Blind Assembly Fastener System

Abstract

To provide a fastening system for forming a sealing blind coupling part for coupling a first panel to a second panel.SOLUTION: Disclosed is a system and a method for coupling a first panel to a second panel via a fastening system. The fastening system includes a fastener, a dog house structure, and a seal assembly. The fastener includes a head assembly coupled to a collar part. The head assembly is configured to be engageable with the dog house structure positioned on the first panel, and the collar part passes through an opening formed inside the second panel and passes through and holds the second panel via the opening. The seal assembly includes a seal part and a seal carrier. The seal carrier is coupled to the fastener via a weak coupling part.SELECTED DRAWING: Figure 1a

Description

[Technical Field]

[0001] [Cross reference] This patent application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 022,612, entitled "Blind Assembly, Close-Panel, Doghouse Interface Fastener System," filed May 11, 2020, and U.S. Provisional Patent Application No. 62 / 056,854, entitled "Readyset Seal," filed July 27, 2020, the contents of which are incorporated herein by reference. [Background technology]

[0002] Automotive parts require fastening techniques that are easy to manufacture and assemble. Furthermore, the fastening techniques must be particularly reliable and efficient. Blind, close-panel assembly is a situation that focuses on fastening between panels (such as automotive panels or other parts) that are fastened together while attempting to keep those same panels positioned very close to each other.

[0003] Typical fastening solutions that enable this type of close-positioning assembly include magnets, adhesive tape, and mechanical fasteners. For example, metal fasteners can be used to create blind joints between panels. Traditionally, simple metal fasteners can be accommodated within openings (e.g., windows or holes) formed in the primary panel and configured to engage blade structures extending from the underside of the secondary panel. Existing metal fasteners suffer from the drawback that their abrasive nature often wears through the paint or corrosion-resistant coatings of the primary panel (e.g., the vehicle's sheet metal frame), thereby promoting corrosion. Additionally, metal fasteners tend to buzz, squeak, and rattle, a condition commonly referred to as "BSR."

[0004] In an attempt to reduce BSR and prevent corrosion, plastic fasteners can be used instead of metal fasteners. However, such plastic fasteners can increase the spacing between panels and may require a moderately high insertion force. In some instances, fasteners are fabricated using a combination of metal and plastic components to reduce wear and avoid BSR. However, such fasteners are typically larger and can be more difficult to manufacture. Furthermore, while many sizes and performance levels of fasteners are available, many fastener types do not utilize blade structures for blind part-in assembly (PIA) procedures.

[0005] It would therefore be highly desirable to have a fastener assembly with improved assembly that allows panels to be positioned very close together while still providing a reliable and tight fastening. Summary of the Invention

[0006] The present disclosure generally relates to a fastening system for forming a blind joint between panels, such as automotive panels, substantially as illustrated by and described in connection with at least one of the drawings and as more fully set forth in the claims.

[0007] These and other objects, features, and advantages of the devices, systems, and methods described herein will become apparent from the following description of specific examples illustrated in the accompanying drawings, in which like or similar reference characters refer to like or similar structure. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the devices, systems, and methods described herein. [Brief explanation of the drawings]

[0008] [Figure 1a]FIG. 1 is a side view of an exemplary fastening system for forming a blind joint between panels according to one aspect of the present disclosure. [Figure 1b] FIG. 1 is a side view of an exemplary fastening system for forming a blind joint between panels according to one aspect of the present disclosure. [Figure 1c] FIG. 1 is a side view of an exemplary fastening system for forming a blind joint between panels according to one aspect of the present disclosure. [Figure 1d] FIG. 1 is a side view of an exemplary fastening system for forming a blind joint between panels according to one aspect of the present disclosure. [Figure 2a] FIG. 1D is a perspective assembly view of the pass-through doghouse-based fastening system of FIG. 1D according to one embodiment of the present disclosure. [Figure 2b] FIG. 2b is a partially assembled perspective view of the through dog-house based fastening system of FIG. 2a. [Figure 2c] FIG. 2b is an assembled perspective view of the through dog-house based fastening system of FIG. 2a. [Figure 3a] FIG. 1 illustrates a push pin fastener used with a through dog-house based fastening system. [Figure 3b] FIG. 1 illustrates a pin and grommet (P&G) fastener used with a through dog-house based fastening system. [Figure 3c] FIG. 1 illustrates a box-prong fastener used with a through dog-house based fastening system. [Figure 3d] 10A-10C illustrate a specialized fastener for use with a through dog-house based fastening system. [Figure 4a] 1A-1C illustrate an exemplary through dog-house based fastening system configured with ribs, according to one aspect of the present disclosure. [Figure 4b] 1A-1C illustrate an exemplary through dog-house based fastening system configured with ribs, according to one aspect of the present disclosure. [Figure 5a]1A-1C illustrate an exemplary through-dog-house based fastening system configured with ribs and wings according to one aspect of the present disclosure. [Figure 5b] 1A-1C illustrate an exemplary through-dog-house based fastening system configured with ribs and wings according to one aspect of the present disclosure. [Figure 6a] FIG. 1 illustrates an exemplary through-dog-house based fastening system configured in accordance with another aspect of the present disclosure. [Figure 6b] FIG. 1 illustrates an exemplary through-dog-house based fastening system configured in accordance with another aspect of the present disclosure. [Figure 6c] FIG. 1 illustrates an exemplary through-dog-house based fastening system configured in accordance with another aspect of the present disclosure. [Figure 6d] FIG. 1 illustrates an exemplary through-dog-house based fastening system configured in accordance with another aspect of the present disclosure. [Figure 7] FIG. 3 is a flow diagram depicting an exemplary method for connecting a first panel to a second panel using the fastener of FIGS. 2a-2c. [Figure 8a] FIG. 1 is a perspective view of a fastener having a seal assembly according to one embodiment of the present disclosure. [Figure 8b] FIG. 1 is a bottom plan view of a fastener having a seal assembly according to one embodiment of the present disclosure. [Figure 8c] 8b is a side view of the fastener of FIG. 8a with the seal assembly assembled between the panels. [Figure 9a] FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 9b] FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 9c] FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 9d]FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 9e] FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 9f] FIG. 1 is a perspective assembly view of a through dog-house base with a seal assembly during assembly, according to one embodiment of the present disclosure. [Figure 10] FIG. 7B is a flow diagram depicting an exemplary method of connecting a first panel to a second panel using a fastener having the seal assembly of FIGS. 7a-7c. [Figure 11] FIG. 1 is a flow diagram illustrating an exemplary method for manufacturing a fastening system having a fastener and a seal assembly. DETAILED DESCRIPTION OF THE INVENTION

[0009] It should be understood that items referred to in the singular include the plural of that item and vice versa, unless expressly stated otherwise or clear from the description. Grammatical conjunctions are intended to represent any and all disjunctive and conjunctive combinations of joined phrases, sentences, words, and the like, unless expressly stated otherwise or clear from the context. The recitation of ranges of values ​​herein is not intended to be limiting and refers individually to any and all values ​​falling within and / or including that range, unless otherwise indicated herein, and each separate value falling within such range is incorporated into the specification as if it were individually listed herein. In the following description, it is understood that terms such as "first," "second," "top," "bottom," "side," "before," "after," etc. are words of convenience and are not to be construed as limiting terms. For example, while in some instances a first side may be adjacent to or proximate to a second side, the terms "first side" and "second side" do not imply any particular order in which the sides are ordered.

[0010] Terms such as "about," "approximately," and "substantially," when accompanied by numerical values, are to be interpreted as indicating a deviation that would be understood by one of ordinary skill in the art to function satisfactorily for the intended purpose. Value ranges and / or numerical values ​​are provided herein as examples only and do not constitute limitations on the scope of the present disclosure. The use of any and all examples or exemplary language (e.g., "such as," etc.) provided herein is intended merely to better highlight the disclosed examples and does not present a limitation on the scope of the present disclosure. The terms "e.g., " and "for example" are intended to introduce a list of one or more non-limiting examples, specific examples, or instances. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the disclosed examples.

[0011] The term "and / or" means any one or more of the items in the list connected by "and / or." 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."

[0012] Fasteners can be used to form a blind joint between a first panel and a second panel, such as an automotive panel. In one example, a fastening system for forming a sealed blind joint between a first panel and a second panel includes a fastener that holds the second panel through an opening formed in the second panel, the fastener having a head assembly that engages with a dog-house structure positioned on the first panel, and a seal assembly having a seal and a seal carrier, the seal carrier coupled to the fastener via a temporary joint. In some examples, the temporary joint is an adhesive, a frangible bond, and / or a mechanical interlock. In some examples, the fastener and the seal carrier are fabricated as a single piece. The fastener and the seal carrier can be fabricated by a plastic injection process. For example, the temporary joint can be a flush 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 transitions from the initial position to the deployed position by breaking the temporary bond. The seal carrier can be configured to engage fastener features to secure the seal carrier in the deployed position. The seal carrier can be configured to surround the dog-house structure when in the deployed position. In some examples, the dog-house structure is configured to pass at least partially through the opening.

[0013] In another example, a method for forming a sealed blind joint between a first panel and a second panel via a dog-house structure, a fastener having a head assembly, and a seal assembly includes sliding the head assembly across a face of the first panel into a chamber of the dog-house structure, sliding the seal assembly, including the seal and seal carrier, from an initial position to a deployed position, and inserting a portion of the fastener through an opening formed on the second panel. In some examples, the initial position is at or adjacent to a collar portion of the fastener, and the deployed position is at or adjacent to the head assembly. In some examples, the seal carrier is coupled to the fastener in the initial position via a temporary joint. In some examples, the temporary joint is a flush gate formed during the plastic injection process.

[0014] In yet another example, a method of manufacturing a fastening system includes forming a fastener by a plastic injection process, the fastener having a head assembly, a neck portion, and a seal carrier, the seal carrier being coupled to the neck portion by a temporary bond, and overmolding a seal portion onto the seal carrier. In some examples, the temporary bond is a flash gate formed during the plastic injection process. In some examples, the seal carrier is coupled to the neck portion via a collar portion. In some examples, the seal carrier separates from the neck portion via the temporary bond and deploys toward the head assembly.

[0015] 1a-1d show side views of exemplary fastening systems 100a, 100b, 100c, and 100d that form a blind joint 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, a metal (or metal alloy), a synthetic or semi-synthetic polymer (e.g., plastics such as acrylonitrile butadiene styrene (ABS) and polyvinyl chloride (PVC)), a composite material (e.g., fiberglass), or a combination thereof. In one example, the first panel 102 is a secondary panel for an automobile, and the second panel 104 is a primary panel for an automobile. In the automotive industry, examples of the first panel 102 include, but are not limited to, door trim panels, moldings, trim pieces, and other substrates (used on interior or exterior surfaces).

[0016] The first panel 102 can have an A-side 102a and a B-side 102b (illustrated as the bottom side). The A-side 102a, also referred to as the class A-side, is typically the side that is visible after assembly and, as such, is more aesthetically pleasing (e.g., textured, painted, or otherwise decorated) and typically does not include attachments and / or associated features. Conversely, the B-side 102b, also referred to as the class B-side, is typically the side that is not visible after assembly and typically includes various attachments and / or associated features.

[0017] The first panel 102 can include, have, or be coupled to attachments and / or associated features, such as one or more tower sections 108 and doghouse structure 106. Depending on the type of material, the attachments and / or associated features can be formed on the B-side 102b during molding or plywood operation of the first panel 102, or can be attached after fabrication (e.g., using adhesives or mechanical fasteners). After assembly, the second panel 104 is at least partially covered by the first panel 102. The second panel 104 can be a structural component of the vehicle, such as a door, a pillar (e.g., A-pillar, B-pillar, C-pillar, etc.), a dashboard component (e.g., crossmember, bracket, frame, etc.), a seat frame, a center console, a fender, sheet metal framing, etc.

[0018] FIG. 1a illustrates a clip-based fastening system 100a connecting a first panel 102 to a second panel 104. As illustrated, the first panel 102 can include one or more towers 108 protruding from side B 102b. Each tower 108 (sometimes referred to as a bezel or protrusion) can be formed, for example, as a blade-like or flat tab. To form a blind joint between the first panel 102 and the second panel 104, the fasteners 112 and towers 108 are inserted into openings 110 formed in or on the second panel 104. In some examples, the fasteners 112 can be pre-installed in either the towers 108 or the openings 110 to define a part-in-assembly (PIA). The towers 108 of the first panel 102 are inserted into the channels formed by the fasteners 112, effectively locking the fasteners 112 in place within the openings 110, thereby securing the first and second panels 102, 104 together. The clip-based fastening system 100a eliminates rib placement variations and allows for a relatively close assembled spacing (D1) between the first and second panels 102, 104. The clip-based fastening system 100a provides a blind PIA solution for positioning the second panel 104 adjacent to the first panel 102, as the towers 108 can pass through the openings 110 in the second panel 104 to side B. The length of the fasteners 112 and the length of the towers 108 together determine the protrusion spacing (P1) on side B.

[0019] FIG. 1b illustrates a dog-house based fastening system 100b connecting a first panel 102 to a second panel 104. As shown, the first panel 102 may include one or more dog-house structures 106 protruding from the B-side 102b. The dog-house structures 106 allow the first panel 102 to be used with a wide variety of fasteners 112, such as W-type fasteners, push-pin fasteners, etc. For example, a variety of different fasteners 112 may be designed with a common head assembly sized and shaped to engage with the dog-house structures 106, thereby allowing the fasteners 112 to be interchangeable.

[0020] The fasteners 112 are coupled to the dog-house structure 106 and engage the second panel 104 at least partially through the openings 110. As shown, the dog-house structure 106 increases the assembled spacing (D2) between the first panel 102 and the second panel 104. Thus, the dog-house-based fastening system 100b can introduce a barrier to achieve close-panel blind PIA fastening because the dog-house structure 106 occupies the space between the first panel 102 and the second panel 104. As shown, the projection spacing (P2) through the B-side of the second panel 104 is dictated by the length of the fasteners 112. Therefore, shorter fasteners 112 can be employed to reduce the projection spacing (P2).

[0021] FIG. 1c illustrates a second dog-house-based fastening system 100c connecting a first panel 102 to a second panel 104. As described in connection with FIG. 1b, the dog-house structure 106 can result in a large post-assembly spacing (D3). To reduce the post-assembly spacing, a recessed panel 114 can be used to form the second panel 104 to accommodate the dog-house structure 106. Using the recessed panel 114 with the dog-house structure 106 allows the first panel 102 and the second panel 104 to be positioned closer together, achieving a smaller post-assembly spacing (D3). However, the recessed panel 114 must be sufficiently sized to accommodate the dog-house structure 106. In some cases, a large recessed panel 114 can adversely affect the overall assembly performance and / or appearance of the second panel 104. Additionally, the recessed panel 114 increases the protrusion spacing (P3) through the B-side of the second panel 104, thereby reducing the usable space on the B-side of the second panel 104.

[0022] 1d illustrates a through-dog-house based fastening system 100d for connecting a first panel 102 to a second panel 104 while minimizing the assembled spacing (D4) between the first panel 102 and the second panel 104 and the protruding spacing (P4) through the B-side of the second panel 104. The through-dog-house based fastening system 100d uses a smaller dog-house structure 106 configured to at least partially pass through an opening 110 in the second panel 104, thereby achieving a small assembled spacing (D4) comparable to the assembled spacing (D3) of FIG. 1c without requiring a recessed panel 114.

[0023] 2a-2c illustrate an exemplary through-dog-house based fastening system 100d. Specifically, FIG. 2a illustrates a perspective assembly view of the exemplary through-dog-house based fastening system 100d of FIG. 1d, and FIGS. 2b and 2c illustrate a partially assembled perspective view and an assembled perspective view thereof, respectively.

[0024] While blind joints will be primarily described, it will be understood that the fastening system can be adapted for use with structures other than the illustrated first and second panels 102, 104, which do not require the described blind joints. Thus, the fastening system is not limited to blind joints only. Furthermore, while only a single dog-house structure 106 and a single opening 110 are shown in the example, it should be understood that a given first panel 102 can include multiple dog-house structures 106 and a second panel 104 can include multiple openings 110, depending on the number of fastener points used between the first and second panels 102, 104. In use, the head assembly 210 slides into the dog-house structure 106, as indicated by the first arrow 202, to form the PIA. Once in place, the fastener 112 can be inserted into the opening 110 in the second panel 104, as indicated by the second arrow 204.

[0025] The fastener 112 generally comprises a head assembly 210, a neck portion 212, a collar portion 214, and one or more retaining features 216. The head assembly 210 engages with the dog-house structure 106 of the first panel 102. The neck portion 212, which connects the head assembly 210 to the collar portion 214, is typically narrower than the head assembly 210 and the collar portion 214. The collar portion 214 is configured to enter and engage (or otherwise retain) the second panel 104, for example, through the opening 110. As can be appreciated, a portion of the neck portion 212 can also pass through the opening 110. The collar portion 214 can be secured within the opening 110 via one or more retaining features 216, which can be outwardly biased legs connected to the collar portion 214. In some examples, the collar portion 214 can be omitted, in which case the retaining features 216 can be directly connected to the neck portion 212. The retention feature 216 can include a return arm 216a resiliently coupled to the collar portion 214, which flexes as the end of the fastener 112 is inserted into the opening 110 in the second panel 104. A catch 216b (e.g., a ledge, lip, etc.) can couple to the tip of the return arm 216a and engage with the second panel 104 (e.g., at the periphery of the opening 110). The retention feature 216 is relatively rigid against outward forces and, as such, locks the collar portion 214 (or neck portion 212) in place within the second panel 104 upon passing through the opening 110. Additionally, the fastener 112 can be configured to engage with one or more features of the second panel 104.

[0026] The fastener 112 can be made in a variety of sizes depending on the application. The illustrated fastener 112 can be described as a "W-shaped" fastener because it generally resembles a "W" when viewed from the side, as best shown in FIGS. 1b-1d. The W-shaped fastener provides a lead-in feature for locating the aperture 110. While the fastener 112 is generally described and illustrated as a W-shaped fastener, the fastener 112 can employ other types of fasteners for use with the through-dog-house based fastening system 100d, as discussed in connection with FIGS. 3a-3d.

[0027] The opening 110 may be generally rectangular and may define a size and shape complementary to the fastener 112 so that the fastener 112 may be inserted and retained therein. However, other shapes of the opening 110 are contemplated. Thus, the opening 110 may be rectangular, a rounded rectangle (e.g., a stadium), circular ( FIGS. 6a-6d ), oval, or any other suitable shape.

[0028] As shown, the second panel 104 is sized and shaped to define a dog-house structure 106. The dog-house structure 106 serves as a receptacle for the head assembly 210 of the fastener 112. The head assembly 210 of the fastener 112 is desirably inserted into and retained within a chamber 218. As shown, the dog-house structure 106 is comprised of a pair of dog-house sidewalls 220 defining the chamber 218 therebetween. The dog-house sidewalls 220 may include one or more features, such as interference features 222, shaped to enhance engagement with the head assembly 210. In some examples, the interference features 222 may exhibit a soft click when the fastener 112 is secured within the chamber 218. The dog-house structure 106 provides a clear path from one or more insertion openings to the chamber 218. In the illustrated example, the fastener 112 can slide into the chamber 218 of the dog-house structure 106 through one of two insertion openings. For example, the fastener 112 can slide in the direction indicated by arrow 202, or in the opposite direction. While it is contemplated that the dog-house structure 106 can be molded when the first panel 102 is molded, in some examples they can be made separately and joined together (e.g., using adhesive, mechanical fasteners, etc.).

[0029] It is contemplated that the dog-house structure 106 may be sized and shaped to suit a particular application. For example, while two opposing dog-house sidewalls 220 are shown, in some instances the dog-house structure 106 may further include dog-house end walls formed to bridge the gap between a pair of dog-house sidewalls 220, thereby walling off three of the four sides of the chamber 218. In this example, the fastener 112 may only slide into the chamber 218 of the dog-house structure 106 through a single insertion opening, with movement restricted on three sides.

[0030] As shown, it may be useful to first insert a fastener 112 into the dog-house structure 106 of the first panel 102 (as indicated by first arrow 202) to form a PIA, and then assemble the first panel 102 and the second panel 104 by inserting the fastener 112 of the PIA into the opening 110 of the second panel 104 (as indicated by second arrow 204). In some examples, to assemble the through-dog-house based fastening system 100d, the head assembly 210 of the fastener 112 is slid laterally across the face of the first panel 102 into the chamber 218 until the fastener 112 stops (e.g., against a wall) or is otherwise aligned between the dog-house sidewalls 220. In some examples, the fastener 112 is held in place by an interference feature 222, which may exhibit a soft click when the fastener 112 is secured within the chamber 218. The now combined PIA component (FIG. 2b) with the first panel 102 and fasteners 112 can be shipped to a customer (e.g., an original equipment manufacturer (OEM)), who can then assemble the PIA component to a second panel (e.g., a vehicle panel) via all of the connected fasteners 112, as shown in FIG. 2c.

[0031] The dog-house structure 106 can position and locate the head assembly 210 of the fastener 112 in a fixed manner, or, if desired, provide the fastener 112 with some linear degree of freedom (e.g., float) to move within the chamber 218. A small dog-house may limit the positional float of the head assembly 210 within the chamber 218, but the positional freedom requirement can be achieved through the opening 110. Thus, the through-dog-house based fastening system 100d allows the dog-house structure 106 to directly interface with the opening 110, allowing the fastener 112, such as a W-type fastener, to be part of the datum or positioning solution.

[0032] The opening 110 can be sized to provide a desired amount of longitudinal movement 208a and / or lateral movement 208b. In some examples, the through-dog-house based fastening system 100d can be configured to accommodate two assembly tolerances or float (e.g., for thermal growth) in the longitudinal direction (length) of the opening 110. The longitudinal tolerance can be, for example, about ±1 mm to ±5 mm, or about ±3 mm. In other examples, a four-way version of the through-dog-house based fastening system 100d is contemplated, with lateral (width) and longitudinal tolerances. The longitudinal tolerance can be, for example, about ±1 mm to ±3 mm, or about ±1 mm. In some examples, the lateral tolerance is smaller than the longitudinal tolerance, resulting in an asymmetric tolerance or float solution (e.g., the longitudinal tolerance can be ±3 mm and the lateral tolerance can be ±1 mm). For example, as best shown in FIG. 2c, the aperture 110 can extend along its longitudinal axis to define a travel gap 206 that allows longitudinal movement 208a. The amount of lateral tolerance depends on the type of fastener 112 used. For example, the width of the aperture 110 cannot be wider than the width of the retention feature 216 when expanded, because the catch 216b must engage a portion of the aperture 110. In some examples, the aperture 110 can be dimensioned to provide minimal longitudinal movement 208a and / or lateral movement 208b, with an assembly gap of, for example, about ±0.25 mm.

[0033] Those skilled in the art will appreciate that the principles of the through dog-house based fastening system 100d can be used with various types of fasteners 112, provided that the head assembly 210 engages with the dog-house structure 106.

[0034] The end of the fastener 112 (e.g., neck portion 212 and / or collar portion 214) can be formed as any desired type of fastener 112. FIGS. 3a-3d respectively show a push pin fastener 112a, a pin and grommet (P&G) fastener 112b, a box-prong fastener 112c, and a specialty fastener 112d (e.g., a CenterLok™ fastener available from Delta™). As shown in FIG. 3a, the push pin fastener 112a (sometimes referred to as a tree, pine tree, Christmas tree, etc.) includes multiple barbs or teeth along its length. Referring to FIG. 3b, the P&G fastener 112b is a reusable, two-piece fastener with a low insertion value. The P&G fastener 112b can be a single-position fastener or a multi-position fastener. Each of the aforementioned fasteners can include a head assembly 210 that engages with the dog-house structure 106 and can be used in place of W-type fasteners to fasten components and panels together in close proximity, while still using the dog-house structure 106. In some examples, as shown in FIG. 3c, the through-the-dog-house based fastening system 100d can include a seal 302 positioned between the first panel 102 and the second panel 104. For example, the seal 302 can be used when it is desirable to mitigate dirt, dust, and / or moisture from passing through the opening 110. The seal 302 can be embodied as a ring (e.g., annular) and can be made of a foam material, a thermoplastic, a rubber, or the like. For example, as shown, the seal 302 can be configured to surround the dog-house structure 106 between the first panel 102 and the second panel 104. In some examples, the through-the-dog-house based fastening system 100d can include additional features, such as ribs and wings.

[0035] 4a and 4b illustrate an exemplary through-dog-house-based fastening system 100d configured with ribs 402. When assembled, the ribs 402 are located at the interface between the dog-house structure 106 and the first panel 102, between the first panel 102 and the second panel 104. The ribs 402 function as supports to strengthen and support the dog-house structure 106 (e.g., the dog-house sidewalls 220) and prevent over-travel, if desired or necessary. Thus, in some examples, the fastener 112 includes one or more ribs 402 that support the dog-house structure 106 and control over-travel.

[0036] 5a and 5b illustrate an exemplary through-dog-house based fastening system 100d configured with ribs 402 and wings 502. The wings 502, which may be flexible, help control overtravel and mitigate BSR. When assembled, the ribs 402 and wings 502 are located 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 press against the second panel 104 when assembled, effectively acting as a spring between the first panel 102 and the second panel 104, absorbing movement between the first and second panels.

[0037] While the dog-house structure 106 is illustrated as generally rectangular, other shapes are contemplated, including other quadrilateral shapes (e.g., square) and rounded shapes (e.g., circular and oval). For example, FIGS. 6a-6d illustrate an exemplary through-dog-house-based fastening system having a generally circular dog-house structure 602 and fasteners 112 (again illustrated as W-shaped fasteners). Similar to the through-dog-house-based fastening system of FIGS. 2a-2c, the dog-house structure 602 includes a pair of dog-house sidewalls 220. However, the dog-house sidewalls 220 are shaped to define a generally circular perimeter.

[0038] 7 is a flow diagram illustrating an exemplary method 700 for connecting a first panel 102 to a second panel 104 using a through-dog-house based fastening system having a dog-house structure 106 and a fastener 112. The fastener 112 has a head assembly 210 and a neck portion 212. In step 702, the head assembly 210 slides across the face of the first panel 102 into a chamber 218 of the dog-house structure 106. In step 704, at least a portion of the neck portion 212 and / or collar portion 214 passes through an opening 110 formed on the second panel 104. The neck portion 212 and / or collar portion 214 engages with the second panel 104 via a retention feature 216. In some examples, the retaining feature 216 includes a return arm 216a resiliently coupled to the collar portion 214, the return arm 216a being coupled to the collar portion 214 and flexing as the collar portion 214 passes through the opening 110. As mentioned above, in some examples, the retaining feature 216 is coupled to the neck portion 212 and the collar portion 214 is omitted. In step 706, at least a portion of the dog-house structure 106 is passed through the opening 110.

[0039] As noted above, it may be advantageous to seal the fasteners to prevent dirt, dust, and / or liquids from passing through the second panel 104 (e.g., through the openings 110). If sealing is necessary or desirable, the seals can be added in one of several different ways. In some examples, the seals can be pre-installed and / or molded integrally with the fasteners 112, allowing overmolded seals to be molded integrally with the fasteners 112 and delivered to the customer as a PIA.

[0040] 8a-8c illustrate an exemplary through-dog-house based fastening system 100d configured with a seal assembly 800. Specifically, FIGS. 8a and 8b illustrate a perspective view and a bottom plan view, respectively, of a fastener 112 having the seal assembly 800, and FIG. 8c illustrates a side view of the fastener 112 having the seal assembly 800 assembled to a first panel 102 and a second panel 104. The right portion of FIG. 8c is shown as a cross-section to better illustrate the placement of the seal 802.

[0041] The seal assembly 800 generally includes a seal portion 802 and a seal carrier 804. The seal carrier 804 is coupled to the fastener 112 by a temporary coupling 806. In some examples, the fastener 112 is molded as a single piece with the seal carrier 804 coupled to the fastener 112 by the temporary coupling 806. In other examples, the fastener 112 and the seal carrier 804 are fabricated separately and coupled by the temporary coupling 806. The seal carrier 804 transitions from the initial position to the deployed position by breaking the temporary coupling 806.

[0042] In one example, the seal carrier 804 is coupled to the fastener 112 at the collar portion 214 by a temporary coupling 806. In another example, the seal carrier 804 is coupled to the fastener 112 at the neck portion 212 by a temporary coupling 806. The temporary coupling 806 may be, for example, one or more of a frangible coupling (e.g., a thin, frangible feature such as a tether and a flush gate), a mechanical connection (e.g., a snap, clip, etc.), an adhesive, or any other suitable connection or coupling mechanism. As shown, the seal assembly 800 is dimensioned to surround the dog-house structure 106 when assembled between the first panel 102 and the second panel 104.

[0043] The seal portion 802 can be made from a foam material, a thermoplastic, a rubber, or the like. Examples of thermoplastics include polyethylene (PE), polyvinyl chloride (PVC), and the like, among others. In some examples, the seal portion 802 is overmolded onto a seal carrier 804 to form the seal assembly 800. Thus, in some examples, the seal carrier 804 is a rigid plastic structure, and the seal portion 802 is overmolded onto the seal carrier 804. The seal carrier 804 can be configured to engage and / or clip onto the fastener 112 or the dog-house structure 106. Referring to FIG. 8 a, the fastener 112 can be provided with the seal portion 802 and seal carrier 804 positioned in a temporary location (e.g., at or near the collar portion 214 or the end of the neck portion 212 opposite the head assembly 210). When the fastener 112 is inserted into the dog-house structure 106, the seal portion 802 and seal carrier 804 can be slid over the fastener 112 toward the head assembly 210 (e.g., toward the dog-house structure 106), as shown by arrow 808, breaking the temporary bond 806. Once the seal assembly 800 is in place, the fastener 112 can be inserted through the opening 110 in the second panel 104, after which the seal portion 802 and seal carrier 804 are sandwiched between the first panel 102 and the second panel 104, sealing the opening 110.

[0044] 9a-9f show perspective assembly views of a through-dog-house-based fastening system with a seal assembly during assembly according to one embodiment of the present disclosure. FIG. 9a shows a fastener 112 to which a seal assembly 800 is coupled via a temporary joint 806. As shown in FIGS. 9b and 9c, the head assembly 210 of the fastener 112 is slid laterally across the face of the first panel 102 into the chamber 218 until the fastener 112 stops (e.g., against a wall) or is otherwise aligned between the dog-house sidewalls 220. The first panel 102 and the second panel 104 can be flat or curved. For example, the first panel 102 can be formed with a first surface profile, and the second panel 104 can be formed with a second surface profile that is complementary to or corresponds to the first surface profile.

[0045] The seal assembly 800 is separated from its temporary initial position on the fasteners 112 using a force that breaks or otherwise separates the temporary bond 806, causing the seal assembly 800 to become separate from the fasteners 112. The force can be applied by manually pressing the second panel 104 against the seal assembly 800 with a tool, or by any other suitable method.

[0046] Referring to FIG. 9d, the seal assembly 800 is pressed against the fasteners 112 and placed in its final deployed position (e.g., around the dog-house structure 106). In some examples, the fasteners 112 or the dog-house structure 106 can be designed to secure the seal assembly 800 in its deployed position using, for example, clips, snaps, a press fit, or the like. The resulting PIA component 900, now consisting of the first panel 102, seal assembly 800, and fasteners 112, can be shipped to a customer (e.g., an OEM). The OEM can then assemble the PIA component 900 to a second panel (e.g., a vehicle panel) via all of the connected fasteners 112, as shown in FIGS. 9e and 9f.

[0047] As can be appreciated, the assembly steps shown in FIGS. 9a-9f can be performed by one or more entities. In some examples, as best shown in FIGS. 9a-9d, the seal assembly 800 can be installed (e.g., by a supplier) as a PIA component onto the fasteners 112 and dog-house structure 106 prior to shipment to a customer (e.g., an OEM). In such cases, the customer can then install the PIA onto the second panel 104, as best shown in FIGS. 9e and 9f. In some examples, the seal assembly 800 can be left in the position shown in FIG. 9c and later installed using force applied during final assembly with the second panel 104 (e.g., effectively skipping the step shown in FIG. 9d). However, there is a risk that the seal assembly 800 will become dislodged from the fasteners 112 or that the fasteners 112 will fall off the dog-house structure 106 during shipping to the customer. For this reason, it may be advantageous to install the seal assembly 800 after the fasteners 112 are placed within the dog-house structure 106, as shown in Figure 9d, before proceeding to the next assembly step. This also allows an operator to verify that the seal assembly 800 is properly seated. Additionally, by protecting the seal assembly 800 with the fasteners 112 and dog-house structure 106, it is much less likely to become dislodged before final assembly.

[0048] FIG. 10 is a flow diagram illustrating an exemplary method 1000 for forming a sealed blind joint between a first panel 102 and a second panel 104 via a dog-house structure 106, a fastener 112 having a head assembly 210, and a seal assembly 800. In step 1002, the head assembly 210 slides across the face of the first panel 102 into the chamber 218 of the dog-house structure 106. In step 1004, the seal assembly 800 slides or otherwise transitions from an initial position to a deployed position. The seal assembly 800 includes a seal portion 802 and a seal carrier 804. In some examples, the initial position is at or adjacent to the collar portion 214 of the fastener 112, and the deployed position is at or adjacent to the head assembly 210. In some examples, the seal portion 802 is overmolded onto the seal carrier 804. The seal carrier 804 can be coupled to the fastener 112 in an initial position via a temporary joint 806. For example, the temporary joint 806 is a flush gate formed during the plastic injection process. In step 1006, a portion of the fastener 112, such as the neck portion 212, the collar portion 214, or portions thereof, passes through an opening 110 formed on the second panel 104.

[0049] FIG. 11 is a flow diagram depicting an example method 1100 of manufacturing a fastening system. In step 1102, the fastener 112 is formed by a plastic injection process, where 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 bond 806. For example, the temporary bond 806 is a flush gate formed during the plastic injection process. In some examples, the seal carrier 804 is coupled directly to the neck 212 or to the neck 212 via a collar 214. The seal carrier 804 separates from the neck 212 or the collar 214 via the temporary bond 806 and deploys relative to the head assembly 210. In step 1104, the seal 802 is overmolded onto the seal carrier 804.

[0050] Although the present method and / or system has been described with reference to certain specific embodiments, those skilled in the art will recognize that various modifications and equivalents may be substituted without departing from the scope of the present method and / or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope of the present disclosure. For example, blocks and / or components of the disclosed examples may be combined, divided, rearranged, and / or otherwise modified. Therefore, the present method and / or system is not limited to the particular embodiments disclosed. Instead, the present method and / or system includes all embodiments falling within the scope of the appended claims, both literally and under the doctrine of equivalents. Some aspects of the invention are described below. [Aspect 1] 1. A fastening system for forming a sealed blind joint between a first panel and a second panel, comprising: a fastener for holding the second panel through an opening formed in the second panel, the fastener including a head assembly that engages with a dog-house structure positioned on the first panel; A fastening system comprising: a seal assembly having a seal portion and a seal carrier, the seal carrier being coupled to the fastener via a temporary joint. [Aspect 2] 10. The fastening system of claim 1, wherein the temporary bond is an adhesive. [Aspect 3] 2. The fastening system of claim 1, wherein the temporary bond is a frangible bond. [Aspect 4] 2. The fastening system of claim 1, wherein the temporary connection is a mechanical connection. [Aspect 5] 10. The fastening system of claim 1, wherein the fastener and the seal carrier are fabricated as a single piece. [Aspect 6] The fastening system of claim 5, wherein the fastener and the seal carrier are made by a plastic injection process. [Aspect 7] 7. The fastening system of claim 6, wherein the temporary joint is a flush gate formed during the plastic injection process. [Aspect 8] 2. The fastening system of claim 1, wherein the seal carrier is a rigid plastic structure and the seal portion is overmolded onto the seal carrier. [Aspect 9] 10. The fastening system of claim 1, wherein the seal carrier transitions from the initial position to the deployed position by breaking the temporary bond. [Aspect 10]

[0023] Aspect 10. The fastening system of aspect 9, wherein the seal carrier engages features of the fastener to secure the seal carrier in the deployed position. [Aspect 11] 10. The fastening system of claim 9, wherein the seal carrier surrounds the dog-house structure when in the deployed position. [Aspect 12] 2. The fastening system of claim 1, wherein the dog-house structure is configured to pass at least partially through the opening. [Aspect 13] 1. A method of forming a sealed blind joint between a first panel and a second panel via a dog-house structure, a fastener having a head assembly, and a seal assembly, comprising: sliding the head assembly across the face of the first panel and into a chamber of the dog-house structure; Sliding the seal assembly, including the seal portion and the seal carrier, from an initial position to a deployed position; and inserting a portion of the fastener through an opening formed on the second panel. [Aspect 14] 14. The method of claim 13, wherein the initial position is located at or adjacent to a collar of the fastener and the deployed position is located at or adjacent to the head assembly. [Aspect 15] 14. The method of claim 13, wherein the seal carrier is coupled to the fastener in the initial position via a temporary joint. [Aspect 16] 16. The method of claim 15, wherein the temporary joint is a flash gate formed during a plastic injection process. [Aspect 17] 1. A method of manufacturing a fastening system, comprising: forming a fastener by a plastic injection process, the fastener having a head assembly, a neck portion, and a seal carrier, the seal carrier being connected to the neck portion by a temporary joint; and overmolding a seal onto the seal carrier. [Aspect 18] 18. The method of claim 17, wherein the temporary joint is a flash gate formed during the plastic injection process. [Aspect 19] 18. The method of claim 17, wherein the seal carrier is coupled to the neck portion via a collar portion. [Aspect 20] 18. The method of claim 17, wherein the seal carrier separates from the neck portion via the temporary joint and deploys toward the head assembly. [Explanation of symbols]

[0051] 100a fastening system 100b fastening system 100c fastening system 100d fastening system 102 First Panel 102a A side 102b Side B 104 Second Panel 106 Doghouse Structure 108 Tower section 110 Aperture 112 Fasteners 112a Pin fastener 112b Grommet fastener 112c Box Prong Fastener 112d Special fasteners 114 Recessed Panel 202 First Arrow 204 Second Arrow 206 Moving Gap 208a Move 208b Move 210 Head assembly 212 Neck 214 Color Section 216 Retention feature 216a Arm 216b Catch part 218 Chamber 220 Doghouse side wall 222 Interference Features 302 Seal part 402 Ribs 502 Wing 602 Doghouse Structure 700 methods 702 steps 704 steps 706 steps 800 Seal Assembly 802 Seal part 804 Seal Carrier 806 Temporary joint 808 Arrow 900 PIA parts

Claims

1. 1. A fastening system for forming a sealed blind joint between a first panel and a second panel, comprising: a fastener for holding the second panel through an opening formed in the second panel, the fastener including a head assembly that engages a dog-house structure positioned on the first panel; a seal disposed between the first and second panels and connected to the fastener via a temporary joint; The fastening system wherein the seal transitions from an initial position to a deployed position by breaking the temporary bond, and in the deployed position, the seal surrounds at least a portion of the head assembly.

2. A fastening system as described in claim 1, wherein the temporary joint is an adhesive.

3. A fastening system as described in claim 1, wherein the temporary joint is a weak joint.

4. A fastening system as described in claim 1, wherein the temporary connection portion is a mechanical connection portion.

5. A fastening system as described in claim 1, wherein the seal portion is coupled to the fastener via a seal carrier, the seal carrier being a rigid plastic structure, and the seal portion being overmolded onto the seal carrier.

6. A fastening system as described in claim 5, wherein the fastener and the seal carrier are fabricated as a single part.

7. A fastening system as described in claim 6, wherein the fastener and the seal carrier are manufactured by a plastic injection process, and the temporary joint is a flash gate formed during the plastic injection process.

8. A fastening system as described in claim 5, wherein the seal carrier engages with a feature of the fastener to secure the seal carrier in the deployed position.

9. A fastening system as described in claim 5, wherein the seal carrier surrounds the doghouse structure when in the deployed position.

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

11. A fastening system as described in claim 1, wherein the sealing portion is made of at least one of a foam material, a thermoplastic plastic, or rubber.

12. A fastening system as described in claim 5, wherein the seal carrier engages with a feature of the doghouse structure to secure the seal carrier in the deployed position.

13. 1. A fastening system for forming a sealed blind joint between a first panel and a second panel, comprising: a fastener for holding the second panel through an opening formed in the second panel, the fastener including a head assembly for engaging the first panel; a seal disposed between the first and second panels and connected to the fastener via a temporary joint; The fastening system wherein the seal transitions from an initial position to a deployed position by breaking the temporary bond, and in the deployed position, the seal surrounds at least a portion of the head assembly.

14. A fastening system as described in claim 13, wherein the seal portion is coupled to the fastener via a seal carrier, the seal carrier being a rigid plastic structure, and the seal portion being overmolded onto the seal carrier.

15. A fastening system as described in claim 14, wherein the fastener and the seal carrier are fabricated as a single part.

16. A fastening system as described in claim 15, wherein the fastener and the seal carrier are fabricated by a plastic injection process, and the temporary joint is a flash gate formed during the plastic injection process.

17. A fastening system as described in claim 14, wherein the seal carrier engages with a feature of the fastener to secure the seal carrier in the deployed position.

18. A fastening system as described in claim 14, wherein the head assembly engages with the first panel via a doghouse structure disposed on the first panel, and the seal carrier, in its deployed position, has a seal portion that surrounds at least a portion of the head assembly.

19. The fastening system described in claim 18, wherein the doghouse structure is configured to pass at least partially through the opening.

20. 1. A fastening system for forming a sealed blind joint between a first panel and a second panel, comprising: a dog-house structure disposed on the first panel; a fastener for holding the second panel through an opening formed in the second panel, the fastener including a head assembly that engages the dog-house structure; a seal disposed between the first and second panels and connected to the fastener via a temporary joint; The fastening system wherein the seal transitions from an initial position to a deployed position by breaking the temporary bond, and in the deployed position, the seal surrounds at least a portion of the head assembly.

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