U.S. patent application number 13/831525 was filed with the patent office on 2016-11-17 for magnetic bracket and method.
The applicant listed for this patent is Daniel James Dickenson, Michael Walter Smith. Invention is credited to Daniel James Dickenson, Michael Walter Smith.
Application Number | 20160334053 13/831525 |
Document ID | / |
Family ID | 51523326 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160334053 |
Kind Code |
A9 |
Dickenson; Daniel James ; et
al. |
November 17, 2016 |
MAGNETIC BRACKET AND METHOD
Abstract
A magnetic bracket includes a base and at least two posts at
opposite ends of the base. The posts bend upwards from the base
such that at least two clips are operable to attach at the posts at
opposite ends of the base. The posts have a notch between the base
and ends of the posts to permit the clips to hook onto the posts.
The magnetic bracket may be clipped into a vehicle chassis by
removably inserting the clips into a slot of the vehicle chassis. A
body panel such as a headliner having a magnetic fastener attached
to the body panel may then be magnetically self-aligned and
removably attached to the base having a magnetic portion. The
magnetic fastener is operable to be removably attached to the
magnetic portion. The magnetic bracket is attached to a
non-magnetic part of a vehicle chassis.
Inventors: |
Dickenson; Daniel James;
(Lincolnshire, IL) ; Smith; Michael Walter; (Lake
Zurich, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dickenson; Daniel James
Smith; Michael Walter |
Lincolnshire
Lake Zurich |
IL
IL |
US
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20140263895 A1 |
September 18, 2014 |
|
|
Family ID: |
51523326 |
Appl. No.: |
13/831525 |
Filed: |
March 14, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12983010 |
Dec 31, 2010 |
8287034 |
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13831525 |
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12464867 |
May 13, 2009 |
8615852 |
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12983010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16B 2001/0035 20130101;
Y10T 29/49959 20150115; F16B 5/123 20130101; B60R 13/0206 20130101;
F16M 13/02 20130101 |
International
Class: |
F16M 13/02 20060101
F16M013/02 |
Claims
1. A magnetic bracket for attachment to a non-magnetic part of a
vehicle chassis comprising: a base having a magnetic portion
operable to attach to a magnetic fastener; and at least two posts
at opposite ends of the base, the posts bend upwards from the base,
such that at least two clips are operable to attach at the
posts.
2. The magnetic bracket of claim 1 wherein the magnetic fastener is
aligned with the non-magnetic part of a vehicle chassis in response
to the magnetic attraction between the magnetic fastener and the
magnetic portion.
3. The magnetic bracket of claim 1 wherein the posts have a notch
opening between the base and at least one post.
4. The magnetic bracket of claim 1 wherein the magnetic portion has
a round, circular, semi circular, rectangular or curved shape.
5. The magnetic bracket of claim 1 wherein the clip comprises of at
least one of: Polypropylene, glass fill, acetal, plastic, vinyl,
rubber, plastisol, plastic, acetal, polyacetal, polyoxymethylene,
nylon, fiberglass and carbon fiber and Acrylonitrile butadiene
styrene (ABS) and the magnetic bracket comprises at least one of:
steel, a steel alloy, iron, and a magnetic material.
6. The magnetic bracket of claim 1 wherein the magnetic fastener
further comprises: a holder, an umbrella or foam, attached to the
holder; and a magnet attached to the holder opposite the umbrella
or foam; wherein the magnetic fastener is removabably coupled to
the magnetic portion on a side of the base opposite the clips.
7. The magnetic bracket clip of claim 1 wherein the at least two
clips further comprise: a pair of laterally offset legs joined at a
head portion, wherein the legs form a clip opening at an opposite
end of the head portion; and a pair of arms coupled to the pair of
legs adjacent to the head portion such that the pair of arms move
substantially independently from the pair of legs, wherein the arms
project toward the clip opening to form a frictional opening and to
permit insertion or withdrawal of the post such that the post
causes a non-compressive force between the arms when the post is
withdrawn.
8. The magnetic bracket of claim 7 wherein at least one of: an end
of the post is tapered and the head portion of the clip is
tapered.
9. The magnetic bracket of claim 7 wherein the clip further
includes a projection located at the end of each corresponding arm,
such that the projections point to each other to create the
frictional opening.
10. The magnetic bracket of claim 7 wherein at least one of: at
least one of the legs passes through a notch opening of the bracket
when the clip is inserted into the post, and the pair of arms are
substantially flush with the legs such that the arms engage a first
engagement structure when the post is withdrawal.
11. The magnetic bracket of claim 7 further comprising at least one
of: a depressed portion on the end of the post, an inner part of a
notch opening on the post, a depressed portion on at least one arm
and a depressed portion on at least one leg.
12. A magnetic bracket assembly for attachment to a non-magnetic
part of a vehicle chassis comprising: a magnetic bracket
comprising: a base having a magnetic portion; at least two posts at
opposite ends of the base, the posts bend upwards from the base; at
least two clips operable to attach at the posts at opposite ends of
the base, wherein the clips are operably clipped into a slot of a
non-magnetic part of a vehicle chassis; and a magnetic fastener
having one end removably attached to the body panel and having a
magnetic side opposite the one side that is magnetically attached
to the magnetic portion.
13. The magnetic bracket assembly of claim 12 wherein the posts
have a notch opening between the base and at least one post.
14. The magnetic bracket assembly of claim 12 wherein the magnetic
portion has a round, circular, semicircular, rectangular or curved
shape and aligns with the magnetic fastener.
15. The magnetic bracket assembly of claim 12 wherein the at least
two clips further comprise: a pair of laterally offset legs joined
at a head portion, wherein the legs form a clip opening at an
opposite end of the head portion; and a pair of arms coupled to the
pair of legs adjacent to the head portion such that the pair of
arms move substantially independently from the pair of legs,
wherein the arms project toward the clip opening to form a
frictional opening and to permit insertion or withdrawal of the
post such that the post causes a non-compressive force between the
arms when the post is withdrawn.
16. The magnetic bracket assembly of claim 15 wherein the clip
further includes a projection located at the end of each
corresponding arm, such that the projections point to each other to
create the frictional opening.
17. A method of assembling a magnetic bracket for attachment to a
non-magnetic part of a vehicle chassis comprising: forming two
posts at opposite ends bending upwards from a base of the magnetic
bracket; and inserting at least two clips into posts at opposite
ends of the base of the magnetic bracket.
18. The method of claim 17 further comprising: removably inserting
the clips into a slot of a non-magnetic part of the vehicle
chassis.
19. The method of claim 17 further comprising: attaching the body
panel attached to a magnet by magnetically and removably attaching
the magnet with the base.
20. The method of claim 17 further comprising: aligning the
magnetic fastener with the non-magnetic part of a vehicle chassis
in response to the magnetic attraction between the magnetic
fastener and the base.
Description
RELATED APPLICATIONS
[0001] This is a continuation in part application claiming priority
from an application entitled "Magnetic Fastener Clip" having a
docket number P055 and a Ser. No. 12/464,867, and having a filing
date of May 13, 2009, the entire disclosure of which is
incorporated herein by reference.
[0002] This is a continuation in part application claiming priority
from an application entitled "CONTINUOUSLY ADAPTIVE FASTENER CLIP"
having a docket number P056 and a Ser. No. 12/651,477, having a
filing date of Jan. 3, 2010;
[0003] which is a continuation in part of an application entitled,
"CONTINUOUSLY ADAPTIVE FASTENER CLIP" having a docket number P054
and a Ser. No. 12/534,119, having a filing date of Aug. 1,
2009;
[0004] which is a continuation in part of an application entitled
"CONTINUOUSLY ADAPTIVE FASTENER CLIP" having a docket number P053
and a Ser. No. 11/870,412, having a filing date of Oct. 10,
2007;
[0005] which is a continuation in part of an application entitled
"Multicontact Adaptive Fastener Clip" having a docket number P042
(04.0002) and a Ser. No. 11/277,107, having a filing date of Mar.
21, 2006; and
[0006] which is a continuation in part of U.S. patent application
Ser. No. 10/906,209, now U.S. Pat. No. 7,178,850 having a docket
number P041 (04.001) filed on Feb. 9, 2005, the entire disclosures
of which are incorporated herein by reference in their
entirety.
FIELD OF THE INVENTION
[0007] The invention relates generally to devices for fastening
objects, and more particularly to a magnetic fastener and/or clip
for insertion into or attachment onto an engagement structure, such
as a vehicle chassis, a hollow substrate, a wall, a plate or any
suitable surface.
BACKGROUND OF THE INVENTION
[0008] A number of devices and fasteners are currently available
for fastening panels such as body panels and automobile interior
trimpiece panels to the chassis of a vehicle. Fastener clips are
used in automobile assemblies to secure body panels such as
headliners, pillar covers, interior panels and the like to roofs,
door structures and body pillars. An example of such a clip is
described in U.S. Pat. No. 7,444,721 incorporated by reference. As
used herein, a body panel refers to, for example, any interior or
exterior structure attached to a vehicle, such as a plastic or
metal interior trim piece or any interior trimpiece. The body panel
may be any suitable exterior body panel, such as a fender, bumper,
quarter panel or door panel. The chassis of the vehicle may include
any substrate, roof, plate, body panel, structural framework,
chassis component or subcomponent, support component, wall or any
suitable object or combination.
[0009] Interior automobile fasteners, such as screws, are also
known to retain a body panel to a vehicle chassis. For example, a
screw may attach a headliner in position within the automobile
roof. However, many of these fasteners only fasten around the
periphery of the headliner. While a dome light or the like may be
located in the middle of the roof area, extensive expanses of the
headliner are not supported or fastened by such structures. Also,
these fasteners allow the headliner to sag, providing an
aesthetically unacceptable appearance.
[0010] An automobile body panel such as a headliner or B pillar
cover is typically made of cloth, foam, plastic or other suitable
material and generally includes a suitable substrate layer. A
fastener clip may be secured to the substrate by an adhesive, such
as glue, and is then attached to the underlying roof structure.
[0011] Attaching the headliner to the interior of the roof
typically requires securing clips already fastened to a headliner
assembly into a hole, slot or mounting point on the roof. At least
some of the clips require blind insertion and installation of the
fasteners because the installer is not able to view the fastener
clip or the mounting point on the roof.
[0012] Fastener clips are also known for attaching body panels to
an automobile chassis. Magnets may be used to reduce the problem of
the blind fastener application. For example, fastener clips are
known that attach to an automobile headliner or the like using
adhesive, and which firmly connects to a magnet. Thus, magnetic
fastening clips do not require aligning a fastener with a mating
hole and attachment of the fastener to the hole.
[0013] Another known clip has a base, a dome spaced from the base
and a plurality of supports between the base and the dome. A hollow
post extends outwardly from the dome and includes at least one
deflectable portion having an outward protuberance thereon. A pin
is substantially aligned with the post and connected thereto by at
least one frangible link. A frangible link between the pin and the
clip is adapted to rupture when the pin is driven. However, since
the pin requires alignment and insertion during manufacture,
assembly is time consuming labor intensive and expensive.
[0014] These known clips however are difficult to install
especially in a blind manner and are neither sufficiently rugged
nor flexible for example on an electrical box, conduit or
automobile assembly line that can be somewhat harsh. These
fastening clips typically do not have a long useful life to support
the headliner or cables and prevent staking throughout the
anticipated life expectancy of the vehicle. During installation the
headliner can be moved, stretched or twisted inconsistently.
However, the fastener device is typically required to secure the
panel to the chassis that may have sheet metal with different
amounts of curvature or thicknesses throughout. If the sheet metal
varies in curvature or thickness or if for example, tolerances in
production of the vehicle chassis or in the trim-piece, i.e.
headliner exist, then engagement of one fastener to the roof may
not provide suitable magnetic engagement or will otherwise result
in movement. Further, less than all these fasteners typically make
engagement with the chassis. Twisting of the body panel will be
likely more prevalent because less than all contact points are
actually made with the roof. As a result, sagging, wear, squeaks,
rattles, buzzing, corrosion and loss of elasticity and loss of
sealing may result, especially after years of vehicle operation and
exposure to vibration and other environmental conditions. As such,
these fastener clips do not provide sufficient flexibility.
[0015] Once installed, during use of the automobile, the headliner
is sometimes contacted or pushed by passengers. The fastener device
is typically required to secure the headliner under a variety of
environmental conditions, such as in the presence of vibration at
various levels of amplitude and frequency. Further, the fastener
device should prevent or minimize the amount of buzzing, rattling
or any other type of noise that may cause attention to the
occupants of the vehicle or otherwise weaken the attachment.
Further yet, another requirement of the fastener device is that the
fastener device accommodates various levels of sheet metal
curvature, thicknesses, and production tolerances, such as various
dimensions amongst, for example, the body panels as well as the
vehicle chassis. Conventional fastener devices typically do not
adequately fasten to a range of sheet metal thicknesses and do not
minimize or eliminate buzzing and rattling and do not sufficiently
accommodate variations in production tolerances. As a result, these
clips do not properly fasten the body panel to the chassis, break
or otherwise fail under these conditions. If the fastener clip is
broken after installation of the body panel, sagging can occur
again presenting the aesthetically undesirable appearance. Further,
replacement of an installed, broken clip can be difficult.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an exploded view of a magnetic bracket and
assembly according to one embodiment;
[0017] FIG. 2 is perspective view of the magnetic bracket according
to one embodiment;
[0018] FIG. 3 is an assembly view of a magnetic bracket and
assembly according to one embodiment;
[0019] FIG. 4 is an assembly view of a magnetic bracket inserted
into a vehicle chassis according to one embodiment;
[0020] FIG. 5 is a side view of a magnetic bracket and assembly
according to one embodiment; and
[0021] FIG. 6 is a bottom perspective view of the magnetic bracket
and assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] A magnetic bracket includes a base and at least two posts at
opposite ends of the base. The posts bend upwards from the base
such that at least two clips are operable to attach at the posts at
opposite ends of the base. The posts have a notch between the base
and the posts to permit the clips to hook onto the posts. The
magnetic bracket may be clipped into a vehicle chassis by removably
inserting the clips into a slot of the vehicle chassis. A body
panel such as a headliner having a magnetic fastener attached to
the body panel may then be magnetically self-aligned and removably
attached to the magnetic portion of the base. The magnetic fastener
is operable to be removably attached to the magnetic portion. The
magnetic bracket may thus be attached to a non-magnetic part of a
vehicle chassis. For example, the non-magnetic part of a vehicle
chassis may be carbon fiber, fiber glass, or aluminum and permits
body panels to be attached to the chassis via the magnetic
bracket.
[0023] Among other advantages, the magnetic bracket is attached to
a chassis or a portion of the chassis which may not be magnetic.
For example, the chassis or a portion of the chassis may be carbon
fiber, fiber glass, or aluminum or any suitable non-magnetic
material. The magnetic bracket permits body panels to be easily
attached to the chassis via the magnetic bracket even in blind
engagement conditions.
[0024] The magnetic fastener bracket relatively easily facilitates
attachment of a body panel with the non-magnetic portion of the
chassis, such as the vehicle door frame, roof, sun-roof section,
instrument panel structure, pillar, such that a single style
adjustable magnetic fastener and/or bracket may be used with
different depth attachment requirements, sheet metal curvatures
and/or thicknesses. For example, a vehicle roof, pillar, instrument
panel structure, chassis, or door may have different sheet metal
curvatures and thicknesses at various parts of the vehicle. Since
the fastener adapts automatically to different attachment
requirements, depths, sheet metal curvatures and thicknesses, the
same style fastener clip may be used throughout the vehicle thus
eliminating the need for specific fastener clips for different
parts of the roof and headliner that otherwise would require a clip
according to specific roof curvatures and thicknesses. The body
panel may be an automatable headliner, door panel, instrument
panel, A, B, C, D, etc. pillar panel, bumper, fender, quarter
panel, grill, hood, roof, trunk panel or any suitable interior or
exterior panel.
[0025] The magnet bracket, along with an optional carrier, permits
relatively easy insertion of the magnetic fastener clip into a
vehicle chassis, pillar, instrument panel structure, door, roof and
permits magnetic attachment and detachment with as suitable body
panel while providing a relatively high level of extraction force
from the body panel. According to one embodiment, if the roof is
made of a non-magnetic material such as aluminum, carbon fiber or
fiber glass, the magnets fastened to the headliner will not attach
at incorrect points on the roof since the magnet is not attracted
to aluminum. Among other advantages, as the headliner and magnet
assembly nears the magnetic bracket, the magnet will automatically
align and attach with the magnetic bracket making headliner
assembly very easy, and significantly easier than conventionally
possible. Assembly of the body panel onto the vehicle chassis is
very easy and requires no or a relatively low level of insertion
force compared to the extraction force, and as a result provides
many ergonomic advantages. For example, the relatively low level of
insertion force is particularly advantageous for assembly line
operators who repetitively insert body panels onto the vehicle
chassis. The relatively low level of insertion force required for
blindly inserting the body panel into the vehicle chassis increases
productivity and may result in fewer injuries to the assembly
workers, including injuries related to repetitive stress syndrome.
Further by selecting a single fastener or reducing the number of
different fasteners for different sheet metal curvatures and
thicknesses, confusion during assembly is eliminated since the same
type or a reduced number of fasteners may be used for all or most
body panel fasteners. Thus, an assembly worker need not worry about
selecting the wrong fastener.
[0026] The relatively high level of extraction force,
characteristic of the clip and magnetic fastener clip, securely
attaches the body panel, such as a door panel, or headliner, to the
vehicle chassis. Further, the fastener clip continuously adapts to
changes in environmental conditions such as vehicle flexing,
pushing by passengers, vibration and thermal expansion. For
example, the magnetic fastener clip may adapt to changes in thermal
expansion, especially due to the differences in thermal expansion
rates between dissimilar metals with respect to the vehicle chassis
components and/or between plastic components such as the interior
trim panels attached to the metal vehicle chassis. The fastener
clip may also fasten to plastic and/or metal engagement structures.
The fastener clip may be made of anti-corrosive material such as
plastic or treated metal to provide long reliable service life.
[0027] Yet another advantage is that the magnetic fastener clip is
relatively easy to manufacture using relatively inexpensive
manufacturing processes and materials. The use of the magnetic
fastener clip decreases production costs, increases worker
productivity and efficiency, improves reliability and quality and
decreases overall vehicle assembly, warranty and maintenance costs.
The magnetic fastener securely attaches a body panel such as a door
panel to a door frame, or headliner to the vehicle roof, such that
the magnetic fastener clip improves reliability both in the short
term and in the long term, while further improving vehicle safety
and quality.
[0028] FIG. 1 is an exploded view of a magnetic bracket 10 and
assembly 20 according to one embodiment. The magnetic bracket 10
includes a base 30 and at least two posts 40 at opposite ends of
the base 30. The magnetic bracket 10 includes a magnetic portion 32
of the base 30 operable to attach to a magnetic fastener 300. The
magnetic bracket 10 may be made of: steel, a steel alloy, iron, and
a magnetic material and/or any suitable material.
[0029] FIG. 2 is perspective view of the magnetic bracket 10
according to one embodiment. The posts 40 bend upwards from the
base 30 such that at least two clips 50 are operable to attach at
the posts 40 at opposite ends of the base 30. According to one
embodiment, the ends of the posts 40 are tapered to guide the posts
upon insertion into the clip opening 430. Further yet, the posts 40
may have a depression to provide a desired retention force with
clip arms 440 as described in more detail below. As shown in FIGS.
1-6, the posts 40 have a notch 60 between the base 30 and ends of
the posts 30 to permit the clips 50 to hook onto the posts 40 upon
insertion. The notch 60 also permits the posts 40 to be bent
precisely during manufacture. The magnetic bracket 10 may be
clipped into a vehicle chassis 80 by removably inserting the clips
50 into a slot 82 of the vehicle chassis 80.
[0030] FIG. 3 is an assembly view of a magnetic bracket 10 and
assembly 20 according to one embodiment. A magnetic fastener 300 is
attached to the body panel (not shown) and may then be magnetically
self-aligned and removably attached to the magnetic portion 32 of
the base 30. The magnetic fastener 300 is operable to be removably
attached to the magnetic portion 32.
[0031] FIG. 4 is an assembly view of the magnetic bracket 10 and
assembly 20 inserted into a vehicle chassis 80 according to one
embodiment. The magnetic bracket assembly 20 is attached via clips
50 to a non-magnetic part of the vehicle chassis 80. As shown best
in FIGS. 2-6, the magnetic fastener 300 magnetically attaches to
the magnetic portion 32 of the magnet bracket 30. For example, the
magnetic portion 32 may have a round, circular, semicircular,
rectangular or curved shape, or any shape or configuration suitable
to magnetically attach to the magnetic fastener 300.
[0032] As the headliner and magnet fastener 300 nears the magnetic
portion 32 of the magnetic bracket 10, magnetic force with the
magnet fastener 300 and headliner will automatically align and
attach with the magnetic bracket 10 making headliner assembly very
easy, and significantly easier than conventionally possible.
Assembly of the body panel onto the vehicle chassis is very easy
and requires no or a relatively low level of insertion force
compared to the extraction force, and as a result provides many
ergonomic advantages. The non-magnetic part of a vehicle chassis 80
may be carbon fiber, fiber glass, or aluminum and permits body
panels to be attached to the chassis via the magnetic bracket 10.
Thus, as the headliner affixed with the various magnetic fasteners
300 is positioned into place with the roof, the magnetic fasteners
300 will not be attracted with the non-magnetic roof. As the
magnetic fasteners 300 pass near the magnetic portion 32 of the
magnetic bracket 10, the magnetic attraction will thus precisely
align and firmly affix (snap) the entire headliner in proper
position. Advantageously, the time consuming problem of moving a
headliner with clips blindly into slots in the roof is eliminated
since the magnetic fastener 300 does not pull into nonmagnetic
areas of the roof, but rather substantially automatically
self-aligns the headliner and magnetic fastener 300 into the
bracket 10.
[0033] FIG. 5 is a side view of a magnetic bracket 10 and assembly
20 according to one embodiment. The fastener clip 50 includes a
pair of laterally offset legs 410 joined at a head portion 420. The
legs 410 form a clip opening 430 at an opposite end of the head
portion 420. Each arm 440 is coupled to each leg 410 such that the
pair of arms 440 are coupled to the pair of legs 410 adjacent to
the head portion 420. The arms 440 move substantially independently
from the pair of legs 410. The arms 440 further include projections
460 pointing toward each other creating the clip opening 430 and to
form a frictional opening 450 upon insertion or withdrawal of the
post 40 such that the post 40 causes a non-compressive force
between the arms 440 when the post 40 is withdrawn. According to
one embodiment, the head portion 420 is tapered to guide the clips
50 into the slot 82 of chassis 80.
[0034] The clip 50 may be made of: Polypropylene, glass fill,
acetal, plastic, vinyl, rubber, plastisol, plastic, acetal,
polyacetal, polyoxymethylene, nylon, fiberglass and carbon fiber
and/or Acrylonitrile butadiene styrene (ABS) or any suitable
material.
[0035] A body panel such as a headliner, not shown, may be attached
to a magnetic fastener 300 via coupler 310. For example, coupler
310 may further include inner rib 320 and outer rib 330 coupled by
a shaft 340. Inner rib 320, outer rib 330 and shaft 340 may be
sized to suitably engage a panel mounted tower with a side-slot in
a body panel such as a headliner. As is understood by one skilled
in the art, the inner rib 320, outer rib 330 and shaft 340 would
engage a corresponding side-slot in a tower of the body panel. The
inner rib 320 and outer rib 330 may be any suitable shape such as
square, oval, round, rectangular. The inner rib 320 and outer rib
330 may have any suitable size and relative spacing between inner
rib 320 and outer rib 330 via appropriately spacing shaft 340.
[0036] According to an alternative embodiment, the coupler 310 may
further comprise base holes 500 shown in FIG. 5 of co-pending
application Ser. No. 12/464,867. The base holes 500 permit
attachment to the body panel by applying glue or any suitable
fastener. Tapered holes that have a larger diameter on the top side
of the coupler 310 (closest to the magnet coupler 350) than on the
bottom side (mating with the body panel) filled with glue will
further provide a mechanical connection as well as the adhesive
connection as a result of the adhesive properties of the glue. The
body panel assembly thus comprises a body panel attached to the
magnetic fastener 300 attached via side slot to mate with coupler
310, glue or other suitable fastener such as a screw, bolt, rivet
or any suitable fastener to attach the body panel to the magnetic
fastener 300.
[0037] Alternatively, coupler 310 may include any attachment
mechanism suitable to couple or attach to a body panel such as a
nut, bolt, weld stud, thread stud, button head, clip, panel clip,
retainer, panel mounted receptacle, retainer washer, or rivet,
cable tie, wire clip, hook and loop fastener (Velcro.RTM.), sticky
tape, double faced tape, spike array, or any suitable combination.
The corresponding mounting structure thus would attach to the base
attachment mechanism with a corresponding attachment mechanism.
[0038] According to one embodiment, the magnetic fastener 300
further comprises a holder 350 and a magnet 370 not shown but
illustrated in parent application Ser. No. 12/464,867. The magnetic
fastener 300 may be a single piece (i.e. a magnet 370 without a
holder) or multi-piece device. Although the magnetic fastener 300
is shown as round, any suitable shape may be used including oval,
square, rectangular, triangular or polygon.
[0039] An optional umbrella 360 is positioned between the coupler
310 and the magnet holder 350 and is also described in parent
application Ser. No. 12/464,867. The umbrella 360 is operative to
flex or compress appropriately to permit the coupler 310 and magnet
holder 350 to pivot relative to each other. The magnetic fastener
300 adapts to different surface curvatures and thicknesses. The
magnetic fastener 300 is operative for blind attachment into a
structure 80, such as a vehicle chassis i.e. door frame, chassis or
roof. An extended shaft 340 provides additional height for suitable
applications. According to one embodiment, the umbrella 360 is made
of rubber, plastic, metal, carbon fiber or any material that is
flexible enough to support the coupler 310 and holder 350 and to
flex. According to an alternative embodiment, the umbrella 360 is
foam suitable to allow the magnet holder 350 to pivot. As shown in
the embodiments of the figures, the optional umbrella 360 may be
flush with the coupler 310, however the umbrella 360 may be
thicker. According to this embodiment, there is relatively little
or no open area between the coupler 310 and the holder 350. This
may be suitable for short height applications where there is little
or a relatively short distance between the chassis and body panel,
i.e. headliner and roof. Thus a body panel assembly may include
magnetic fasteners of various heights. For example the magnetic
fasteners of various heights may be used where the distance between
the headliner and roof varies.
[0040] According to another embodiment, a boss is welded to form a
T-shaped head to secure the magnet 370 to the magnetic holder 350,
as is also described in the above referenced parent application. As
the umbrella 350 flexes, the magnetic fastener 300 may pivot about
the boss for example at an angle to allow the magnetic fastener 300
to adapt to different surface curvatures while securely fastened to
the body panel. According to one embodiment, the magnet 370 does
not engage the boss. Thus, the magnet 370 and optional umbrella 360
support structure adapts to different attachment lengths,
variations of sheet metal roundness and thicknesses thus allowing
the magnet fastener 310 and assembly 20 to adjust to different
depths while pivoting and maintaining a high level of extraction
force. During installation, the assembly 20 continuously adapts to
variations in curvature and dimensions of the vehicle roof and/or
in the body or headliner panel. Thus, only a single style assembly
20 and magnetic fastener 300 need be used with a vehicle or
application even if different attachment lengths are required at
different attachment points or even if the curvature or thickness
of the sheet metal varies substantially. The magnetic bracket
assemblies 20 securely fasten the headliner to the roof and provide
long reliable life.
[0041] The magnetic bracket assembly 10 may be pre-assembled by
attaching the bracket 10 to clips 50 in preparation for insertion
into the vehicle chassis 80. Similarly, the magnetic fastener clip
300 may be pre-assembled by attaching coupler 310 of the magnetic
fastener clip 300 to a body panel as described above, such as a
headliner, to form a body panel assembly (not shown).
[0042] The body panel assembly is operatively inserted as a single
unit and aligns with the structure, such as a vehicle chassis,
pillar, roof, instrument panel or frame to form a vehicle with the
magnetic clip. The magnetic fastener 300 adapts to different
chassis curvatures such that an angle between the magnet holder 350
and the coupler 310 is operative to vary continuously.
[0043] The body panel may be constructed from plastic or from any
suitable material such as plastic, vinyl, cloth, wood, steel,
aluminum, magnesium, carbon fiber or any suitable material.
[0044] FIG. 6 is a bottom view of the magnetic bracket assembly 20
inserted into a vehicle chassis 80. According to one embodiment,
the posts 40 may have any suitable shape, such as for example:
ratchets, tapered, depressions, straight, curved or any suitable
shape.
[0045] It is understood that the implementation of other variations
and modifications of the present invention in its various aspects
will be apparent to those of ordinary skill in the art and that the
invention is not limited by the specific embodiments described. It
is therefore contemplated to cover by the present invention any and
all modifications, variations or equivalents that fall within the
spirit and scope of the basic underlying principles disclosed and
claimed herein.
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