Molded article with captured fasteners

• US 5,839,847 A
• Filed: 02/21/1997
• Issued: 11/24/1998
• Est. Priority Date: 02/21/1997
• Status: Expired due to Fees

• Current Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Original Assignee: Mcdonnell Douglas Corporation (The Boeing Co.)
• Inventors: Patel, Jayant D.
• Primary Examiner(s): Knight, Anthony
• Application Number:
  US08/801,852
• Time in Patent Office: 641 Days
• Field of Search: 264/274, 264/273, 264/271.1, 411/429, 411/902, 403/269, 403/267, 403/265
• US Class Current: 403/269
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 37/0082 Mechanical anchoring B29C66/303 takes precedence
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 70/72 Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components B29C70/742 takes precedence
• CPC Class Codes: Y10T 403/47 Molded joint

Abstract

A pressure-molded article having integral attachment points is achieved by providing, during the molding process, a fastener having a base surface portion, a side surface portion, and an internal passage defining an air path from the base surface portion to the side surface portion. The fastener'"'"'s base surface portion is positioned on a molding surface of a pressure-molding tool such that the passage is placed in fluid communication with a hole in the molding surface. A formable material, such as a sheet of thermoplastic material heated to a formable state, is positioned adjacent to both the molding surface and the fastener. The sheet is pressure-formed onto the molding surface while preferably evacuating the hole in the molding surface, such that air disposed between the sheet and the molding surface adjacent to the side surface portion of the fastener is drawn into the passage and down into the hole, with the sheet partially flowing into the passage to mechanically capture the fastener within the sheet.

Claims

1. An article molded from a formable material, the article comprising:

a molded body having a first molded surface; and

a fastener within the molded body, the fastener including a base surface portion, a side surface portion, and an internal passage connecting the base surface portion to the side surface portion,

wherein a first section of the passage adjacent to the side surface portion is filled with the formable material to mechanically capture the fastener within the molded body, wherein the side surface portion includes a first recess, and the first section opens into the first recess.

2. The article of claim 1, wherein the first section extends in a first direction generally parallel to the base surface portion.

3. The article of claim 1, wherein the side surface portion includes a textured surface.

4. The article of claim 1, wherein a second section of the passage adjacent to the base surface portion defines a threaded bore.

5. The article of claim 4, wherein the fastener includes a top surface portion, and wherein the second section extends from the base surface portion to the top surface portion.

6. The article of claim 1, wherein the base surface portion is aligned with the first molded surface.

7. A fastener adapted to be mechanically integrated within an article pressure-formed onto a molding surface from a formable material, the fastener comprising:

a base surface portion,

a side surface portion, wherein the side surface portion includes a first recess, and

a passage defining an internal path from the side surface portion to the base surface portion along which air and formable material adjacent the side surface portion flow toward the base surface portion when the article is formed about the fastener, wherein a first section of the passage adjacent to the side surface portion opens into the first recess.

8. The fastener of claim 7, wherein the first section extends in a first direction generally parallel to the base surface portion.

9. The fastener of claim 7, wherein the first recess is an external groove extending about the periphery of the fastener.

10. The fastener of claim 7, wherein the side surface portion includes a textured surface immediately adjacent to the first recess.

11. The fastener of claim 7, wherein the first recess is an external groove extending away from the base surface portion.

12. The fastener of claim 7, wherein a second section of the passage adjacent to the base surface portion defines a threaded bore.

13. The fastener of claim 12, wherein the fastener includes a top surface portion, and wherein the second section extends from the base surface portion to the top surface portion.