TECHNICAL FIELD

Aspects of the invention relate to a vehicle panel with one or more integrally formed connectors, a socket, a connection system, a panel including a socket, a vehicle, and methods for making a vehicle panel.

BACKGROUND

Many connectors and connection systems are known for connecting one component to another. One such known connection system is the press-stud or "popper" which permits the releasable coupling of a male part and a female part. The male and female parts may be coupled to one another by pressing the male part against the female part with a sufficient force. The two parts remain coupled to one another until they are pulled apart from one another with a sufficient force. The press-stud connection system therefore offers a simple and effective releasable coupling.

There exists a need, however, for a connection system that may be used in a variety of applications and that can form a releasable, yet strong, load-bearing coupling between a vehicle panel and another component.

It is an object of embodiments of the invention to at least mitigate one or more of the problems of the prior art.

SUMMARY OF THE INVENTION

In accordance with an aspect of the present invention, there is provided a vehicle panel including one or more integrally formed connectors where each connector comprises:

a tubular wall upstanding from a surface of the vehicle panel, the tubular wall defining a bore extending along a longitudinal axis of the connector;

restraining means projecting radially outwardly from the tubular wall; and

a screw thread on a radially inwardly facing surface in the bore;

wherein each connector is configured to be received in a socket and the restraining means are configured to axially restrain the connector in the socket so as to affix the vehicle panel to the socket. The vehicle panel may form part of a connection system that may provide a releasable, yet strong, load-bearing coupling that may be manufactured at a low cost.

The screw thread may be formed in a radially inwardly facing surface of the tubular wall.

Each connector may comprise a tubular member disposed in the bore wherein the tubular member is hollow and the screw thread is formed in a radially inwardly facing surface of the tubular member.

The restraining means of each connector may comprise a flange projecting radially outwardly from the tubular wall.

In accordance with another aspect of the present invention, there is provided a socket for receiving one of the connectors of the vehicle panel as defined above, the socket comprising engagement means for engaging with the restraining means of the connector to axially restrain the connector in the socket, wherein the engagement means are radially moveable so as to permit the passage of the engagement means around the restraining means of the connector.

The socket may comprise a tubular wall, wherein the engagement means form part of the tubular wall. In certain embodiments, the engagement means may comprise a projection that projects radially inwardly from the tubular wall. In alternative embodiments, the tubular wall tapers radially in an axial direction and the engagement means comprises a radially inward portion of the tubular wall.

In accordance with another aspect of the present invention, there is provided a panel comprising one or more sockets as defined above. A first of said one or more sockets may be fixed relative to the panel and at least a second of said one or more sockets may be moveable relative to said panel. Each of the at least a second of said one or more sockets may be moveable in a slot of the panel. In accordance with another aspect of the present invention, there is provided a connection system comprising a vehicle panel as defined above, and a socket as defined above. The connection system may comprise a threaded bolt for being received in the screw thread of the connector. In accordance with another aspect of the present invention, there is provided a connection system comprising a vehicle panel as defined above and a panel comprising one or more sockets as defined above. The connection system may comprise a threaded bolt for being received in the screw thread of the connector. The panel may be connectable to the vehicle panel by engagement of the threaded bolt in the screw thread of the connector and engagement between the engagement means of the socket and the restraining means of the connector.

In accordance with another aspect of the present invention, there is provided a vehicle including the vehicle panel as defined above.

In accordance with another aspect of the present invention, there is provided a vehicle including the connection system as defined above. In accordance with another aspect of the present invention, there is provided a method of making a vehicle panel comprising:

pressing a panel to form an integrally formed connector comprising a tubular wall upstanding from a surface of the panel, the tubular wall defining a bore extending along a longitudinal axis of the connector;

forming restraining means that project radially outwardly from the tubular wall; and

forming a screw thread on a radially inwardly facing surface in the bore.

In certain embodiments, forming a screw thread on a radially inwardly facing surface in the bore may comprise machining a screw thread on a radially inwardly facing surface of the tubular wall.

In alternative embodiments, forming a screw thread on a radially inwardly facing surface in the bore may comprise inserting a tubular member in the bore where the tubular member is hollow and the screw thread is formed in a radially inwardly facing surface of the tubular member. Forming restraining means may comprise pressing the tubular wall to form a flange projecting radially outwardly from the tubular wall.

In accordance with another aspect of the present invention, there is provided a vehicle panel including one or more integrally formed connectors where each connector comprises:

a tubular wall upstanding from a surface of the vehicle panel, the tubular wall defining a bore extending along a longitudinal axis of the connector;

restraining means projecting radially inwardly from the tubular wall; and

a screw thread on a radially ouwardly facing surface in the bore;

wherein each connector is configured to receive a male connector and the restraining means are configured to axially restrain the male connector so as to affix the vehicle panel to the male connector.

In some embodiments the tubular wall may include one or more axial cutaways. In such embodiments the external or internal thread may comprise one or more aligned partial threads.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the invention will now be described by way of example only, with reference to the accompanying figures, in which:

Figure 1 shows a cross-sectional view of a connector according to an embodiment of the present invention;

Figure 2 shows a cross-sectional view of a socket according to an embodiment of the present invention;

Figure 3 shows a cross-sectional view of a connection system in accordance with an embodiment of the present invention that includes the connector of Figure 1 and the socket of Figure 2;

Figure 4 shows a cross-sectional view of a connection system in accordance with an alternative embodiment of the present invention; Figure 5 shows a socket and a panel in accordance with an embodiment of the present invention; and Figure 6 shows a vehicle according to embodiments of the present invention.

Figure 7 shows a cross-sectional view of a connector according to another embodiment of the present invention. Figure 8 shows a cross-sectional view of a male connector configured to be connected to the connector shown in figure 7.

DETAILED DESCRIPTION

Figure 1 shows a cross-sectional view of a vehicle panel 8 that includes an integrally formed connector 10 according to an embodiment of the present invention. The vehicle panel 8 has a base panel 14 and at least one connector 10 that comprises a tubular wall 12 that is upstanding from a surface of the base panel 14 and defines a bore that extends along a longitudinal axis 100 of the connector 10. Throughout the present specification, the terms "radial", "radially", and similar terms when used in relation to the connector 10 are considered to relate to directions that are perpendicular to the longitudinal axis 100, where a radially inward direction is towards the longitudinal axis 100 and a radially outwardly direction is away from the longitudinal axis 100. The terms "axial", "axially" and similar terms when used in relation to the connector 10 are considered to relate to directions that are parallel to the longitudinal axis 100.

The connector 10 includes restraining means in the form of a flange 16 that projects radially outwardly from the tubular wall 12. The connector 10 has a screw thread 18a on a radially inwardly facing surface in the bore. In the specific embodiment shown in Figure 1 , the screw thread 18a is formed on a radially inwardly facing surface of a hollow tubular member 18 that is disposed in the bore. In alternative embodiments, the screw thread 18a may be formed on any suitable radially inwardly facing surface in the bore. For example, the screw thread 18a may be formed on a radially inwardly facing surface of the tubular wall 12. Figure 2 shows a cross-sectional view of a socket 50 in accordance with an embodiment of the present invention. The socket 50 has a tubular wall 52 that is upstanding from a base 54 and defines a bore that extends along a longitudinal axis 500 of the socket 50.

Throughout the present specification, the terms "radial", "radially", and similar terms when used in relation to the socket 50 are considered to relate to directions that are perpendicular to the longitudinal axis 500, where a radially inward direction is towards the longitudinal axis 500 and a radially outwardly direction is away from the longitudinal axis 500. The terms "axial", "axially" and similar terms when used in relation to the socket 50 are considered to relate to directions that are parallel to the longitudinal axis 500.

The tubular wall 52 includes engagement means in the form of a lip 56 that projects radially inwardly from the tubular wall 52.

The socket 50 is made of a deformable material (e.g. plastics material) that permits the lip 56 (or other engagement means) to move radially. The lip 56 defines an opening into the bore of the socket 50 where the opening has a diameter that is less than the diameter of the flange 16 of the connecter 10 (when the socket 50 is in an undeformed configuration). The deformability of the socket 50 permits the tubular wall 52 to deflect so as to allow the lip 56 to pass over the flange 16 when the connector 10 and the socket 50 are brought together with an applied axial force. The lip 56 and/or the flange 16 may have a profile (such as a taper) that causes a camming action that facilitates easier deflection of the tubular wall 52 of the socket 50.

The geometry of the socket 50 is such that the socket may be easily moulded with straight up and down cavities with no sliding cores.

Figure 3 shows a connection system 60 that includes the vehicle panel 8 and the socket 50. In the configuration shown in Figure 3, one connector 10 of the vehicle panel 8 is received in the bore of the socket 50. In order to reach this configuration, the lip 56 of the socket must move radially outwardly to locate on the tubular wall 12 of the connector 10. Once the lip has axially passed the flange 16 (i.e. to a point where the lip 56 is no longer radially aligned with the flange 16), the tubular walls 52 of the socket relax to an unstressed or less stressed configuration in which the lip 56 is axially aligned with the flange 16. If the inner diameter defined by the lip 56 in an unstressed state is less than the outer diameter of the part of the tubular wall 12 of the connector 10 that the lip 56 is finally radially aligned with, then the tubular wall 52 of the socket 50 will remain in a slightly stressed configuration and the lip 56 will bear against the tubular wall 12 of the connector 10. On the other hand, if the inner diameter defined by the lip 56 in an unstressed state is greater than the outer diameter of the part of the tubular wall 12 of the connector 10 that the lip 56 is finally radially aligned with, then the tubular wall 52 of the socket 50 will relax to its unstressed configuration. In either case, axial movement of the lip 56 towards the flange 16 results in an engagement that causes the connector 10 to be axially restrained in the socket 10 and thereby connect the vehicle panel 8 to the socket 50. Only if a sufficient axial force is applied may the tubular wall 52 of the socket 50 be caused to deform and allow the lip 56 to move out of axial alignment with the flange 16 and permit separation of the vehicle panel 8 and the socket 50.

The form of the lip 56 (or other engagement means) and its ability to move radially (e.g. as determined by the stiffness of the tubular wall 52 of the socket 50) may be tailored to tune the axial force required to couple and decouple the socket 50 and connector 10.

Figure 4 shows a variation of the connection system 60 of Figure 3 within the scope of the present invention. In the configuration shown in Figure 4, the socket 50 is captively retained in a slot 58a of a panel 58. The connector 10 of the vehicle panel 8 is coupled to the socket 50 by axial engagement between the lip 56 and the flange 16 as described above in relation to Figure 3. Additionally, a threaded bolt 62 passes through the panel 58, the bore of the socket 50 and the bore of the connector 10 and is secured with a nut 64 so as to bolt the vehicle panel 8 to the panel 58. Since the socket 50 is captively retained in the slot 58a of the panel 58, the panel 58 is coupled to the vehicle panel 8 by two mechanisms; firstly, by engagement between the socket 50 and the connector 10, and, secondly, by the nut 64 and bolt 62. Decoupling of panel 58 from the vehicle panel 8 may only occur when the nut 64 is removed from the bolt 62 and when a sufficient axial force is applied to the socket 50 relative to the connector 10 that causes radial movement of the lip 56 so as to permit the lip 56 to move out of axial alignment with the flange 16 and allow separation of the socket 50 from the connector 10. In alternative embodiments, the bolt 62 may be used to couple other components to the vehicel panel 8 where the other components may or may not include the panel 58 and/or the socket 50. In some circumstances, the vehicle panel 8 may be coupled to the socket 50 only, by engagement between the engagement means and the restraining means and/or by the bolt 62 and nut 64. In other circumstances the vehicle panel 8 may be connected to another component only, by way of the bolt 62 and nut 64. In other circumstances, the vehicle panel 8 may be coupled to the socket 50 by engagement between the engagement means and the restraining means and another component by the bolt 62 and nut 64.

Coupling via the bolt 62 and nut 64 increases the load bearing ability of the connection system 60 in contrast with a simple press-stud or popper arrangement.

In certain embodiments, the tubular wall 12 and flange 16 of the connector 10 may be integrally formed in the vehicle panel 8 by mechanically pressing the base panel 14. The tubular member 18 may then be pressed into the bore of the connector 10 of the screw thread 18a may be formed in a radially inwardly facing surface of the tubular wall 12 of the connector 10. Figure 5 shows a socket 50 that is captively retained in a slot 58a of a panel 58. The slot 58a is sized and shaped so as to permit movement of the socket 50 along directions A which are parallel to the plane of the panel 58. In particular, the length of the slot 58a is greater than the corresponding length of the base 54 of the socket 50 so that the socket 50 may move along directions A before contact between the base 54 of the socket 50 and the panel 58 prevents further movement. The slot 58a may be configured to permit movement along a single axis that is parallel to the plane of the panel 58 (e.g. an elongate slot that has a width approximately equal to the width of the base 54 of the socket 50 but a length greater than the length of the base 54 of the socket 50). In another embodiment, the slot 58a may be circular and have a diameter that is greater than the diameter (or largest dimension) of the base 54 of the socket 50 such that movement along two orthogonal axes parallel to the plane of the panel 58 is permitted. In any embodiment, the slot 58a should be formed so that the base 54 of the socket 50 remains captively retained therein. In certain embodiments, the panel 58 may include one or more sockets 50 that are not able to move relative to the panel 58. Such immovable sockets 50 may, in some embodiments, be integrally formed into the panel 58. In addition, the panel 58 may also include one or more sockets 50 that are able to move in one or more directions relative to the panel 58. For example, each of the one or more moveable sockets 50 may be captively retained in slots 58a in the panel 58. The panel 58 may then be coupled to a vehicle panel 8 that includes a plurality of connectors 10 as described above. In particular, the one or more immovable sockets 50 may first be coupled to corresponding connectors 10. The one or more moveable sockets 50 may then be moved relative to the panel 58 to achieve the required alignment for the moveable sockets 50 to couple with corresponding connectors 10 of the vehicle panel 8. Such a configuration may ensure that any inaccuracies (e.g. caused by manufacturing tolerances or deformation of materials) may be compensated for and permit coupling between the panel 58 and the vehicle panel 8.

In alternative embodiments, the restraining means may take the form of any restraining projection that extends radially outwardly from the tubular wall 12 of the connector 10 that is suitable for axially engaging with the engagement means of the socket 50 so that the connector 10 is axially restrained relative to the socket 50 when the connector 10 is received in the socket 50. The restraining means may be circumferentially continuous or circumferentially discontinuous. Similarly, the engagement means may take the form of any radially moveable engagement portion that is suitable for axially engaging with the restraining means of the connector 10 so that the connector 10 is axially restrained relative to the socket 50 when the connector 10 is received in the socket 50, and that is suitable for moving radially so as to move out of axial alignment with the restraining means. The engagement means may be circumferentially continuous or circumferentially discontinuous. In certain embodiments the engagement means may be in the form of a radially inward projection. In other embodiments, the socket may include a tubular wall that tapers radially inwardly in an axial direction such that the engagement means may be in the form of a radially inward portion of the tubular wall. Figure 6 shows a vehicle 600 that may incorporate any or all of a vehicle panel 8, a socket 50, or a connection system 60 according to embodiments of the present invention. The connection system 60 according to embodiments of the present invention is particularly suitable for coupling components within the vehicle 600. For example, the connection system 60 may be used to attach trim components, panels and other accessories to the vehicle 600. The connection system 60 offers a low cost, yet effective, coupling means that may be used for coupling and decoupling components multiple times. Certain embodiments have the advantage that when the connection system 60 is used to connect two panels (one being the vehicle panel 8), any misalignment between the panels may result in one panel standing off the other which is easily recognised by the operator connecting the connection system 60. This is in contrast to certain prior art arrangements where panels are connected to one another "blind" using a so-called fir tree connector. Misalignment of such panels may result is the fir tree connector becoming bent or otherwise deformed which may not be immediately obvious to the operator, but will result in a non-optimum connection of the panels.

Figures 7 and 8 show, respectively a connector 210 integrally formed in a vehicle panel 208 and a male connector 250 configured to connect to connector 210. The connection of male connector 250 to connector 210 is similar to the connection of socket 50 to connector 10 shown in figures 1 -3; a "popper" connection is formed when axes 200, 700 are aligned and the male connector 250 is pushed towards connector 210. However, male connector 250 fits inside, not outside, connector 210. Accordingly, when male connector 250 is pushed into connector 210 flange 256 and base 254 of the male connector are moved radially inwardly rather than radially outwardly. Alternatively, lip 216 on the connector 250 may be moved radially outwardly, or both the connector 210 and the male connector 250 may be caused to deform during the connection. It will be understood that the male connector 250 may be constructed from a similar deformable material to socket 50 shown in figure 2. Furthermore, one or more axial cutouts (not shown) may be provided on either the wall 212 of connector 210 or the base 254 of male connector 250. Such cutouts may improve the ability of the connector 210 or the male connector 250 to undergo radial deformation.

Connector 210 may additionally accommodate screwed fixings of components under circumstances where a connection with high resistance to axial loads is required. External thread 218 may cooperate with a corresponding internal thread to provide such a screwed fixing.

Certain aspects of the invention are defined in the numbered paragraphs below. 1 . A vehicle panel including one or more integrally formed connectors where each connector comprises: a tubular wall upstanding from a surface of the vehicle panel, the tubular wall defining a bore extending along a longitudinal axis of the connector;

a restraining projection projecting radially outwardly from the tubular wall; and

a screw thread on a radially inwardly facing surface in the bore;

wherein each connector is configured to be received in a socket and the restraining projection is configured to axially restrain the connector in the socket so as to affix the vehicle panel to the socket.

The vehicle panel of paragraph 1 , wherein the screw thread of each connector is formed in a radially inwardly facing surface of the tubular wall.

The vehicle panel of paragraph 1 , where each connector comprises a tubular member disposed in the bore wherein the tubular member is hollow and the screw thread is formed in a radially inwardly facing surface of the tubular member.

The vehicle panel of paragraph 1 , wherein the restraining projection of each connector comprises a flange projecting radially outwardly from the tubular wall.

A socket for receiving one of the connectors of the vehicle panel of paragraph 1 , the socket comprising an engagement portion for engaging with the restraining projection of the connector to axially restrain the connector in the socket, wherein the engagement portion is radially moveable so as to permit the passage of the engagement portion around the restraining projection of the connector.

The socket of paragraph 5, comprising a tubular wall, wherein the engagement portion forms part of the tubular wall.

The socket of paragraph 6, wherein the engagement portion comprises a projection that projects radially inwardly from the tubular wall.

The socket of paragraph 6, wherein the tubular wall tapers radially in an axial direction and the engagement portion comprises a radially inward portion of the tubular wall. A panel comprising one or more sockets according to paragraph 5.

The panel of paragraph 9, wherein a first of said one or more sockets is fixed relative to the panel and at least a second of said one or more sockets is moveable relative to said panel.

The panel of paragraph 10, wherein each of the at least a second of said one or more sockets is moveable in a slot of the panel.

A connection system comprising a vehicle panel according to paragraph 1 and a socket according to paragraph 5.

The connection system of paragraph 12, comprising a threaded bolt for being received in the screw thread of the connector.

A connection system comprising a vehicle panel according to paragraph 1 and a panel according to paragraph 9.

The connection system of paragraph 14, comprising a threaded bolt for being received in the screw thread of the connector.

The connection system of paragraph 15, wherein the panel is connectable to the vehicle panel by engagement of the threaded bolt in the screw thread of the connector and engagement between the engagement portion of the socket and the restraining projection of the connector.

A vehicle including the vehicle panel of paragraph 1 .

A vehicle including the connection system of paragraph 12.

A method of making a vehicle panel comprising:

pressing a panel to form an integrally formed connector comprising a tubular wall upstanding from a surface of the panel, the tubular wall defining a bore extending along a longitudinal axis of the connector;

forming a restraining projection that projects radially outwardly from the tubular wall; and forming a screw thread on a radially inwardly facing surface in the bore.

20. The method of paragraph 19, wherein forming a screw thread on a radially inwardly facing surface in the bore comprises machining a screw thread on a radially inwardly facing surface of the tubular wall.

21 . The method of paragraph 19, wherein forming a screw thread on a radially inwardly facing surface in the bore comprises inserting a tubular member in the bore where the tubular member is hollow and the screw thread is formed in a radially inwardly facing surface of the tubular member.

22. The method of paragraph 19, wherein forming the restraining portion comprises pressing the tubular wall to form a flange projecting radially outwardly from the tubular wall.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims.