U.S. patent application number 10/350515 was filed with the patent office on 2004-07-29 for mounting clip for plastic containers.
Invention is credited to Engle, Brian, Rabideau, Michael A., Schulte, Kale S., Vorenkamp, Erich J..
Application Number | 20040144779 10/350515 |
Document ID | / |
Family ID | 30444049 |
Filed Date | 2004-07-29 |
United States Patent
Application |
20040144779 |
Kind Code |
A1 |
Schulte, Kale S. ; et
al. |
July 29, 2004 |
Mounting clip for plastic containers
Abstract
A clip for attaching a component to a container. The clip has a
generally tubular body including folds giving the clip a corrugated
appearance. The clip and container are formed from similar plastic
materials so that when the clip is placed in contact with a
container having latent heat from formation, the exterior surface
of the folds melts to the container to form a bond area. The folds
also define a passageway in which the component is retained.
Inventors: |
Schulte, Kale S.; (Canton,
MI) ; Rabideau, Michael A.; (Belleville, MI) ;
Engle, Brian; (Armada, MI) ; Vorenkamp, Erich J.;
(Pinckney, MI) |
Correspondence
Address: |
Dickinson Wright PLLC
Suite 800
1901 L. Street NW
Washington
DC
20036
US
|
Family ID: |
30444049 |
Appl. No.: |
10/350515 |
Filed: |
January 24, 2003 |
Current U.S.
Class: |
220/4.14 |
Current CPC
Class: |
B60K 2015/03467
20130101; B60K 15/035 20130101; F16L 3/12 20130101; B60K 15/01
20130101; B60K 2015/03523 20130101; B60K 2015/03453 20130101 |
Class at
Publication: |
220/004.14 |
International
Class: |
B65D 006/00; B65D
008/00 |
Claims
What is claimed is:
1. A clip for securing a component, said clip comprising: a
generally tubular body having a plurality of ridges and a
continuous internal surface to receive and completely encircle the
component.
2. The clip of claim 1, wherein said tubular body includes a
longitudinal axis, said ridges being axially aligned along said
longitudinal access.
3. The clip of claim 1, wherein said tubular body includes grooves
between said ridges, said grooves defining said continuous internal
surface.
4. The clip of claim 1, wherein said tubular body is formed from a
material compatible for heat bonding.
5. The clip of claim 4, wherein said material is polyethylene.
6. A component attachment assembly comprising: a component; and a
clip having a plurality of ridges and a continuous internal surface
to receive and completely encircle said component.
7. The assembly of claim 6, wherein said clip includes a
longitudinal axis, said ridges being axially aligned along said
longitudinal access.
8. The assembly of claim 6, including a container, said container
being formed from a material compatible for heat bonding with said
clip.
9. The assembly of claim 8, wherein said clip is attached to said
container with said ridges, said container and said ridges forming
a bond area.
10. The assembly of claim 9, wherein said container is formed from
a material having a first melting point, said clip being formed
from a material having a second melting temperature lower than said
first melting temperature.
11. The assembly of claim 8, wherein said container is formed from
a high density polyethylene and said clip is formed from a low
density polyethylene.
12. The assembly of claim 8, wherein said container is a fuel tank
for a vehicle.
13. The assembly of claim 6, wherein said clip includes grooves
between said ridges, said grooves defining said continuous internal
surface.
14. A method of attaching a component to a container comprising:
forming a clip having a plurality of ridges axially arranged about
a longitudinal axis, said clip having a continuous interior
surface; forming the container by a thermal process resulting in
latent heat at a mounting surface; placing said clip against said
mounting surface to melt said folds to said fuel tank to form a
bond area.
15. The method of claim 14 wherein said clip includes a plurality
of grooves between said ridges, said interior surface being defined
by said grooves.
16. The method of claim 15 wherein said interior surface defines a
passageway.
17. The method of claim 16 including the step of assembling the
component into said passageway.
18. The method of claim 14 wherein the component is a vapor valve
line, a wiring harness or a fuel delivery line.
19. The method of claim 14 wherein said ridges and said grooves are
flexible to allow said clip to attach to curved geometric surfaces.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to fasteners for
plastic containers and particularly to mounting clips to attach a
component to the wall of a plastic container, such as a fuel
tank.
[0002] Plastic containers are widely used to store fluids and other
materials to take advantage of a number of benefits including
weight savings and corrosion resistance. One problem with plastic
containers is that many types of plastics used to form containers
allow permeation of vapors through the container walls. To prevent
permeation, manufacturers have added permeation resistant layers to
the containers. Even if a container includes a permeation resistant
layer, as items are attached, permeation pathways may be created
where the permeation resistant layer is pierced.
[0003] One particular area in which manufacturers have strived to
address permeation is vehicle fuel tanks. As emission standards
have become more stringent, manufacturers have attempted to move
fuel system components, and connector lines within the tank to
minimize permeation pathways by limiting the number of openings
which pierce the permeation resistant layer.
[0004] The problem with placing components in a container that is
subject to movement, such as a fuel tank, is that certain
components such as connector lines may contact the container walls
during movement causing undesirable noises and vibrations. Further,
movement of the components increases the stress and wear rates
which may result in decreased component service life.
[0005] One method of attaching components, such as vapor valve
lines, and wiring harnesses to the walls of the tank is to create a
die lock in the molded tank. Creating a die lock is generally
difficult, expensive, and occasionally impossible due to geometry
constraints. In fact, in most forming processes used to create fuel
tanks and similar containers, it is almost impossible to create a
die lock, much less multiple die locks.
[0006] Some manufacturers have attempted to address these problems
by adding clips after the container is formed. Some of these clips
are attached with adhesive to the sidewalls of the container.
However, certain chemicals or fuels stored in the container may
degrade the adhesive over time so that it no longer forms a secure
bond with the container walls. Another method of attaching clips to
the container walls is by hot plate welding. Hot plate welding
involves heating the surface of the clip, as well as a portion of
the surface of the tank, and then placing the respective heated
areas of the clip and tank in contact with each other to form a
bond. After the clips are welded to the surface of the tank, the
components are then placed in the tank. Problems with hot plate
welding include increased manufacturing costs; penetration or
degradation performance of the permeation resistant layer; by the
heating of the container wall; and the difficulty in assembling
without first creating a large opening in the tank to facilitate
placement of components in the interior of the tank. A large
opening may create a large permeation area, which defeats the
benefits of reducing evaporative emissions by placing the
components in the fuel tank.
[0007] A further deficiency of container wall mounting clips is
that they have a specific mounting surface that must be properly
oriented to the exterior surface of the container to provide proper
assembly and adequate bonding. A problem with many of these clips
is that over time a percentage of them fail to securely retain the
component. A clip may fail to retain a component if the retention
members of the clip are too large or small for the component. Wear
or stress of the component may occur as the clip rubs against the
component. If the retention members are weakened, the clip may lose
its grip on the component, causing wear, stress, noise, and
vibration concerns. If the component is removed and replaced within
the retention members during servicing, this may weaken or break
the retention members.
SUMMARY OF THE INVENTION
[0008] In view of the above, the present invention is directed to a
clip for retaining components against the walls of a plastic
container and a related method of securing components to the
container. The clip traps a component in a plurality of continuous
folds and may be secured to the tank using its outer surfaces.
[0009] The present invention is also directed to a method for
attaching a component to a container wall. The method includes
forming a clip having a plurality of folds axially arranged around
the longitudinal axis of the clip, securing a component with the
clip and bonding the folds to the container through the latent heat
from formation of the container.
[0010] Further scope of applicability of the present invention will
become apparent from the following detailed description, claims,
and drawings. However, it should be understood that the detailed
description and specific examples, while indicating preferred
embodiments of the invention, are given by way of illustration
only, since various changes and modifications within the spirit and
scope of the invention will become apparent to those skilled in the
art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will become more fully understood from
the detailed description given here below, the appended claims, and
the accompanying drawings in which:
[0012] FIG. 1 is a perspective view of the clip;
[0013] FIG. 2 is a front elevational view of the clip;
[0014] FIG. 3 is a perspective view of a clip attached to the
container wall and retaining a component; and
[0015] FIG. 4 is a sectional view of the clip taking along lines
4-4 in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] A clip constructed in accordance with the illustrated
embodiment is shown in FIG. 1 and designated 10. The clip 10
generally includes a tubular body 12 having a plurality of folds
14, which give the clip 10 a corrugated appearance. The clip 10 may
be operatively coupled to a component 40 to form an accessory
assembly for attachment to a container. As shown in FIG. 3, the
clip 10 is attached to a container 30 (inside or outside) to
securely retain a component 40 such as a wiring harness, fuel line,
or vapor line. The clip 10 is attached to the container by melting
the folds 14 to the container 30 to form a bond area 34 (FIG. 4).
While a variety of melting techniques may be used, in the
illustrated embodiment, the folds 14 are melted to the container 30
through the latent heat from the formation of the container 30.
[0017] The tubular body 12 may vary in size, shape, and
configuration to accommodate various components 40 and attach to
various container geometries. In the illustrated embodiment, the
tubular body 12 has a circumferential shape that completely
encircles a component 40 to prevent the component from being
released by the clip 10. The complete encirclement of the component
40 also allows various sized components 40 to be retained by the
clip 10, even if the component 40 is much smaller than the
retaining tubular body 12. The clip 10 preferably does not have an
opening along the longitudinal axis 26 and preferably does not
provide snap fit retention of a component 40. The clip 10 secures
the component 40 by complete encirclement of the component 40. This
complete encirclement further minimizes the frequency with which
the component may become free due to stress, wear, age, or a force
exerted upon the components. In assembly, the component 40 is
attached to the clip 10 by being passed through the tubular body
12, therefore, so long as the component 40 fits within the tubular
body 12, it will be securely retained within the clip 10. The clip
10 may be configured to snugly retain the component 40 to prevent
vibrations by the component 40.
[0018] The tubular body 12 includes a plurality of folds 14. The
folds 14 may extend along the entire length of the tubular body 12,
as illustrated in FIG. 1, or along a portion of the tubular body 12
(not illustrated). The folds 14 include ridges 16 and grooves 18,
which may be formed in a variety of sizes, shapes, or
configurations. For example, the ridges 16 and grooves 18 may be
rounded, pointed, or have flat apexes 17 and nadirs 19. The height
difference between the ridges 16 and the grooves 18 may vary as
well as the pitch between adjacent ridges 16 or grooves 18. The
configurations of the ridges 16 and the grooves 18 may also be
varied along the tubular body 12 in a non-uniform manner to allow
for better attachment to certain oddly shaped geometric
configurations. In the illustrated embodiment, the folds 14 are
somewhat axially aligned around the longitudinal axis 26. The shape
formed by this axial alignment may be a continuous spiral like the
threading on a screw or nut or as individual rings. The folds 14
also provide flexibility to facilitate bending around or over
certain geometric configurations of the container 30, as well as
better direct and secure the component 40. The length of the
tubular body 12 may depend on various considerations such as space,
geometry, and the required retention force.
[0019] The outside diameter 22 of the tubular body 12 is formed by
the apexes 17 of the ridges 16, while the inside surface 24 may be
formed by the nadirs 19 of the grooves 18. The inside surface 24
may be determined by the size of the component 40 as well as if it
is desirable to tightly hold the component 40 or allow it to slide
somewhat freely through the tubular body 12. In an alternative
embodiment, the inside diameter 24 may have a relatively smooth
surface (not shown) with projections therefrom forming the ridges
16. The outer ridges 16 provide a bonding surface for the clip 10
to be attached to a container as described below.
[0020] The container 30 may be formed out of a variety of materials
depending on the application. In the illustrated embodiment, the
container 30 is formed through a thermal process. Examples of well
known thermal processes to form containers such as fuel tanks for
vehicles include blow molding, twin sheet forming, thermo-forming,
and roto-molding.
[0021] For material compatibility, the clip 10 is generally formed
from the same, or other suitably compatible, material with the
container 30. If the container 30 includes a multi-layer wall as
shown in FIG. 4, the clip 10 is typically formed from materials
similar to the layer to which it is bonded. Forming the clip 10
from a compatible material as the container 30 allows for ease of
attachment of the clip-10 during manufacturing. In the illustrated
embodiment, the clip 10 is formed from a polyethylene, preferably
low-density polyethylene or high-density polyethylene. To improve
the melting characteristics of the clip 10, the clip may be formed
out of a material having a lower melting point than the container
30. Within a suitably short period after formation or during
formation of the container 30, the clip 10 is attached to the
container 30. More specifically, the apexes 17 are melted to the
container 30 to form a bond area 34. The shape and height of the
ridges 16 and apexes 17 may be varied to provide an optimal bond
between the tubular body 12 and the container 30. The ridges 16
should be sized and shaped to melt in a manner suitable to form the
bond area 34 while preventing deformation of the inner surface 24
of the tubular body 12. Preventing deformation of the inner surface
24 may prevent any potential damage to the component 40 retained
within the clip 10. The thickness of material used to form the clip
10 as well as the ridges 16 may depend on the material selected and
how well that material conducts heat. The conduction of heat is
related to how well the ridges 16 melt to the container 30. An
exemplary clip, formed from high-density polyethylene and suitable
for attachment to the walls of a polyethylene container, may have a
wall thickness of 0.6 mm. Of course, the ridges 16 may have the
suitable thickness while the thickness may vary for other parts of
the clip 10. For example, a clip 10 may have ridges with a set
thickness and thicker grooves 18 to protect the component 40
secured within the clip 10 from being deformed when the ridges 16
are melted to the container 30 to form the bond area 34.
[0022] The above described configuration and technique facilitate
suitable bonding of the container 30 and clip 10 in a variety of
clip orientations including tight radius bends. The clip 10 may
also be bonded in any orientation around the clip's 10 longitudinal
axis 26, as shown in FIG. 3. Prior art clips include an opening
that was directed way from the container surface and required
careful placement during attachment. The clip 10 of the present
invention completely encircles a component 40 so that the
rotational position of the clip 10, about the axis 26, does not
matter.
[0023] The assembly of the present invention is efficient as well
as cost saving during the manufacturing process. In the illustrated
embodiment, the clips 10 are first attached to the components 40.
More specifically, the component 40 is passed through the tubular
body 12 until the clip 10 reaches a desired location on the
component 40. As shown in FIG. 3, more than one clip 10 may be used
to route components 40 around items attached to the container 30 or
over curved surfaces and complex geometries. After the component 40
is disposed within the passage 28, the clip 10 is ready to be
attached to the container 30. Of course, it should be readily
recognized by one skilled in the art that the above described
sequence of steps may be varied. For example, the clips 10 may
first be attached to the container 30 and then the components 40
may be disposed within the passage 28 and secured to the clips
10.
[0024] As noted above, the clips 10 are secured to the container 30
while the container 30 is at a suitably elevated temperature to
permit the latent heat to provide attachment. For example, if the
container 30 is manufactured by forming, as in the described
embodiment, the clip 10 is attached shortly after container 30 is
formed by pressing the tubular body 12 against the surface of the
container 30 so that the latent heat from the formation of the
container 30 melts the apexes 17 of the ridges 16 to form the bond
area 34. In the illustrated embodiment, the container 30 preferably
has a latent heat of at least 120.degree. C. more preferably
180.degree. C. to 233.degree. C. and yet more preferably
198.degree. C. to 205.degree. C. to melt the ridges 16 of the
exemplary clip 10 described above to the container 30. These
temperatures may vary depending on the materials used to form the
container 30 as well as the material used to form the clip 10 and
the thickness of the walls of the clip 10. Of course, if necessary,
the container may be reheated to attach the clips 10.
[0025] Alternative methods of attachment may be used if the
container 30 does not have enough latent heat when the clip 10 is
to be attached. One such method that does not require heat is
ultrasonic welding. Another such method is where melted plastic is
placed on the container 30 where the clip 10 is to be attached. The
clip 10 is then placed into the melted plastic so that upon
cooling, the clip 10 is bonded to the container 30. Yet another
method is where the clip 10 is placed against the container 30 and
hot air is blown against the clip 10 and container 30 until they
melt to form a bond area 34.
[0026] The foregoing discussion discloses and describes an
exemplary embodiment of the present invention. One skilled in the
art will readily recognize from such discussion, and from the
accompanying drawings and claims that various changes,
modifications and variations can be made therein without departing
from the true spirit and fair scope of the invention as defined by
the following claims.
* * * * *