Fabric securing components and methods

Abstract

A fabric is secured to a surface, structure or object using cooperating mounting components. A first component is installed in a hole formed in the fabric and cooperates with a second component that attaches to the surface, structure or object. The first component includes a head and a stem extending from the head. The stem has a number of thread formations and an unthreaded stem section between the head and the thread formations. The first component is installed on the fabric by applying a turning force to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section.

Description

[0001] FABRIC SECURING COMPONENTS AND METHODS

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] This application relates to and claims priority from United States provisional application No. 63 / 541,526 filed 29 September 2023, the entire contents of which are incorporated herein by reference.

[0004] BACKGROUND OF THE INVENTION

[0005] Field of the Invention

[0006] The invention relates to mounting or securing of fabrics, for example to surfaces, structures or objects.

[0007] Description of the Related Art

[0008] Various mounting arrangements are used for detachably mounting fabrics in different applications. In other applications, fabrics may be permanently or semi-permanently attached (e.g. by gluing carpets down).

[0009] The current invention is concerned with detachable mounting of fabrics, and not with permanent or semipermanent mounting of fabrics.

[0010] In marine applications, carpets, rugs or mats may be detachably mounted to a deck or floor. This is usually done using stainless-steel press studs. Other clips are used in automotive industries, e.g. for securing carpets in footwells.

[0011] Existing clips and studs suffer from a number of drawbacks.

[0012] Installation of existing studs is often difficult and may require specialised tools and equipment, such as clinching presses. This is problematic outside of factory settings. Easier to install clips may not provide a secure attachment to the fabric, or of the fabric to the supporting surface.

[0013] Metal studs or clips can become very hot, particularly when exposed to the sun. This is particularly problematic in marine applications, since crew members and passengers are often bare-foot and may burn their feet on the hot metal hardware.

[0014] Existing hardware can also be visually unappealing.

[0015] It would be desirable to provide improved components and / or methods for mounting fabrics, or at least to provide the public with a useful choice. SUMMARY OF THE INVENTION

[0016] In one embodiment a fabric securing assembly is provided, for detachably securing a fabric to a surface, structure or object. The assembly may include a first component configured for installation in a hole formed in the fabric. The first component may include a head and a stem extending from the head. The stem may have one or more thread formations and an unthreaded stem section between the head and the thread formations. The first component may be arranged, in use, to be installed on the fabric by applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section. The first component may also include one or more first engagement elements. The assembly may also include a second component arranged to attach, in use, to the surface, structure or object and including one or more second engagement elements arranged to cooperate with the first engagement elements to secure the fabric to the surface, structure or object.

[0017] The fabric may be a deck covering, floor covering, carpet, rug or mat and the surface, structure or object may be a deck or floor. The fabric may be a textile, wall covering, wall hanging, tarpaulin, shade cloth or shade sail.

[0018] The head may sit against a facing surface of the fabric. The head may have one or more drive formations arranged to receive a turning force from a drive tool during installation of the first component on the fabric. The one or more drive formations may include one or more slots, cavities or protrusions.

[0019] The unthreaded stem section may have a length suitable to receive a desired thickness of fabric, such that the thread formations pass entirely through the thickness of the fabric when the first component is installed on the fabric. The unthreaded stem section may be 2 to 12 mm long. The unthreaded stem section may be 3 to 5 mm long. The unthreaded stem section may be 7 to 12 mm long.

[0020] A diameter of the unthreaded stem section may be approximately the same as a diameter of the hole in the fabric.

[0021] The one or more thread formations may include a plurality of separate thread tabs, wherein each thread tab has a lead-in from a minimum thread diameterto a maximum thread diameter. The minimum thread diameter may be the same as the diameter of the unthreaded stem section. The one or more thread formations may include 2 to 6 separate thread tabs. The one or more thread formations may include 4 separate thread tabs.

[0022] An upper surface of each thread tab may sit against a back surface of the fabric when installed. The second component may be arranged to attach, in use, to the surface, structure or object using a fastener. The second component may be arranged to attach, in use, to the surface, structure or object using an adhesive. The second component may be arranged to be sewn, in use, to the surface, structure or object.

[0023] The first and second engagement elements may provide a detachable engagement between the first and second components.

[0024] The first engagement element may include a recess having an opening, a constriction and a relief, and the second engagement element may include a stud having one or more protrusions; such that, on engagement of the first and second components, the one or more protrusions move past the constriction and reside in the relief.

[0025] The first component may be formed from a moulded plastic material. The moulded plastic material may be acetal or glass-reinforced nylon. The moulded plastic material may be a translucent, frosted material.

[0026] In one embodiment a method of securing a fabric to a surface, structure or object, may include forming a hole in the fabric and installing a first component on the fabric. The first component may include a head and a stem extending from the head. The stem may have one or more thread formations and an unthreaded stem section between the head and the thread formations. The first component may also include one or more first engagement elements. Installing the first component onto the fabric may include applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section. The method may include engaging the one or more first engagement elements with one or more second engagement elements of a second component that is attached to the surface, structure or object, thereby securing the fabric to the surface, structure or object.

[0027] In one embodiment a fabric securing component may be configured to engage with a hole formed in a fabric. The component may include a head and a stem extending from the head. The stem may have one or more thread formations and an unthreaded stem section between the head and the thread formations. The first component may be arranged, in use, to engage with the fabric by applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section. The component may also include one or more engagement elements configured to engage with cooperating engagement elements of a further component to secure the fabric to a surface, structure or object.

[0028] The other aspects, features, objects, and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings for exemplary but nonlimiting embodiments, in which like reference numerals designate related elements. The above presents a simplified summary of the invention as claimed below in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.

[0029] BRIEF DESCRIPTION OF DRAWINGS

[0030] The invention will be described by way of example only, with reference to the accompanying drawings, in which:

[0031] Figure 1 shows a first component according to one embodiment;

[0032] Figure 2 is a side view of the component of Figure 1;

[0033] Figure 3 is a further side view of the component of Figure 1;

[0034] Figure 4 shows an underside of the component of Figure 1;

[0035] Figure 5 is a top view of the component of Figure 1;

[0036] Figure 6 is a bottom view of the component of Figure 1;

[0037] Figure 7 is a cross-section along the line 7'-7' in Figure 3;

[0038] Figure 7A is an enlarged view of the region marked "A" in Figure 7;

[0039] Figure 8 shows the component of Figure 1 installed in a fabric;

[0040] Figure 9 is a top view of the component of Figure 1 installed in a fabric;

[0041] Figure 10 is a side view of the component of Figure 1 installed in a fabric;

[0042] Figure 11 is a cross-section along the line ll'-ll' in Figure 9;

[0043] Figure 12 shows a second component according to one embodiment;

[0044] Figure 13 is a cross-section through the second component of Figure 12;

[0045] Figure 13A is an enlarged view of the region marked "A" in Figure 13;

[0046] Figure 14 shows a second component according to another embodiment;

[0047] Figure 15 is a cross-section through the second component of Figure 14;

[0048] Figure 15A is an enlarged view of the region marked "A" in Figure 15; Figure 16 shows the first component of Figure 1 and the second component of Figure 14 cooperating to secure a fabric to a surface;

[0049] Figure 17 is a top view corresponding to Figure 16;

[0050] Figure 18 is a side view of the first component of Figure 1 and the second component of Figure 15 cooperating to secure a fabric to a surface; and

[0051] Figure 19 is a cross-section along the line 19'-19' in Figure 17.

[0052] DESCRIPTION OF PREFERRED EMBODIMENTS

[0053] Figures 1 to 7A show a first or female component 1 according to one embodiment. Figures 8 to 11 show the first component 1 of Figures 1 to 7A installed on a fabric 2.

[0054] Referring to Figures 1 to 7 , the first component 1 may include a head 3 and a stem 4. The stem 4 may include a bare or unthreaded section 5, which may be positioned between the head 3 and a number of thread formations 6. In the embodiment shown, the thread formations are four thread tabs 6, but any number of thread tabs (e.g. 2, 3, 4, 5, 6 or more thread tabs) or continuous threads of any suitable type may be used. The first component 1 may also include a recess, bore or other female element 7, which is arranged to engage with cooperating features of a further component, as will become clear below.

[0055] The head 3 may be formed with one or a number of drive formations 8, allowing a turning force to be applied to the first component 1 using a drive or installation tool (not shown). In the embodiment shown the drive formations are a pair of recesses or slots, which are chosen to fit with an existing drive tool in the Applicant's tool range (Applicant's CT-10 installation tool). However, any suitable drive formation may be used, including e.g. any one or more of: slots, recesses, cavities, holes, protrusions, internal shapes, external shapes, or any suitable combination thereof. Any suitable drive tool that cooperates with the chosen drive formations may be used, including e.g. screwdrivers, pin wrenches, spanners, hex keys, torx wrenches or any suitable proprietary drive tools.

[0056] The first component may be installed into a hole or aperture formed in a fabric 2. The hole or aperture may be created by any suitable method, including punching, cutting, stamping or otherwise penetrating the fabric. Punching may be advantageous, since it allows an accurate hole to be quickly formed with a small number of tools and may easily be performed at the site of the installation. The hole may have a diameter approximately the same as the diameter of the stem 4. This can be seen, for example, in Figure 11 where the edge 5a of the hole in fabric 2 sits around the unthreaded section 5 of the stem 4.

[0057] The distal end 10 of the stem 4 may be introduced into the hole in the fabric 2. Applying a turning force to the head 3 with a suitable driving or installation tool causes thread formations 6 to engage with the hole and drive the thread formations 6 and stem 4 through the hole. Each thread formation may have a tapered lead-in, which helps the thread to begin engaging with the hole. In the embodiment shown, each thread tab has a continuous outer edge 12 extending from the lead-in 11, where the threads merge with the diameter of the stem 4, to a maximum thread diameter at their upper extremity 13. The thread tabs 6 may be considered to define a diameter that increases continuously from a minimum thread diameter (which in the embodiment shown is the same as the stem diameter) to the maximum thread diameter at upper edge 13.

[0058] In some forms, the first component 1 may be installed by hand, the hand applying the turning force to the head 1 to cause the thread formations 6 to engage with the hole and drive the thread formations 6 and stem 4 through the hole, i.e. without using a drive or installation tool (not shown).

[0059] As shown most clearly in Figures 2, 3, 10 and 11, the unthreaded section 5 between the upper edge 13 of thread formations 6 and the underside of the head 3 may be sized to receive a desired thickness of fabric. For example, a length of the unthreaded section may be around 4mm, for thin carpets and rugs often used in marine applications, which may be around 4mm thick. When installed, the thickness of the carpet may be accommodated entirely in this unthreaded section (see Figures 10 and 11). That is, after installation, the thread formations may no longer be engaged within the thickness of the fabric but may have been driven all the way through the fabric 2. The fabric may be securely held between the head 3 and the upper edge or shoulder 13 of the thread tabs 6, with the underside of the head sitting against a front or facing side of the fabric 2 and the upper edge or shoulder 13 sitting against a back side of the fabric 2.

[0060] In other embodiments, the length of the unthreaded section may have any suitable length for a desired fabric thickness. In general, for many applications, the unthreaded section may be 2 to 12mm in length. A length around 3 to 5mm, or around 4mm, may be suitable for marine carpets having a thickness around 4. A length around 7 to 12mm, or around 8 to 10mm, or around 8mm, may be suitable for thicker marine carpets having a thickness around 8mm.

[0061] Figures 12 to 13A show a second component 20 according to one embodiment. Figures 14 to 15A show a second component 20' according to a further embodiment. These components differ in the way they are secured or attached to a structure, surface or object but engage with the first component in the same way.

[0062] The second component 20 of Figures 12 to 13A may be configured to receive a fastener for attaching the second component 20 to a structure, surface or object. The fastener may be any suitable screw, nail, rivet, bolt or other type of fastener, and the second component 20 may include features adapted to the particular fastener to be used. In the embodiment shown in Figures 12 to 13A, the second component 20 includes a countersunk bore 21 configured to receive a countersink headed wood screw or machine screw.

[0063] The second component 20' of Figures 14 to 15A may include a larger base or flange 22, providing greater surface area for mounting or attaching the second component 20' using an adhesive. Any suitable glue, adhesive tape or other adhesive may be used. The second component 20' may be supplied with adhesive (e.g. a 3M™ VHB™ tape) already applied and protected by a peelable cover.

[0064] In further embodiments, the second component may be attached, secured or mounted to a surface, structure or object in any suitable manner, including fasteners, adhesives, sewing or any other suitable manner.

[0065] The second component 20, 20' may include one or more engagement elements that cooperate with corresponding engagement elements in the first component to secure the fabric 2 to a surface, structure or object. In the embodiments shown, these engagement elements include internal elements in the bore 7 of the first or female component 1 and external elements of the boss or stud 24 of the second or male component 20, 20'. However, the skilled reader will understand that many combinations of cooperating engagement elements are possible.

[0066] Referring to Figures 7 and 7A, the bore 7 may include an opening 25, tapering to a constriction 26 with a relief 1 positioned past the constriction 26. The constriction may be in the form of an annular region of lesser diameter than the relief 27.

[0067] Referring to Figures 13 and 15, the second component 20, 20' has a boss or stud 24 with a protrusion 28 that has a diameter greater than the neck 29. The protrusion 28 may be a continuous, annular protrusion as shown, but other arrangements of one or more features may be used.

[0068] Figure 19 shows the first and second cooperating engagement elements in the installed mounting assembly. The top of the second component's stud 24 has moved into the relief 27, with the second engagement element 28 now sitting above the first engagement element 26 to mount the fabric 2 to the structure, surface or object 30.

[0069] The arrangement shown allows a detachable or removable mounting of the fabric 2 to the structure, surface or object 30. The first component 1 can be removed from the second component 20, and may be later reattached. The mounting assembly arrangement allows for repeated engagement and disengagement of the first component 1 to and from the second component 20, 20' to facilitate the mounting and demounting of the fabric 2 to the structure, surface or object 30. For example, when used in marine applications, the fabric 2, such as carpets, rugs or mats may be detachably mounted to a deck or floor to facilitate removal of the fabric 2 for cleaning of the deck or floor. The force required to attach or detach the first component from the second component may be altered by design of the first and second engagement elements (including sizes and shapes) and / or by selection of materials. For example, in the embodiments shown and where acetal or glass-reinforced nylon is used, the required force depends on the relative dimensions of the constriction 26 and protrusion 28 and can be altered by changing one or both of these dimensions.

[0070] Installation of the Applicant's mounting assembly may involve the following. A hole may be formed (e.g. punched) in the fabric for each mounting assembly. The required positions of the second components may be laid out on the surface, structure or object (e.g. by positioning the fabric in place and marking through the holes, or using a template or in any other suitable manner). A second component may be secured, attached or mounted in each required position. A first component 1 may be installed in each hole. The first and second components may be engaged with each other to secure the fabric to the surface, structure or object.

[0071] The Applicant’s invention may be used in securing any suitable fabric to any suitable structure, surface or object. The fabric may be a carpet, rug, mat, floor covering, other covering, textile, wall hanging, tarpaulin, canvas, rubber, shade sail, shade cloth or any other fabric. The fabric may be mounted to a deck (e.g. a boat deck) or floor, wall, ceiling, fence, structural frame, machinery, vehicle body etc.

[0072] Components of the Applicant's mounting arrangement may be formed from any suitable material. The first component may be formed from a plastic, including a moulded plastic. Acetal plastic may be used. Alternatively, a glass-reinforced nylon material may be used. Other plastics may also be suitable.

[0073] For exterior or marine applications, suitable UV stabilisers may be used as is well known in the field. Other known plastic additives, such as impact modifiers, may also be used.

[0074] In some embodiments the first component may be formed from a translucent plastic material, preferably with a frosted appearance. The frosted appearance may be achieved using any suitable additives and / or surface treatments. This allows the colour of the fabric to come through the plastic, improving the aesthetics of the installed first component and allowing the same component to be used with a range of fabric colours and / or patterns.

[0075] However, in other embodiments the first component may be coloured to provide a desired colour match or colour contrast.

[0076] In marine applications, the plastic material helps the first component to stay relatively cool (when compared to current stainless steel studs), such that crew and passengers are less likely to burn their feet.

[0077] Other components may be formed from the same material as the first component, but in some embodiments the second component may be formed from a different plastic material. For many embodiments, the materials used should allow limited deformation, to allow cooperating engagement elements to come together and be separated repeatedly while providing a sufficiently strong connection and acceptable product life.

[0078] While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in anyway limit the scope of the appended claims to such detail. Further, the above embodiments may be implemented individually, or may be combined where compatible. Additional advantages and modifications, including combinations of the above embodiments, will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept.

[0079] The detailed description is made with reference to the accompanying drawings and is provided to assist in a comprehensive understanding of various example embodiments of the present disclosure. Changes may be made in the function and arrangement of elements discussed without departing from the spirit and scope of the disclosure. Various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, features described with respect to certain embodiments may be combined in other embodiments. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the examples described herein can be made without departing from the spirit and scope of the present disclosure.

[0080] Various modifications to the disclosure will therefore be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the present disclosure. Throughout the present disclosure the terms "example," "examples," or "exemplary" indicate examples or instances and do not imply or require any preference for the noted examples. Thus, the present disclosure is not to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed.

Claims

WHAT IS CLAIMES IS:

1. A fabric securing assembly for detachably securing a fabric to a surface, structure or object, including: a first component configured for installation in a hole formed in the fabric, the first component including: a head; a stem extending from the head, the stem having one or more thread formations and an unthreaded stem section between the head and the thread formations, wherein the first component is arranged, in use, to be installed on the fabric by applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section; and one or more first engagement elements; and a second component arranged to attach, in use, to the surface, structure or object and including one or more second engagement elements arranged to cooperate with the first engagement elements to secure the fabric to the surface, structure or object.

2. A fabric securing assembly as claimed in claim 1 wherein the fabric is a deck covering, floor covering, carpet, rug or mat and the surface, structure or object is a deck or floor.

3. A fabric securing assembly as claimed in claim 1 wherein the fabric is a textile, wall covering, wall hanging, tarpaulin, shade cloth or shade sail.

4. A fabric securing assembly as claimed in claim 1 wherein the head sits against a facing surface of the fabric.

5. A fabric securing assembly as claimed in claim 1 wherein the head has one or more drive formations arranged to receive a turning force from a drive tool during installation of the first component on the fabric.

6. A fabric securing assembly as claimed in claim 5 wherein the one or more drive formations include one or more slots, cavities or protrusions.

7. A fabric securing assembly as claimed in claim 1 wherein the unthreaded stem section has a length suitable to receive a desired thickness of fabric, such that the thread formations pass entirely through the thickness of the fabric when the first component is installed on the fabric.

8. A fabric securing assembly as claimed in claim 7 wherein the unthreaded stem section is 2 to 12 mm long.

9. A fabric securing assembly as claimed in claim 7 wherein the unthreaded stem section is 3 to 5 mm long.

10. A fabric securing assembly as claimed in claim 7 wherein the unthreaded stem section is 7 to 12 mm long.

11. A fabric securing assembly as claimed in claim 1 wherein a diameter of the unthreaded stem section is approximately the same as a diameter of the hole in the fabric.

12. A fabric securing assembly as claimed in claim 1 wherein the one or more thread formations include a plurality of separate thread tabs, wherein each thread tab has a lead-in from a minimum thread diameter to a maximum thread diameter.

13. A fabric securing assembly as claimed in claim 12 wherein the minimum thread diameter is the same as the diameter of the unthreaded stem section.

14. A fabric securing assembly as claimed in claim 1 wherein the one or more thread formations include 2 to 6 separate thread tabs.

15. A fabric securing assembly as claimed in claim 1 wherein the one or more thread formations include 4 separate thread tabs.

16. A fabric securing assembly as claimed claim 12 wherein an upper surface of each thread tab sits against a back surface of the fabric when installed.

17. A fabric securing assembly as claimed in claim 1 wherein the second component is arranged to attach, in use, to the surface, structure or object using one or more of the following:(i) a fastener;(ii) an adhesive; or(iii) by sewing.

18. A fabric securing assembly as claimed in claim 1 wherein the first and second engagement elements provide a detachable engagement between the first and second components.

19. A fabric securing assembly as claimed in claim 1 wherein the first engagement element includes a recess having an opening, a constriction and a relief, and the second engagement element includes a stud having one or more protrusions; such that, on engagement of the first and second components, the one or more protrusions move past the constriction and reside in the relief.

20. A fabric securing assembly as claimed in claim 1 wherein the first component is formed from a moulded plastic material.

21. A fabric securing assembly as claimed in claim 20 wherein the moulded plastic material is acetal or glass-reinforced nylon.

22. A fabric securing assembly as claimed in claim 20 or 21 wherein the moulded plastic material is a translucent, frosted material.

23. A method of securing a fabric to a surface, structure or object, including: forming a hole in the fabric; installing a first component on the fabric, the first component including: a head; a stem extending from the head, the stem having one or more thread formations and an unthreaded stem section between the head and the thread formations; and one or more first engagement elements; wherein installing the first component ono the fabric includes applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section; and engaging the one or more first engagement elements with one or more second engagement elements of a second component that is attached to the surface, structure or object, thereby securing the fabric to the surface, structure or object.

24. A fabric securing component configured to engage with a hole formed in a fabric, the component including: a head; a stem extending from the head, the stem having one or more thread formations and an unthreaded stem section between the head and the thread formations, wherein the first component is arranged, in use, to engage with the fabric by applying a turning force to the first component to drive the thread formations through the hole such that the fabric is positioned around the unthreaded stem section; and one or more engagement elements configured to engage with cooperating engagement elements of a further component to secure the fabric to a surface, structure or object.

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