined pattern of cut-outs, fold lines and apertures may be fabricated by any one of punching, stamping, cutting and bending.

Example embodiments of the description 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. The embodiment(s) of the invention 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' 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, unless otherwise specified, the use of ordinal adjectives, such as, "first", "second", "third" etc. merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking or in any other manner.

Referring now to <FIG>, <FIG>, <FIG>, an example embodiment of the fastening clip <NUM> is shown before it is used for assembly, i.e. when securing an airbag to an attachment panel. In particular, the clip <NUM> of the present invention comprises an improved airbag clip of the type of clips which are used for the attachment of airbags, such as, for example side-impact or curtain airbags, the air bag clips are of the type formed by a pre-cut 2D blank (patterned and cut for folding). The clip <NUM> has a head portion <NUM> from which extend flexible elements, such as spring elements <NUM>, that, during use, are adapted to bear against an outer surface of an attachment panel <NUM> when the clip <NUM> enters an aperture <NUM> of the panel <NUM>, and a body <NUM>, comprising descending tangs <NUM> which give rise to different structures for the clip <NUM>, such as, for example, side limbs <NUM> having surfaces configured to bear against an inner surface of the panel <NUM> in such a way that the supporting surfaces and those provided by the flexible spring elements <NUM> engage the attachment panel <NUM> on both sides, i.e. in the form of a sandwich, thus, enabling the clip <NUM> to be fixedly supported on the attachment panel <NUM>. The improvements of the clip <NUM> comprise a pushing surface with an improved ergonomic shape, as well as, a head portion configured to protect from potential injuries during assembly. Furthermore, the improved airbag clip <NUM> has been simplified to include spring elements <NUM> extending directly from the head portion <NUM> and formed by a single fold of the spring elements <NUM> toward the distal end of the body <NUM>.

Clips <NUM> for airbags such as those according to this invention are inserted into an opening made in the surface of the attachment panel <NUM>. This surface effectively divides the clip <NUM> into an upper outer part, i.e. the head portion <NUM>, which is not inserted into the opening and an inner lower part, i.e. the body portion <NUM>, which is inserted into the opening (see <FIG>). The upper part or head portion <NUM> of the clip <NUM> corresponds to the outer part and the lower part or body portion <NUM> of the clip <NUM> corresponds to the inner part. Likewise, the ascending direction is from the inner part to the outer (lower to upper) and the descending part is from the outer part to the inner (upper to lower). The body portion <NUM> may be formed by a box <NUM> that is formed by the union of two surfaces which are approximately "U"-shaped in transverse cross-section, being attached by one of their ends, and the attachment being strengthened by respective tabs <NUM> produced by division of the portions of the connecting part forming opposite surfaces. As may be seen from the attached figures, tabs <NUM> which are located within box <NUM> may have nails (not shown) that are shaped so as to engage in the openings provide in box <NUM>.

Tangs <NUM> have an inclination towards the central axis <NUM> of the clip and extend downwards from box <NUM> towards the centre of clip <NUM> to then form a loop and extend away from the centre of the clip <NUM> in the opposite direction as ascending side limbs <NUM>. In the preferred construction of the invention and as illustrated in the drawings, the loops of tangs <NUM> may be in contact with each other. This contact provides strength to the clip against pull-out forces.

Tangs <NUM> may have an enlarged surface <NUM>, almost in the form of a triangle, which allows its base to extend beyond the walls forming box <NUM>. This obviously prevents box <NUM> from "descending" under pressure and passing beyond those stops represented by the enlarged surface <NUM>.

Side limbs <NUM> are configured to emerge from the inner part of box <NUM> towards the exterior of the same, through a hollow space, opening or window <NUM> made in its surface, creating a bearing surface <NUM> that is approximately parallel to the flat upper surface of the head portion <NUM> and which is configured to engage with the panel <NUM> (whin in use).

The sides of window <NUM> may have lateral tabs <NUM> which provide a support for the bearing surfaces <NUM> of box <NUM> against the inner surface of the panel <NUM> in response to forces which tend to extract clip <NUM>.

The upper part or head portion <NUM> of the clip <NUM> comprises a substantially rectangularly shaped plate <NUM> with a flat upper surface. The plate <NUM> is arranged transverse to a longitudinal axis <NUM> of the body portion <NUM>. Resilient spring elements <NUM> (i.e. flexion leg) extend transversely away from opposing edges at diagonally opposing corners of the plate <NUM>. Each spring element <NUM> is folded towards the body portion <NUM>, so as to form an obtuse angle with the flat upper surface of the plate <NUM>. Respective folds are uniaxial about a single axis <NUM> that is perpendicular to the longitudinal axis <NUM> of the clip <NUM>. The fold of the spring elements <NUM> forms a rounded side edge <NUM> of the plate <NUM>. Further, a distal end portion of each spring element <NUM> is looped back, so as to form a rounded spring element end (i.e. a tear-drop hem).

A central portion <NUM> of two opposing protruding side edges of the plate <NUM> is folded towards and merging into a respective side of the body portion <NUM> (i.e. forming the box <NUM>), so as to form a rounded side edge (e.g. a closed or open hem).

In addition, the plate <NUM> may be provided with two centrally aligned apertures <NUM>, so as to allow access to the inner part of box <NUM>.

Referring now to <FIG>, the clip <NUM> may be formed from a single laminar surface <NUM> (i.e. a sheet material or blank) that is cut and punched in a unique way, so as to allow forming a three-dimensional embodiment of the clip <NUM> by simply folding respective cut or punched portions of the sheet material <NUM> at predetermined fold lines. In particular, the laminar surface (i.e. sheet material or blank) may be a sheet metal blank <NUM> comprising predetermined cuts, bends and apertures that when folded form the specific parts and portions of the three-dimensional clip <NUM>. <FIG> includes the reference signs pointing to the 2D portion of the parts of the clip <NUM> once formed. The sheet metal material may be cut, punched, stamped or bent utilising suitable tooling (e.g. press, drills, laser cutting etc.).

It is understood by the person skilled in the art, that the unique cut-out pattern of the sheet metal allows for a clip with two spring elements <NUM> extending directly from the plate <NUM> of the head portion <NUM> and uniaxially bent about a single axis <NUM> that is perpendicular to the longitudinal centre axis <NUM> of the clip <NUM>, thus, minimising the material required to form the intended shape (and functionality) of the clip <NUM>.

The laminar surface or sheet metal blank may be made from a metal, such as, for example, carbon steel which has been heat treated to impart improved strength qualities to it. Further, clip <NUM> may undergo treatment to prevent corrosion and/or receive a suitable coating in order to improve its service life and wear in relation to dust, moisture and other elements which might attack the clip.

During assembly, the user simply pushes the fastening clip <NUM> into the mounting aperture <NUM> of the attachment panel <NUM> thus fixingly engaging the side limbs <NUM> with an inner surface of the attachment panel <NUM>. The flat surface and round edges of the plate <NUM> provide an ergonomic pushing surface adapted to minimise potential injuries to the user during assembly.

Claim 1:
A fastening clip (<NUM>) for mounting a component part, such as an airbag, to a support structure (<NUM>), comprising:
a body portion (<NUM>), extending between an upper end region and a lower end region along a longitudinal axis (<NUM>), comprising at least one elastically deflectable retaining member (<NUM>), projecting laterally from said lower end region of said body portion (<NUM>), so as to fixingly engage when inserted into an orifice (<NUM>) of the support structure (<NUM>);
a head portion (<NUM>), provided at said upper end region of said body portion (<NUM>), comprising a rectangularly shaped plate member (<NUM>), having a flat upper surface extending in a transverse plane relative to said longitudinal axis (<NUM>), and two opposing resilient spring members (<NUM>) extending transversely away from opposing first and second edges of said plate member (<NUM>) and folded towards said lower end region of said body portion (<NUM>), and
wherein each one of said two opposing resilient spring members (<NUM>) is uniaxially folded about a respective first and second folding axis (<NUM>).