CROSS-REFERENCE TO RELATED APPLICATIONS

[0601 J This application claims the benefit of, and priority from, US Provisional Application 61/773,986 having a filing date of March 7, 2013. The contents of such application and all other referenced documents are hereby incorporated by reference in their entirety as if set forth fully herein.

TECHNICAL FIELD

[0002] The present disclosure relates to fasteners, and more particularly, to fasteners for assemblies requiring quick and easy attachment with strong retention. Still more particularly the invention pertains to fastener assemblies suitable for side curtain airbag installations i motor vehicles and similar uses.

BACKGROUND

[0063] Side curtain airbags are used as an additional measure of passenger safety in automobiles. A side curtain airbag assembly is typically retained behind interior trim of the head-liner, just above the vehicle side window. During a crash event, the airbag is deployed between the vehicle occupant and the window or other side structures of the vehicle. Upon deployment, the side curtain airbag provides a degree of cushioning as well as a barrier against imdesired ejection of the vehicle occupants.

[0004] A fastener for holding a side curtain airbag in place must be strong enough to retain the airbag assembly in place even during aggressi ve, rapid deployment of the air bag during a vehicle crash event. Moreover, it is necessary also to retai a side curtain airbag assembly in a fixed position without rattling during vehicle operation. In a preferred practice, the fastener can

I be inserted quickly and easily in a simpl operation, yet has strong retention force. Still further desirable is a fastener assembly that is conducive to pre-assembly steps so that final installation of the airbag assembly can be performed quickly and efficiently at the point of vehicle assembly.

18005} One known fastener assembly for side curtain airbags includes a bolt and a weld nut of standard design. The use of such a fastener assembly requires providing an opening by punching or stamping a frame-like member of the vehicle roof structure and securing a nut in the correct location by welding or similar techniques. This process requires an additional manufacturing step for welding the nut in place, in addition to the subsequent securing steps for installing the airbag assembly in position. As will be appreciated, such assembly practices can be time consuming and complex, including positioning the bag in the proper location, separately acquiring a bolt, inserting the bolt through the bag assembly, and rotating the bolt into the out that was welded in place in the roof structure during a previous step. This type of fixation is robust but can be expensive in materials and assembly costs. Further, it is necessary to fix the bolt in the tightened position so that vibrations during subsequent operation of the vehic le do not cause the bolt to work loose and back out of the weld nut.

(0100} Another fastener assembly is disclosed in US Patent 7,837,225 the contents of which are hereby incorporated herein by reference. That patent discloses an airbag fastener assembly with a body having first and second body components foldable one against another for capturing a portion of an airbag assembly therebetween. A collet affixed to one of the body components extends through the other of the body components when the body components are folded together, A pin secures the collet in a vehicle. While such an arrangement may provide an excellent final connection, in some instances it may be desirable to attach the fastener assembly to the airbag assembly at a location remote for shipment to the point of vehicle assembly and to thereafter provide a simple connection procedure for final assembly with the vehicle. [0006 ^' j Accordingly, while prior assemblies are believed to be fully functional, further advancements in fastener assembly structures and installation processes to promote secure attachment with reduced complexity may be desirable and advantageous.

SUMMARY

[0007) According to one exemplary feature, the present disclosure provides a fastener adapted to clip onto an airbag at a preliminary assembly stage for subsequent final installation of the air bag to the vehicle in a simple, rapid step. In one exemplary construction, the present disclosure provides a clip including an insertable pin for receipt within a body to force apart a pair of locking legs on the body to a first degree for use in securing the body to an opening in the airbag assembly and to a second degree for attachment to a roof rail or other vehicle support structure. The body has first and second body components which mate against one against an other for capturing a portion of an airbag assembly therebetween when the pin i s inserted and retained to a first degree. Thereafter, the locking legs on the bod may be inserted into a receiving opening in the roof rail or other vehicle support structure and the pin may be lockingiy inserted and retained to the second degree more deeply within the body so as to spread and hold the legs in locking relation within the receiving opening.

[0008J In accordance with one exemplary aspect, the present disclosure provides a fastener assembly adapted for stable attachment to an airbag in a first stage of use and subsequent locking attachment to a vehicle support structure in a second stage of use. The fastener assembly includes a body having an anchoring body component defining a concave receiving well and an outwardly projecting integral latch structure of spilt leg construction extending away from the underside of the receiving well. A back plate body component is adapted to matedly engage the latch structure and capture a portion of an airbag assembly between the anchoring body component and the back plate body component. The fastener assembly further includes a variable diameter pin having a shank portion extending away from a head portion. The head portion is of greater diameter than the shank portion. The shank portion is adapted to pass through an opening in the anchoring body component for disposition at the interior of the latch structure, so as to increase the effective diameter of the latch structure when the shank portion is fully inserted. The head portion includes at least one rib structure projecting from the underside of the head portion. The anchoring body component includes at least one integral down wardly descending ramp structure including a notch adapted to receive anti retain the rib structure at a preliminary stage of insertion of the s hank portion into the latch structure. The rib structure and the notch are adapted to cooperatively permit the rib structure to rise out of the notch upon application of torque to the head portion by a driving tool. The ramp structure is adapted to thereafter guide the head portion downwardly during continued clockwise rotation by the driving too! to a final stage of insertion of the shank portion into the latch structure wherein the shank portion holds the latch structure in an expanded condition.

[0009) A method of establishing a connection between an airbag and a vehicle using a fastener consistent with the present disclosure is also provided. Other exemplary aspects and features will become apparent upon review of the following detailed description of potentially preferred embodiments and accompanying drawings.

BRIEF DESCRIPTION OF THE DRA WINGS

[OOIOJ FIG. 1. is a schematic cross-sectional view of an exemplary side curtain airbag assembly illustrating a fastener consistent with the present disclosure engaging a vehicle support;

[0011] FIG. 2 is a schematic assembly view of a fastener consistent with the present disclosure;

[0012] FIG. 3 is a schematic view of the assembled fastener of FIG, 2 prior to attachment to an airbag; [0013] FIG. 4 is a. schematic view taken generally along line 4-4 in FIG. 1 illustrating an interior ramp and notch structure within a fastener consistent with the present disclosure;

[0014] FIG. 5 is a schematic perspective view a pin used in a fastener consistent with the present disclosure;

[0015) FIG. 6 is a schematic view of a latching structure of a fastener consistent with the present disclosure with the pin of FIG. 5 at a preliminary stage of insertion between the fastener legs;

[0016] FIG. 7 is a schematic view illustrating the pin of FIG. 5 in seated relation to the notch of FIG. 4;

[0017] FIGS. 8 and 9 illustrate an exemplary attachment of an airhag assembly to the assembled attachment clip of FIG . 3 to form an intermediate assembly;

[0018) FIGS. 10-13 are a series of views illustrating activation of final locking engagement of a fastener consistent with the present disclosure; and

[0019] FIGS. 14 and 15 are schematic views illustrating a alternative embodiment for a fastener consistent with the preseni disclosure.

[0020] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of "including", "comprising" and variations thereof is meant, to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof

DESCRIPTION

j0021] Reference will now be made to the drawings, wherein, to th extent possible, like reference numerals are used to designate like elements in the various views. As show in FIG. 1 , a fastener assembly 10 consistent with the present disclosure is shown adapted to secure an airbag assembly 12 within a roof component 14 of a motor vehicle. The fastener assembly 10 may have particular advantages when used for fastening an airbag assembly 12. However, it should be understood that a fastener assembly having features of the present disclosure may be used for other purposes as well.

[0022) In the exemplary environment of use, the airbag assembly 12 includes a fastening tab 16 and an airbag 18. Those skilled in the art will readily understand that the airbag 18, which is depicted herein as a generally elongated cylindrical body, may include an openabie frame o holder, an inflatable cushion, a trigger mechanism and the like. It is to be understood that airbag 18 may be of different constructions, and the fastener assembly 10 can be used with different constructions. Accordingly, airbag 18 will not be described in further detail in that those skilled in the art will readily understand other structures and details included in the airbag assembly. It is likewise to be understood that while a single fastener assembly 10 is illustrated, in actual use, a multiplicity of such fastener assemblies may engage the airbag assembly at different positions along the -fastening tab 16 to achieve a secure attachment to the roof component 14.

[0023] in the illustrated exemplary construction, the roof component 14 may include an outer shell 20 and an inner structure 22 defining a. hole 24 to which airbag assembly 12 is connected via fastener assembly 10. As will be understood, the configura tions of roof component 14, including outer shell 20, inner structure 22 and hole 24 are merely exemplary of suitable configurations, and still other constructions and arrangements can be used together with a fastener of the present disclosure. [0024] Referring now jointly to FIGS, 1 and 2, in the illustrated exemplary construction the fastener assembly 10 includes a body 30 and a pin 32 received and retained in the body 30 as w ll be described further hereinafter, in the illustrated exemplary construction, the body 30 includes an anchoring body component 34 and a hack plate body component 36 connected one to another by a hinge 35. The anchoring body component 34 and back plate body component 36 are pivotal about hinge 35 towards one another to secure fastening tab 16 there between in clamping fashion.

[0025} in accordance with one exemplary construction, the body 30 may be of a single piece (i.e. unitary) molded construction formed from a suitable polymer such as nylon, acetal resin or the like using techniques such as injection molding or the like. The pin 32 may likewise be formed as a single piece from a substantially rigid molded polymer using techniques such as injection molding or the like. The body 30 and the pin 32 may be formed from either the same material or from different materials. As will be described further hereinafter, the body 30 is adapted to capture and retain the fastening tab 16 of the a rbag 18 in clamped relation between the anchoring body component 34 and back plate body component 36 prior to being secured within an acceptance opening in the roof component 1 . Moreover, as will be described hereinafter in relation to FIGS. 14 and 15, it is likewise contemplated that the back plate body component may be formed separately from the anchoring body component for mating attachment without the use of a connecting hinge if desired.

[0026] Referring now to FIGS. 2-6, it may be seen that the fastener assembly 10 may be preassembled so as to establish a stable preliminary mating relation between the pin 32 and the anchoring body component 34 (FIG. 3) prior to attachment to the airbag fastening assembly. As will be appreciated, this preliminary mating relation permits the body 30 and the pin 32 to be engaged to one another at a point of initial manufacture and then shipped to another location where the airbag assembly 12 is attached. Thus, the fastener assembly 10 may be shipped as a single component with the pi 32 embedded in anchoring body component 34 thereby reducing the risk of component loss and lowering the complexity of the airhag attachment procedure as will be described hereinafter, 0O27| As best seen through reference to FIG. 2, the anchoring body component 34 has a generally cup-shaped construction defining a receiving well 37 surrounded by contoured walls. An axial through hole 38 projects through the floor of the recei ving well 37 for mating acceptance of the pin 32. As illustrated, the pin 32 includes a head portion 40 of enhanced diameter and an elongated shank; portion 42 extending away .from the underside of the head portion 40. As illustrated, the head portion 40 may have a slightly convex upper surface defining a tool-engagement depression 44 adapted to receive a hex wrench or other torque application tool adapted to depress and rotate the pin 32 within the anchoring body component 34. in the illustrated exemplar)' construction, the head portion 40 also includes a pair of tab elements 46 projecting radially away from the head portion 40 at an elevation corresponding substantially with the base of the head portion. As best seen in FIGS, 2 and 5, the tab elements 46 each ma have a generally right trapezoidal shape defining a first lateral leg 48 extending at a substantially right angle to the side of the head portion 40, and a second lateral leg 50 disposed in sloped relation to the side of the head portion 40. As will be readily understood, the right angle first lateral legs 48 define the leading edges of the tab elements 46 during a tightening (clockwise) rotation of the pin 32 within the receiving wel l 37,

[0028] As best seen in FIG. 5, in the exemplary construction, a pair of raised ribs 52 extends across the underside of the head portion below the tab elements 46 such that the raised ribs 52 project radially away from opposing sides of the shank portion 42. As will be described further hereinafter, the raised ribs 52 are useful in preventing undesired rotational movement of the pin 32 when the pin 32 and the anchoring body component 34 are in preliminary mating relation,

10029} As best seen in FIG. 5, in the exemplary construction, the shank portion 42 of pin 32 extends to a reduced diameter distal neck segment 54. A pair of opposing curved finger elements 56 extends reanvardly away from the end of the distal neck segment 54 back towards

S the proximal segment of the shank portion 42 so as to cooperatively form a. generally "IF shaped spring. In this regard, the curved finger elements 56 are substantially resilient so as to be flexible in a spring-like manner towards and away from the distal neck segment 54 such that the tips of the carved finger elements 56 flex inwardly towards the distal neck segment 54 upon application of radially inward pressure and thereafter spring outwardly i recovery upon the removal of such pressure.

[0030} As best seen in FIGS. 4 and 7, the interior of the anchoring body component 34 is molded to inc lude a pair of opposin g raised ramp structures 60 adapted to gu ide the tab elements 46 in a downward spiral during rotation of the pi 32 as will be described further herinafter. As illustrated, the ramp structures 60 each include an upper notch 62 having a cross-section corresponding substantially to the cross-section of the raised ribs 52. By way of example only, and not limitation, the upper notch 62 and the raised ribs 52 each may have a substantially right trapezoidal cross section sized such that the raised rib52 may fit within the upper otch 62 in nesting relation. In this regard, in the exemplary construction, the raised ribs 52 each may include a sloped lateral leg 64 definin the leading edge of the rib during tightening (clockwise) rotation of the pin 32 and a substantially verticai lateral leg 66 defining the trailing edge of the raised rib 52 during tightening rotation of the pin 32.

[0031 As best illustrated in FIG. ? _s when segments of the raised ribs 52 are nested within the notches 62 on the ramp structures, loosening (counterclockwise) rotation is substantially blocked by the substantiall verticai lateral leg 66 and the opposing substantially vertical wall of the notch 62. In addition, tightening (clockwise) rotation will require the application of substantial rotational force by use of a he wrench or the like to raise the ribs 52 out of the notch 62.

Moreover, the base of notches 62 supports the pin against excessive insertion into the receiving well 37. Thus, m the preliminary stable insertion condition shown in FIG. 3, the pin 32 is held at a predefined depth within the anchoring body component 34 since the pi 32 protected against being pushed in or rotated inadvertently. [0032] As indicated, previously, the axial through hole 38 is disposed in. the base of receiving well 37. The through hole 38 is adapted to receive the shank portion 42 of pin 32 for disposition between a pair of axia!ly extending latching legs 70. The latching legs 70 cooperatively form a latch structure 71 (FIG. 6). I n this regard, each of the latching legs 70 may ha ve a generally pyramid shaped profile to define a hip dimension of greatest width between the opposing outwardly projecting apexes 72. As will be appreciated, this hip dimension defines the effective diameter of the latch structure 71 formed by the cooperating latching legs 70, j0033| As shown in FIG. 6, when the pin 32 is inserted to the preliminary mating condition with the raised ribs 52 in the notches 62, the finger elements 56 are disposed in a plane oriented substantially parallel to the inner surfaces of latching legs 70 such that the finger elements are not pressed radially inwardly . In this condition, the tips of the finger elements are permitted to spring outwardly after insertion through the axial through hole 38 and are blocked from being retracted. Thus, the pin 32 is prevented from falling out of the anchoring body component 34 during shipment, to the location of attachment to the airbag assembly as will now be described. However, in this condition it is possible to press the latchmg legs slightl towards one another in a spring-like manner to reduce the hip dimension of the latch structure 71.

[0034] Referring now to FIGS. 8 and 9, with the body 30 and the pin 32 in the preliminary engagement condition, the fastener assembly 10 may engage an airbag assembl fastening tab 16 by pressing the latching legs 70 through an opening in the fastening tab (FIG. 8). Thereafter, the back plate component 36 may be pressed over the latching legs 70 so as to hold the fastening tab 16 in sandwiched relation between the anchoring body component 34 and the back plate component 36. In this regard, the back plate component 36 includes an aperture73 sized such that the latching legs 70 are urged towards one another to reduce the hip dimension of the latch structure as they pass through the aperture 73. The latching legs 70 thereafter spring outwardly in locking relation behind the back plate component 36 once insertion is complete. In this condition, the airbag assembly 12 with the attached fastening assembly 10 may be shipped to the point of final vehicle assembly for installation. As noted previously, in this condition, the pin 32 will be prevented from being pushed in the wrong position or corning out by accident thereby maintaining the attached condition.

[0035]: As shown through joint reference to FIGS. I and 10, during attachment of the fastener assembly 10 to the roof component 14 or other support structure, the latching legs 70 of the cl ip body 30 may be pushed into a recei ving hole 24 in the inner structure 22 of roof component 14 (FIG. 1 ), In this regard, it will he understood that the receiving hole 24 may be sized such that the latching legs 70 are urged towards one another to reduce the hip dimension of the latch structure 1 as the latching legs pass through the receiving hole. The latching legs 70 thereafter spring outwardly in locking relation behind the inner structure 22 of roof component 14 once insertion is complete.

[0036]: As shown in FIG. 1 1 , in order to secure the fastener assembly in place, the installer may then use a driving tool 80 such as a hex wrench or the like to rotate the pin 30 in a tightening (clockwise) direction. The torque rotation applied by the driving tool 80 urges the raised ribs 52 to move up and out of notches 62 and causes tab elements 46 to be guided

downwardly in a spiral manner in camming relation to ramp structures 60. That is, the tab elements 46 are caused to follow the ramp structures in a downward spiral for approximately ISO degrees as the pin 32 is simultaneously rotated and pressed inwardly to a lowered position within the recei ving well of anchoring body component 34.

[0037} As best seen through join t reference to FIGS. 4, 12 and .13, the integral ramp structures 60 extend downwardly along the inner wall surrounding the receiving well 37 to an extent which permits the underside of the head portion 40 to ultimately rest at the base of the receiving well 37 in the anchoring body component 34. As rotation continues, the raised ribs 52 at the underside of head portion 40 become aligned with an acceptance groove 82 extending substantially across the base of the receiving well 37 on either side of the through hole 38 such that the raised ribs 52 enter the acceptance groove 82 to establish a final depressed condition of the pin 32 within the anchoring body component. As shown, acceptance groove may have a generally trapezoidal cross section and ma b oriented substantially in alignment with notch 62, in the final insertion condition, the engagement between the raised ribs 52 and acceptance groove 82 blocks forward or rearward rotation. Moreover, a pair of integral spring arms 84, extending downwardly from the undersides of the ramp structures 60, biases downwardly against tab elements 46 thereby holding the pin 32 down and preventing vertical removal. Thus, the pin 32 is held in a stable depressed condition within the receiving well of the anchoring body component 34, As will be appreciated, with the pin in this depressed condition, the shank portion 42 of the pin extends deeply between the Iatching legs 70. With the shank portion 42 disposed between the latching legs 70, the latching legs 70 are held apart from one another such that a expanded hip dimension of the latch structure 71 is maintained. The fastener assembly 10 is thereby secured against withdrawal

[0038]: As illustrated, in the exemplar)' embodiment, the ramp structures 60 each include a proximal nose portion 86 projecting in angled relation away from the notch 62 downwardly in a counterclockwise direction. As will be understood, in the event that the pin 32 is not pressed completely into the receiving wel l 37 of the anchori g body component, the nose portion 86 will engage tab elements 46 and will cause the pin 30 to be carried upwardly back to the starting position as it is rotated. This return mechanism avoids the potentially undesirable condition in which the pin 32 is only partially depressed into the anchoring body component without being locked in place.

[0039} As best seen through reference to FIGS. 2, and 12 the tool engagement depression 44 cm the head portion 40 of pin 32 may optionally include a pattern of crash ribs 90 at the interior of the engagement depression. The crash ribs 90 may be broken by the driving tool 80 when high resistance is encountered as the pi 32 is locked into the final depressed condition. Thus, the fracture of the crash ribs 90 may be used as an indicator of proper locked installation.

According to one contemplated practice, the hex wrench or other driving tool 80 may be operatively connected to a torque measurement and recording device during use. When the crash ribs 90 are broken, the measured torque value will drop and this torque change may be detected and recorded as installation verification.

|0040) Referring now to FIGS. 14 and 15, an alternative construction for a fastener assembly consistent with the present disclosure is illustrated wherein elements corresponding to those described previously are designated by like reference numerals within a 100 series. As will be appreciated, this alternative construction is substantially similar to the prior described embodiment, but uses an independent back plate body component 136 without a hinge connecting the back plate body component to the anchoring body component However, the fastener assembly operates in substantially the same manner as described in relation to the previous embodimen t.

[0041 J Of course, variations and modifications of the foregoing are within the scope of the present disclosure. Thus, it is to be understood that the disciosure disclosed and defined, herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text, and/or drawings. A ll of these different combinations constitute various alternative aspects of the present disclosure. The embodiments described herein explain the best modes known for practicing the disclosure and will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.

[0042} Various features of the disclosure are set forth in the following claims.