MXPA97007057A - Sheet with integ bra - Google Patents

Abstract

The present invention relates to a sheet material for mounting to a wall and through the sheet of material, a fastener formed with the sheet having an opening therethrough adapted to receive the cross member and to hold it securely therein, where the improvement comprises that: the fastener is made of unitary construction with the sheet and having a protuberance with the opening in a central portion of the protuberance;

Description

SHEET WITH INTEGRAL BRA BACKGROUND OF THE INVENTION Field of the Invention The invention relates to sheet material with integral fasteners for securing the sheet material to a structural member. In one of its aspects, the invention relates to a sound barrier mat having an integral fastener for securing the mat to a vehicle fire wall. In another of its aspects, the invention relates to a method for assembling a sheet material to a structural wall. In yet another of its aspects, the invention relates to a structural wall assembly comprising a structural wall and a sheet material affixed thereto.

In most contemporary automobiles, a steel fire wall separates the engine compartment from the passenger compartment. To reduce the transmission of sound from the engine compartment through the fire wall and into the passenger compartment, a sound barrier mat is mounted on and substantially covers the fire wall. The sound barrier mat is mounted on a plurality of crosspieces that extend from the surface of the fire wall. Typically, to mount the sound barrier mat to the fire wall, the sound barrier mat has corresponding openings in register with the cross members so that the cross members extend through the openings and hang the sound barrier mat in the wall of fire. An absorbent mat is usually attached to the sound barrier mat. When the sound barrier mat is installed to the fire wall, the absorbent mat reduces the contact area between the sound barrier mat and the fire wall. The sound barrier mat will lie under the carpet and extends beyond the carpet to the top of the fire wall. To secure the sound barrier mat to the fire wall, separate fasteners are mounted on the cross members. The fasteners prevent the accidental removal or re-positioning of the sound barrier mat and the underlying absorbent mat. A fastener for attaching an article such as an ornamental strip to a motor vehicle body is described in U.S. Patent No. 5,291,639, issued to Baum et al., On March 8, 1994. The Baum fastener is a push button plastic fastener, consisting of a dome head with a circular stem that is received at one end in a circular skirt. A pair of resilient fingers project towards an axial bore of the rod. To attach the fastener to the vehicle, a threaded cross member mounted to the carriage body is received within the axial bore of the rod. By exerting pressure on the push button, the squeeze rod on and on the cross member to deflect the retention fingers so that they link the threads on the cross member to secure the clip to the body panel. The dome head bumps on the trim strip to keep the trim strip to the body of the vehicle. Other similar fasteners are disclosed in U.S. Patent Nos. 4,874,276, issued October 17, 1989; 5,014,369, issued May 14, 1991; 5,195,793, issued March 23, 1993; and 1,197,906, issued September 12, 1916. Cop-pendio of the Invention According to the invention, a sheet material for mounting to a wall with a cross member extending from the wall has a fastener formed integrally with the material of the invention. blade and an opening through it adapted to receive the crossbar and be safely retained in it. The bra has a protrusion with the opening in a central portion of the protrusion. In one embodiment, the protrusion has a hemispherical shape. In another embodiment, the protrusion has a conical shape. Preferably, the opening of the fastener is grooved and defines multiple fins that can be deformed when the cross member is pushed through the opening of the fastener. Typically, the crossbar is threaded and the fins link the threads of the crossbar to securely mount the dome on the crossbar. Preferably, the portion of the protuberance forming the fins is thicker than the rest of the protrusion to stiffen the fins. The protrusion preferably has a hollow interior. In one embodiment, the fastener is spaced from the sheet by a flexible weft so that the fastener can be rotated to a position covering the sheet. In another embodiment, the fastener is formed integrally within the sheet and receives the cross member when the sheet is mounted on the wall. The invention also contemplates a structural wall assembly comprising a structural wall having at least one cross member projecting therefrom and a sheet material, as described above, is mounted on the structural wall. In one embodiment, the cross member is threaded and the fastener links the threads of the cross member. In another embodiment, the cross member comprises a T-shaped flange and the fastener has a groove at an acute angle to the plane of the fastener. Furthermore, according to the invention, a method of assembling a sheet material with at least one opening to a structural wall having at least one cross member extending therefrom comprises the steps of integrally forming a fastener with the sheet material, the fastener having an opening for receiving the at least one cross member, mounting the sheet material on the structural wall by aligning the at least one opening with the at least one cross member and moving the sheet material towards the structural wall to insert the at least one cross through the at least one opening. The sheet material is then secured to the structural wall by aligning the opening of the fastener with the at least one cross member and moving the fastener toward the structural wall to insert the at least one cross member through the opening of the fastener. Preferably, the sheet material is injection molded. The invention provides fast and inexpensive assembly of a sheet material, such as an absorbent mat, in a structural wall such as a fire wall in a car. The invention eliminates the need for separate fasteners that must be secured to the crossbar after the sheet is mounted on the wall. The integral nature of the fasteners results in a more cost effective way to mount a sheet material on a wall. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to the drawings, in which: Figure 1 is a perspective view of a vehicle sound barrier mat incorporating the integral fastener according to the invention;; Figure 2 is a sectional view of a fastener illustrated in the disassembled condition; Figure 3 is a plan view of the first embodiment of the integral fastener illustrated in Figure 2, in the disassembled condition; Figure 4 is an elevational view, in sections, of the integral fastener of Figure 2 in the clamped position; Figure 5 is a plan view of a second embodiment of the integral fastener according to the invention; Figure 6 is a sectional view taken along line 6-6 of Figure 5; Figure 7 is an elevational view, in sections, of a third embodiment of the integral fastener according to the invention, in a disassembled condition; Figure 8 is a plan view of the integral fastener of Figure 7; and Figure 9 is an elevational view, in sections, of the integral fastener of Figure 7 in the fastened position. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates a typical fire wall assembly 10 incorporating the integral or unitary fastener 30 according to the invention. The fire wall assembly 10 comprises a fire wall 12, which separates the engine compartment from the passenger compartment of an automobile. The fire wall 12 is generally made of steel and has a plurality of threaded cross-pieces 14 extending therefrom. The crosspieces 14 are often placed around the periphery of the fire wall 12; however, depending on the application, the crosspieces 14 may be placed within the interior of the fire wall 12. The fire wall 12 is substantially covered by an absorbent mat 16, which has a plurality of apertures 18 corresponding thereto. in register with the crosspieces 14. The absorbent mat 16 is oriented with respect to the fire wall 12 so that the openings 18 are aligned with the crosspieces 14. When the absorbent mat 16 is placed against the fire wall 12, the crosspieces 14 they extend through the openings 18 and the absorbent mat 16 is suspended from the crosspieces 14. A sound barrier mat 22, preferably made of thermoplastic olefin, covers the absorbent mat and separates the absorbent mat 16 from a carpet layer 24, which looks to the passenger compartment. The sound barrier mat 22, like the absorbent mat 16, has a plurality of openings 26 through the crosspieces 14 which extend to hang or suspend the sound barrier mat 22 of the fire wall 12. The mat of sound barrier 22 has several integral fasteners 30, each of which is associated with a sound barrier mat opening 26. Referring to Figures 2 to 4, the integral fastener 30 comprises a fastener or cap 32 connected to the sound barrier mat 22 by a weft 34. The lid 32 and the weft 34 are an integral part of the sound barrier mat 22 and are preferably injection molded as a single part. In its preferred form, the lid 32 is a hollow hemispherical dome 36 having a circular, open bottom 38 and a cross-shaped opening 40 in the upper part of the dome 36. The cross-shaped opening 40 defines multiple fins 42 on the surface of the dome 36 and which are flexible with respect to the dome 36. The thickness of the dome 36 is substantially uniform, except that the portion of the dome 36 that surrounds and includes the fins 42 may have a greater thickness to give more rigidity to the dome. fins. The diameter of the opening 40 is smaller than the diameter of the crosspieces. To assemble the fire wall assembly 10, the sound barrier mat 22, with the absorbent mat 16, is positioned with respect to the fire wall 12 so that the openings 26 of the sound barrier mat are aligned with the crossbars 14. The sound barrier mat 22 is mounted on the fire wall 12 so that the crossbars 14 extend through the openings of the sound barrier mat 26. Once the sound barrier mat 22 is hung from the crossbars 14, each fastener 30 is mounted on its associated cross member 14 by placing the dome 36 on the cross member 14 and pushing down on the dome to force the cross member 14 through the cross-shaped ing 40. The downward force of the dome deflects the flaps 42 a sufficient distance so that the cross member 14 extends through the cross-shaped ing 40 of the dome 36. The inherent resiliency of the fins 42 presses the fins 42 against the sides of the threaded cross member 14 where the fins link the threads of the crossbar 14 to prevent accidental removal of the dome 36. Advantageously, because the clip is integrally connected to the sound barrier mat 22 by means of the weft 34, the clip 32 is always within easy reach for the installer, allowing the simple and quick installation of the sound barrier mat. Also, there is no longer any need for the installer to keep an inventory of separate fasteners, which can fall or be imprly placed during assembly. The integral fastener 30 is most suitable for use in the crosspieces 14 positioned near the periphery of the sound barrier mat 22. However, in certain applications, it is desirable to place the crosspieces further into the periphery of the mat of sound barrier 22. In those cases, the crosspieces 14 can extend from an interior portion of the fire wall 12. Figures 5 and 6 illustrate a second embodiment of the integral fastener according to the invention, which is more suitable for mounting the sound barrier mat 22 on a cross member located inside the periphery of the fire wall 12. In the description of the second embodiment, many of the elements are identical to the elements described in the first embodiment. embodiment. Therefore, similar parts are identified with similar reference numbers. The second embodiment of the integral or unitary holder 50 comprises a cup-shaped depression 52 formed in the sound barrier mat 22. The cup-shaped depression 52 has an annular side wall 54, which terminates in a bottom wall 56 from which a protuberance extends having a cone-shaped portion 58. The cone-shaped portion 58 is truncated at its upper end to form an ing 60. Preferably, the diameter of the ing 60 is slightly smaller than the diameter of the ing 60. The diameter of the threaded cross member 14 is such that when the threaded cross member is inserted through the ing 60, the material forming the cone-shaped portion 58 is deformed to hold the sound barrier mat 22 to the cross member 14. The fire wall 10 is assembled using the integral fastener 50 to a large extent in the same manner as previously described with respect to the first embodiment of the integral fastener 30. the only substantive difference is that the ing 60 of the cone-shaped portion 58 for the integral fastener 50 is aligned with a cross-member 14. Once aligned, the integral fastener 50 is pressed down on the cross-member 14 to force the threaded cross-member 14 through the ing 60 of the cone-shaped portion, deforming the material comprising the cone-shaped portion and holding the sound barrier mat 22 to the threaded cross-member 14. Although the integral holder 50 is better adapted to be assembled in crosspieces placed inside the periphery of the fire wall, in comparison with the integral fastener 30, the integral fastener 50 is also suitable for mounting on the crosspieces at the periphery of the fire wall. To mount on crosspieces in the periphery of the fire wall, the integral fastener 50 only needs to be molded into the sound barrier mat at its periphery. The second embodiment can also be used to improve the placement of the sound barrier mat in the fire wall. The first and second embodiments of the integral fastener are mounted on a threaded cross member extending from the fire wall. Nevertheless, in some applications it is desirable to use a flange or other similar flattened element instead of the cross member. Figures 7 to 9 illustrate a third embodiment of an integral fastener 80 specifically designed to be mounted on a support or box wall having flanges instead of cross members. Many of the elements of the third embodiment are similar to the elements of the first and second embodiments. Therefore, similar parts are identified by similar reference numbers. In the third embodiment, a wall 70 has erect traverses or eyelashes 72 having a head formed by outwardly facing ears 74, providing the tab 72 with a T-shaped profile. The line connecting the ears 74 defines a center line cross. The absorbent mat 16 is mounted on the wall in the same manner as described above with respect to the first embodiment, except that the openings 18 are replaced by slots 76. Similarly, the sound barrier mat 22 has slots 78 adapted to receive the flange 72. An integral or unitary bra 80 is integrally molded with the sound barrier mat 22 and comprises a fastener 82 and a weft 84 which connects the fastener to the sound barrier mat 22. The fastener 82 is substantially flattened and it has a retention slot 86, which is oriented at an angle with respect to the transverse center line of the flange 72. In operation, the absorbent mat 16 is mounted on the wall 70 by inserting the flange 72 through the slots 76 of the absorbent mat 16. Similarly, to mount the sound barrier mat 22, the flanges 72 are inserted through the grooves 78 of the sound barrier mat 22. The fastener 82 is then placed on the flange 72. The fastener 82 is rotated so that the retaining groove 86 aligns with the transverse axes of the flange 72 and is pressed down on the flange 72 so that the ears 74 extend. through the retaining slot 86. Upon release of the fastener 82, the inherent resiliency of the material comprising the integral fastener 80 applies twisting or twisting motion to the fastener 82 to rotate the retaining slot 86 with respect to the flange 72 so that they are no longer aligned. In this position, it is difficult for the fastener 82 to be accidentally removed from the flange 72. The three embodiments of the integral fastener allow quick and easy assembly of the fire wall assembly and the fastening of the sound barrier mat to the fire wall. Unlike separate fasteners, the integral fastener according to the invention eliminates the need to accumulate separate fasteners and the reduction in assembly speed associated with the fall or mishandling of the separate fastener. Although particular embodiments of the invention have been shown, of course, it will be understood that the invention is not limited thereto, as many modifications may be made by those skilled in the art, particularly in light of the above teachings. Reasonable variations and modifications are possible within the scope of the prior disclosure of the invention, without departing from the spirit of the invention.

Claims (28)

REIVINPICATIONS

1. In a sheet material for mounting to a wall with a cross member extending from the wall and through the sheet of material, a fastener formed with the sheet having an opening therethrough adapted to receive the cross member and to hold it securely in place. it, wherein the improvement comprises that: the fastener is made of unitary construction with the sheet and having a protuberance with the opening in a central portion of the protrusion.

2. A sheet material according to claim 1, wherein the protrusion has a hemispherical shape.

3. A sheet material according to claim 1, wherein the protrusion has a cone shape. A sheet material according to claim 1, wherein the aperture of the fastener is grooved and defines multiple fins, which can be deformed when the cross member is pushed through the aperture of the fastener. 5. A sheet material according to claim 4, wherein the cross member is threaded and the fins are adapted to link the threads of the cross member to securely mount the protrusion on the cross member. 6. A sheet material according to claim 4, wherein the portion of the protrusion forming the fins is greater in thickness than the rest of the protrusion to stiffen the fins. 7. A sheet material according to claim 1, wherein the protrusion has a hollow interior. 8. A sheet material according to claim 1, wherein the fastener is spaced from the sheet by a flexible weft so that the fastener can be rotated to a position covering the sheet. 9. In a sheet material for mounting to a wall with a cross member extending from the wall, the sheet material having an aperture therethrough adapted to receive the cross member; a fastener formed integrally with the sheet and having an opening therethrough, the fastener being adapted to cover the sheet, receive the cross-piece and be securely retained in it to hold the sheet in the crosspiece; the improvement comprising: a flexible, narrow web having a first end and a second end, the first end being formed integrally with the web, the second end being formed integrally with the fastener such that the fastener is spaced from the web; opening of the sheet by the weft, the holder having a first surface facing outwardly when the holder is separated from the sheet, the first surface of the holder facing inwardly when the holder is rotated to a position covering the opening of the sheet , such that the first surface of the fastener faces the sheet when the opening links the crosspiece. 10. A sheet material according to claim 9, wherein the fastener has a hemispherical shape, and the first fastener surface is concave. A sheet material according to claim 9, wherein the aperture of the fastener is grooved and defines multiple fins, which can be deformed when the cross member is pushed through the aperture of the fastener. 12. A sheet material according to claim 9, wherein the first surface of the fastener defines a hollow interior. A sheet material according to claim 9, wherein the opening in the sheet is elongated and has a longitudinal axis, and the opening of the holder is elongated and has a longitudinal axis that is oriented at an acute angle with the longitudinal axis of the sheet opening, such that a twist is applied to the fastener when the fastener is attached to the cross member. 1

4. A structural wall assembly, comprising: a structural wall having at least one cross member projecting therefrom; a flexible sheet material mounted on the structural wall; an integral fastener with the flexible sheet material and having an opening therethrough to receive the cross member to securely retain the sheet material to the structural wall; and the fastener having a cup-shaped depression extending downward from a surface of the flexible sheet material, and a protrusion extending upwardly from the cup-shaped depression with the opening in a central portion of the protrusion. 1

5. A structural wall assembly according to claim 14, wherein the protrusion has a hemispherical shape. 1

6. A structural wall assembly according to claim 14, wherein the protrusion is cone-shaped. A structural wall assembly according to claim 14, wherein the diameter of the fastener opening is smaller than the diameter of the cross member, such that the opening of the fastener is deformed as the cross member is pushed through the opening of the fastener. 18. A structural wall assembly according to claim 14, wherein the protrusion has a hollow interior. 19. A structural wall assembly, comprising: a structural wall having at least one cross member projecting therefrom; a sheet material having at least one opening that receives the at least one cross member for mounting the sheet material to the structural wall; a fastener formed integrally with the sheet material and having an opening therethrough which receives the cross member and configured to securely retain the fastener in the cross member to thereby retain the sheet material in the structural wall; and the fastener being spaced from the at least one aperture of the sheet by a flexible weave of unitary construction with the sheet and the fastener, the fastener having a first surface facing outwardly when the fastener is spaced from the sheet, the first surface of the fastener facing inwardly when the fastener is rotated to a position covering the at least one aperture of the sheet, such that the first fastener surface faces the sheet when the aperture links the crosspiece. 20. A structural wall assembly according to claim 19, wherein the fastener has a hemispherical shape and the first fastener surface is concave. 21. A structural wall assembly according to claim 19, wherein the aperture of the fastener is grooved and defines multiple fins, which can be deformed when the at least one cross member is pushed through the opening of the fastener. 22. A structural wall assembly according to claim 19, wherein the first surface of the fastener defines a hollow interior. A structural wall assembly according to claim 19, wherein the at least one opening in the sheet is elongated and has a longitudinal axis, and the opening of the holder is elongated and has a longitudinal axis that is oriented at an acute angle with the longitudinal axis of the at least one aperture of the sheet, such that a twist is applied to the fastener when the fastener is attached to the cross member. 24. A structural wall assembly according to claim 19, wherein the cross member comprises an upstanding flange having laterally extending ears defining a plane and the holder having a groove at an acute angle with the plane of the erect flange, such that a torsion be applied to the fastener when the fastener is attached to the crossbar. 25. A method of assembling a sheet material with at least one opening with a structural wall having at least one cross member extending therefrom, the method comprising: forming a fastener with the sheet material as a unitary construction, fastener having an opening for receiving the at least one crossbar and being configured to securely grip the crossbar when it is received therein; mounting the sheet material on the structural wall by aligning the at least one opening with the at least one cross member and moving the sheet material towards the structural wall to insert the at least one cross member through the at least one opening; and securing the sheet material to the structural wall by aligning the aperture of the fastener with the at least one cross member and moving the fastener toward the structural wall to insert the at least one cross member through the aperture of the fastener. The method according to claim 25, wherein the step of forming the fastener comprises the step of forming a weft with the sheet material and the fastener as a unitary construction for connecting the fastener to the sheet material and separating the fastener of the at least one opening of the sheet, and the step of securing the sheet material to the structural wall further comprises rotating the fastener so as to cover the at least one sheet aperture. 2

7. A structural wall assembly according to claim 14, wherein the cup-shaped depression is formed of unitary construction with the sheet material, the cup-shaped depression having an annular side wall and a bottom wall formed integrally with the annular side wall, the protuberance being integral with and extending from the lower wall. 2

8. A sheet material according to claim 1, wherein there is a plurality of said fasteners formed of unitary construction in the sheet.