Article With Tethered Prong Fastener

The present invention relates generally to articles having pronged fasteners, and more particularly to an improved pronged fastener configurable as a clip useable for engageably retaining body members, configurable as a w-prong fastener fastenable through an opening in a workpiece, and configurable as a spacing member useable for engaging and retaining first and second workpieces in spaced relation, among other configurations.

Articles having pronged fasteners are known generally and are useable for fastening the article to a workpiece or alternatively for fastening one or more body members to a workpiece. U.S. Pat. No. Des. 269,851 entitled "Retainer Clip for Pipes, Rods and Other Elongated Bodies or the Like" issued on 26 Jul. 1983 to Kimura and commonly assigned herewith, for example, discloses a plurality of at least two adjacently arranged resilient w-prong fasteners, each formed by a corresponding stem portion having first and second outwardly divergently directed prongs or arm members. In operation, adjacent resilient arm members of adjacent w-prong fasteners are flexed inwardly flexible toward their corresponding stems so as to permit insertion of a body member therebetween, whereupon the resilient arm members subsequently flexibly return to the outwardly divergently directed configuration so as to retainably clip the body member to the article. The article itself is typically mountable to a workpiece by another w-prong fastener retainably disposeable in an opening through the workpiece, or by other means, whereby the body member is fastenably retained to the workpiece. This type of pronged fastener is formed of a lightweight plastic at a relatively low cost, and is used widely as a harness for mounting bundled wires, and more generally for mounting elongated members in automotive and other industries.

Yet another application of pronged fasteners is the separation of two or more plate members, or workpieces. U.S. Pat. No. 3,893,208 entitled "Plastic Device for Spacing and Holding Two or More Plates" issued on 8 July 75 to Yuda also commonly assigned herewith, for example, discloses first and second resilient w-prong fasteners disposed in spaced relation along corresponding first and second stems connectedly arranged along a common axis, wherein the first stem has a head portion and an enlarged diameter relative to the second stem forming a shoulder therebetween. Corresponding first and second resilient arms of each w-prong fastener are inwardly flexible so as to permit passage thereof through first and second openings of corresponding first and second workpieces oriented in spaced relation. According to the operation of U.S. Pat. No. 3,893,208, the first workpiece is engaged between the head portion and the first w-prong fastener, and the second workpiece is engaged between the shoulder formed by the first and second stems and the second w-prong fastener, whereby the first and second workpieces are maintained in separated spaced relation by the pronged fastener.

While articles having pronged fasteners of the types discussed above are used successfully in many applications, the pronged fasteners are subject to failure upon application of a sufficiently great external load thereto. More specifically, in applications of the type discussed generally in U.S. Pat. No. 3,893,208 wherein the resilient prongs form part of a w-prong fastener retainably disposed through an opening of a workpiece, a load applied axially along the stem, in a direction tending to withdraw the w-prong fastener back through the opening of the workpiece, tends to outwardly deflect the resilient prongs, which anchor the w-prong fastener in the opening of the workpiece. At some load level, the resilient prongs eventually fail by folding backwardly along the stem axis, possibly shearing or otherwise breaking away therefrom, whereupon the w-prong fastener is withdrawn from the opening of the workpiece. A similar failure of the resilient prongs occurs under excessive loading conditions imposed by the body member in applications of the type discussed in U.S. Pat. No. Des 269,851, whereupon the clipped body member is withdrawn from between the failed resilient prongs. To compensate for these overloading conditions, it is possible to use heavier duty pronged fasteners, but this solution increases weight, requires additional space, and very likely increases material and production costs.

The present invention is accordingly drawn toward novel advancements in pronged fasteners, and more particularly to novel articles having novel pronged fasteners that overcome problems in the prior art.

It is thus an object of the invention to provide articles having novel pronged fasteners with improved fastening performance, articles with novel pronged fasteners that are economical, and more particularly unitary articles with novel pronged fasteners that are readily formed in a plastic molding operation, and articles with novel pronged fasteners that are useable interchangeably in applications fitted presently with prior art pronged fasteners.

It is another object of the invention to provide an article with a novel pronged fastener useable for fastening the article to a workpiece, for fastening one or more body members, elongated or otherwise, to a workpiece, for maintaining first and second workpieces in separated spaced relation, among other applications, and for combinations thereof.

It is a more particular object of the invention to provide an article with a novel tethered prong fastener having a first stem protruding from the article, the first stem having a distal end portion with a first resilient arm extending divergently outwardly therefrom and back toward the article, and the tethered prong fastener having a first flexible tether coupling the first resilient arm to the first stem, the first resilient arm being flexible inwardly toward the first stem and subsequently flexible back outwardly away from the first stem, whereby the first flexible tether member limits the outward deflection of the first resilient arm away from the first stem, thereby improving fastening performance thereof.

It is a related object of the invention to provide an article with a novel tethered prong fastener having a first stem with a first resilient arm extending divergently outwardly therefrom, the tethered prong fastener having a first flexible tether member coupling the first resilient arm to the first stem, the first flexible tether member having a first end coupled to a base of the first stem and a second end coupled to a distal end of the first stem, whereby the first flexible tether member is oriented at an angle relative to the first stem, and in another configuration, the first flexible tether member has a pre-flex radius between the first stem and the first resilient arm, and in yet another configuration, either or both of the first resilient arm and the first stem has a recess about the first flexible tether member so as to extend the flexible length of the flexible tether member.

It is a further object of the invention to provide an article having a novel tethered w-prong fastener defined by a first stem protruding from the article, the first stem having a distal end with a plurality of at least two resilient prongs, or resilient arms, extending divergently outwardly therefrom and back toward the article, the tethered w-prong fastener also having a plurality of flexible tethers each coupling a corresponding one of the plurality of resilient arms to the first stem, the plurality of resilient arms being flexible inwardly toward the first stem so as to permit insertion of the tethered w-prong fastener through an opening in a workpiece, the plurality of resilient arms subsequently flexing back outwardly away from the first stem so as to retainably fasten the article to the workpiece, whereby the plurality of flexible tether members limit outward deflection of the plurality of resilient arms away from the first stem, but do not prevent insertion of the w-prong fastener through the opening of the workpiece.

It is still another object of the invention to provide an article with a plurality of at least two novel tethered w-prong fasteners arranged serially for engaging and retaining a corresponding plurality of workpieces in spaced relation.

It is yet another object of the invention to provide an article with a plurality of at least two novel tethered w-prong fasteners arranged adjacently, wherein adjacent resilient arm members of adjacently arranged w-prong fasteners are inwardly flexible toward their corresponding stems as so to permit insertion of a body member therebetween, whereupon the resilient arm members subsequently flexibly return to the outwardly divergently directed configuration so as to retainably clip the body member to the article.

These and other objects, features and advantages of the present invention will become more fully apparent upon careful consideration of the following Detailed Description of the Invention and the accompanying Drawings, which may be disproportionate for ease of understanding, wherein like structure and steps are referenced by corresponding numerals and indicators; and wherein:

FIG. 1 is a side elevation view of an article having a tethered prong fastener according to an exemplary embodiment of the invention.

FIG. 2A is a side elevation view of an article having a tethered prong fastener according to another exemplary embodiment of the invention.

FIG. 2B is an end elevation view along lines 2B--2B of FIG. 2a.

FIG. 2C is a partially enlarged view of a tether portion of FIG. 2A.

FIG. 3 is a partial side elevation view of an article having a tethered prong fastener according to a third exemplary embodiment of the invention.

FIG. 4 is a partially enlarged view of an alternative tether portion configuration.

FIG. 5 is a side elevation view, partly in cross-section of an article having a tethered prong fastener according to still another exemplary embodiment of the invention.

FIG. 6 is a side elevation view of an article having a tethered prong fastener according to yet another exemplary embodiment of the invention.

FIG. 1 shows an article 10 having a plurality of tethered prong fasteners 100 each defined generally by a stem 110 protruding from the article 10 and at least one resilient arm 120 coupled to a distal end portion 112 of the stem 110. The resilient arm 120 has an end portion 122 extending divergently outwardly away from the stem 110 and toward a base portion 114 of the stem 110, which is generally back toward the article 10. The resilient arm 120 is flexible inwardly toward the stem 110 and outwardly away from the stem 110 as discussed further below.

A flexible tether member 130 couples the stem 110 and the resilient arm 120, and includes generally a first end 132 coupled to the stem 110 and a second end 133 coupled to the resilient arm 120, whereby the flexible tether member 130 limits outwardly deflection of the resilient arm 120 away from the stem 120, but does not interfere with the inwardly flexing of the resilient arm 110. In one embodiment, the the flexible tether member 130 forms a thin flexible web between the stem 110 and the resilient arm 120, which is particularly suitable to formation in a plastic molding operation.

In the exemplary embodiment of FIGS. 1 and 2, the flexible tether member 130 has a pre-flex radius 134 between the stem 110 and the resilient arm 120 to facilitate inwardly flexing of the resilient arm 120 toward the stem 110. In the exemplary embodiment of FIG. 3, the first end 132 of the flexible tether member 130 is coupled to the stem 110 toward the base 114 thereof, and the second end 133 of the flexible tether member 130 is coupled to the resilient arm 120 toward the distal end portion 112 of the stem 110, whereby the first flexible tether member 130 is oriented at an angle relative to the first stem as as to facilitate inwardly flexing of the resilient arm 120 toward the stem so as 110. The pre-flexed radius 134 of the flexible tether member 130 shown in FIGS. 1 and 2 may be combined with the angled flexible tether member configuration of FIG. 3, or the first and second ends of the flexible tether member 130 may coupled to the stem 110 along a line substantially perpendicular thereto as shown in FIG. 2.

According to a related aspect of the invention, the flexible tether member 130 is resiliently stretchable to some extent when the resilient arm 120 is flexed outwardly. FIG. 4 accordingly shows an alternative embodiment, wherein the stem 110 and the resilient arm 120 have a recess 136 formed in the stem 110 and in the resilient arm 120 each about the first and second ends of the flexible tether member 130 where the flexible tether member 130 is coupled thereto. According to this aspect of the invention, the recess 136, which is formed about the tether member 130 on at least one of the stem 110 or the resilient arm 120, extends the overall effective length of the flexible tether member 130 between the stem 110 and the resilient arm 120 thereby increasing the amount or extent to which the flexible tether member 130 is resiliently stretchable when the resilient arm 120 is flexed outwardly under loading conditions as discussed further below. The flexible tether member configurations of FIG. 4 are useable in combination with any one or more of the flexible tether member configurations discussed above.

The article 10 of FIG. 1 is configured with a plurality of J-clips for retainably clipping corresponding body members, not shown, to the article 10. The tethered prong fasteners 100 each have associated therewith a support member 150 protruding from the article 10 in spaced relation to a corresponding stem 110 of the corresponding tethered prong fastener 100. The support member 150 in the exemplary embodiment is advantageously the stem 110 of an adjacent tethered prong fastener, but more generally is any structural member protruding from the article 10. In operation, the resilient arm 120 of each tethered prong fastener 100 is flexible inwardly away from the corresponding support member 150 and toward its stem 110 so as to permit insertion of the body member between the stem 110 and the support member 150 and into a seat 160, which may be configured to accommodate an elongated wire bundle or other body member. The resilient arm 120 is subsequently flexed from the stem away from the stem 110 upon insertion of the body member into the seat 160 wherein the end portion 122 of the resilient arm 120 retainably clips the body member in the seat 160 between the stem 110 and the support member 150. The resilient arm 120 reacts to gravitational or other loading conditions tending to unseat the body member by flexing, or deflecting, outwardly to retainably clip the body member to the article. The flexible tether member 130 however resiliently limits outward deflection of the resilient arm 120 thereby increasing the degree of loading that the resilient arm 120 may withstand before failure and providing remarkable performance improvement over non-tethered prior art pronged fasteners.

The article 10 of FIG. 2 is configured as a tethered w-prong fastener retainably fastenable through an opening in a workpiece W, shown in phantom in FIG. 2B, wherein the article 10 has some useful body configuration 15. The stem 110 includes first and second resilient arms 120 coupled toward the distal end portion thereof, wherein the first and second resilient arms each have a first end portion 122 extending divergently outwardly away from the stem 110 and toward the base portion 114 thereof. Associated with each resilient arm 120 is a corresponding flexible tether member 130 coupling the corresponding resilient arm 120 to the stem 110. In operation, the first and second resilient arms 120 are flexible inwardly toward the stem 110 so as to permit insertion of the stem 110 and the first and second resilient arms 120 through the opening of the workpiece. The first and second resilient arms 120 are subsequently flexed outwardly away from the stem 110 upon insertion through the opening of the workpiece W so that the workpiece is engaged between a clamping surface 12 of the article 10 and the end portions 122 of the first and second resilient arms 120 of the tethered w-prong fastener so as to retainably fasten the article 10 to the workpiece W. The first and second resilient arms 120 react to gravitational or other loading conditions tending to withdraw the article, and particularly the w-prong fastener, from the opening in the workpiece by deflecting outwardly to retainably fasten the article 10 to the workpiece. The flexible tether member 130 however resiliently limits outward deflection of the first and second resilient arms 120 thereby increasing the degree of loading that the resilient arms 120 may withstand before failure and providing a remarkable performance improvement over non-tethered prior art w-prong fasteners.

The article 10 of FIG. 5 includes first and second tethered w-prong fasteners arranged serially along a common axis and retainably fastenable through first and second openings in corresponding separated first and second workpieces W1 and W2, wherein the article 10 maintains the first and second workpieces in spaced relation. The first tethered w-prong fastener is formed by first and second resilient arms 120 coupled toward the distal end portion 112 of a first stem 110, and tethered to the first stem 110 by corresponding first and second flexible tether members 130 as discussed above. The second tethered w-prong fastener is formed by first and second resilient arms 121 coupled toward the distal end portion 113 of a second stem 111, and tethered to the second stem 111 by corresponding first and second flexible tether members 131 as discussed above. The first stem 110 has a larger diameter than the second stem 111 thereby forming a shoulder 115 therebetween. In operation, the resilient arms of the first and second w-prong fasteners are inwardly flexible toward the corresponding first and second stems so as to permit insertion of the first and second w-prong fasteners through corresponding openings of the first and second workpieces W1 and W2. The first and second resilient arms are subsequently flexed outwardly away from the corresponding first and second stems upon insertion through the openings of the workpieces, wherein the first workpiece W1 is engaged between a clamping surface 12 of the article 10 and corresponding end portions 122 of the first and second resilient arms 120 of the first tethered w-prong fastener, and the second workpiece W2 is engaged between the shoulder 115 and corresponding end portions 123 of the first and second resilient arms 121 of the second tethered w-prong fastener. The resilient arms react to any loading condition tending to withdraw the article 10, and particularly the tethered w-prong fasteners, from the openings in the workpieces W1 and W2 by deflecting outwardly to retainably fasten the article 10 to the workpieces. The flexible tether members however resiliently limit outward deflection of the resilient arms thereby increasing the degree of loading that the resilient arms may withstand without failure and providing a remarkable performance improvement over non-tethered prior art w-prong fasteners.

The article 10 of FIG. 6 includes a plurality of at least first and second tethered w-prong fasteners arranged adjacently for retainably clipping one or more body members, not shown, to the article 10. The first tethered w-prong fastener is formed by first and second resilient arms 120 coupled toward the distal end portion 112 of a first stem 110, and tethered to the first stem 110 by corresponding first and second flexible tether members 130 as discussed above. The second adjacent tethered w-prong fastener is formed by first and second resilient arms 121 coupled toward the distal end portion 113 of a second stem 111, and tethered to the second stem 111 by corresponding first and second flexible tether members 131 as discussed above. The resilient arms associated with a particular stem may alternatively be axially offset as shown to accommodate different size body members, and tethered prong fasteners at end portions of the article 10 may have only one resilient arm, as shown. The article 10 moreover may have an additional fastener 16, which may also be a tethered w-prong fastener, for mounting the article 10 to a workpiece, thereby coupling body members to the workpiece. In operation, resilient arms 120 and 121 of the adjacent tethered w-prong fasteners are flexed inwardly toward the corresponding first and second stems 110 and 111 so as to permit insertion of the body member between the adjacent stems 110 and 111 and into a seat 160, configured to accommodate a wire bundle or other body member. The resilient arms 120 and 121 are subsequently flexed outwardly away from the corresponding stems 110 and 111 upon insertion of the body member into the seat 160 wherein corresponding end portion 122 of the resilient arms retainably clip the body member in the seat 160. The resilient arms react to loading conditions tending to unseat the body member by deflecting outwardly to retainably clip the body member to the article. The flexible tether members however resiliently limit outward deflection of the resilient arms thereby increasing the degree of loading that the resilient arms withstand before failure and providing a remarkable performance improvement over non-tethered prior art fasteners.

While the foregoing written description of the invention enables anyone skilled in the art to make and use what is at present considered to be the best mode of the invention, it will be appreciated and understood by anyone skilled in the art the existence of variations, combinations, modifications and equivalents within the spirit and scope of the specific exemplary embodiments disclosed herein. The present invention therefore is to be limited not by the specific exemplary embodiments disclosed herein but by all embodiments within the scope of the appended claims.