FIELD OF THE INVENTION

[0001] The present invention relates to a fastener clip, and in particular, a fastener clip for securing a side curtain airbag to a body panel.

BACKGROUND OF THE INVENTION

[0002] Side curtain airbags have for many years provided an increased measure of safety from side impacts. Side curtain airbags are unique in their point of attachment to the vehicle. Rather than being mounted within a steering wheel or a dashboard, side curtain airbags are typically secured directly to the vehicle frame and concealed from view beneath the headliner. One or more impact sensors within each B-pillar can trigger a gas inflator, causing the side curtain airbag to deploy downward from the headliner, typically in less than half a second.

[0003] The fastener clips that join the side curtain airbag to the vehicle frame play an important role in the performance of the side curtain airbag. The fastener clips must secure the curtain assembly to the vehicle frame while being easy to install and remove in the event the side curtain airbag needs to be repaired. The fastener clips should have a small assembly time, without the need for pre-hanging the curtain assembly, and if possible, without the need for welding operations, for example the application of a weld nut to a body panel.

[0004] Accordingly, there remains a continued need for an improved fastener clip for securing a side curtain assembly to a vehicle frame. In particular, there remains a continued need for a robust fastener clip that can be more easily installed to a vehicle frame and removed as needed, optionally without the need for pre -hanging the curtain assembly or weld nuts. SUMMARY OF THE INVENTION

[0005] An improved fastener clip for a side curtain airbag is provided. The fastener clip includes a head portion and a body portion having first and second expansion legs. During installation, the fastener clip is manually inserted through aligned openings in an airbag attachment member and a body panel. When a bolt is threaded into the fastener clip, the head portion engages an upper surface of the airbag attachment member and the expansion legs flex laterally outward and engage an underside of the body panel. Spring tabs extend from the head portion and absorb vibrations to provide a secure attachment over the life of the fastener clip.

[0006] In one embodiment, the head portion of the fastener clip includes an upward facing surface terminating at first and second elongated peripheral edges. Each peripheral edge is inwardly curved to provide a smooth engagement surface for the airbag attachment member. The spring tabs extend downward from the upward facing surface and can flex to accommodate a full range of stackup tolerances (e.g., airbag materials, body frame thicknesses, airbag attachment members). The spring tabs provide sufficient tension to minimize fastener squeak and rattle when the fastener clip is pre-assembled within the airbag assembly.

[0007] In another embodiment, the body portion includes first and second preliminary retention tabs. The retention tabs include a rounded knuckle to prevent withdrawal of the fastener clip from the airbag assembly. The retention tabs also include an angled outer surface, such that the fastener clip can be easily inserted into an aligned opening in a body panel. In addition to the retention tabs, first and second expansion legs extend upward into the interior of the fastener clip. The expansion legs include a curved portion that comprises a hinge, such that the expansion legs can flex laterally outward when engaged by the shank of a threaded bolt. The expansion legs include folded tabs that extend through openings in the fastener clip to engage the underside of the airbag / body panel stackup.

[0008] The fastener clip of the present invention can provide a number of advantages over existing designs. For example, the fastener clip can eliminate the need for a weld nut and can eliminate the need for pre-hanging of the curtain assembly. The fastener clip can be pre-attached to an airbag attachment member with a bolt partially within the barrel opening. If the fastener clip is not fully seated in the airbag / body panel stackup, the expansion legs will bottom on the inside edge of the body panel opening, preventing the bolt (or screw) from being driven. In addition, the rolled or curved peripheral edges allow for a larger bearing surface to distribute the load on the fastener clip during airbag deployment, while also preventing cutting of the airbag curtain material. The body portion of the fastener clip also includes a sidewall with overlapping locking features to ensure the body portion does not spread out during assembly.

[0009] These and other features and advantages of the present invention will become apparent from the following description of the invention, when viewed in accordance with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a perspective view of a fastener clip for a side curtain airbag.

[0011] Figure 2 is a first side elevation view of the fastener clip of Figure 1.

[0012] Figure 3 is a second side elevation view of the fastener clip of Figure 1.

[0013] Figure 4 is a first cross-sectional view of the fastener clip shown in Figure 1.

[0014] Figure 5 is a second cross-sectional view of the fastener clip shown in Figure 1.

[0015] Figure 6 is a bottom view of the fastener clip shown in Figure 1.

[0016] Figure 7 is a top view of the fastener clip shown in Figure 1.

[0017] Figure 8 is a perspective view of a fastener clip with a bolt partially seated therein.

[0018] Figure 9 is a cross-sectional view of the fastener clip and bolt of Figure 9.

[0019] Figure 10 is a side-view of a fastener secured to an airbag stackup.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENT

[0020] Referring to Figures 1-10, a fastener clip in accordance with one embodiment is illustrated and generally designated 10. The fastener clip 10 includes a head portion 12 and a body portion 14 and can be formed from a metal or metal alloy, for example spring steel. The head portion 12 includes a barrel opening 16 for a bolt, and the body portion 14 includes first and second expansion legs 18, 20. As discussed below, the expansion legs 18, 20 flex outward when a bolt is fully inserted to retain the fastener clip 10 within a body panel opening.

[0021] More specifically, the head portion 12 includes an upward facing surface 22 defining the barrel opening 16 for receiving a bolt. The upward facing surface 22 terminates at a first elongated peripheral edge 24 and a second elongated peripheral edge 26. Each peripheral edge 24, 26 is inwardly curved, optionally by about 180 degrees, such that each peripheral edge 24, 26 curves downward and inward when viewed from the side. As also shown, each peripheral edge 24, 26 extends laterally beyond the body portion 14, such that the upward facing surface 22 is generally H-shaped when viewed from above. The curved (or rolled) peripheral edges 24, 26 provide a bearing surface to distribute compressive loads onto an airbag attachment member and prevent cutting or tearing of the airbag curtain material. The upward facing surface 22 is otherwise planar, and first and second spring tabs 28, 30 extend at a downward angle from the upward facing surface 22. The spring tabs 28, 30 can flex to accommodate a full range of stackup tolerances (e.g., airbag material, body frame, airbag attachment member). The spring tabs 28, 30 provide sufficient tension to minimize fastener squeak and rattle when the fastener clip 10 is in an intermediate fixed position, that is, partially inserted within a body panel opening.

[0022] As noted above, the fastener clip 10 also includes a body portion 14. The body portion 14 includes first and second sidewalls 32, 34 extending downward from a midportion of the first and second peripheral edges 24, 26 respectively. The first sidewall 32 includes a central panel 36, a left-side panel 38 and a right-side panel 40. Similarly, the second sidewall 34 includes a central panel 42, a left-side panel 44, and a right-side panel 46. As shown in Figure 6, the first and second sidewalls 32, 34 form a rigid box-like structure. The left-side panel 38 of the first sidewall 32 is co-planar with the right-side panel 46 of the second sidewall 34, with a partition therebetween. Similarly, the right-side panel 40 of the first sidewall 32 is co-planar with the left-side panel 44 of the second sidewall 34, with a partition therebetween. The adjoining panels include overlapping locking features, visible in Figures 3 and 4, to ensure that the body portion 14 does not spread apart during bolt assembly.

[0023] As best shown in Figures 1 and 2, the body portion 14 includes first and second retention tabs 48, 50 that protrude outward from the first and second sidewalls 32, 34. The retention tabs 48, 50 are flexibly joined to the sidewalls 32, 34 and include an angled outer surface, such that the body portion 14 can be easily inserted into a body panel opening. Once the body panel opening clears a rounded knuckle 52 on the retention tabs 48, 50, the retention tabs 48, 50 spring outward, preventing removal of the fastener clip 10 from the body panel opening until depressed by a user. In this respect, the retention tabs 48, 50 retain the body portion 14 in the intermediate fixed position and can be depressed for easy removal of the fastener clip 10.

[0024] As shown in Figures 4 and 5, the body portion 14 also includes first and second expansion legs 18, 20 joined to a lower peripheral edge of the first and second sidewalls 32, 34 The expansion legs 18, 20 curve upward into an interior cavity defined in the body portion 14. The lowermost portion of the expansion legs 18, 20 comprise a hinge that imparts elasticity to the expansion legs 18, 20 so that they can flex laterally. Each expansion leg 18, 20 includes first and second folded tabs 54, 56 that are parallel to each other and that are spaced apart from each other. When the expansion legs 18, 20 are engaged by a bolt, the bolt causes the expansion legs to flex laterally outward from within the interior cavity. From this position, the first and second folded tabs 54, 56 of the first expansion leg 18 protrude through first and second openings 58, 60 in the first sidewall 32. Similarly, the first and second folded tabs 54, 56 of the second expansion leg 20 protrude through first and second openings 58, 60 in the second sidewall 34. Each such opening 58, 60 comprises a vertical slot where the central panel joins the side panels.

[0025] In use, the fastener clip 10 is inserted through aligned openings in an airbag attachment member and a vehicle frame. A threaded bolt 100 is pre-positioned within the fastener clip 10 and extends into the barrel 62, generally shown in Figure 9. At its terminal edge 64, the barrel 62 is narrowed to prevent withdrawal of the bolt prior during shipment and prior to final assembly. When the bolt is substantially fully inserted into the fastener clip 10, the head portion 12 lowers against the stackup, and the expansion legs 18, 20 flex laterally outward. Because the expansion legs 18, 20 are on the inside of the stackup 102 as shown in Figure 10, the expansion legs 18, 20 (and in particular a U-shaped end-portion 66 and the folded tabs 54, 56) engage an underside of the stackup 102, for example the body panel. The spring tabs 28, 30 absorb vibrations and minimize squeak and rattle over the life of the fastener clip 10. When the bolt 100 is removed from the fastener clip 10, the expansion legs 18, 20 return to their initial position as shown in Figures 4 and 5, and the fastener clip 10 can be manually retracted from the body panel opening by depressing the retention tabs 48, 50 on either side of the body portion. [0026] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements by ordinal terms, for example “first,” “second,” and “third,” are used for clarity, and are not to be construed as limiting the order in which the claim elements appear. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.