Overmolded metal-plastic clip

Abstract

The present invention relates to an overmolded metal - plastic clip, a system and a method including a fastening clip, the fastening clip including a first part made of an elastic first material. The first part includes: a pair of legs joined at a head; and one or more pairs of barbs coupled to the pair of legs. The barbs are configured to drill into a blade and secure the fastening clip to the blade at least based on the fastening clip being placed on the blade. The fastening clip includes a second part made of a softer second material. The second part includes an inner portion and an outer portion that are both outside and inside the first part. The outer portion is configured to engage a slot in a chassis.

Description

Technical Field

[0001] The present invention mainly relates to a device for fastening an object, and more particularly to a fastening clip assembly for insertion into a joining structure (such as a vehicle chassis, a hollow substrate, a wall, a panel or any suitable surface). Background Art

[0002] Currently, there are many devices and fasteners available for fastening panels (such as body panels and automotive interior trim 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, plastic interior trim, a door panel, a roof panel or any interior trim. Additionally, the panel can be any suitable exterior body panel, such as a fender, a bumper, a quarter panel or a door panel. The chassis of a vehicle can include any substrate, panel, body panel, structural frame, chassis component or sub-component, wall or any suitable object.

[0003] These conventional fastener devices provide approximately relatively equal levels of insertion force and extraction force. These body panels are typically attached to the chassis of an automobile with a relatively high level of insertion force, while providing a relatively low level of extraction force.

[0004] It is well known that fastening clips, such as two-piece (multi-piece) fasteners, attach body panels to the chassis of an automobile. With a two-piece fastener, if the panel is removed after the original installation (such as to repair a component in a door), the panel can be pulled apart such that a portion of the fastener remains attached to the sheet metal part while other portions of the fastener remain attached to the decorative panel. After separation, the two pieces can also be reattached. However, two-piece fasteners require the manufacture of multiple pieces and a laborious two-piece assembly, and are thus relatively expensive.

[0005] One-piece fasteners are generally less expensive than two-piece or multi-piece fasteners. A one-piece fastener has: a base that is attached to the body panel; and a blade that is attached to the base; and a wing that is attached at least to the top of the blade at the top end of the fastener for being fastened into a frame slot. However, if the frame slot and the fastener are not aligned, the forces on the wings are not equal because the wing closest to the edge of the slot will experience a higher wing compression, while the other wings will not have sufficient resilience to engage the slot. When the clip is pressed into the slot, such a large force on one wing may cause the wing to break, thereby preventing the fastener from fastening the body panel to the frame. Worse yet, a broken, damaged or weakened wing may cause the body panel to become detached or cause rattling.

[0006] The wings of traditional fasteners have sharp, non-smooth grooves to engage with the edges of the frame slots. However, when the clip is removed, the sharp edges of the frame slots cut into the softer plastic and cut out grooves. During the manufacturing process, slots are typically formed in the vehicle's frame, such as in the interior roof or door sheet metal structure, by stamping sheet metal. When the punch enters the sheet metal, the exterior of the sheet metal is pushed inward, and metal perforations or bulges are formed on the interior of the sheet metal. The slot edges obtained on the exterior of the slot are relatively smooth; however, the interior of the slot edges is sharp and rough. After the fastening clip is removed, the sharp edges of the frame cut off the grooves, making it possible that the clip cannot be reinserted and reused.

[0007] For example, if the slot is off-center, or if the sheet metal thickness is different, or if there are production tolerances for the slots in the vehicle chassis or trim pieces, engaging a portion of the slot in the chassis with one of the wings may not provide proper frictional engagement. Distortion of the body panel will likely be more prevalent because not all contact points are actually made through the slots in the vehicle chassis. As a result, when the fastener and the body panel are misaligned, conventional single-piece fasteners cannot self-align and are prone to wing breakage, rendering the fastener unable to be reattached.

[0008] Conventional fasteners generally cannot adequately secure the panel to a vehicle chassis with slot size and position variations or to a sheet metal piece with different curvatures or thicknesses. When the fastener and the body panel are misaligned, conventional single-piece fasteners do not self-align and are prone to wing breakage, making the fastener unable to be reattached. Moreover, conventional fasteners are not suitable when subjected to various environmental conditions, such as in the presence of vibrations at various amplitude and frequency levels. For example, this type of conventional fastener generally cannot prevent or minimize buzzing, rattling, or any other type of noise that may draw the attention of vehicle occupants or otherwise weaken the attachment. Conventional fasteners cannot adequately accommodate various levels of production tolerances, such as the various dimensions between the body panel and the vehicle chassis. Thus, conventional fastener devices generally cannot self-align or properly fasten to a range of sheet metal thicknesses, and cannot minimize or eliminate buzzing and rattling, and cannot adequately accommodate changes in production tolerances. As a result, wear, squeaking, rattling, buzzing, corrosion, loss of elasticity, and loss of sealing may occur, especially after years of vehicle operation and exposure to vibrations, heat, moisture, and other environmental conditions. Summary of the Invention

[0009] The object of the present invention is to provide a new type of fastening clip to solve the problems in the prior art.

[0010] This object is achieved by providing a fastening clip, which includes: a first part made of a first material, wherein the first material is elastic, and the first part includes: a pair of legs joined at a head, wherein the legs form a clip opening at opposite ends of the head; one or more pairs of barbs coupled to the pair of legs, wherein the barbs are configured to drill into a blade, and the blade is configured to be coupled to a panel, and the fastening clip is configured to be fixed to the blade at least based on the barbs being configured to drill into the blade when the fastening clip is pushed onto the blade; a second part made of a second material, the second part being coupled to the first part, wherein the second material is softer than the first material, and the second material includes an inner portion inside the first part and an outer portion outside the first part, and the outer part of the second part is configured to engage a slot in a chassis and fix the fastening clip to the chassis. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Other objects and advantages of the present invention will become apparent by reading the detailed description and referring to the accompanying drawings.

[0012] Figure 1 is a perspective view of a fastening clip assembly according to some embodiments.

[0013] Figure 2 is a perspective view of a two-piece fastening clip according to some embodiments.

[0014] Figure 3 is another perspective view of a two-piece fastening clip according to some embodiments.

[0015] Figure 4 is yet another perspective view of a two-piece fastening clip according to some embodiments.

[0016] Figure 5 is yet another perspective view of a two-piece fastening clip according to some embodiments.

[0017] Figure 6 is a perspective view of a blade configured to receive a fastening clip according to some embodiments.

[0018] Figure 7 is a perspective view of a fastening clip attached to a chassis according to some embodiments.

[0019] Although the present invention may be subject to various modifications and alternative forms, specific embodiments of the present invention are shown by way of example in the drawings and the following detailed description. However, it should be understood that the drawings and the detailed description are not intended to limit the present invention to the specific embodiments. On the contrary, the present disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. Detailed Description

[0020] Figure 1 is a perspective view of a fastening clip assembly according to some embodiments.

[0021] In some embodiments, the fastening clip 100 is configured to fasten a top surface 300 and a bottom surface 400 together. A blade 210 extending from the surface 400 is configured to receive the fastening clip 100 and be fixed to the fastening clip. In some embodiments, the blade 210 may be molded on the surface 400. In other embodiments, the blade 210 may be attached to the surface 400 using various other measures.

[0022] In some embodiments, the fastening clip 100 may be configured to be inserted through a slot 250 in the top surface 300 and fix itself to the top surface 300. In some embodiments, the fastening clip assembly is configured to fasten the top surface 300 and the bottom surface 400 together at least based on the slot 250 in the surface 300 to which the fastening clip is fixed and the blade 210 in the surface 400.

[0023] In some embodiments, the surface 400 may be a part of a panel, and the surface 300 may be a part of the chassis / frame of an automobile. Thus, the fastening clip assembly may be configured to fasten the panel to the chassis / frame of the automobile.

[0024] Figure 2 is a perspective view of a two-piece fastening clip according to some embodiments.

[0025] Figure 3 is another perspective view of a two-piece fastening clip according to some embodiments.

[0026] Figure 4 is yet another perspective view of a two-piece fastening clip according to some embodiments.

[0027] Figure 5 is yet another perspective view of a two-piece fastening clip according to some embodiments.

[0028] In some embodiments, the fastening clip 100 can be made of at least two different materials. The first material can be a material with high elasticity (such as metal), allowing the clip to rebound between at least two positions to facilitate insertion and engagement. The second material can be a softer material (such as plastic) to allow the clip to make better and / or safer contact with the surface to which the clip will engage. These softer materials can prevent premature wear of, for example, the clip or the surface engaged by the clip.

[0029] In some embodiments, the fastening clip 100 can be made of a combination of metal and plastic that can be injection molded. In some embodiments, for example, a sheet metal part made of metal and a stamping process can be used to first make the metal part. Then plastic can be injected around the metal. In some embodiments, the plastic can be injected into the interior and exterior of the metal clip, as described elsewhere herein.

[0030] In some embodiments, the fastening clip 100 includes a first part 101 and a second part 102, which are combined to form the fastening clip 100. In some embodiments, the first part 101 can be made of an elastic material, such as metal, and the second part 102 can be made of a softer material, such as plastic.

[0031] In some embodiments, the first part 101 includes a pair of legs 60 joined at a head 70. The pair of legs 60 form a clip opening 80 at opposite ends of the head 70, allowing entry of a blade 210 (the clip 100 is configured to attach to the blade 210). In some embodiments, each leg 60 terminates at a foot 200 at an end opposite the head 70.

[0032] In some embodiments, the first part 101 can also include windows 90 and 92 on each leg 60, which can be configured to allow the molding material of the part 102 to flow between the interior and exterior of the part 101. In some embodiments, molding the material of the second part 102 between the interior and exterior of the first part 101 significantly strengthens the connection between the first part 101 and the second part 102. Additionally, the first part 101 can include protrusions, such as protrusion 94, to further enhance the connection between the first part 101 and the second part 102.

[0033] In some embodiments, the first part 101 can also include a pair of barbs (four barbs in one embodiment) on each leg 60. In some embodiments, each barb 65 is attached to the side of the leg 60. At least based on the barbs 65 being sharp at their ends and harder than the material of the blade 210, when the fastening clip 100 is inserted onto the blade 210, the barbs are configured to drill and attach the first part 101 to the blade 210.

[0034] In some embodiments, when the fastening clip 100 is inserted onto the blade 210, the blade 210 is configured to bend the barbs 65 apart, and the barbs 65 are configured to snap back onto the blade 210. During insertion, the blade 210 slides upward toward the barbs 65, and the barbs 65 are also pushed away by the blade 210. When the clip 100 is inserted onto the blade 210, the barbs 65 are configured to drill into the material of the blade 210, thereby further increasing the removal force required to separate the clip from the blade. Additionally, the barbs 65 provide additional support for the connection between the fastening clip 100 and the blade 210.

[0035] In some embodiments, the second part 102 includes a pair of legs 62 joined at a head 72. The pair of legs 62 form a clip opening 82 at opposite ends of the head 72, thereby allowing entry of the blade 210 (the clip 100 is configured to attach to the blade 210). In some embodiments, each leg 62 terminates at a foot 202 at an end opposite the head 72.

[0036] In some embodiments, the second part 102 can be injection molded around the first part 101. In some embodiments, multiple portions of the second part 102 can be molded on the outside of the first part 101, while other portions of the second part 102 can be molded on the inside of the first part 101.

[0037] In some embodiments, the second part 102 can be molded as a continuous part and can be woven, for example, through windows 90 and 92, inside and outside of the first part 101. In some embodiments, the legs 62 and the feet 202 can be on the outside of the first part 101, while the head 72 and the inner part 96 can be on the inside of the first part 101. In some embodiments, weaving the second part in this manner significantly improves the connection between the first part and the second part. For example, by making the first part have strength and elasticity at the position where the second part is configured to engage a slot 250 (described below) after the second part, the connection between the clip 100 and the surface 300 is significantly improved. Additionally, the head 72 on the inside of the head 70 is configured to tightly engage the blade 210, thereby improving the connection between the clip 100 and the blade 210.

[0038] In some embodiments, each leg 62 may include an inclined face such that when engaging the slot 250, the leg 63 is configured to snap in and then snap back when the clip 100 engages the slot 250. In some embodiments, each leg 62 may include at least one recess 600. The recess 600 is formed and configured to engage a portion of the surface 300 of the slot 250. In some embodiments, the slot 250 may have any shape, such as circular, square, rectangular, pentagonal, hexagonal, polygonal, n-sided polygon (where n is an integer), oval, ovoid, etc.

[0039] In some embodiments, the recess 600 may include, for example, a steep edge, a gradually angled edge, such as a curve, a single angled edge, discrete multi-angled edges, or a sharp edge. The recess 600 may be formed on each leg 60 of the recess 600 to engage the slot 250, thereby increasing the force required to pull the fastening clip 20 out of the slot 250. The size of the recess 600 may be set to appropriately engage the slot 250 of the first engagement structure 30 in order to obtain a desired level of pull-out force. According to one embodiment, the recess 600 may be a recess formed on the leg 60. The size and shape of the recess 600 may be formed in any suitable manner to allow the fastening clip 20 to be relatively easily inserted into the slot 250 while increasing the pull-out force.

[0040] Figure 6 is a perspective view of a blade configured to receive a fastening clip according to some embodiments.

[0041] In some embodiments, the blade 210 is configured to receive and attach to the fastening clip 100. The blade 210 may be attached to the surface 400 or be part of the surface 400. In embodiments where the surface 400 is made of, for example, plastic, the structure of the blade 210 may be molded as part of the surface / structure 400. In some embodiments, the surface / structure 400 may be an automotive panel to be attached to an automotive chassis.

[0042] In some embodiments, the guiding structures 750 located on either side of the blade 210 are configured to guide the fastening clip 100 on the blade 210 as the fastening clip is inserted onto the blade. Additionally, the guiding structures 750 are configured to provide additional stability to the connection between the blade 210 and the fastening clip 100 after installation.

[0043] Figure 7 is a perspective view of a fastening clip attached to a chassis according to some embodiments.

[0044] In some embodiments, the fastening clip assembly is configured to couple two surfaces, such as surfaces 300 and 400. The fastening clip 100 is configured to fit over and attach to the vane 210, which is attached to surface 400. Additionally, the fastening clip 100 is configured to removably attach to a slot in surface 200. For example, the fastening clip system can be used to fasten a fastener to a body panel to a vehicle chassis together.

[0045] It should be understood that other variations and modifications of the invention in its various aspects will be apparent to those skilled in the art, and the invention is not limited to the specific embodiments described. Accordingly, the invention encompasses any and all variations, changes or equivalents that fall within the spirit and scope of the basic principles disclosed and claimed herein.

[0046] One or more embodiments of the invention have been described above. It should be noted that these and any other embodiments are exemplary and are intended to illustrate the invention rather than limit it. Although the invention may be widely applied to various types of systems, those skilled in the art should recognize that it is not possible to include all possible embodiments and contexts of the invention in this disclosure. After reading this disclosure, many alternative embodiments of the invention will be apparent to those skilled in the art.

[0047] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the 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 herein.

[0048] The benefits and advantages that the invention can provide have been described above with respect to specific embodiments. These benefits and advantages, as well as any elements or limitations that may cause them to occur or become more apparent, should not be construed as critical, essential or necessary features of any or all of the claims. The terms "comprising...", "including..." or any other variant thereof used herein are intended to be construed as non-exclusively including the elements or limitations that follow those terms. Thus, a system, method or other embodiment that includes a set of elements is not limited to those elements and may include other elements inherent in the embodiment that are not expressly listed or claimed.

[0049] Although the present invention has been described with reference to specific embodiments, it should be understood that these embodiments are illustrative and the scope of the present invention is not limited to these embodiments. Many variations, modifications, additions and improvements to the above embodiments are possible. It is contemplated that these variations, modifications, additions and improvements all fall within the scope of the present invention as detailed in the appended claims.

Claims

1. A fastening clip, comprising: A first part, the first part being made of a first material, wherein the first material is elastic, and wherein the first part comprises: A pair of first part legs, the pair of first part legs being joined at a first part head, wherein the pair of first part legs form a clip opening at opposite ends of the first part head; One or more pairs of barbs, the barbs being coupled to the pair of first part legs, Wherein the barbs are configured to drill into a blade, wherein the blade is configured to be coupled to a panel, and wherein the fastening clip is configured to be fixed to the blade at least based on the barbs being configured to drill into the blade when the fastening clip is pushed onto the blade; A second part, the second part being made of a second material, the second part being coupled to the first part, and wherein the second part comprises: A pair of second part legs, the pair of second part legs being joined at a second part head, and wherein each second part leg of the pair of second part legs comprises at least one recess, Wherein the second material is softer than the first material, and wherein the second part comprises an inner portion inside the first part and an outer portion outside the first part, Wherein the outer portion comprises the pair of second part legs, Wherein the pair of second part legs are configured to snap into and then snap back when the fastening clip engages a slot in a chassis, Wherein the recesses of the pair of second part legs are configured to engage a portion of the slot in the chassis and secure the fastening clip to the chassis.

2. The fastening clip according to claim 1, wherein, The second part head is inside the first part head.

3. The fastening clip according to claim 1, wherein, The first part further comprises a pair of feet, the pair of feet being correspondingly coupled to the pair of first part legs at ends of the pair of first part legs opposite the first part head.

4. The fastening clip according to claim 1, wherein, The fastening clip is configured to couple the chassis to the panel at least based on the fastening clip being configured to be fixed to the blade and to the slot in the chassis.

5. The fastening clip according to claim 1, wherein, The second part is configured to fit on top of the blade.

6. A fastening assembly system, comprising: A chassis, the chassis comprising a slot; A panel, the panel comprising blades; A fastening clip, the fastening clip comprising: A first part, the first part being made of a first material, wherein the first material is elastic, and wherein the first part comprises: A pair of first part legs, the pair of first part legs being joined at a first part head, wherein the pair of first part legs form a clip opening at opposite ends of the first part head; One or more pairs of barbs, the barbs being coupled to the pair of first part legs, Wherein the barbs are configured to drill into the blade, wherein the blade is configured to be coupled to a panel, and wherein the fastening clip is configured to be fixed to the blade at least based on the barbs being configured to drill into the blade when the fastening clip is pushed onto the blade; A second part, the second part being made of a second material, the second part being coupled to the first part, wherein the second part includes: A pair of second part legs, the pair of second part legs being joined at a second part head, wherein each second part leg of the pair of second part legs includes at least one recess, Wherein the second material is softer than the first material, wherein the second part includes an inner portion that is inside the first part and an outer portion that is outside the first part, Wherein the outer portion includes the pair of second part legs, Wherein the pair of second part legs are configured to snap in and then snap back when the fastening clip engages a slot in the chassis, Wherein the recesses of the pair of second part legs are configured to engage a portion of the slot in the chassis and secure the fastening clip to the chassis.

7. The fastening component system according to claim 6, wherein, The second part head is inside the first part head.

8. The fastening component system according to claim 6, wherein, The first part further includes a pair of feet, the pair of feet being correspondingly coupled to the pair of first part legs at ends of the pair of first part legs opposite the first part head.

9. The fastening component system according to claim 6, wherein, The fastening clip is configured to couple the chassis to the panel at least based on the fastening clip being configured to be secured to the blade and to the slot in the chassis.

10. The fastening component system according to claim 6, wherein, The second part is configured to fit on top of the blade.

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