Blind vision assembly fastener system

Abstract

Systems and methods for coupling a first panel to a second panel via a fastening system are disclosed. The fastening system includes a fastener, a boss structure, and a seal assembly. The fastener includes a head assembly coupled to a neck ring. The head assembly is configured to engage with the boss structure positioned on the first panel, and the neck ring is configured to pass through the second panel and retain the second panel via an opening formed in the second panel. The seal assembly includes a seal and a seal carrier. The seal carrier is coupled to the fastener via a frangible connection.

Description

[0001] Related Art

[0002] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Serial No. 63 / 022,612, filed May 11, 2020, entitled “Blind Assembly, Close-Panel, Doghouse Interface Fastener System,” and U.S. Provisional Patent Application Serial No. 63 / 056,854, filed July 27, 2020, entitled “Ready Set Seal,” the contents of which are incorporated herein by reference. BACKGROUND

[0003] Automotive components require fastening technology that is simple to manufacture and assemble. Further, the fastening technology should first be reliable and efficient. Close-panel blind assembly is a condition in which fastening action is concentrated between panels (such as automotive panels or other components) that need to be fastened to one another while at the same time trying to keep these same panels positioned very closely to one another.

[0004] Typical fastening solutions that allow this type of close-positioned assembly include magnets, adhesive strips, and mechanical fasteners. For example, metal fasteners can be used to make a blind connection between panels. Conventionally, a simple metal fastener can be received within an opening (e.g., a window or aperture) formed in a primary panel and configured to engage a blade structure extending from an underside surface of a secondary panel. A drawback of existing metal fasteners is that the abrasive nature of the metal fastener often wears away the paint or corrosion-resistant coating of the primary panel (e.g., a sheet metal frame of a vehicle), thereby increasing the degree of corrosion. Additionally, metal fasteners have a tendency to emit a buzzing, squeaking, and rattling sound, a condition often referred to as “BSR.”

[0005] To mitigate BSR and prevent corrosion, plastic fasteners can be used as an alternative to metal fasteners. However, such plastic fasteners can increase the distance between the panels and sometimes require a suitably high insertion force. In some examples, fasteners are manufactured using a combination of metal and plastic components to mitigate abrasion and avoid BSR. However, such fasteners are often larger and can be more difficult to manufacture. Further, while fasteners come in many sizes and performance levels, many fastener types cannot utilize blade structure blind assembly for a parts-in-assembly (PIA) strategy.

[0006] Accordingly, it would be highly desirable to have a fastener assembly with improved assembly characteristics that provides reliable and secure fastening while allowing panels to be positioned very closely to one another. SUMMARY

[0007] The present disclosure relates generally to a fastening system for forming a blind- vision connection between panels, such as automotive panels, substantially as shown and described with respect to at least one of the accompanying drawings, and as more fully set forth in the claims. BRIEF DESCRIPTION OF DRAWINGS

[0008] The foregoing and other objects, features and advantages of the apparatus, systems, and methods described herein will be apparent from the following description of particular examples, as illustrated in the accompanying drawings; wherein like or similar reference numbers refer to like or similar structures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the apparatus, systems, and methods described herein.

[0009] Figure 1 a FIG. 1d illustrates a side view of exemplary fastening systems configured to form a blind- vision connection between panels, in accordance with aspects of the present disclosure.

[0010] Figure 2a A perspective assembly view of the convex-hood based through fastening system of FIG. 1d is illustrated, in accordance with aspects of the present disclosure.

[0011] Figure 2b And Figure 2c Partial assembly and fully assembled perspective views of the convex-hood based through fastening system of Figure 2a are illustrated, in accordance with aspects of the present disclosure.

[0012] Figures 3a to 3d A push-on fastener, pin and grommet (P&G) fastener, box-prong fastener, and a proprietary fastener for use with the convex-hood based through fastening system are illustrated, in accordance with aspects of the present disclosure.

[0013] Figure 4a And Figure 4b An exemplary convex-hood based through fastening system configured with ribs is illustrated, in accordance with aspects of the present disclosure.

[0014] Figure 5a And Figure 5b An exemplary convex-hood based through fastening system configured with ribs and wings is illustrated, in accordance with aspects of the present disclosure.

[0015] Figures 6a to 6d An exemplary convex-hood based through fastening system configured in accordance with another aspect of the present disclosure is illustrated.

[0016] Figure 7 is a flowchart representing an example of a method of coupling a first panel to a second panel using the fastener of Figures 2a to 2c .

[0017] Figure 8a and Figure 8b illustrates a perspective view and a bottom view, respectively, of a fastener having a sealing assembly according to aspects of the present disclosure.

[0018] Figure 8c illustrates Figure 8a a side view of a fastener of

[0019] Figures 9a to 9f illustrates a perspective assembly view of a mushroom-based pass-through fastening system having a sealing assembly during assembly according to aspects of the present disclosure.

[0020] Figure 10 is a flowchart representing an example of a method of coupling a first panel to a second panel using a fastener having a sealing assembly of Figures 8a to 8c

[0021] Figure 11 is a flowchart representing an example of a method of manufacturing a fastening system having a fastener and a sealing assembly. DETAILED DESCRIPTION

[0022] References to singular items shall include the plural unless otherwise stated or clear from the context. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Unless otherwise indicated herein, recitations of values for ranges of values herein are not intended to be limiting, but rather individually refer to any and all values falling within the range and / or comprising the range, and each individual value within such ranges is incorporated in the specification as if it were recited individually herein. In the following description, it is to be understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” and the like are words of description used for convenience and are not to be construed as limiting terms. For example, although in some examples a first side is positioned adjacent or proximate to a second side, the terms “first side” and “second side” do not imply any particular order in which these sides occur in sequence.

[0023] ​The terms “about,” “approximately,” “substantially” and the like, when used in connection with a numerical value, should be interpreted as indicating a deviation of less than the number that one of ordinary skill in the art would understand as a satisfactory result for the intended purpose. Values and / or ranges of values should be provided herein as examples only and should not be construed as limiting the scope of the disclosure. The use of any and all examples, or exemplary language (e.g., “such as,” “for instance,” “like,” etc.), provided herein is intended merely to better illuminate examples of the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. The terms “consisting of’ and “consisting essentially of’ shall have their plain and ordinary meaning to a person of ordinary skill in the art. Any language in the specification claiming priority to any patent document is meant to use the language found in the patent document to interpret the claims.

[0024] The term “and / or” means any one or more of the items in the list of which “and / or” is used in conjunction. For example, “x and / or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and / or y” means “one or both of x and y”. As another example, “x, y, and / or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y, and / or z” means “one or more of x, y and z”.

[0025] A fastener can be used to form a blind vision connection between a first panel and a second panel, such as an automotive panel. In one example, a fastening system for forming a sealed blind vision connection between a first panel and a second panel includes a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener includes a head assembly configured to engage a boss structure positioned on the first panel, and a seal assembly having a seal and a seal carrier, wherein the seal carrier is coupled to the fastener via a temporary connection. In some examples, the temporary connection is an adhesive, a frangible connection, and / or a mechanical coupling. In some examples, the fastener and the seal carrier are manufactured as a single component. The fastener and the seal carrier can be manufactured via a plastic injection process. For example, the temporary connection can be a flash-gate formed during the plastic injection process. In some examples, the seal carrier is a rigid plastic structure and the seal is overmolded onto the seal carrier. In some examples, the seal carrier is configured to transition from an initial position to a deployed position by breaking the temporary connection. The seal carrier can be configured to engage a feature of the fastener to secure the seal carrier in the deployed position. The seal carrier can be configured to enclose the boss structure when in the deployed position. In some examples, the boss structure is configured to at least partially pass through the opening.

[0026] In another example, a method of forming a blind vision connection between a first panel and a second panel via a boss structure and a fastener having a head assembly and a sealing assembly includes sliding the head assembly across a surface of the first panel into a cavity of the boss structure, sliding the sealing assembly from an initial position to a deployed position, wherein the sealing assembly includes a seal and a seal carrier, and passing a portion of the fastener through an opening formed in the second panel. In some examples, the initial position is at or near a neck ring of the fastener and the deployed position is at or near the head assembly. In some examples, the seal carrier is coupled to the fastener via a temporary connection at the initial position. In some examples, the temporary connection is a flash gate formed during a plastic injection process.

[0027] In yet another example, a method of manufacturing a fastening system includes forming a fastener via a plastic injection process, wherein the fastener defines a head assembly, a neck, and a seal carrier, wherein the seal carrier is coupled to the neck by a temporary connection, and overmolding a seal onto the seal carrier. In some examples, the temporary connection is a flash gate formed during the plastic injection process. In some examples, the seal carrier is coupled to the neck via a neck ring. In some examples, the seal carrier is configured to detach from the neck via the temporary connection and deploy to the head assembly.

[0028] Figure 1 a To FIG. Id illustrates a side view of an example fastening system 100a, 100b, 100c, 100d configured to form a blind vision connection between a first panel 102 and a second panel 104. The first panel 102 and the second panel 104 can be, for example, automotive panels. Depending on the application, the first panel 102 and the second panel 104 can be made of, for example, metal (or metal alloy), synthetic or semi-synthetic polymer (e.g., plastic, such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC), etc.), composite material (e.g., fiberglass), or a combination thereof. In one example, the first panel 102 is an automotive sub-panel and the second panel 104 is an automotive main panel. In the automotive industry, example first panels 102 include, but are not limited to, door trim panels, moldings, trim pieces, and other substrates (whether used as an interior or exterior surface).

[0029] The first panel 102 can define an A-surface 102a and a B-surface 102b (illustrated as a lower surface). The A-surface 102a (also referred to as a Class A surface) is generally a surface that is visible after assembly and is therefore more aesthetically pleasing (e.g., textured, coated, or otherwise decorated) and typically free of attachment devices and / or related features. In contrast, the B-surface 102b (also referred to as a Class B surface) is generally a surface that is not visible after assembly and typically includes various attachment devices and / or related features.

[0030] The first panel 102 can include, define, or otherwise be associated with attachment devices and / or related features such as one or more tower portions 108, doghouse structures 106, etc. Depending on the material type, the attachment devices and / or related features can be formed on the B-surface 102b during molding or co-laying of the first panel 102, or attached after manufacture (e.g., using adhesives or mechanical fasteners). After assembly, the second panel 104 is at least partially obscured by the first panel 102. The second panel 104 can be, for example, a structural component of a vehicle such as a door, a pillar (e.g., A-pillar, B-pillar, C-pillar, etc.), an instrument panel component (e.g., a cross-car beam member, a bracket, a frame, etc.), a seat frame, a center console, a fender, a sheet metal frame, etc.

[0031] Figure 1 a A clip-based fastening system 100a configured to couple the first panel 102 to the second panel 104 is illustrated. As illustrated, the first panel 102 can include one or more tower portions 108 protruding from the B-surface 102b. Each tower portion 108 (sometimes referred to as a dog or a protrusion) can be shaped, for example, as a blade or a flat tab. To form a blind vision connection between the first panel 102 and the second panel 104, a fastener 112 and a tower portion 108 are inserted into an opening 110 formed in or on a surface of the second panel 104. In some examples, the fastener 112 can be pre-attached to the tower portion 108 or the opening 110 to define a parts-in-assembly (PIA). The tower portion 108 of the first panel 102 is inserted into a channel formed by the fastener 112 to effectively lock the fastener 112 in place within the opening 110, thereby securing the first panel 102 and the second panel 104 to one another. The clip-based fastening system 100a has no rib set variables and allows for a relatively tight post-assembly distance (D1) between the first panel 102 and the second panel 104. The clip-based fastening system 100a provides a blind vision PIA solution that tightly positions the second panel 104 to the first panel 102 because the tower portion 108 can pass through the opening 110 in the second panel 104 to the B-side. Both the length of the fastener 112 and the length of the tower portion 108 determine the protrusion distance (P1) on the B-side.

[0032] Figure 1 bA second fastening system 100c based on a boss is shown configured to couple the first panel 102 to the second panel 104. As shown, the first panel 102 can include one or more boss structures 106 protruding from the B surface 102b. The boss structures 106 allow the first panel 102 to be used with various fasteners 112, such as W-style fasteners, push-on fasteners, etc. For example, various different fasteners 112 can be designed to have a common head assembly that is sized and shaped to engage with the boss structures 106, thereby enabling interchangeability of the fasteners 112.

[0033] The fasteners 112 are coupled to the boss structures 106 and are configured to at least partially pass through the openings 110 and engage the second panel 104. As shown, the boss structures 106 increase the assembled distance (D3) between the first panel 102 and the second panel 104. Accordingly, the second fastening system 100c based on a boss can introduce a barrier to achieve flush panel, blind vision PIA fastening, as the boss structures 106 occupy space between the first panel 102 and the second panel 104. As shown, the protrusion distance (P3) from the B side of the second panel 104 is dictated by the length of the fasteners 112. Accordingly, shorter fasteners 112 can be employed to reduce the protrusion distance (P3).

[0034] FIG. 1c shows a second fastening system 100c based on a boss configured to couple the first panel 102 to the second panel 104. As explained in connection with Figure 1 b the boss structures 106 can result in a greater assembled distance (D3). To reduce the assembled distance, the second panel 104 can be shaped to have a recessed panel 114 to accommodate the boss structures 106. By using the recessed panel 114 and the boss structures 106, the first panel 102 and the second panel 104 can be positioned much closer together to achieve a smaller assembled distance (D3). However, the recessed panel 114 must be large enough to accommodate the boss structures 106. In some cases, a large recessed panel 114 can negatively impact the overall assembly performance and / or appearance of the second panel 104. Further, the recessed panel 114 increases the protrusion distance (P3) from the B side of the second panel 104, thereby reducing the available space on the B side of the second panel 104.

[0035] FIG. Id illustrates a convex-hood based through fastening system 100d configured to couple a first panel 102 to a second panel 104 while minimizing an assembled distance (D4) between the first panel 102 and the second panel 104 and a protrusion distance (P4) from the B side of the second panel 104. The convex-hood based through fastening system 100d uses a smaller convex-hood structure 106 configured to at least partially pass through an opening 110 in the second panel 104 to achieve a small assembled distance (D4) comparable to the assembled distance (D3) of FIG. Ic without the need for a concave panel 114.

[0036] Figures 2a to 2c An exemplary convex-hood based through fastening system 100d is illustrated. Specifically, Figure 2a A perspective assembled view of the exemplary convex-hood based through fastening system 100d of FIG. Id is illustrated in FIG. Ie, while Figure 2b and Figure 2c perspective views of a partially assembled and a fully assembled, respectively, are illustrated in FIGS. If and Ig.

[0037] While blind vision connections will be primarily described, it should be understood that the present fastening system can be adapted for use with structures other than the illustrated first panel 102 and second panel 104 that do not require the blind vision connections. Thus, the present fastening system is not limited to blind vision connections. Further, while only a single convex-hood structure 106 and a single opening 110 are illustrated in the example, it should be understood that a given first panel 102 can include multiple convex-hood structures 106 and a second panel 104 can include multiple openings 110 depending on the number of fastener points to be used between the first panel 102 and the second panel 104. In use, a head assembly 210 is slid into the convex-hood structure 106 as illustrated by a first arrow 202 to form a PIA. Once in place, a fastener 112 can be inserted into the opening 110 of the second panel 104 as illustrated by a second arrow 204.

[0038] The fastener 112 generally includes a head assembly 210, a neck 212, a neck ring 214, and one or more retention features 216. The head assembly 210 is configured to engage the boss structure 106 of the first panel 102. The neck 212, which couples the head assembly 210 to the neck ring 214, is generally narrower than the head assembly 210 and the neck ring 214. The neck ring 214 is configured to enter and engage (or otherwise retain) the second panel 104 via, for example, the opening 110. As can be appreciated, a portion of the neck 212 can also pass through the opening 110. The neck ring 214 can be secured within the opening 110 via one or more retention features 216, which can be outwardly biased legs coupled to the neck ring 214. In some examples, the neck ring 214 can be omitted, in which case the retention features 216 can be directly coupled to the neck 212. The retention features 216 can include a return arm 216a that is resiliently connected to the neck ring 214, which deflects when an end of the fastener 112 is inserted into the opening 110 of the second panel 104. A catch structure 216b (e.g., a tab, a lip, etc.) can be coupled to a distal end of the return arm 216a to engage the second panel 104 (e.g., at a perimeter of the opening 110). The retention features 216 are relatively rigid to outward forces, and thus, once the neck ring 214 (or neck 212) has passed through the opening 110, the retention features lock the neck ring (or neck) in place within the second panel 104. Additionally, the fastener 112 can be configured to engage one or more features of the second panel 104.

[0039] The fastener 112 can be manufactured in various sizes depending on the application. The fastener 112 illustrated can be described as a “W-type” fastener, as it generally resembles a “W” when viewed from the side, as Figure 1 b illustrated in FIG. Id. The W-type fastener provides an introduction feature for finding the opening 110. While the fastener 112 is generally described and illustrated as a W-type fastener, as will be discussed in connection with Figures 3a to 3d the various embodiments, the fastener 112 can take on other types of fasteners for use with the boss-based pass-through fastening system 100d.

[0040] The opening 110 can be generally rectangular and define dimensions and a shape that are complementary to the dimensions and shape of the fastener 112, such that the fastener 112 can be inserted and retained in the opening. However, other shaped openings 110 are also contemplated. Thus, the opening 110 can be rectangular, a rounded rectangular (e.g., a stadium shape), circular Figure 6a (see FIG. 6d), oval, or any other suitable shape.

[0041] As shown, the second panel 104 is sized and shaped to define at the boss structure 106. The boss structure 106 serves as a receptacle for the head assembly 210 of the fastener 112. It is desirable to insert the head assembly 210 of the fastener 112 into the cavity 218 and retain it therein. As shown, the boss structure 106 is comprised of a set of boss sidewalls 220 that define the cavity 218 therebetween. The boss sidewalls 220 can include one or more features shaped to enhance engagement with the head assembly 210, such as interference features 222. In some examples, the interference features 222 can exhibit a soft click when the fastener 112 is secured in the cavity 218. The boss structure 106 provides a clear path from one or more insertion openings to the cavity 218. In the example shown, the fastener 112 is able to slide from one of two insertion openings into the cavity 218 of the boss structure 106. For example, the fastener 112 would be able to slide as shown by arrow 202 or in the opposite direction. It is contemplated that the boss structure 106 can be molded during molding of the first panel 102; however, in some examples, they can be manufactured separately and joined to one another (e.g., using an adhesive, mechanical fasteners, etc.).

[0042] It is contemplated that the boss structure 106 is modified in size and shape to suit various applications. For example, while two opposing boss sidewalls 220 are shown, in some examples, the boss structure 106 can further include a boss end wall formed to bridge the gap between the set of boss sidewalls 220, thereby walling off three of the four sides of the cavity 218. In this example, the fastener 112 would only be able to slide from a single insertion opening into the cavity 218 of the boss structure 106, but movement would be restricted at three sides.

[0043] As will become apparent, it is sometimes useful to assemble the first and second panels 102, 104 by first inserting the fastener 112 into the boss structure 106 of the first panel 102 (as shown by the first arrow 202) to form a PIA and subsequently inserting the fastener 112 of the PIA into the opening 110 of the second panel 104 (as shown by the second arrow 204). In some examples, to assemble the boss-based through fastening system 100d, the head assembly 210 of the fastener 112 is slid laterally over the surface of the first panel 102 and into the cavity 218 until the fastener 112 stops (e.g., against a wall) or otherwise aligns between the boss sidewalls 220. In some examples, the fastener 112 is held in place by the interference features 222, which can exhibit a soft click when the fastener 112 is secured in the cavity 218. The fastener 112, now a PIA component assembled with the first panel 102, Figure 2b), can be shipped to a customer (e.g., original equipment manufacturer (OEM)). The OEM can then assemble the PIA component with a second panel (e.g., a vehicle panel) via all of the fasteners 112 coupled to the second panel, as shown in Figure 2c

[0044] The boss structure 106 can position the head assembly 210 of the fastener 112 in a fixed manner, or, if desired, provide the fastener 112 with a certain linear degree of freedom (e.g., float) to move within the cavity 218. While a smaller boss can limit the positional float of the head assembly 210 within the cavity 218, positional freedom requirements can be achieved through the opening 110. Thus, the boss-based pass-through fastening system 100d enables the boss structure 106 to directly interact with the opening 110 to allow the fastener 112 (such as a W-style fastener) to be part of a reference or positioning solution.

[0045] The opening 110 can be sized to provide a desired amount of longitudinal motion 208a and / or lateral motion 208b. In some examples, the boss-based pass-through fastening system 100d can be configured to accommodate bi-directional assembly tolerances or float (e.g., due to thermal growth) in the longitudinal direction (length) of the opening 110. The tolerance in the longitudinal direction can be, for example, about ±1 mm to ±5 mm or about ±3 mm. In other examples, a quad-directional version of the boss-based pass-through fastening system 100d is contemplated, with tolerances in the lateral direction (width) as well as the longitudinal direction. The tolerance in the longitudinal direction can be, for example, about ±1 mm to ±3 mm or about ±1 mm. In some examples, the lateral direction tolerance is less than the longitudinal direction tolerance, resulting in an asymmetric tolerance or float solution (e.g., the longitudinal direction tolerance can be ±3 mm, while the lateral direction tolerance can be ±1 mm). For example, as most clearly shown in Figure 2c The opening 110 can be elongated along its longitudinal axis to define a motion gap 206 that allows for longitudinal motion 208a, as most clearly shown in

[0046] It will be appreciated by those skilled in the art that the principles of the boss-based pass-through fastening system 100d can be used with various types of fasteners 112, provided that the head assembly 210 is configured to engage the boss structure 106.

[0047] ​The ends of the fastener 112 (e.g., neck 212 and / or collar 214) can be shaped into any desired type of fastener 112. Figures 3a to 3d The following fasteners are shown: push-to-open fastener 112a, pin and grommets (P&G) fastener 112b, box-fork fastener 112c, and special fastener 112d (e.g., available from...). Centerlok obtained TM Fasteners). Figure 3a The push-button fastener 112a shown (sometimes called tree, pine, Christmas tree, etc.) includes multiple barbs or teeth along its length. See reference. Figure 3b P&G fastener 112b is a reusable two-piece fastener with a low insertion value. P&G fastener 112b can be a single-position fastener or a multi-position fastener. Each of the aforementioned fasteners may include a head assembly 210 configured to engage the hood structure 106 and, instead of a W-type fastener, be used to secure components and panels very tightly to each other while still using the hood structure 106. In some examples, such as Figure 3c The illustrated through-hole fastening system 100d based on a hood may include a seal 302 positioned between the first panel 102 and the second panel 104. For example, the seal 302 may be used to mitigate leakage of dust, dirt, and / or moisture through the opening 110. The seal 302 may be implemented as a ring (e.g., annulus) and made of foam material, thermoplastic, rubber, etc. For example, as illustrated, the seal 302 may be configured to surround the hood structure 106 between the first panel 102 and the second panel 104. In some examples, the through-hole fastening system 100d based on a hood may include additional features such as ribs and wings.

[0048] Figure 4a and Figure 4b An exemplary through-type fastening system 100d based on a hood is shown, configured with ribs 402. When assembled, the ribs 402 are positioned between the first panel 102 and the second panel 104 at the interface between the hood structure 106 and the first panel 102. The ribs 402 act as support walls to reinforce and support the hood structure 106 (e.g., hood sidewall 220), while also controlling overtravel when desired or required. Thus, in some examples, the fastener 112 includes one or more ribs 402 configured to support the hood structure 106 and control overtravel.

[0049] Figure 5a and Figure 5bAn example mushroom-based through fastening system 100d configured with ribs 402 and wings 502 is shown. The wings 502 (which can be flexible) help control over travel and mitigate BSR. When assembled, the ribs 402 and wings 502 are positioned between the first panel 102 and the second panel 104. As shown, the wings 502 are coupled to the head assembly 210 (e.g., near the retention feature 216) and are biased to push against the second panel 104 when assembled, effectively acting as a spring between the first panel 102 and the second panel 104 to absorb motion between the first panel and the second panel.

[0050] While the mushroom structure 106 is shown as generally rectangular, other shapes are also contemplated, including other quadrilaterals (e.g., squares) and rounded shapes (e.g., circles and ovals). For example, Figures 6a to 6d An example mushroom-based through fastening system having a generally circular mushroom structure 602 and fastener 112 (also shown as a W-style fastener) is shown. Like the mushroom-based through fastening system of Figures 2a to 2c The mushroom structure 602 includes a set of mushroom sidewalls 220; however, the mushroom sidewalls 220 are shaped to define a generally circular outer perimeter.

[0051] Figure 7 is a flowchart representing an example method 700 of coupling a first panel 102 to a second panel 104 using a mushroom-based through fastening system having a mushroom structure 106 and a fastener 112. The fastener 112 has a head assembly 210 and a neck 212. At step 702, the head assembly 210 is slid across a surface of the first panel 102 into the cavity 218 of the mushroom structure 106. At step 704, at least a portion of the neck 212 and / or the neck ring 214 is passed through the opening 110 formed in the second panel 104. The neck 212 and / or the neck ring 214 are configured to engage the second panel 104 via the retention feature 216. In some examples, the retention feature 216 includes a return arm 216a that is resiliently connected to the neck ring 214, the return arm being coupled to the neck ring 214 and configured to deflect when the neck ring 214 is passed through the opening 110. As mentioned above, in some examples, the retention feature 216 is coupled to the neck 212 and the neck ring 214 is omitted. At step 706, at least a portion of the mushroom structure 106 is passed through the opening 110.

[0052] As noted above, it is sometimes advantageous to seal the fastener, thereby preventing dirt, dust, and / or liquids from passing through the second panel 104 (e.g., via the opening 110). If sealing is desired or expected, the seal can be added in one of a variety of different ways. In some examples, the seal can be pre-installed on the fastener 112 and / or molded integrally with the fastener, which allows the overmolded seal to be integrally molded to the fastener 112 and delivered to the customer as a PIA.

[0053] Figures 8a to 8c An example convex-hood based pass-through fastening system 100d is shown configured with a sealing assembly 800. Specifically, Figure 8a and Figure 8b A perspective view and a bottom view of a fastener 112 having a sealing assembly 800 are shown, respectively, while Figure 8c A side view of a fastener 112 having a sealing assembly 800 is shown, assembled with a first panel 102 and a second panel 104. To better show the arrangement of the seal 802, Figure 8c the right portion of which is shown as a cross-sectional view.

[0054] The sealing assembly 800 generally includes a seal 802 and a seal carrier 804. The seal carrier 804 is connected to the fastener 112 by a transitory connection 806. In some examples, the fastener 112 is molded as a single component, with the seal carrier 804 connected to the fastener 112 by the transitory connection 806. In other examples, the fastener 112 and the seal carrier 804 are manufactured separately and connected by the transitory connection 806. The seal carrier 804 is configured to transition from an initial position to a deployed position by breaking the transitory connection 806.

[0055] In one example, the seal carrier 804 is connected to the fastener 112 by the transitory connection 806 at the neck ring 214. In another example, the seal carrier 804 is connected to the fastener 112 by the transitory connection 806 at the neck 212. The transitory connection 806 can be one or more of, for example, a frangible connection (e.g., a thin, breakable feature such as a tether and a flash gate), a mechanical coupling (e.g., a clasp, a clip, etc.), an adhesive, or any other suitable connection or coupling mechanism. As shown, the sealing assembly 800 is sized to surround the convex-hood structure 106 when assembled between the first panel 102 and the second panel 104.

[0056] The seal 802 can be made of a foam material, a thermoplastic, a rubber, or the like. Exemplary thermoplastics include polyethylene (PE), polyvinyl chloride (PVC), and the like, among others. In some examples, the seal 802 is overmolded onto the seal carrier 804 to form the seal assembly 800. Thus, in some examples, in which the seal carrier 804 is a rigid plastic structure, and the seal 802 is overmolded onto the seal carrier 804. The seal carrier 804 can be configured to engage the fastener 112 or the boss structure 106 and / or be sandwiched therebetween. Referring to Figure 8a The fastener 112 can be provided with the seal 802 and the seal carrier 804 positioned in a temporary position (e.g., at or near the neck ring 214, or at or near the end of the neck 212 opposite the head assembly 210). Once the fastener 112 is inserted into the boss structure 106, the seal 802 and the seal carrier 804 can slide over the fastener 112, thereby breaking the temporary connection 806, and slide toward the head assembly 210 (e.g., toward the boss structure 106), as indicated by the arrow 808. Once the seal assembly 800 is in place, the fastener 112 can be inserted through the opening 110 of the second panel 104, after which the seal 802 and the seal carrier 804 are sandwiched between the first panel 102 and the second panel 104 to seal the opening 110.

[0057] Figures 9a to 9f A perspective assembly view of a boss-based pass-through fastening system assembled with a seal assembly during assembly is illustrated in accordance with aspects of the present disclosure. Figure 9a A fastener 112 is illustrated, in which a seal assembly 800 is coupled to the fastener via a temporary connection 806. As Figure 9b and Figure 9c illustrated, the head assembly 210 of the fastener 112 is slid laterally across the surface of the first panel 102 into the cavity 218 until the fastener 112 stops (e.g., against a wall) or is otherwise aligned between the boss sidewalls 220. The first panel 102 and the second panel 104 can be planar or curved. For example, the first panel 102 can be shaped to define a first surface profile, while the second panel 104 can be shaped to define a second surface profile that is complementary or otherwise corresponds to the first surface profile.

[0058] A force is used to separate the seal assembly 800 from its temporary initial position on the fastener 112. The force breaks or otherwise separates the temporary connection 806, such that the seal assembly 800 is independent of the fastener 112. The force can be applied by hand, by using a tool, by pressing the second panel 104 against the seal assembly 800, or by any other suitable manner.

[0059] Referring to Figure 9d , the sealing assembly 800 is pushed onto the fastener 112 and into its final deployed position (e.g., around the boss structure 106). In some examples, the fastener 112 or the boss structure 106 can be designed to secure the sealing assembly 800 in its deployed position using, for example, a clip, a snap, a press fit, etc. The fastener 112 (now a PIA component 900 assembled with the first panel 102 and the sealing assembly 800) can be shipped to a customer (e.g., an OEM). The OEM can then assemble the PIA component 900 with a second panel (e.g., a vehicle panel) via all of the fasteners 112 coupled to the second panel, as Figure 9e and Figure 9f illustrate.

[0060] As can be appreciated, Figures 9a to 9f the assembly steps illustrated in Figures 9a to 9d may be performed by one or more entities. In some examples, as most clearly illustrated in Figure 9e , the sealing assembly 800 can be installed to the fastener 112 and the boss structure 106 as a PIA (e.g., by a certain level of supplier) prior to shipping to the customer (e.g., the OEM). In this case, the customer can then install the PIA to the second panel 104, as Figure 9c and Fig. 9f most clearly illustrate. In some examples, the sealing assembly 800 can remain in the position shown in Figure 9d and subsequently installed by using the force applied by the second panel 104 during final assembly (e.g., effectively omitting the step illustrated in Figure 9d ). However, there is a risk that the sealing assembly 800 gets knocked off the fastener 112 or the fastener 112 falls off the boss structure 106 during shipping to the customer. Therefore, as illustrated in , it can be advantageous to install the sealing assembly 800 after the fastener 112 is disposed in the boss structure 106 prior to moving to the next assembly step. This would also enable the operator to confirm that the sealing assembly 800 is properly seated. Further, with the sealing assembly 800 protected by the fastener 112 and the boss structure 106, there is much less chance of the sealing assembly being dislodged prior to final assembly.

[0061] Figure 10is a flowchart representing an exemplary method 1000 of forming a blind view connection between a first panel 102 and a second panel 104 via a boss structure 106 and a fastener 112 having a head assembly 210 and a seal assembly 800. At step 1002, the head assembly 210 is slid across a surface of the first panel 102 into a cavity 218 of the boss structure 106. At step 1004, the seal assembly 800 is slid or otherwise transitioned from an initial position to a deployed position. The seal assembly 800 includes a seal 802 and a seal carrier 804. In some examples, the initial position is at or near a neck ring 214 of the fastener 112 and the deployed position is at or near the head assembly 210. In some examples, the seal 802 is overmolded onto the seal carrier 804. The seal carrier 804 can be coupled to the fastener 112 via a temporary connection 806 at the initial position. For example, the temporary connection 806 is a flash gate formed during a plastic injection process. At step 1006, a portion of the fastener 112 (e.g., the neck 212, the neck ring 214, or a portion thereof) passes through an opening 110 formed in the second panel 104.

[0062] Figure 11 is a flowchart representing an exemplary method 1100 of manufacturing a fastening system. At step 1102, a fastener 112 is formed via a plastic injection process, wherein the fastener 112 defines a head assembly 210, a neck 212, and a seal carrier 804. The seal carrier 804 is coupled to the neck 212 by a temporary connection 806. For example, the temporary connection 806 is a flash gate formed during the plastic injection process. In some examples, the seal carrier 804 is coupled to the neck 212 directly or via a neck ring 214. The seal carrier 804 is configured to be separated from the neck 212 or the neck ring 214 via the temporary connection 806 and deployed to the head assembly 210. At step 1104, a seal 802 is overmolded onto the seal carrier 804.

[0063] While the present method and / or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the present method and / or system. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, the block diagrams and / or components of disclosed examples can be combined, divided, re arranged, and / or otherwise modified. Therefore, the present method and / or system are not limited to the particular implementations disclosed. Instead, the present method and / or system will include all implementations that fall within the scope of the appended claims, both literally and under the doctrine of equivalents.

Claims

1. A fastening system for forming a sealed, blind-visibility joint between a first panel and a second panel, the fastening system comprising: a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener includes a head assembly configured to engage a male cap structure positioned on the first panel; and a seal assembly having a seal and a seal carrier, wherein the seal carrier is coupled to the fastener via a temporary connection, and wherein the seal carrier is configured to transition from an initial position to a deployed position by breaking the temporary connection, such that the seal carrier encloses at least a portion of the head assembly when in the deployed position.

2. The fastening system of claim 1, wherein, The temporary connection is an adhesive.

3. The fastening system of claim 1, wherein, The temporary connection is a frangible connection.

4. The fastening system of claim 1, wherein, The temporary connection is a mechanical coupling.

5. The fastening system of claim 1, wherein, The fastener and the seal carrier are manufactured as a single component.

6. The fastening system of claim 5, wherein, The fastener and the seal carrier are manufactured via a plastic injection process.

7. The fastening system of claim 6, wherein, The temporary connection is a flash gate formed during the plastic injection process.

8. The fastening system of claim 1, wherein, The seal carrier is a rigid plastic structure and the seal is overmolded onto the seal carrier.

9. The fastening system of claim 1, wherein, The seal carrier is configured to engage a feature of the fastener to secure the seal carrier in the deployed position.

10. The fastening system of claim 1, wherein, The seal carrier is configured to enclose at least a portion of the male cap structure when in the deployed position.

11. The fastening system of claim 1, wherein, The male cap structure is configured to at least partially pass through the opening.

12. The fastening system of claim 1, wherein, The seal includes at least one of a foam material, a thermoplastic, or a rubber material, or wherein the seal carrier is configured to engage a feature of the male cap structure to secure the seal carrier in the deployed position.

13. A fastening system for forming a sealed, blind-visibility joint between a first panel and a second panel, the fastening system comprising: a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener includes a head assembly configured to engage the first panel; and a seal assembly having a seal carrier and a seal formed on the seal carrier, wherein the seal carrier is configured to transition from an initial position to a deployed position by breaking a frangible connection between the fastener and the seal carrier, and wherein the seal carrier is configured to enclose at least a portion of the head assembly when in the deployed position.

14. The fastening system of claim 13, wherein, The seal assembly is generally rectangular.

15. The fastening system of claim 13, wherein, The seal carrier is a rigid plastic structure and the seal is overmolded onto the seal carrier.

16. A fastening system for forming a sealed, blind-visibility joint between a first panel and a second panel, the fastening system comprising: a male cap structure positioned on the first panel; a fastener configured to retain the second panel via an opening formed in the second panel, wherein the fastener includes a head assembly configured to engage the male cap structure; and a seal assembly having a seal and a seal carrier, wherein the seal carrier is coupled to the fastener via a temporary connection, and wherein the seal carrier is configured to transition from an initial position to a deployed position by breaking the temporary connection, such that the seal carrier encloses at least a portion of the head assembly when in the deployed position. a seal assembly having a seal carrier and a seal formed on the seal carrier, wherein the seal carrier is configured to transition from an initial position to a deployed position by breaking a temporary connection between the fastener and the seal carrier, and wherein the seal carrier is configured to enclose at least a portion of the boss structure when in the deployed position.

17. The fastening system of claim 16, wherein, the boss structure is generally rectangular and configured to laterally receive the head assembly, or wherein the seal carrier is configured to engage a feature of the boss structure to secure the seal carrier in the deployed position.

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