Fasteners for use with ultraviolet light sensitive adhesives

Abstract

The invention discloses a fastener for use with an ultraviolet light sensitive adhesive. The fastener is configured to attach to the panel and support an article. The fastener has a body constructed from a first material, and wherein the body has an opening extending into the body at a first end. A flange constructed from a second material is connected to the body and is dimensioned to extend laterally outward beyond the body. The first material has a higher melting point than the second material. The first material has a lower UV light transmittance than the second material.

Description

Technical Field

[0001] The present disclosure relates generally to the field of fasteners, and more particularly to fasteners including a body and a flange constructed of different materials and configured for use with a UV adhesive. Background Art

[0002] Traditionally, items are attached to panels inside a vehicle using potted fasteners. The fastener is placed into a hole in the panel and then the potting (i.e., adhesive) is injected. Once secured, the item can be attached to the fastener to secure the item to the panel. Potted fasteners typically have an internal thread feature and provide a simple and strong way to attach an item to a panel. However, existing potted inserts have various disadvantages.

[0003] Attempts to automate the installation process have proven difficult and expensive. Therefore, in most applications, potted fasteners are installed manually. Manual installation requires a technician to insert each fastener into the panel individually. One problem with manual installation is inconsistent installation. This can result in fasteners that do not meet quality specifications.

[0004] Another problem with existing fasteners is the relatively long time required for the adhesive to cure. In some examples, the potting cure time is four hours, which significantly increases the overall cycle time for the installation. Summary of the invention

[0005] One aspect relates to a fastener configured to attach to a panel and support an article. The fastener includes a body constructed of a first material, and wherein the body includes an opening extending into the body at a first end. A flange constructed of a second material is connected to the body and is sized to extend laterally outward beyond the body. The first material includes a higher melting point than the second material. The first material includes a lower UV light transmittance than the second material.

[0006] In another aspect, the flange is connected to the second end of the body and is spaced apart from the first end of the body.

[0007] In another aspect, the first material comprises a higher strength than the second material.

[0008] In another aspect, the flange includes a central opening and the body is positioned within the central opening.

[0009] In another aspect, an insert is positioned within the opening of the body at a first end, wherein the insert is constructed of a third material different than the first material and the second material.

[0010] In another aspect, the body includes grooves on opposite sides of the opening to crimp the insert.

[0011] In another aspect, the body includes a main section including a first end and a lip positioned at a second end, wherein the lip includes a greater width than the main section.

[0012] In another aspect, the opening in the body extends completely through the body.

[0013] In another aspect, the flange is substantially translucent to accommodate transmission of UV light, and the body is opaque.

[0014] One aspect relates to a fastener configured to attach to a panel and support an article. The fastener includes a body including a first end, a second end, and an opening extending from the first end through the body to the second end. A flange is positioned at the second end of the body and includes a greater width than the body, wherein the flange extends laterally outward beyond the body. The body has a higher melting point and lower UV light transmittance than the flange.

[0015] In another aspect, the flange is translucent and the body is opaque.

[0016] In another aspect, the body comprises a cylindrical shape and the flange comprises a disc shape.

[0017] In another aspect, the flange extends completely around the body.

[0018] In another aspect, the flange includes a central opening, and the second end of the body is positioned within the central opening.

[0019] In another aspect, an insert is positioned within the opening of the body, wherein the insert is constructed of a different material than each of the body and the flange.

[0020] In another aspect, the body includes a main section extending inwardly from a first end, wherein the main section has a first width, and a lip positioned at a second end, wherein the lip has a second width greater than the first width.

[0021] One aspect relates to a method of attaching a fastener to a panel. The method includes positioning an opaque body of the fastener into an opening in the panel, wherein a first end of the body is on a first side of the panel and a second end of the body is on an opposite second side of the panel; positioning a translucent flange across the opening at a second side of the panel, wherein the translucent flange is connected to the second end of the opaque body; positioning an adhesive between the translucent flange and the second side of the panel; and securing the fastener to the panel by passing UV light through the translucent flange and to the adhesive and curing the adhesive.

[0022] In another aspect, the method further includes applying an adhesive to the translucent flange prior to positioning the translucent flange across the second side of the panel.

[0023] In another aspect, the method further includes aligning the first end of the opaque body with the first side of the panel.

[0024] In another aspect, the method further includes applying adhesive only to the translucent flange and not to the opaque body.

[0025] The features, functions, and advantages that have been discussed may be achieved independently in various aspects or may be combined in yet other aspects, further details of which may be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1A is a schematic diagram of a fastener having a body and a flange and having an opening extending therethrough.

[0027] Figure 1B is a schematic diagram of a fastener installed in an opening in a panel and an item attached to the fastener.

[0028] Figure 2A is an isometric view of the first side of the fastener.

[0029] Figure 2B yes Figure 2A Side view of the fastener.

[0030] Figure 2C yes Figure 2A An end view of a second side of the fastener.

[0031] Figure 3 is an isometric view of the first side of the fastener.

[0032] Figure 4A is an isometric view of the fasteners attached to the first side of the panel.

[0033] Figure 4B is on the second side of the panel Figure 4A Isometric view of a fastener.

[0034] Figure 5 is a schematic side view of a fastener connected within an opening in a panel.

[0035] Figure 6 is a flow chart of a method of attaching a fastener to a panel. DETAILED DESCRIPTION

[0036] Figure 1AA fastener 20 configured to be connected to a panel is illustrated. The fastener 20 includes a body 30 and a flange 40. An opening 21 extends into the fastener 20 and may extend partially or completely through the fastener 20. The body 30 is constructed of a first material, and the flange 40 is constructed of a different second material. The first material of the body 30 has a higher melting point and a lower UV light transmittance than the second material of the flange 40. In some examples, the body 30 is designed to have strength to engage with and support an article, and the flange 40 is designed to allow UV light to be transmitted to the adhesive below and resist torque of the fastener 20 relative to the panel.

[0037] In some examples, the first material of body 30 is functionally strong and lightweight. In some examples, the first material has a higher melting point than the second material. In some examples, the first material is not formulated based on its UV light transmittance.

[0038] Figure 1B The fastener 20 is shown installed in an opening 103 in a panel 100. The fastener 20 is positioned with its body 30 extending through the opening 103 and the flange 40 positioned at the first side 101 of the panel 100. During use, the fastener 20 is inserted into the opening 103 in the direction indicated by the arrow A. The flange 40 has a width greater than the opening 103 to remain on the first side 101 of the panel 100. The body 30 is sized to extend through the opening 103. The light-curing adhesive 110 positioned at the flange 40 keeps the fastener 20 connected to the panel 100. The flange 40 is a translucent material with high light transmittance and a relatively low melting temperature. The body 30 is a high-strength, high-melting-point material with relatively low UV light transmittance. This construction supports UV light passing through the flange 40 to cure the adhesive 110. After the adhesive 110 is cured, the body 30 is configured to be connected to the article 200 to connect the article 200 to the panel 100.

[0039] Figure 2A , Figure 2B and Figure 2C The fastener 20 is illustrated as including a body 30 and a flange 40. The body 30 and the flange 40 are coaxially aligned along a centerline CL of the fastener 20. The body 30 has an elongated shape having a first end 31 and a second end 32 and an outer lateral side 34. In some examples, the edges formed between the first end 31 and the lateral side 34 are rounded to facilitate insertion of the body 30 into the opening 103 in the panel 100. In some examples, the body 30 is cylindrical with a substantially circular cross-sectional shape. In other examples, the body 30 has a different shape.

[0040] The body 30 includes an opening 33 extending inwardly from the first end 31. Figure 2A and Figure 2CIn some examples shown, the opening 33 extends through the length of the body 30, wherein the second end 32 is also open. In other examples, the opening 33 extends a limited distance into the first end 31 to form a cavity, and wherein the second end 32 is closed. In some examples, the opening 33 includes substantially smooth sides. In other examples, the opening 33 includes threads.

[0041] exist Figure 2A and Figure 2C In some examples shown, the insert 50 is installed in the opening 33. The insert 50 has a cylindrical shape with a central opening 51 coaxially aligned with the body 30. In some examples, the exterior of the insert 50 has threads to engage with threads along the opening 33. In other examples, the exterior of the insert 50 is substantially smooth. In some examples, the insert 50 is inserted into the opening 33 with the first end 52 aligned with the first end 31 of the body 30. The length of the insert 50 can vary, with one example including the insert 50 being shorter than the body 30 and spaced from the second end 32. In other examples, the insert 50 extends the entire length of the opening 33.

[0042] The insert 50 is a separate component that is inserted into and connected to the body 30. The insert 50 can be connected in various ways, including but not limited to one or more of threaded engagement, bonding, and molding together. In some examples, the insert 50 is co-molded with the body 30, and the molten material of the body 30 flows around the insert 50 and fixes the insert 50. In other examples, the body 30 includes one or more grooves 36 along the lateral side 34. The groove 36 provides a force to apply to crimp the insert 50 to create deformation, thereby creating a thread locking feature.

[0043] The body 30 includes a main section 37 and a lip 35 at the second end 32. The lip 35 is configured to engage with the flange 40. Figure 2B As shown, the lip 35 has a width W2 measured between opposite lateral sides that is greater than the width W1 of the main section 37. The lip 35 may include a variety of shapes and sizes, including but not limited to, Figure 2A-2C The circles, polygons and Figure 3 The non-circular shape shown.

[0044] The body 30 is constructed of a material having high strength and a high melting point. The material also has low light transmittance. An example of the material includes polyetherimide, which is commonly known by the trade name ULTEM.

[0045] The flange 40 is connected to the body 30 at the second end 32. The connection can be made in various ways, including one or more of threaded engagement, bonding, and molding together. In some examples, the body 30 and the flange 40 are co-molded or overmolded together. In some examples, the flange 40 has a disc shape that extends completely around the body 30.

[0046] The flange 40 includes a central opening 41 for receiving the body 30. Figure 2B As shown, the bottom of the flange 40 is aligned with the second end 32 of the body 30. The flange 40 also includes an outer edge 42 that defines a shape. The flange 40 may include a variety of shapes, including but not limited to, Figure 2A and 2C The illustrated circular, oval, and polygonal shapes. In some examples, the flange 40 has a cup shape, wherein the outer edge 42 is axially offset from the opening 41 along the centerline CL. The cup shape is configured to receive the adhesive 110. The outside of the flange 40 can be tapered to provide an aesthetically pleasing appearance (and optimized for weight and strength) and to prevent the flange 40 from getting caught on an object when the fastener 20 is installed to the panel 100. One or more standoffs 43 on the inside extend upwardly above the outer edge 42. The standoffs contact the panel 100 and provide spacing for the adhesive 110.

[0047] Flange 40 has a width W3 measured between opposing points on outer edge 42. Width W3 is greater than width W1 of main section 37 of body 30. This larger dimension prevents fastener 20 from being fully inserted into opening 103 when flange 40 is retained on first side 101 of panel 100.

[0048] The flange 40 is constructed of a translucent material having high light transmittance. The material also has a lower melting temperature than the body 30. Examples of the material include, but are not limited to, transparent nylon, transparent polyamide, and TROGAMID material.

[0049] Figure 4A and Figure 4B The fastener 20 is shown connected to the panel 100. The flange 40 is positioned at the first side 101 and extends laterally across the opening 103. The first end 31 of the body 30 is aligned with the second side 102 of the panel 100. Likewise, the edge of the insert 50 positioned in the body 30 is aligned with the first end 31 and the second side 102.

[0050] Figure 5A side view of the fastener 20 connected to the panel 100 is shown. The flange 40 extends laterally outwardly beyond the opening 103 along the first side 101. This sizing prevents the body 30 from being pulled through the opening 103. The standoffs 43 on the flange 40 contact the first side 101 of the panel 100 and space the top edge of the flange 40 outwardly away from the first side 101. This provides space for the adhesive 110 to be positioned between the flange 40 and the first side 101. The body 30 is positioned in the opening 41 in the flange 40, and the second end 32 of the body 30 is aligned with the bottom of the flange 40.

[0051] The body 30 extends within the opening 103. The first end 31 is positioned adjacent the second side 102. The insert 50 is mounted in the opening 33 at the first end 31. The opening 51 in the insert 50 is exposed to receive an article (not shown).

[0052] During installation, adhesive 110 is positioned between flange 40 and first side 101. In some examples, adhesive 110 is positioned on flange 40 before body 30 is inserted into opening 103. Additionally or alternatively, adhesive 110 is inserted into a space formed between flange 40 and first side 101 after body 30 is inserted into opening 103. In some examples, adhesive 110 is applied only to flange 40 and not to body 30.

[0053] After fastener 20 is positioned in panel 100, UV light is applied through flange 40 to adhesive 110. The material of flange 40 supports the UV light to pass through to adhesive 110. The UV light is applied for the necessary time to cure adhesive 110. The UV light does not affect body 30, and thus body 30 maintains its structural properties.

[0054] In some examples, flange 40 may fail. This may be caused by a variety of reasons, including but not limited to melting by a high temperature event (such as a fire), and tearing from body 30 during use. The lip 35 on flange 35 has a width W2 that is greater than the width of opening 103 in panel 100. This width difference is Figure 5 The lip 35 contacts the first side 101 of the panel 100 and prevents the body 30 from being pulled through the opening 103 .

[0055] Figure 6A method of attaching the fastener 20 to the panel 100 is illustrated. The opaque body 30 is positioned in the opening 103 in the panel 100 (frame 200). The first end 31 of the body 30 is positioned at the first side 101 of the panel 100, and the second end 32 of the body 30 is positioned at the opposite second side 102 of the panel 100. The translucent flange 40 connected to the second end 32 of the opaque body 30 is positioned across the opening 103 at the second side 102 of the panel 100 (frame 202). The adhesive 110 is positioned between the translucent flange 40 and the second side of the panel 100 (frame 204). The fastener 20 is fixed to the panel 100 by passing UV light through the translucent flange 40 and reaching the adhesive 110 and curing the adhesive 110 (frame 206).

[0056] The opening 33 extends from the first end 31 into the body 30. In some examples, the opening 33 extends completely through the body 30. The through hole 33 accommodates a full-length insert 50 that is threaded at both ends. The first item 200 can be threaded on the first end, and the second item can be attached from the flange side using the threads at the second end.

[0057] Various items 200 may be connected to the fastener 20. Examples include, but are not limited to, bolts, screws, pins, wiring brackets, magazine racks, mating panels, environmental control ducts and features, electronic boxes, and video monitors.

[0058] Panel 100 can be constructed from a variety of materials. In some examples, panel 100 is a composite material.

[0059] In some examples, the fastener 20 includes an insert 50 mounted in the body 30. In other examples, the fastener 20 does not include an insert. Instead, the opening 33 in the body 30 is configured to receive the article 200. In some examples, the opening 33 has threads to connect to the article.

[0060] With respect to quantities or measurements, the term "substantially" means that the characteristic, parameter or value described need not be achieved precisely. Rather, deviations or changes (including, for example, tolerances, measurement errors, measurement precision limitations and other factors known to those skilled in the art) may occur by some amount that does not preclude the effect that the characteristic is intended to provide.

[0061] Of course, without departing from the essential characteristics of the present invention, the present invention may be implemented in other ways than those specifically described herein. The present embodiment should be considered illustrative and non-restrictive in all aspects, and all changes within the meaning and equivalent scope of the appended claims are intended to be included therein.

Claims

1. A fastener configured to attach to a panel and support an article, the fastener comprising: a body (30) constructed of a first material, the body (30) including an opening (33) extending into the body (30) at a first end (31); a flange (40) constructed of a second material, the flange (40) being connected to the body (30) and the flange (40) being sized to extend laterally outward beyond the body (30); wherein the first material comprises a higher melting point than the second material; and Wherein the first material comprises a lower UV light transmittance than the second material.

2. The fastener of claim 1, wherein the flange (40) is connected to the second end (32) of the body (30) and is spaced apart from the first end (31) of the body (30).

3. The fastener of claim 1, wherein the first material comprises a higher strength than the second material.

4. The fastener of claim 1, wherein the flange (40) includes a central opening (41), and the body (30) is positioned within the central opening (41).

5. The fastener of claim 1, further comprising an insert (50) positioned within the opening (33) of the body (30) at the first end (31), the insert (50) being constructed of a third material different from the first material and the second material.

6. The fastener according to claim 5, wherein the body (30) comprises grooves on opposite sides of the opening (33) to crimp the body (30).

7. The fastener according to claim 1, wherein the body (30) comprises: a main section (37) comprising said first end (31); a lip (35) positioned at said second end (32); Wherein said lip (35) comprises a greater width than said main section (37).

8. The fastener of claim 1, wherein the opening (33) in the body (30) extends completely through the body (30).

9. The fastener of claim 1, wherein the flange (40) is substantially translucent to accommodate transmission of the UV light, and the body (30) is opaque.

10. A fastener configured to attach to a panel and support an article, the fastener comprising: a body (30) comprising a first end (31), a second end (32), and an opening (33), wherein the opening (33) extends from the first end (31) through the body (30) to the second end (32); a flange (40) positioned at the second end (32) of the body (30) and comprising a greater width than the body (30), and wherein the flange (40) extends laterally outward beyond the body (30); and The main body (30) has a higher melting point and lower UV light transmittance than the flange (40).

11. The fastener of claim 10, wherein the flange (40) is translucent and the body (30) is opaque.

12. The fastener of claim 10, wherein the body (30) comprises a cylindrical shape and the flange (40) comprises a disc shape.

13. The fastener of claim 12, wherein the flange (40) extends completely around the body (30).

14. The fastener of claim 10, wherein the flange (40) includes a central opening (41), and the second end (32) of the body (30) is positioned within the central opening (41).

15. The fastener of claim 10, further comprising an insert (50) positioned within the opening (33) in the body (30), the insert (50) being constructed of a different material than each of the body (30) and the flange (40).

16. The fastener of claim 10, wherein the body (30) comprises: a main section (37) extending inwardly from the first end (31), the main section (37) having a first width; A lip (35) is positioned at the second end (32), the lip (37) having a second width greater than the first width.

17. A method of attaching a fastener to a panel, the method comprising: Positioning an opaque body (30) of the fastener into an opening (103) in the panel (100), wherein a first end (31) of the body (30) is on a first side (101) of the panel (100) and a second end (32) of the body (30) is on an opposing second side (102) of the panel (100); positioning a translucent flange (40) across the opening (103) at the second side (102) of the panel (100), the translucent flange (40) being connected to the second end (32) of the opaque body (30); positioning an adhesive (110) between the translucent flange (40) and the second side of the panel (100); as well as The fastener is secured to the panel (100) by passing UV light through the translucent flange (40) and reaching the adhesive (110) and curing the adhesive.

18. The method of claim 17, further comprising applying the adhesive (110) to the translucent flange (40) prior to positioning the translucent flange (40) across the second side (102) of the panel (100).

19. The method of claim 17, further comprising aligning the first end (31) of the opaque body (30) with the first side (101) of the panel (100).

20. The method of claim 17, further comprising applying the adhesive (110) only to the translucent flange (40) and not to the opaque body (30).

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