Fastener for use with ultraviolet light-sensitive adhesive

Abstract

To provide fasteners comprising a body and a flange that are constructed from different materials and configured for use with a UV adhesive.SOLUTION: The invention provides a fastener configured to be attached to a panel and to support an item. The fastener has a body constructed from a first material and having an opening that extends into the body at a first end. A flange constructed from a second material is connected to the body and sized 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 transmissibility of UV light than the second material.SELECTED DRAWING: Figure 2A

Description

[Technical field]

[0001]

[0001] The present disclosure relates generally to the field of fasteners, and more specifically to a fastener having a body and a flange constructed from different materials and configured for use with ultraviolet adhesives. [Background technology]

[0002]

[0002] Items are conventionally attached to panels within the interior of a vehicle with potted fasteners. The fasteners are positioned in holes in the panel and then the potting (i.e., adhesive) is injected. Once secured, the item may 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 robust method of attaching the item to the panel. However, existing potted inserts suffer from various drawbacks.

[0003]

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

[0004] Another problem with existing fasteners is the relatively long time required for the adhesive to cure. In some embodiments, the potting cure time is up to four hours, which adds significantly to the total installation cycle time. Summary of the Invention

[0005] One aspect is directed to a fastener configured to attach to a panel to support an item. The fastener comprises a body constructed from a first material, the body including an opening extending into the body at a first end. A flange constructed from a second material is connected to the body and 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 ultraviolet light transmission than the second material.

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

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

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

[0009] In another aspect, an insert is constructed from a third material different from the first material and the second material and is disposed within the opening in the body at the first end.

[0010] In another aspect, the body includes grooves on either side of the opening for pressing the insert therein.

[0011] In another aspect, the body includes a main portion having a first end and a lip disposed at the second end, the lip including a width greater than that of the main portion.

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

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

[0014] One aspect is directed to a fastener configured to be attached to a panel to support an item. The fastener includes a body having a first end, a second end, and an opening extending therethrough from the first end to the second end. A flange is disposed at the second end of the body and includes a width greater than the body and extends laterally outwardly beyond the body. The body has a higher melting point and a lower UV transmission than the flange.

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

[0016] In another aspect, the body has a cylindrical shape and the flange has a disk shape.

[0017] In another aspect, the flange extends around the entire circumference of the body.

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

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

[0020]

[0020] In another aspect, the body includes a main portion extending inwardly from a first end, the main portion having a first width, and a lip disposed at a second end, the lip having a second width greater than the first width.

[0021] One aspect is directed to a method of attaching a fastener to a panel, the method including placing an opaque body of the fastener within an opening in the panel with a first end of the body on a first side of the panel and a second end of the body on an opposing second side of the panel, placing a translucent flange across the opening on the second side of the panel, the translucent flange being connected to the second end of the opaque body, placing an adhesive between the translucent flange and the second side of the panel, and applying ultraviolet light through the translucent flange and onto the adhesive to cure the adhesive, thereby securing the fastener to the panel.

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

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

[0025] The above-described features, functions, and advantages can be realized alone in various aspects or can be combined in yet other aspects, and further details thereof can be ascertained by reference to the following description and drawings. [Brief description of the drawings]

[0026] [Figure 1A] 1 is a schematic diagram of a fastener having a body and a flange, and an opening through both. [Figure 1B]

[0027] 1 is a schematic diagram of a fastener installed in an opening in a panel and an item attached to the fastener. [Figure 2A]

[0028] FIG. 2 is an isometric view of a first side of the fastener. [Figure 2B]

[0029] FIG. 2B is a side view of the fastener of FIG. 2A. [Figure 2C]

[0030] FIG. 2B is an end view of a second side of the fastener of FIG. 2A. [Diagram 3]

[0031] FIG. 2 is an isometric view of a first side of the fastener. [Figure 4A]

[0032] FIG. 2 is an isometric view of a fastener connected to a first side of a panel. [Figure 4B]

[0033] FIG. 4B is an isometric view of the fastener of FIG. 4A on a second side of the panel. [Diagram 5]

[0034] FIG. 2 is a schematic side view of a fastener connected within an opening in a panel. [Figure 6]

[0035] FIG. 1 is a flow diagram of a method for installing fasteners in a panel. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027]

[0036] 1A shows a fastener 20 configured to connect to a panel. The fastener 20 includes a body 30 and a flange 40. An opening 21 extends into the fastener 20 and may partially or completely pass through the fastener 20. The body 30 is constructed from a first material and the flange 40 is constructed from a different, second material. The first material of the body 30 has a higher melting point and a lower UV light transmission rate than the second material of the flange 40. In some embodiments, the body 30 is designed for strength to engage and support an item, and the flange 40 is designed to allow UV light transmission to the adhesive underneath and to resist torque of the fastener 20 against the panel.

[0028]

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

[0029]

[0038] FIG. 1B shows the fastener 20 installed in an opening 103 of a panel 100. The fastener 20 is positioned with the body 30 passing through the opening 103 and the flange 40 positioned on the first side 101 of the panel 100. In use, the fastener 20 is inserted into the opening 103 in the direction indicated by 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 pass through the opening 103. A light curable adhesive 110 disposed on the flange 40 holds the fastener 20 connected to the panel 100. The flange 40 is a translucent material with high light transmission and a lower melting temperature. The body 30 is a high strength, high melting point material with lower UV transmission. This construction allows UV light to pass through the flange 40 to cure the adhesive 110. After the adhesive 110 has cured, the body 30 is configured to connect to the item 200 and connect the item 200 to the panel 100 .

[0030]

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

[0031]

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

[0032]

[0041] In some embodiments shown in FIGS. 2A and 2C, the insert 50 is mounted within the opening 33. The insert 50 has a cylindrical shape with a central opening 51 coaxially aligned with the body 30. In some embodiments, the exterior of the insert 50 is threaded to engage with threads along the opening 33. In other embodiments, the exterior of the insert 50 is substantially smooth. In some embodiments, the insert 50 is inserted within 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 embodiment including the insert 50 being shorter than the body 30 and spaced apart from the second end 32. In other embodiments, the insert 50 extends the entire length of the opening 33.

[0033]

[0042] The insert 50 is a separate member that is inserted into and connected to the body 30. The insert 50 can be connected in a variety of ways, including, but not limited to, one or more of threaded engagement, adhesive, and co-molding. In some embodiments, the insert 50 is co-molded with the body 30, and the molten body 30 material flows around it to secure the insert 50. In other embodiments, the body 30 includes one or more grooves 36 along the lateral sides 34. The grooves 36 apply a force compressing the insert 50, creating a strain and thereby providing a thread locking feature.

[0034]

[0043] Body 30 includes a main portion 37 and a lip 35 at second end 32. Lip 35 is configured to engage flange 40. As shown in FIG. 2B, lip 35 has a width W2 measured between opposing lateral sides that is greater than a width W1 of main portion 37. Lip 35 can include a variety of shapes and sizes, including, but not limited to, circular, polygonal, and non-circular shapes as shown in FIG. 3, as shown in FIG. 2B.

[0035]

[0044] The body 30 is constructed from a material that has high strength and a high melting point. The material also has a low optical transmission. One example of a material includes polyetherimide, often referred to under the trade name ULTEM.

[0036]

[0045] The flange 40 is connected to the body 30 at the second end 32. The connection can be by various means including one or more of threaded engagement, adhesive, and co-molding. In some embodiments, the body 30 and the flange 40 are co-molded or over-molded together. In some embodiments, the flange 40 has a disk shape that extends around the entire circumference of the body 30.

[0037]

[0046] The flange 40 includes a central opening 41 that receives the body 30. As shown in FIG. 2B, 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 can include a variety of shapes, including, but not limited to, circular, elliptical, and polygonal, as shown in FIGS. 2A and 2C. In some embodiments, the flange 40 has a cup shape with the outer edge 42 axially offset from the opening 41 along a centerline CL. The cup shape is configured to receive the adhesive 110. The exterior of the flange 40 can be tapered to provide an aesthetic appearance (and optimize for weight and strength) and to prevent the flange 40 from catching on objects when the fastener 20 is attached to the panel 100. An inner standoff or standoffs 43 extend upwardly above the outer edge 42. The standoffs contact the panel 100 and provide spacing for the adhesive 110.

[0038]

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

[0039]

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

[0040]

[0049] 4A and 4B show fastener 20 connected to panel 100. Flange 40 is disposed on first side 101 and extends laterally across opening 103. First end 31 of body 30 is aligned with second side 102 of panel 100. Similarly, an edge of insert 50 disposed in body 30 is aligned with first end 31 and second side 102.

[0041]

[0050] FIG. 5 shows a side view of the fastener 20 connected to a panel 100. The flange 40 extends laterally outwardly along the first side 101 beyond the opening 103. This sizing prevents the body 30 from being pulled out of the opening 103. The standoff 43 of the flange 40 contacts against the first side 101 of the panel 100 to space the top edge of the flange 40 outwardly away from the first side 101. This provides a spacing between the flange 40 and the first side 101 where the adhesive 110 is placed. The body 30 is placed into the opening 41 of the flange 40 such that the second end 32 of the body 30 is aligned with the bottom of the flange 40.

[0042]

[0051] The body 30 extends into the opening 103. The first end 31 is disposed proximate the second side 102. The insert 50 is attached to the opening 33 at the first end 31. The opening 51 of the insert 50 is exposed for receiving an item (not shown).

[0043]

[0052] During installation, adhesive 110 is disposed between flange 40 and first side 101. In some embodiments, adhesive 110 is disposed 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 embodiments, adhesive 110 is applied only to flange 40 and not to body 30.

[0044]

[0053] After the fastener 20 is placed on the panel 100, ultraviolet light is applied through the flange 40 to the adhesive 110. The material of the flange 40 allows the ultraviolet light to pass through to the adhesive 110. The ultraviolet light is applied for a time required to cure the adhesive 110. The ultraviolet light does not affect the body 30, and thus the body 30 maintains its structural properties.

[0045]

[0054] In some embodiments, the flange 40 may disappear. This can occur for a variety of reasons, including, but not limited to, melting due to a high temperature event such as a fire, and being pulled away from the body 30 during use. The lip 35 on the flange 35 has a width W2 that is greater than the width of the opening 103 in the panel 100. This width difference is best seen in FIG. 5. The lip 35 contacts against the first side 101 of the panel 100 to prevent the body 30 from being pulled out of the opening 103.

[0046]

[0055] 6 illustrates a method of attaching the fastener 20 to the panel 100. The opaque body 30 is disposed within the opening 103 of the panel 100 (Block 200). The first end 31 of the body 30 is disposed on the first side 101 of the panel 100 and the second end 32 of the body 30 is disposed on 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 disposed across the opening 103 on the second side 102 of the panel 100 (Block 202). An adhesive 110 is disposed between the translucent flange 40 and the second side of the panel 100 (Block 204). The fastener 20 is secured to the panel 100 by irradiating the adhesive 110 with ultraviolet light through the translucent flange 40 to cure the adhesive 110 (Block 206).

[0047]

[0056] The opening 33 extends into the body 30 from the first end 31. In some embodiments, the opening 33 extends through the body 30. The through opening 33 accommodates the entire length of the insert 50, which is threaded on both ends. The first item 200 can be threaded on the first end, and the second item can be attached from the flange side utilizing the threads on the second end.

[0048]

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

[0049]

[0058] The panel 100 may be constructed from a variety of materials. In some embodiments, the panel 100 is a composite material.

[0050]

[0059] In some embodiments, fastener 20 includes an insert 50 mounted within body 30. In other embodiments, fastener 20 does not include an insert. Rather, opening 33 in body 30 is configured to receive item 200. In some embodiments, opening 33 is threaded to connect the items.

[0051]

[0060] The term "substantially" in connection with a quantity or measurement means that the recited characteristic, parameter, or value need not be achieved exactly, but rather deviations or variations (including, for example, tolerances, measurement errors, measurement accuracy limits, and other factors known to those of ordinary skill in the art) may occur to the extent that they do not eliminate the effect intended to be produced by the characteristic.

[0052]

[0061] The present invention can, of course, be practiced otherwise than as specifically set forth herein without departing from the essential characteristics thereof. The present embodiments are to be considered in all respects as illustrative and not restrictive, and all changes which come within the meaning and range of equivalency of the appended claims are intended to be embraced therein.

Claims

1. A fastener configured to be attached to a panel to support an item, comprising: a body (30) constructed from a first material, said body (30) including an opening (33) extending into said body (30) at a first end (31); a flange (40) constructed from a second material, said flange (40) being connected to said body (30) and sized to extend laterally outward beyond said body (30); the first material comprising a higher melting point than the second material; The first material comprises a lower ultraviolet light transmission rate than the second material.

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

3. The fastener of claim 1 , wherein the first material comprises a greater 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 disposed within the central opening (41).

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

6. 6. The fastener according to claim 5, wherein the body (30) is provided with grooves on either side of the opening (33) for compressing the body (30).

7. The body (30) a main portion (37) having said first end (31); a lip (35) disposed on the second end (32); The fastener of claim 1, wherein said lip (35) includes a width greater than said main portion (37).

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

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

10. A fastener configured to be attached to a panel to support an item, comprising: a body (30) having a first end (31), a second end (32), and an opening (33) extending through the body (30) from the first end (31) to the second end (32); a flange (40) disposed at the second end (32) of the body (30), the flange (40) including a width greater than the body (30) and extending laterally outward beyond the body (30); Equipped with The fastener wherein the body (30) has a higher melting point and a lower UV transmission rate than the flange (40).

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

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

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

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

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

16. The body (30) a main portion (37) extending inwardly from said first end (31), said main portion (37) having a first width; a lip (35) disposed at the second end (32), the lip (37) having a second width greater than the first width; The fastener of claim 10 comprising:

17. 1. A method of attaching a fastener to a panel, comprising: placing an opaque body (30) of the fastener within an opening (103) of the panel (100) with a first end (31) of the body (30) on a first side (101) of the panel (100) and a second end (32) of the body (30) on an opposing second side (102) of the panel (100); disposing a translucent flange (40) across the opening (103) on the second side (102) of the panel (100), the translucent flange (40) being connected to the second end (32) of the opaque body (30); placing an adhesive (110) between the translucent flange (40) and the second side of the panel (100); applying ultraviolet light through the translucent flange (40) to the adhesive (110) to cure the adhesive and thereby secure the fastener to the panel (100); A method comprising:

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

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

20. 18. 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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