Double-headed hybrid stud fastener assembly

Abstract

A fastener assembly is disclosed for coupling a first component to a second component via an opening associated with the first component and a doghouse-like structure associated with the second component. The fastener assembly includes a stud, a plastic base member, and a seal. The stud has a first shank and a second shank. The second handle part penetrates through the opening to be fixed with the nut; the plastic base member has a first platform spaced from a second platform via a rod. The plastic base member defines a passage configured to receive at least a portion of the first handle. The first platform is configured to be fixed with the doghouse-shaped structure; and a seal coupled to the second platform.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 573,420, filed April 2, 2024, and U.S. Provisional Patent Application No. 63 / 657,525, filed June 7, 2024, both entitled “Double Ended Hybrid Stud Fastener Assembly,” which are hereby incorporated by reference in their entirety. BACKGROUND

[0003] Automotive components require fastening techniques that are simple to manufacture and assemble. Further, the fastening techniques should first be reliable and efficient. For example, automotive assemblies include various panels and structures that are connected to other panels or structures or to the automobile frame itself.

[0004] Double ended stud fasteners (often simply referred to as double ended studs or threaded studs) can be used to secure different components together. A double ended stud fastener is a type of fastener that has threads on both ends with an unthreaded section in the middle. It is used to join two components together, where one end of the stud is threaded into a threaded hole and the other end receives a nut or is threaded into another threaded hole. In different applications, fasteners of different sizes, shapes, configurations, etc. are used to secure components together.

[0005] Despite some advances to date, it would be highly desirable to be able to have a fastener system that uses a double ended stud with a doghouse structure. SUMMARY

[0006] The present disclosure is generally directed to a fastener system substantially as illustrated and described in connection with at least one of the figures, as more fully described in the claims. More particularly, the present disclosure is generally directed to a fastener system having a double ended stud configured to engage a doghouse structure via a sealed plastic base assembly. BRIEF DESCRIPTION OF DRAWINGS

[0007] 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 reference numbers refer to like structures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the apparatus, systems, and methods described herein.

[0008] Figure 1a An assembled side view of a fastener system having a stud fastener assembly according to an aspect of the present disclosure is shown.

[0009] Figure 1b An assembled side view of a fastener system according to an aspect of the present disclosure is shown.

[0010] Figure 1c An assembled isometric view of a stud fastener assembly is shown.

[0011] Figure 1d Shows an assembled isometric view of a stud fastener assembly.

[0012] Figure 1e Shows a top view of a stud fastener assembly.

[0013] Figure 1f Shown is a side view of a stud fastener assembly.

[0014] Figure 1g Shows the stud fastener assembly along the section line AA ( Figure 1e ) is a cross-sectional side view taken from the top of the figure.

[0015] Figure 2a According to one aspect of the present disclosure, Figures 1a to 1g A side view of the base assembly of a stud fastener assembly.

[0016] Figure 2b Shows the base assembly along the section line AA ( Figure 1e ) side view taken from the top.

[0017] Figure 3 According to one aspect of the present disclosure, Figures 1a to 1g A side view of a stud of a stud fastener assembly. DETAILED DESCRIPTION

[0018] Reference to a singular item should be understood to include the plural item, and vice versa, unless otherwise expressly stated or clear from the context. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of connected clauses, sentences, words, etc., unless otherwise stated or clear from the context. Unless otherwise indicated herein, the description of the range of values ​​herein is not intended to be limiting, but refers individually to any and all values ​​falling within and / or including the range, and each individual value within such a range is incorporated into the specification as if it were separately stated in this article. In the following description, it should be understood that terms such as "first", "second", "top", "bottom", "side", "front", "back" are words of convenience and should not be interpreted as restrictive terms. For example, although in some examples, the first side is positioned adjacent to or near the second side, the terms "first side" and "second side" do not mean any particular order in which these sides are sorted.

[0019] The terms “about,” “approximately,” “substantially” and the like, when used in connection with a numerical value, are understood to indicate a deviation that is acceptable to the person of ordinary skill in the art in order to achieve the intended purpose. Values and / or ranges of values are provided herein solely as examples and do not constitute a limitation on the scope of the disclosure. The use of any and all examples, or exemplary language (e.g., “such as,” “for instance,” etc.), provided herein is intended merely to better illuminate the examples disclosed, and does not pose a limitation on the scope of the disclosure. The terms “such as,” and “for example,” introduce a list of one or more non-limiting examples, instances, or illustrations. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0020] The term “and / or” means any one or more of the items in the list of which “and / or” is used in connection with. As an 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”.

[0021] The present disclosure provides a fastener system having a double headed stud configured to engage a kennel-like structure via a plastic base assembly having a base component and a seal. The base component can have a shape with a first platform spaced apart from and connected to a second platform by a stem. The stem has a passage (e.g., an opening or a channel) therethrough to accommodate a first shank of the double headed stud that is screwed into the passage to be retained therein. The seal can be a softer plastic than the base component and can be overmolded onto the second upper platform to attach the seal thereto. A plurality of gaps are formed around the stem between the first and second platforms such that the base component can be inserted into the kennel-like structure. When assembled, the base component is attached to the kennel-like structure, a second shank of the double headed stud is attached to a component (e.g., a spoiler) via an opening therein and a nut, with the seal forming a water-tight barrier with the component.

[0022] In one example, a fastener assembly for coupling a first component to a second component via an opening associated with the first component and a kennel-like structure associated with the second component includes a stud having a first shank and a second shank, wherein the second shank is configured to pass through the opening to secure with a nut, and a base component having a first platform spaced apart from a second platform via a stem, wherein the base component defines a passageway configured to receive at least a portion of the first shank, and wherein the first platform is configured to secure with the kennel-like structure.

[0023] In another example, a base component for coupling a first component to a second component via a stud having a first shank and a second shank includes a first platform and a second platform spaced apart from the first platform via a stem, wherein the base component defines a passageway configured to receive at least a portion of the first shank, and wherein the first platform is configured to secure with a kennel-like structure formed on the second component.

[0024] In yet another example, a fastener assembly for coupling a first component to a second component via an opening associated with the first component and a kennel-like structure associated with the second component includes a stud having a first shank and a second shank, wherein the second shank is configured to pass through the opening to secure with a nut, a plastic base component having a first platform spaced apart from a second platform via a stem, wherein the plastic base component defines a passageway configured to receive at least a portion of the first shank, and wherein the first platform is configured to secure with the kennel-like structure, and a seal coupled to the second platform.

[0025] In some examples, the fastener assembly further includes a seal.

[0026] In some examples, the seal is coupled to the second platform.

[0027] In some examples, the second shank includes a head as a distal end thereof.

[0028] In some examples, the head is configured to define one or more screwdriver head shapes.

[0029] In some examples, the base component is plastic.

[0030] In some examples, the stud is metal.

[0031] In some examples, the seal is a foam material, a thermoplastic, or a rubber.

[0032] In some examples, the stud includes a neck ring positioned between the first shank and the second shank.

[0033] In some examples, the neck ring is configured to abut the second platform when assembled.

[0034] Figure 1a An assembled side view of a fastener system 100 having a stud fastener assembly 102 is shown in accordance with one aspect of the present disclosure. Figure 1b An assembled side view of a fastener system 100 according to an aspect of the present disclosure is shown. Figure 1c and Figure 1d Assembled and assembled isometric views of the stud fastener assembly 102 are shown, respectively. Figure 1e A top view of the stud fastener assembly 102 is shown, and Figure 1f A side view of the stud fastener assembly 102 is shown. Figure 1g The stud fastener assembly 102 is shown along the section line AA ( Figure 1e ) is a cross-sectional side view taken from the top of the figure.

[0035] The illustrated fastener system 100 includes a stud fastener assembly 102, a first component 104, and a second component 106. The stud fastener assembly 102 is configured to join the first component 104 and the second component 106 via, for example, a nut 108 and / or one or more features formed in or on the first component 104 and the second component 106. In this example, the stud fastener assembly 102 generally includes a stud 110 and a base assembly 112.

[0036] As shown, each of the first component 104 and the second component 106 can include one or more engagement features that facilitate attachment to the stud fastener assembly 102. For example, the first component 104 is shown as having an opening 114 formed therein, while the second component 106 is shown as having a doghouse-like structure 116 formed thereon. As shown, the doghouse-like structure 116 defines a slot 126. The opening 114 and / or the doghouse-like structure 116 can be formed in or on the first component 104 and / or the second component 106 during manufacturing, or added after manufacturing by a mechanical process (e.g., drilling, cutting, engraving, etc.), adhesives, or other means. In some examples, the opening 114 can be threaded. For example, the opening 114 in the second component 106 can be threaded and configured to engage the stud 110.

[0037] Although Figure 1aThe fastener system 100 is shown coupled to the first component 104 via the nut 108, but other fastening techniques and arrangements can be contemplated. For example, friction-based fasteners (e.g., clips, sleeves, etc.) can be used instead of the threaded nut 108. In another example, the opening 114 formed in the first component 104 can be threaded and configured to engage the second shank 110b of the stud 110, thereby obviating the need for an additional fastener (e.g., the nut 108).

[0038] As most clearly shown in FIG. 1, the second component 106 can be at least partially covered by the first component 104 after assembly of the first and second components 104, 106. In some examples, one or both of the first and second components 104, 106 can include additional attachment features. Figure 1b

[0039] The first and second components 104, 106 can be, for example, automotive panels or other automotive components. Depending on the application, one or both of the first and / or second components 104, 106 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 the automotive industry, example first components 104 include, but are not limited to, spoilers, door trim panels, moldings, trim, and other substrates (whether used as an interior or exterior surface). The second component 106 can be, for example, a vehicle frame, an automotive panel, 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, a support, a frame, etc.), a seat frame, a center console, a fender, a sheet metal frame, etc. Depending on the application, the first and / or second components 104, 106 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.

[0040] The illustrated stud 110 includes a first shank 110a and a second shank 110b. While the first shank 110a of the stud 110 is shown as being shorter in length than the second shank 110b, in other examples, the first shank 110a can have the same length or a longer length than the second shank 110b. The first and second shanks 110a, 110b can each define one or more threads configured to engage one of the nut 108 (or other type of female fastener) and / or the base assembly 112 (e.g., via the passage 118 formed therein).

[0041] ​The base assembly 112 is shown as a multi-part component having a base part 120 and a seal 122. The seal 122 can be implemented as a ring (e.g., an annular member). In one example, the base part 120 can be a hard plastic structure and the seal 122 is a softer material overmolded onto the base part 120 to form the base assembly 112.

[0042] The base part 120 generally includes a pair of platforms 120a, 120b (i.e., a first platform 120a and a second platform 120b) that are spaced apart via a stem 120c. The base part 120 defines a passage 118 along a central axis 124 that is configured to receive and / or engage an end of the first shank 110a. While the passage 118 is shown as passing completely through the base part 120 (e.g., forming an opening on each side of the base part 120), the passage 118 need not pass completely through the base part 120 and can stop partway such that one side (e.g., at the first platform 120a) does not define an opening. The passage 118 can be threaded or unthreaded. For example, the passage 118 can be unthreaded (e.g., have a smooth inner surface) and configured for use with a stud 110 having self-tapping threads.

[0043] During assembly, the first shank 110a of the stud 110 can be inserted into the passage 118 and rotated about the central axis 124 relative to the base assembly 112 to join the stud 110 to the base assembly 112 and thereby form the fastener assembly 102. Once assembled, the first platform 120a can be slid into the slot 126 of the kennel structure 116, thereby securing the fastener assembly 102 relative to the second part 106. The second shank 110b of the stud 110 can then be inserted into the opening 114 formed in the first part 104. The nut 108 can be installed on the second shank 110b of the stud 110 and rotated about the central axis 124 relative to the second shank to join the first part 104 and the seal 122 and compress against the second platform 120b. The seal 122 abuts a surface of the first part 104 at or near the opening 114 of the first part 104.

[0044] It is contemplated that certain components of the stud fastener assembly 102 can be made of metal, while other components can be made of plastic or a flexible material.

[0045] The stud 110 and the nut 108 can be made of metal, for example, using metal drawing or other metal forming techniques. For example, the body of the stud 110 and / or the nut 108 can be made using cold metal forming techniques, where threads are added via thread rolling or threading techniques. The stud 110 and / or the nut 108 can be heat treated to increase strength and hardness.

[0046] The base assembly 112 can be made of a plastic material using plastic injection techniques, additive manufacturing, or other means. It is contemplated, however, that the stud 110 and / or the base assembly 112 can also be made using material extrusion methods (e.g., fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), material jetting, binder jetting, powder bed fusion, directed energy deposition, VAT photopolymerization, and / or any other suitable type of additive manufacturing / 3D printing process). In one example, the base component 120 is formed of a plastic (e.g., 3D printed or injection molded) or other such material and is configured to interact with a drawn metal compression limiting seal 122.

[0047] The seal 122 can be made of a foam material, a thermoplastic, a rubber, or the like. For example, the seal 122 can be configured to surround a portion of the stud 110 (e.g., the second platform 120b) and positioned to form a seal between the second platform 120b and the first component 104.

[0048] The stud fastener assembly 102 can be sized to accommodate different sizes of the first component 104 and the second component 106 as desired. In one example, referring to Figure 1f , the first platform 120a can have a width (W1) between 15 mm and 25 mm (or about 20 mm), while the seal 122 can have a width (W2) (or outer diameter) between 20 mm and 30 mm (or about 25 mm). The height (H1) of the stud fastener assembly 102 (i.e., the distance between the outer surface of the first platform 120a and the distal end of the second shank 110b) can be between 20 mm and 30 mm (or about 25 mm). Turning to Figure 1g , the first shank 110a can have a width (W3) (or outer diameter) between 2 mm and 8 mm (or about 5 mm), while the second platform 120b can have a width (W4) (or inner diameter) between 20 mm and 30 mm (or about 24 mm) and a thickness (T1) between 1 mm and 3 mm (or about 2 mm). The height (H2) of the seal 122 (e.g., at the periphery) can be between 2 mm and 8 mm (or about 5 mm). The height (H3) of the base component 120 can be between 5 mm and 15 mm (or about 7.5 mm), while the height (H4) of the seal 122 plus the base component 120 can be between 5 mm and 15 mm (or about 10 mm).

[0049] Figure 2a A side view of a base assembly 112 of a stud fastener assembly 102 according to an aspect of the present disclosure is shown at Figures 1a to 1g , while a perspective view of the base assembly 112 of the stud fastener assembly 102 is shown at Figure 2bA side view of the base assembly 112 taken along the cut line A-A Figure 1e is shown.

[0050] Each of the first platform 120a and the second platform 120b is shown as generally flat, but other shapes (e.g., concave, convex, etc.) can be used as a complement to the shape of the respective first component 104 or second component 106. Similarly, while each of the first platform 120a and the second platform 120b is shown as having a generally quadrilateral (e.g., square) shape with rounded or chamfered corners, other shapes are also contemplated, including, for example, circular, elliptical, triangular, and non-quadrilateral polygonal shapes.

[0051] The base assembly 112 can be sized to accommodate different sizes of the first component 104 and the second component 106 as desired. In one example, with reference to Figure 2b , the width (W5) (or inner diameter) of the cavity defined by the seal 122 can be between 15 mm and 25 mm (or about 21 mm), and the width (W6) (or inner diameter) of the passage 118 can be between 2 mm and 8 mm (or about 4 mm). As can be appreciated, the diameter of the passage 118 can be less than the diameter of the first shank 110a to enable the threads of the first shank 110a to cut into the material (e.g., inner sidewall) of the passage 118.

[0052] Figure 3 A side view of the stud fastener assembly 102 of the stud 110 is shown in accordance with an aspect of the present disclosure. The diameter, pitch, thread type, etc. can be adjusted or selected based on, for example, the size and material type of the nut 108 and / or the base assembly 112 to meet particular needs. Figures 1a to 1g

[0053] In one example, with reference to Figure 3 , the first shank 110a can be formed of a Boscrew TM , and / or the second shank 110b can be a M6.0 x 1.0 grade and have a self-correcting thread design to mitigate thread damage or jamming (e.g., cross threading). For example, the Boscrew TM is designed to have a thread shape that directly mates with the creep properties of plastic in plastic applications to interlock with the boss and not loosen. Additional details of the Boscrew TM thread are described in commonly-owned U.S. Patent No. 7,677,851 to Desai et al.

[0054] ​​In the illustrated example, a neck ring 110c (e.g., a platform or plate) is positioned between the first shank 110a and the second shank 110b. The second shank 110b can further define a head 110d configured to engage a tool to facilitate rotation of the double-ended stud 110 about the central axis 124 during installation. The head 110d can be shaped to define one or more screwdriver head shapes, such as one or more of a Phillips, a cruciform, a pozidriv, a torx (star), an internal hex (hexalobular), a square (Robertson), a tri-wing, a plus, a spanner (allen), a clutch, a hexalobular, a bristol, a spline drive, etc.

[0055] The patents and patent publications cited above are hereby incorporated by reference in their entireties. Although the 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 method and / or system. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from its scope. For example, the blocks and / or components of the disclosed examples can be combined, divided, re-arranged, and / or otherwise modified. Therefore, the method and / or system are not limited to the particular implementations disclosed. Instead, the method and / or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.

Claims

1. A fastener assembly for coupling a first component to a second component via an opening associated with the first component and a kennel-like structure associated with the second component, the fastener assembly comprising: a stud having a first shank and a second shank, wherein the second shank is configured to pass through the opening to be secured with a nut; and a base member having a first platform spaced apart from a second platform via a rod, wherein the base member defines a passageway configured to receive at least a portion of the first handle, and Wherein, the first platform is configured to be fixed to the kennel-like structure.

2. The fastener assembly of claim 1 further comprising a seal.

3. The fastener assembly of claim 2, wherein: The seal is coupled to the second platform.

4. The fastener assembly of claim 1, wherein: The second handle includes a head as a distal end thereof.

5. The fastener assembly of claim 4, wherein: The head is configured to define one or more screwdriver bit shapes.

6. The fastener assembly of claim 1, wherein: The base member is plastic.

7. The fastener assembly of claim 1, wherein: The studs are metal.

8. The fastener assembly of claim 1, wherein: The sealing member is made of foam material, thermoplastic plastic or rubber.

9. The fastener assembly of claim 1, wherein: The stud includes a collar positioned between the first shank and the second shank.

10. The fastener assembly of claim 9, wherein: The neck ring is configured to abut the second platform when assembled.

11. A base component for coupling a first component to a second component via a stud having a first shank and a second shank, the base component comprising: First platform; as well as a second platform, the second platform being spaced apart from the first platform via a rod, wherein the base member defines a passageway configured to receive at least a portion of the first handle, and Wherein, the first platform is configured to be fixed to a kennel-like structure formed on the second component.

12. The base component of claim 11, further comprising a seal.

13. The base member of claim 12, wherein: The seal is coupled to the second platform.

14. The base member of claim 11, wherein: The base member is plastic.

15. The base member of claim 11, wherein The sealing member is made of foam material, thermoplastic plastic or rubber.

16. A fastener assembly for coupling a first component to a second component via an opening associated with the first component and a kennel-like structure associated with the second component, the fastener assembly comprising: a stud having a first shank and a second shank, wherein the second shank is configured to pass through the opening to be secured with a nut; a plastic base component having a first platform spaced apart from a second platform via a rod, wherein the plastic base component defines a passageway configured to receive at least a portion of the first handle, and wherein the first platform is configured to be fixed to the kennel-like structure; and A seal is coupled to the second platform.

17. The fastener assembly of claim 16, wherein: The second handle includes a head as a distal end thereof, the head being configured to define one or more screwdriver bit shapes.

18. The fastener assembly of claim 16, wherein: The stud is metal and includes a collar positioned between the first and second shanks.

19. The fastener assembly of claim 18, wherein: The neck ring is configured to abut the second platform when assembled.

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