CN107117111B

CN107117111B - Magnetic fastener clip

Info

Publication number: CN107117111B
Application number: CN201710006781.9A
Authority: CN
Inventors: 迈克尔·蒂雷尔; 丹尼尔·詹姆斯·迪金森; 约翰·克拉森
Original assignee: Termax LLC
Current assignee: Termax LLC
Priority date: 2016-02-25
Filing date: 2017-01-05
Publication date: 2020-06-16
Anticipated expiration: 2037-01-05
Also published as: CN207257547U; CN107117111A

Abstract

The present invention provides a magnetic fastener clip comprising a cup having at least one aperture, an overmold attached to the cup and a magnet. The overmold has: the lid is injection molded on an outer side of the cup and the inner ring is injection molded on at least a portion of an inner side of the cup. The inner ring is attached to the cap via the at least one aperture. A magnet is operably attached to the inner ring. According to one embodiment, a rotational coupler is attached to the cap. The magnetic fastener clips are operable for blind attachment to a structure such as a vehicle chassis, i.e., a pillar, door frame, chassis, or headliner.

Description

Magnetic fastener clip

RELATED APPLICATIONS

This application claims priority from U.S. application 15/335,415 and claims priority from U.S. provisional application 62/299,597, having docket number P055H, entitled "Magnetic Fastener Clip," and filed 2016, 2/25/2016. This application 62/299,597 is a continuation-in-part application claiming priority to an application entitled "Magnetic Fastener Clip", having a case number of P055F and a serial number of 14/622,893 and filed on 15 days 2 and 15 days 2015, the application 14/622,893 is a continuation-in-part application claiming priority to an application entitled "Magnetic Fastener Clip", having a case number of P055D, having a serial number of 13/831,525 and filed on 14 days 2013, the application 13/831,525 is a continuation-in-part application claiming priority to an application entitled "Magnetic Fastener Clip", having a case number of P55A and a file number of 12/983,010, and the application filed on 31 days 2010 and 16 days 2012 us patent 8,287,034, and the us patent 8,287,034 is a continuation-in-part application claiming priority to a Magnetic Fastener Clip (Magnetic Fastener Clip) " The application of docket No. P055 and docket No. 12/464,867, and continuation-in-part application of priority of application of U.S. patent 8,615,852 filed on 3.2009, 5.13.d. and published on 31.12.d. 2013, the entire disclosure of which is incorporated herein by reference.

Technical Field

The present invention relates generally to devices for fastening objects, and more particularly to a magnetic fastener clip for insertion into an engaging structure (e.g., a vehicle chassis, hollow base, wall, panel, or any suitable surface).

Background

There are a variety of devices and fasteners currently available for fastening panels (e.g., body panels and automotive interior trim panels) to the chassis of a vehicle. Fastener clips are used in automotive assemblies to secure body panels, such as pillar covers, headliners, interior panels, and the like, to chassis structures, such as headliners, door structures, and body pillars. As used herein, body panel refers to any interior or exterior structure, such as a plastic or metal interior trim or any interior trim, for example, attached to a vehicle. The body panel may be any suitable outer body panel, such as a fender, bumper, quarter panel, or door panel. The chassis of the vehicle may include any substrate, plate, body panel, structural frame, chassis component or sub-component, support component, wall, or any suitable object or combination.

Interior automotive fasteners such as screws are known to hold the body panel to the vehicle chassis. For example, screws may attach the headliner in place within the vehicle roof. However, many of these fasteners may only fasten around the perimeter of the headliner. Although dome lights and the like may be located in the middle of the headliner area, a large area of the headliner is not supported or secured by such structure. However, if the middle of the body panel is attached by the fastener, the perimeter is not supported. As a result, these fasteners allow the body panels, such as the headliner, to sag, thereby providing an aesthetically unacceptable appearance.

Attaching the headliner to the interior of the headliner typically requires securing the clips, which have been secured to the headliner assembly, into holes, slots, or mounting points on the headliner. At least some clips require blind insertion and installation of fasteners because the installer cannot view the fastener clips or the mounting points on the headliner.

Fastener clips are also known for attaching body panels to automotive chassis. For example, fastener clips that attach to an automotive headliner or the like and connect to a magnet using an adhesive are known. Magnets may be used to reduce the problems of blind fastener applications. Thus, the magnetic fastener clip can automatically position the body panel, and thus does not require as much alignment between the fastener and the mating hole as possible.

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 strut extends outwardly from the dome and includes at least one deflectable portion having an outward projection thereon. The pin is generally aligned with the post and the pin is connected to the post by at least one frangible connection. The frangible connection between the pin and the clip is adapted to break when the pin is actuated. However, assembly is time consuming, labor intensive, and expensive because the pins need to be aligned and inserted during manufacture. Further, assembly of the magnet to the fastener typically requires drilling a hole into the magnet in order to attach the magnet to the fastener by a pin, screw, or other fastener to pass through the hole. The holes reduce the magnetic flux and therefore the magnetic field strength, require additional processing steps and increase costs.

However, these known clips are neither strong nor flexible enough on, for example, an automotive assembly line that may be somewhat harsh. During installation, the headliner may be unevenly moved, stretched, or twisted. These fastener clips typically do not have a long service life to support the headliner and prevent riveting throughout the expected life of the vehicle. In addition, these fasteners are sandwiched between the chassis and the body panel with a fixed engagement length.

Fastener means are typically required to secure the panel to the chassis, which may have sheet metal throughout varying amounts of curvature or thickness. If the curvature or thickness of the sheet metal varies, or if tolerances in production occur in a vehicle chassis or trim (i.e., headliner), for example, the engagement of one fastener with the headliner may not provide a suitable magnetic engagement, or may result in movement. In addition, less than all of these fasteners are typically engaged with the chassis. Twisting of the body panel will likely be more prevalent because in practice there are fewer than all points of contact with the roof. As a result, sag, wear, squeaking, rattling, buzzing, corrosion, and loss of resiliency and seal loss may result, particularly after years of vehicle operation and exposure to vibration and other environmental conditions. Thus, these fastener clips do not provide suitable magnetic engagement or sufficient flexibility.

Once installed, the headliner is sometimes contacted or pushed by the occupant during use of the vehicle. Fastener devices typically secure the headliner under various environmental conditions, such as in the presence of various levels of vibration of amplitude and frequency. Further, the fastener arrangement should prevent or minimize the amount of buzz, rattle, or any other type of noise that may be noticeable to vehicle occupants or otherwise impair attachment. In addition, fasteners seek the conflicting goals of securing the body panel to the chassis while accommodating various levels of sheet metal curvature, thickness, and manufacturing tolerances. For example, tolerances such as various dimensions in the body panel and vehicle chassis may be accommodated. Conventional fastener arrangements typically do not adequately fasten to a range of sheet metal thicknesses and do not minimize or eliminate buzzes and rattles and do not adequately accommodate variations in production tolerances. As a result, these clips do not properly secure the body panel to the chassis. If the fastener clip breaks after installation of the body panel, sagging may reoccur, presenting an aesthetically undesirable appearance. Furthermore, it may be difficult to replace an installed, broken clip.

Disclosure of Invention

The magnetic fastener clip includes a cup having at least one aperture, and the overmold is attached to the cup and the magnet. The overmold has: the lid is injection molded on an outer side of the cup and the inner ring is injection molded on at least a portion of an inner side of the cup. The inner ring is attached to the cap via the at least one aperture. A magnet is operably attached to the inner ring. According to one embodiment, a rotational coupler is attached to the cap. The magnetic fastener clips are operable for blind attachment into a structure such as a vehicle chassis, i.e., pillar, door frame, chassis, or headliner.

Among other advantages, the magnet does not require a hole in the magnet to attach to the cup. Since the magnet is not drilled to create the hole, the magnet does not suffer from a reduction in magnetic flux. Therefore, the magnet maintains a high level of magnetic flux, and thus the magnetic force is maximized. Furthermore, since the steps of drilling and fastening via the magnet hole are not required, attachment of the magnet to the cup is significantly reduced, costs are reduced, and manufacturing time is reduced.

Another significant advantage is: a magnetic fastener clip including a cup can be manufactured with a few stamping and overmolding steps. According to one embodiment, the cup is punched out in one or several pressing steps. For example, the cup can be made without expensive milling, cutting or drilling, and is therefore ready to be overmolded directly after stamping. According to one embodiment, the cup may be made in a single stamping step, with a ring around the cup having a recess to allow for flash formation from the stamping. The recess accommodates burr formation during punching and therefore does not interfere with the cup edge. As a result, the cup rim remains uniformly and evenly engaged with the chassis plane. The recess avoids the need to fill the burr.

According to yet another advantage, the over-molding step directly forms the cup lid and the inner ring in one injection process. The magnetic fastener is relatively easy to manufacture using relatively inexpensive manufacturing processes and materials, particularly as compared to known manufacturing processes. The use of magnetic fastener clips reduces manufacturing costs, increases worker productivity and efficiency, improves reliability and quality, and reduces overall vehicle assembly, warranty and maintenance costs.

The optional coupling is operable to flex or compress according to an appropriate curvature. As the coupler flexes, the magnetic fastener may pivot about the coupler boss, for example at an angle, to allow the magnetic fastener to accommodate different surface curvatures while being securely fastened to the body panel. Thus, the coupler and/or boss structure accommodates different attachment lengths, variations in sheet metal roundness and thickness, allowing the magnet fastener to be adjusted to different depths while pivoting and maintaining a high level of extraction force. During installation, the magnets continuously accommodate changes in curvature and dimensions in the vehicle headliner and/or body or headliner panel. Thus, only a single magnetic fastener clip need be used with a vehicle or application, even if different attachment points or even if the curvature or thickness of the sheet metal varies substantially.

Yet another advantage of the magnet and optional coupler allows the magnetic fastener clip to be relatively easily inserted into a vehicle chassis, pillar, instrument panel structure, door, headliner, or appropriate body panel while providing a relatively high level of extraction force from the body panel. Assembly of the body panel to 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 a number of ergonomic advantages. For example, a relatively low level of insertion force is particularly advantageous for assembly line operators who repeatedly insert body panels onto a vehicle chassis. The relatively low level of insertion force required to blind insert the body panel into the vehicle chassis may result in less injury to the assembly worker, including injuries associated with 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, as the same type or reduced number of fasteners can be used for all or most body panel fasteners. Thus, the assembly worker does not have to worry about selecting the wrong fastener.

The magnetic fastener clips relatively easily facilitate attachment of the body panel to a structure such as a vehicle door frame, chassis, instrument panel structure, pillar, or headliner, such that a single adjustable magnetic fastener clip may be used with different depth attachment requirements, sheet metal curvatures, and/or thicknesses. For example, a vehicle door, pillar, instrument panel structure, chassis, or headliner may have different sheet metal curvatures and attachment points at various portions of the vehicle. The body panel may be an automotive headliner, door panel, instrument panel, pillar panel such as A, B, C, D, bumper, fender, quarter panel, grille, hood, headliner, trunk panel, or any suitable interior or exterior panel.

A relatively high level of extraction force (characteristic of the magnetic fastener clip) securely attaches a body panel (e.g., a door panel or headliner) to the vehicle chassis. In addition, fastener clips continuously adapt to changes in environmental conditions, such as vehicle flexing, pushing by passengers, vibration, and thermal expansion. For example, the magnetic fastener clips can accommodate thermal expansion, particularly changes in thermal expansion due to differences in the rates of thermal expansion between dissimilar metals with respect to vehicle chassis components and/or between plastic components (e.g., interior trim panels) attached to a metal vehicle chassis. The fastener clips may also be fastened to plastic and/or metal engaging structures. The fastener clips may be made of a corrosion resistant material, such as plastic or treated metal, to provide a long reliable service life.

The magnetic fastener clip securely attaches a body panel, such as a door panel, to a door frame or a headliner to a vehicle headliner, making the magnetic fastener clip easy to install, securely fasten, improve reliability both in the short term and in the long term, while further improving vehicle safety and quality.

Drawings

FIG. 1 is a view of a magnetic fastener clip and body panel assembly according to one embodiment;

FIG. 2 is an exploded view of a magnetic fastener clip and body panel assembly according to another embodiment;

FIG. 3 is an exploded view of a magnetic fastener clip according to another embodiment;

FIG. 4 is a perspective view of a magnetic fastener clip according to one embodiment;

FIG. 5 is a side cross-sectional view of a magnetic fastener clip according to one embodiment;

FIG. 6 is a bottom perspective view of a magnetic fastener clip according to one embodiment;

FIG. 7 is a side view of a magnetic fastener clip according to one embodiment;

FIG. 8 is a top view of a magnetic fastener clip according to yet another alternative embodiment;

FIG. 9 is a bottom view of the magnetic fastener clip in an unlocked position;

FIG. 10 is a bottom view of the magnetic fastener clip in a rotated position;

FIG. 11 is a bottom view of the magnetic fastener clip in the locked position;

FIG. 12 is a top view of a portion of an overmold and a cup according to an embodiment; and is

FIG. 13 is a magnetic fastener according to another embodiment.

Detailed Description

Fig. 1, 2, and 3 are perspective views of a magnetic fastener clip 10 according to an embodiment. The magnetic fastener clip 10 includes: a cup 20, the cup 20 having at least one aperture 30; a magnet 40; and an overmold 50 attached to the cup 20. The overmold 50 has: a cap 60, the cap 60 being attached to an outer side of the cup 20; and an inner ring 70, the inner ring 70 being attached to the inner side of the cup 20; and an optional coupler 90. The inner ring 70 may be attached to the cap 60 via the at least one aperture 30. The magnet 40 is operably attached into the inner ring 70, such as via glue, press fit, or any suitable attachment. According to one embodiment, the cap 60 and inner ring 70 are injection molded over at least a portion of the cup 20 to form the inner ring 70 and cap 60. The magnetic fastener clip 10 is operable for blind attachment into a structure 80, such as a vehicle chassis, i.e., a door frame, chassis, or headliner.

As shown in fig. 3-7, an optional coupler 90 is attached to the cap 60. According to one embodiment, the coupler 90 is operable to flex. For example, the cap 60 may be or include an optional coupler 90 adapted to engage a mounting structure 100 (shown in fig. 1 and 2). The coupler 90 of the magnetic fastener clip 10 accommodates different surface curvatures and thicknesses.

As shown in fig. 5 and 7, but not limited to fig. 5 and 7, optional coupler 90 may further include: wings 22 and keyway bases 24 connected by struts 600; and a boss 610 attaching the wings 22 and the keyway base 24 with the cap 60. The wings 22, keyway base 24, and brace 600 may be sized to suitably engage a panel mount tower 110 having side slots 200 in a body panel 100 (e.g., a headliner, internal cover, stud cover, panel cover, or any object suitable for magnetic fastening to a chassis 80).

The wings 22 and keyway base 24 may be keyed or designed in any suitable shape, such as square, oval, circular, rectangular, or as shown in fig. 2. For example, the keyway base 24 may be similar to a keyhole such that the keyway base 24 is inserted into a correspondingly shaped slot 200 in the body panel 100 or the tower 110.

Fig. 9 is a bottom view of the body panel 100 in an unlocked position in which the keyway base 24 is inserted into a correspondingly shaped slot 200 in the body panel 100.

Fig. 10 is a bottom view showing the key way base 24 during rotation. The wings 22 and the keyway base 24 may have any suitable dimensions and relative spacing between the wings 22 and the keyway base 24 via the posts 600. For example, as their keyway bases 24 rotate about the post 600 in the socket 200, the keyway bases 24 end and the wings 22 press against the

body panels

100, 110 to stabilize the magnetic fastener 10.

Fig. 11 is a bottom view showing the key groove base 24 in the locked position. The locking tab 72 on at least one wing 22 causes the wing 22 and keyway base 24 to spring up and cause compression on the

body panels

100, 110. This compression reduces rotation from the locked position and further stabilizes the magnetic fastener from rocking from side to side while in the socket 200. Among other advantages, magnetic fastener 10 is easily serviced by reversing the rotation of keyway base 24 until aligned with socket 200 to allow removal of magnetic fastener 10.

As shown in fig. 7 and 8, the wings 24, and in particular the wing tips, may be curved. Among other advantages, curved wings 24 are easier to injection mold, allow more efficient packaging space (because corners 24 are reduced as shown in fig. 13), and facilitate handling, and thus magnetic fastener 10 is easier to grasp.

According to the embodiment shown in fig. 3-7, the wings 24 may be angled. The shape of the wings may be adapted to the application and environment.

Alternatively, optional coupler 90 may include any attachment mechanism suitable for coupling or attaching to

body panels

100, 110, such as a nut, bolt, weld stud, threaded stud, button head, clip, panel clip, retainer, panel mount socket, retainer washer, or rivetNail, cable tie, clamp, hook and loop fastener

Tape, double-sided tape, glue, an array of spikes, or any suitable combination. The corresponding mounting structure 90 would thus attach to the base attachment mechanism 110, such as a U-shaped compression flange, on the body panel 100 to engage the post 600 and wing 22 and keyway base 24, a bolt and nut, or any suitable pair of fasteners.

As shown in fig. 1, overmold 50 may be manufactured by injection molding cap 60 and inner ring 70 over at least a portion of cup 20 to form inner ring 70 and cap 60. The inner ring 70 may be formed as follows: by temporarily inserting the core pin inside the cup, the plastic forms the inner ring 70 and the inside of the cup 20 as the heated and liquefied plastic is injected. The core pin diameter may be sized such that the diameter 70 of the inner ring allows the corresponding diameter of the magnet 40 to be properly press fit into the inner ring 70. For example, the core pin diameter may be sized smaller than the diameter of the magnet 40 so that the magnet 40 may be securely press fit into the cup 20. Accordingly, the plastic molded inner ring 70 may be elastically compressed between the magnet 40 and the cup 20 to firmly fix the magnet 40 in the cup 20. According to alternative embodiments, the magnet 40 may be secured to the cup 20 via holes, glue, pins, screws, nuts, rivets, adhesive, or any suitable fastener.

As shown in fig. 5, the thickness of the inner ring (gap 62) is suitably sized to allow the magnetic flux to bend from the two poles toward the bottom disk 80. To maximize the magnetic flux and thus the magnetic force, the cup 20 may have a gap 62 between the inside of the cup 20 and the magnet 40, the gap 62 being sized so as to maximize the flow of magnetic flux lines from the cup side to the bottom disk 80. For example, the inner ring 70 may have a diameter thickness 62 such that magnetic flux flows from the cup side of the magnet 40 to the metal chassis 80. As a result, the magnetic flux of both sides and poles of the magnet 40 generates a magnetic force that attracts the metal chassis 80. The combination of magnetic flux from both sides or poles of the magnet 40 produces a greater magnetic force than from only one side or pole of the magnet 40. Although the gap 62 is formed by an inner ring 70 as shown in the figures, the gap 62 may be air, partially plastic and air, glass, rubber, or any suitable material or combination. Alternatively, the inner ring 70, and thus the gap 62, may be or include aluminum, titanium, magnesium, or any other suitable metal or material to allow magnetic flux to flow from the cup side 22 to the metal chassis 80.

According to one embodiment, the inner ring 70 is sized so as to position the magnet 40 in the cup 20 at a predetermined distance from the inner surface of the cup 20. For example, as the magnets 40 are pressed into the inner ring 70, the inner ring 70 properly positions and positions the magnets 40 to direct the flow of magnetic flux from the cup side 22 to the metal chassis 80 and securely retain the magnets 40. According to another embodiment, the magnet 40 is removable and re-mountable from the cup 20 to allow for example servicing.

According to one embodiment, the magnet 10 does not contact the magnetic attachment surface 80. Instead, the magnet 10 is positioned at the attachment distance between the magnet 10 and the magnetic attachment surface 80 in order to maximize the flow of magnetic flux on the bottom of the magnet to the top and thus maximize the magnetic attachment force. As shown in fig. 5, according to one embodiment, the magnet 40 is a distance 530 from the magnetic attachment surface 80, and thus never contacts the magnetic attachment surface 80. For example, the magnet 40 is located 0.1mm or any suitable distance below the sheet metal or contact surface 80. Distance 530 may be determined to provide a maximum magnetic flux and thus a magnetic force. The non-zero distance 530 may provide more than zero magnetic flux.

As shown in fig. 2 and 3, the at least one aperture 30 allows injection molding of the inner ring 70. For example, molten plastic is injection molded around the cup 20, causing the molten plastic to flow through the holes 30 in the cup 20. The molten plastic flows inside the cup 20 and around the core pin to form the inner ring 70. The number and arrangement of the holes 30 may be selected to suitably allow the molten plastic to completely and thoroughly fill the mold-forming inner ring 70 between the cup 20 and the core pin.

As best shown in fig. 12, according to one embodiment, the cup 20 has a recess 500 and an optional ring 520 around the periphery of the cup 20, the ring 520 being sized to avoid punch burrs (not shown) from contacting the magnetic attachment surface. For example, the recess 500 and the outer ring 520 of the cup 20 may be formed by stamping the cup 20 to form the recess 520 a distance 510 below the cup rim. The burr is caused by the punching of the cup 20. Alternatively, a burr dresser or lathe may provide the top recess 520 on the cup 20 with a uniform surface. However, the process of burr trimming or lathe trimming is more process intensive. Instead of burr trimming or lathe trimming, the recess 500 may be formed during the stamping of the cup 20 in the same process as the cup 20 and hole 30 are formed. The recess 500 may be formed such that the magnetic cup lip is flush with the magnetic attachment surface 80. For example, the burr height is typically four thousandths of an inch, and thus the height of recess 500 may be greater than four thousandths of an inch.

The inner ring 70 and the cap 60 may be made of plastic, metal, or any suitable material or materials as described below. Although some examples of the inner ring 70 and cap 60 are described and illustrated below and further described as including adjustable fasteners, any suitable material may be used. By way of example, the inner ring 70 is attached to the cap 60 as an injection molded piece, or alternatively via two components by micro-welding, ultrasonic welding (a sonotrode melts a plastic boss in a predetermined position to attach the inner ring 70 and the cap 60), thermal welding, spring fingers, screws, and pins, or any suitable combination thereof.

Although fastener clip 10 is shown in fig. 1-8 as having a circular magnet 40, any suitable shape may be used, including oval, square, rectangular, triangular, or polygonal.

As shown in fig. 2, 5, 6, and 7, the coupler 90 is operable to bend or compress about the boss 610 and/or the stanchion 600 to allow the fastener clip 10 to pivot. The boss 610 and/or the pillar 600 allow the magnetic fastener to engage a magnetic surface or according to the curvature of the automobile body panel. Any suitable combination of parameters may be sized to allow a desired amount of pivoting, flexing, and/or compression depending on, for example, the curvature of the automotive body panel (e.g., roof).

Accordingly, the body panel assembly 100 may include magnetic fasteners 10 of various heights. For example, magnetic fasteners 10 of various heights may be used, with varying distances between the headliner and the headliner. As shown in fig. 7, the height of the body panel 100/110 (such as is the case in a roof panel) is relatively thin. Alternatively, the body panel 100 shown in fig. 1 and 2 illustrates a tower of suitable height.

The magnetic fastener clip 10 may replace one or more conventional fasteners to be inserted into holes or slots of a body panel. Instead of requiring different conventional fasteners for different size and height requirements, the magnetic fastener 10 may be magnetically attached to a chassis or metal ring that surrounds a slot in the body panel and adjusted to different size and height requirements.

The coupler 90, wings 22, and keyway base 24 may be of any suitable size, and the relative spacing between the wings 22, keyway base 24, or any suitable combination thereof via the post 600 may be sized to provide suitable flexure and spacing between a body panel, such as a headliner, and a chassis, such as a headliner.

Fig. 1 is a perspective view of a body panel assembly 100. The body panel assembly 100 may be preassembled by attaching the stanchion 600 of the magnetic fastener clip 10 to the body panel 100 (e.g., pole cover, headliner) as described above or other suitable body panel to form the body panel assembly. Alternatively, the coupler 90 according to one embodiment may instead include a base aperture (500 shown in fig. 5 of pending application serial No. 12/464,867, incorporated by reference). The base aperture (500) allows attachment to the body panel by application of glue or any suitable fastener. A tapered hole of larger diameter filled with glue on the top side of the base (closest to the magnetic fastener 50) rather than the bottom side (matching the body panel) will further provide a mechanical connection as well as a chemical connection (as a result of the adhesive properties of the glue). The body panel assembly 100 thus includes the body panel 100 attached to the magnetic fastener clip 10, the magnetic fastener clip 10 being attached to the tower 110 via the coupler 90, glue or other suitable fasteners (such as screws, bolts, rivets or any suitable fastener) to attach the body panel to the magnetic fastener clip 10.

The body panel assembly 100 is operatively inserted as a single unit into a structure, such as a vehicle chassis 80, pillar, roof, instrument panel, or frame, to form a vehicle with magnetic clips. Magnetic fastener clip 10 accommodates different chassis curvatures such that the angle between magnetic fastener 10 and coupler 90 is operable to vary continuously. As previously described, the coupler 90 may be secured to the body panel, the frame, or any suitable structure via suitable fasteners.

According to one embodiment, the overmold 50 is injection molded as a single plastic component, allowing for multiple components to be assembled in one or more injection steps. The angle or inclination, sharpness of the cup cover 60 and inner ring 70 may vary depending on the diameter and shape of the slot in the vehicle chassis. Thus, it will be apparent to those skilled in the art that: a suitable fastener 10 is shown and described as yet another embodiment to illustrate that the structure for fastening the magnetic fastener 10 is not limited to the examples provided.

According to one embodiment, the cup 20 is made in whole or in part of magnetic steel as described below or any suitable metal or alternatively plastic. The tower 110 and body panels 100 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.

Any combination of the overmold 50, the cap 60, and the inner ring 70, cup 20, or components may be made of the following materials: polypropylene, glass fillers, acetal, plastic, vinyl, rubber, plastisol, plastic, acetal, polyacetal, polyoxymethylene, nylon, glass fiber and carbon fiber and Acrylonitrile Butadiene Styrene (ABS) or any suitable material and combinations thereof.

According to one embodiment, wings 22, keyway base 24, boss 610, and post 600 are made of rubber, plastic, metal, or any material that is flexible enough to support overmold 50 and allow magnetic fastener 10 to flex. The wings 22, keyway base 24, bosses 610 and posts 600 are made of polypropylene as described in co-pending application serial No. 12/464,867, which is incorporated by reference. Polypropylene or polypropylene is generally tough and flexible, especially when copolymerized with ethylene. This allows polypropylene to be used as an engineering plastic and therefore can be used to replace other materials such as ABS, acrylic or some other plastic. Polypropylene is quite economical and has good fatigue resistance. Polypropylene (PP)The alkene has a value determined by Differential Scanning Calorimetry (DSC)

(320 ° f) and is therefore suitable for injection molding. Melt processing of polypropylene can be achieved via extrusion and molding. Injection molding may be used to obtain the desired shape.

It should be understood that: the implementation of other variations and modifications of the invention in its various aspects will be apparent to those of ordinary skill in the art, and 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.

Claims

1. A magnetic fastener clip, comprising:

a cup having at least one aperture;

a lid injection molded on an outer side of the cup;

an inner ring injection molded over at least a portion of the inner side of the cup;

a rotational coupler including a keyway base attached to the lid; and

a magnet operably attached to the inner ring.

2. The magnetic fastener clip of claim 1, wherein the inner ring is injection molded over at least a portion of the inner side of the cup via the at least one hole.

3. The magnetic fastener clip of claim 1, wherein the inner ring positions the magnet in the cup at a predetermined distance from an inner surface of the cup.

4. The magnetic fastener clip of claim 1, wherein the at least one aperture allows injection molding of the inner ring.

5. The magnetic fastener clip of claim 1, wherein the rotating coupler further comprises a wing, and wherein the keyway base engages a slot on a body panel.

6. The magnetic fastener clip of claim 5, wherein the keyway base includes a projection.

7. The magnetic fastener clip of claim 1, wherein the magnet has no holes.

8. A magnetic fastener clip, comprising:

a cup having at least one aperture;

a lid injection molded on an outer side of the cup;

an inner ring injection molded over at least a portion of the cup;

a magnet operably inserted into the inner ring;

at least one wing attached to the lid; and

a keyway base attached to the at least one wing via a post, wherein the at least one wing has a curved end, an

Wherein the inner ring is sufficiently flexible to allow the magnet to be press fit into the inner ring.

9. The magnetic fastener clip of claim 8, wherein the keyway base includes a projection.

10. The magnetic fastener clip of claim 8, wherein the inner ring positions the magnet in the cup at a predetermined distance from an inner surface of the cup.

11. The magnetic fastener clip of claim 8, wherein the at least one aperture allows injection molding of the inner ring.

12. The magnetic fastener clip of claim 8, wherein the cup has a recess around a periphery of the cup, the recess sized to avoid punch burrs from contacting the magnetic attachment surface.

13. The magnetic fastener clip of claim 8, wherein the magnet has no holes.

14. The magnetic fastener clip of claim 8, wherein the inner ring is formed by temporarily inserting a core pin such that an injected material is formed between an exterior of the core pin and the cup.

15. The magnetic fastener clip of claim 8, wherein the magnetic cup lip is flush with the magnetic attachment surface.

16. A vehicle, comprising:

a vehicle chassis having a magnetic attachment surface;

a magnetic fastener clip, the magnetic fastener clip comprising:

a cup having at least one aperture;

a lid injection molded on an outer side of the cup;

an inner ring injection molded over at least a portion of the cup;

a magnet operably inserted into the inner ring; and

a rotating coupler including a keyway base attached to the lid.

17. The vehicle of claim 16, wherein the rotating coupler further comprises at least one wing attached to the keyway base via a post.

18. The vehicle of claim 17, wherein the at least one wing includes a tab operable to cause the at least one wing to spring away from the keyway base.

19. The vehicle of claim 16, wherein the cup has a height to form a gap between the magnet and the magnetic attachment surface.