Technical Field

[0001] The present disclosure relates to fasteners. More particularly, the present disclosure is directed to electrically conductive fasteners.

Background

[0002] There are many applications which require fastening of an electrical vehicle component to a panel of a vehicle, and electrically powering the component. One example is fastening a light to an exterior of a panel of a vehicle, such as the exterior of a roof panel, and powering the light. One application of fastening and powering a vehicle light is fastening and powering a running light, marker light, or clearance light to the exterior of a truck, for example a tractor unit. The running light, marker light, or clearance light may be fastened to a roof fairing, hood panel, cab panel, or sleeper panel of a tractor unit.

[0003] Many existing systems for fastening and powering a vehicle component require separate fasteners and power cables. For example on a tractor unit, a first set of holes is drilled though a panel of the tractor unit to install a set of screws fastening lights to the panel, and a second set of holes is drilled through the panel to feed electrical wires to the lights.

[0004] There are many disadvantages to using separate fasteners and power cables. The exterior of a tractor unit is frequently subject to rain and wind, for example when travelling along a road. The ingress of water through a panel of a tractor unit and into the tractor unit may damage the tractor unit, and poses a significant maintenance issue. As such, any holes drilled through the panels of a tractor unit must be sealed against water ingress. Increasing the number of holes through the panels of a tractor unit, for example by using separate holes for fasteners and power cables, increases the number of holes which require sealing, and increases the number of potential points of failure.

[0005] Furthermore, conventional methods of feeding an electrical cable through a hole in a panel of a tractor unit are laborious and difficult to seal against water ingress. [0006] There is a general desire for an improved method and apparatus for fastening electrical vehicle components to vehicle panels and powering those components.

[0007] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

Summary

[0008] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above- described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

[0009] One aspect of the invention provides an electrically conductive fastener comprising: an electrically conductive shaft with a first end and a second end and a threaded section between said first and second ends, a tool interface provided between said first end of the shaft and said threaded section, said first end provided with a first electrically conductive connector, and said second end provided with a second electrically conductive connector electrically connected to the first electrical connector.

[0010] In some embodiments of the electrically conductive fastener: the second electrical connector is electrically connected to the first electrical connector by the electrically conductive shaft, the first connector comprises a ball-stud connector, the second connector comprises a snap-fit connector, and/or the fastener is self-tapping.

[0011] In some embodiments of the electrically conductive fastener the fastener comprises a stop flange extending radially from the shaft between the threaded section and the tool interface.

[0012] In some embodiments of the electrically conductive fastener the fastener comprises a flexibly resilient gasket mounted on the stop flange.

[0013] One aspect of the invention provides an external vehicle light comprising: an electrically conductive fastener extending through an aperture in an electrically insulating vehicle panel, wherein the fastener comprises: an electrically conductive shaft with a first end and a second end and a threaded section between said first and second ends and the threaded section engaged with cooperating grooves along an interior surface of the aperture, a tool interface provided between said first end of the shaft and said threaded section, a stop flange extending radially from the shaft and between the threaded section and the tool interface and abutting an exterior surface of the panel, said first end provided with a first electrically conductive connector, said second end provided with a second electrically conductive connector electrically connected to the first electrical connector, and a vehicle light comprising: a body, a light emitting element mounted within the body, and an electrically conductive receptacle mounted within the body, wherein the receptacle is electrically connected to the light emitting element and the first connector is securely received by the receptacle.

[0014] One aspect of the invention provides a method for mounting and powering an external vehicle light comprising: forming an aperture in an electrically insulating vehicle panel, screwing an electrically conductive fastener through the aperture in the panel, connecting a power cable to the first end of the fastener, and securely and removably receiving a second end of the fastener in an electrically conductive receptacle of a vehicle light.

[0015] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.

Brief Description of the Drawings

[0016] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

[0017] Figure 1A is a front elevation view of an electrically conductive fastener according to an example embodiment.

[0018] Figures 1 B and 1 C are respective bottom side and top side perspective views of an electrically conductive fastener as shown in Fig. 1A. [0019] Figure 2 is a perspective view of an electrical receptacle for receiving the electrically conductive fastener shown in Fig. 1A.

[0020] Figure 3 is a vertical cross-sectional front view of an electrically conductive fastener as shown in Fig. 1A installed in a vehicle panel according to an example embodiment.

[0021] Figure 4A is a front elevation view of an electrical vehicle component incorporating two electrically conductive fasteners as shown in Fig. 1 A securing the component to a vehicle panel, according to an example embodiment.

[0022] Figure 4B is a right side view of the electrical vehicle component shown in Fig. 4A.

[0023] Figure 5A is a schematic transverse vertical cross-sectional view along line A-A of Fig. 4A of an electrical vehicle component fastened to a vehicle panel by an electrically conductive fastener as shown in Fig. 1A.

[0024] Figure 5B and 5C are schematic transverse vertical cross-sectional views of alternative embodiments of an electrical vehicle component fastened to a vehicle panel by an electrically conductive fastener as shown in Fig. 1 A.

[0025] Figure 6 is an exploded perspective view of the electrical vehicle component shown in Fig. 4A using two electrically conductive fasteners as shown in Fig. 1A to secure a light to a vehicle roof panel, and connect two power cables according to an example embodiment.

[0026] Figures 7A, 7B and 7C are perspective views of lights mounted on vehicles by one or more electrically conductive fastener as shown in Fig. 1A.

Description

[0027] Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0028] Fig. 1A depicts an embodiment of an electrically conductive fastener 100 comprising a first connector 110, a tool interface 120, a stop flange 130, a threaded shaft 140, and a second connector 150. First and second connectors 110 and 150 are both electrically conductive, and electrically connected to each other. The latter feature may be achieved for ease of manufacture by forming the entire fastener 100 from an electrically conductive material. Accordingly, fastener 100 conducts electricity between first connector 110 and second connector 150.

[0029] First and second connectors 110 and 150 may be any connector capable of securely and conductively mating with an electrical receptacle, port, jack or socket, and conducting electricity to the respective mating electrical receptacle, port, jack or socket. For example, one or both of connectors 1 10 and 150 may comprise: a snap-fit connector, a ball-stud connector, or any other type of friction connector.

[0030] Fig. 1A depicts an embodiment where first connector 110 comprises a ball-stud connector, and second connector 150 comprises a recessed section configured to receive a snap-fit connector, for example a Han™ E female power connector.

[0031] Tool interface 120 may comprise any feature capable of interfacing with a tool to transmit a rotational force to fastener 100. Fig. 1A depicts an embodiment of fastener 100 where tool interface 120 comprises a hexagonal head capable of interfacing with a socket wrench to transmit a rotational force to fastener 100 Alternatively, tool interface 120 may comprise a square head or any shape of head capable of transmitting a rotational force.

[0032] Stop flange 130 may be any feature which provides a planar lower surface for abutting against a vehicle panel through which threaded shaft 140 is screwed. Fig. 1A depicts an embodiment where stop flange 130 comprises a circular stop flange projecting radially from threaded shaft 140 and beyond tool interface 120. In some embodiments, stop flange 130 may be provided by a surface of tool interface 120.

[0033] Threaded shaft 140 extends below stop flange 130 and allows fastener 100 to be screwed through a vehicle panel until stop flange 130 encounters a surface of the vehicle panel. The shape, angle, pitch and lead of the thread of threaded shaft 140 may be selected specifically for the type of vehicle panel in which fastener 100 is to be installed.

[0034] In some embodiments, fastener 100 may be self-tapping, and capable of forming a threaded aperture through a vehicle panel. In embodiments where fastener 100 is selftapping, fastener 100 may be installed in a vehicle panel without first drilling a hole through the vehicle panel. In such embodiments, second connector 150 may be configured to form an aperture through the vehicle panel, for example by hammering second connector 150 into the vehicle panel, or by rotating second connector 150 against the vehicle panel.

[0035] Fastener 100 may be integrally formed or formed by attaching two or more parts. Fastener 100 may comprise any non-corrosive electrically conductive material, for example, stainless steel, brass, titanium, copper, aluminum, or any combination thereof.

[0036] In embodiments where fastener 100 comprises two or more attached parts, some parts of fastener 100 may be electrically conductive, and other parts of fastener 100 may be electrically insulating. In these embodiments, at least some parts mechanically connecting first connector 110 to second connector 150 are electrically conductive in order to conduct electricity between first connector 1 10 and second connector 150. If the vehicle panel into which fastener 1 10 is intended to be installed is electrically insulating, such as fiberglass, then the entirety of fastener 1 10 may be electrically conductive. Otherwise those parts of fastener 1 10 between first connector 110 to second connector 150 which contact the panel must be electrically insulated from the electrically conductive panel.

[0037] Fig. 2 depicts an example embodiment of electrical receptacle 200 for fastener 100. Electrical receptacle 200 comprises a body 210 and two or more receiving arms 220A and 220B extending over an aperture 230. In the embodiment depicted in Fig. 2, receiving arms 220A and 220B comprise flexibly resilient projections configured to flex away from aperture 230. Aperture 230 is dimensioned to receive first connector 110 where first connector comprises a ball-stud connector. Arms 220A and 220B are configured to securely receive ball-stud connector 1 10 by flexing away from aperture 230 as the ball of ball-stud connector 1 10 is inserted through aperture 230, and flex in towards aperture 230 as the ball of ball- stud connector 1 10 passes beyond arms 220A and 220B and securely hold the stud of ball- stud connector 1 10 below the ball. Electrical receptacle 200 is formed of an electrically conductive, durable material, such as nickel plated spring steel. Electrical receptacle 200 is provided with conductor tabs 240A, 240B, 240C and 240D which electrically connect to PCB 646 depicted in Fig. 6.

[0038] Fig. 3 depicts fastener 100 installed in vehicle panel 310. Vehicle panel 310 has an exterior surface 315A, and an interior surface 315B. Exterior surface 315A forms an exterior of the vehicle, and interior surface 315B is interior to the vehicle. Vehicle panel 310 comprises an electrically insulating material, for example, fiberglass, sheet molding compound (SMC), plastic, carbon fibre, or dry carbon fibre. In some embodiments, vehicle panel 310 may be a wall or a roof of vehicle, for example a fiberglass wall or roof of a hood, cab, or sleeper of a tractor unit.

[0039] In other embodiments, vehicle panel 310 may be a wall of a body of any vehicle, including a tractor trailer, bus, recreational vehicle, boat, train, or airplane.

[0040] Fastener 100 is installed in vehicle panel 310 by piercing vehicle panel 310 with second connector 150 to form aperture 320 through vehicle panel 310, and screwing fastener 100 through aperture 320. Fastener 100 is screwed through aperture 320 by interfacing a tool with tool interface 120 and rotating fastener 100 about axis A1. As fastener 100 is rotated about axis A1 , the threads of threaded shaft 140 grip the sides of aperture 320 and advance fastener 100 through aperture 320. As fastener 100 is screwed through vehicle panel 310, the threads of threaded shaft 140 cut cooperating groves into the walls of aperture 320.

[0041] Fastener 100 is screwed through vehicle panel 310 until stop flange 130 abuts exterior surface 315A of vehicle panel 310. Once stop flange 130 abuts exterior surface 315A, fastener 100 may be additionally rotated about axis A1 to tighten fastener 100 against vehicle panel 310 and create pressure between stop flange 130 and vehicle panel 310. The pressure between stop flange 130 and vehicle panel 310 may resist the ingress of water between stop flange 130 and vehicle panel 310 and form a water resistant seal.

[0042] In some embodiments, a sealing member may be provided or formed between stop flange 130 and vehicle panel 310. For example, a flexibly resilient body may be provided between stop flange 130 and vehicle panel 310, such as first flexibly resilient body 432 depicted in Fig. 5C. In other embodiments, a sealant may be provided on one or both of stop flange 130 and vehicle panel 310. A sealant and/or a gasket may resist the ingress of water between stop flange 130 and vehicle panel 310 and form a water resistant seal.

[0043] In some embodiments, a sealant may be provided on the threads of threaded shaft 140 to form a seal between threaded shaft 140 and the interior wall of aperture 320 and form a water resistant seal. The sealant may comprise one or more of: silicone,

polyurethane, polytetrafluoroethylene, and Loctite™ thread sealant. [0044] Figs. 4A and 4B are respective front and side views of an electrical vehicle component 410 incorporating two electrically conductive fasteners 100 to secure the component 410 to a vehicle panel 310, according to an example embodiment.

[0045] Fig. 5A is a cross-sectional view along line A-A in Fig. 4A of an electrical vehicle component 410 fastened to vehicle panel 310 by fastener 100.

[0046] Component 410 shown in Figs. 5A-5C and 6 comprises electrical receptacle 520 mounted within body 530 and configured to securely receive first connector 110 of fastener 100. In the embodiment depicted in Fig. 5A, first connector 1 10 comprises a ball-stud connector, and electrical receptacle 420 comprises a spring connector. Component 410 may be for example a running light for mounting on the roof of a tractor unit.

[0047] To fasten component 410 to vehicle panel 310, fastener 100 is first installed in vehicle panel 310 as described above. Once fastener 100 is installed, component 410 may be securely fastened to fastener 100 by securing ball-stud connector 1 10 into electrical receptacle 520.

[0048] Fig. 5B depicts an embodiment where flexibly resilient body 430 is provided between component 410 and vehicle panel 310, for example a foam pad or a rubber gasket. In the embodiment depicted in Fig. 5B, electrical receptacle 520 may be positioned within component 410 to securely receive first connector 1 10 at a point within component 410 less than the height of first connector 1 10 above vehicle panel 310. Through this configuration, flexibly resilient body 430 is compressed between component 410 and vehicle panel 310. Compressing flexibly resilient body 430 between component 410 and vehicle panel 310 may provide a water resistant seal between component 410 and vehicle panel 310.

[0049] In some embodiments, flexibly resilient body 430 may comprise two or more distinct bodies, for example as depicted in Fig. 5C. Fig. 5C depicts first flexibly resilient body 432 between stop flange 130 of fastener 100 and vehicle panel 310, and second flexibly resilient body 434 between component 410 and vehicle panel 310.

[0050] Fig. 6 depicts light 600 fastened to vehicle panel 610 by first and second electrically conductive fasteners 620A and 620B, and powered by first and second power cables 630A and 630B, according to an example embodiment. [0051] Light 600 comprises light-transitive cover 642, light-reflective cover 644, PCB 646, backing 648, and gasket 650. PCB 646 includes light-emitting elements 660 and electrical receptacles 670.

[0052] Light-emitting elements 660 may comprise one or more of: light emitting diodes (LEDs), incandescent light bulbs, halogen light bulbs, and high-intensity discharge (HID) lamps.

[0053] Figs. 7A, 7B and 7C depict clearance, running, or marker lights 600 mounted by one or more fasteners 100 respectively on a tractor unit 701 , a bus 702, and a recreational vehicle (RV) 703.

[0054] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are consistent with the broadest interpretation of the specification as a whole.

Interpretation of Terms

[0055] Unless the context clearly requires otherwise, throughout the description and the claims:

• “comprise”,“comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”;

• “connected”,“coupled", or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof;

• “herein”,“above",“below”, and words of similar import, when used to describe this specification, shall refer to this specification as a whole, and not to any particular portions of this specification;

• “or”, in reference to a list of two or more items, covers all of the following

interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list; • the singular forms“a”,“an”, and“the” also include the meaning of any appropriate plural forms.

[0056] Words that indicate directions such as“vertical”,“transverse”,“horizontal”,“upward ”, “downward”,“forward”,“backward”,“inward”,“ outward”,“vertical”,“transverse”,“left”,“rig ht”, “front”,“back”,“top”,“bottom”,“below”,� �above”,“under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.