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Receptacle for fasteners and an associated installation method

Receptacle for fasteners and an associated installation method description/claims

Embodiments of the present invention are related to a receptacle for mounting objects on a surface and a method for installing the receptacle and mounting objects. In particular, embodiments of the present invention are directed to a receptacle for mounting objects on an aircraft interior surface using fasteners and an associated method.

In aircraft and other structures, it is often desirable to mount objects, such as magazine display racks or control panels, to various surfaces. One common method of mounting objects is by using Nylatch® or other expandable fasteners. Nylatch® fasteners are designed to attach a removable member, such as a magazine display rack, to a fixed member, such as the interior wall or other interior surface of an aircraft, by expanding latching members of a fastener, such as a grommet end of a Nylatch® fastener, to lock the two members together.

Another common method of mounting objects is by using pegs or other fasteners having a head portion and a shank portion, the head being wider than the shank. With these types of fasteners, the shank portion of the fastener is attached or integral to the object to be mounted, such as the magazine rack. The object is mounted by hooking the head of the fastener into an appropriately shaped aperture in the fixed member, such as the interior surface of the aircraft.

In at least some instances, the construction of a wall or other surface to which an object is to be mounted makes it difficult or impossible to mount a fastener directly to the wall or other surface, at least with the surety that is desired. For example, some interior surfaces of aircraft consist of honeycomb panels. As a result, mounting an object to the honeycomb panel with a Nylatch® or other expandable fastener currently requires the use of a sheet metal plate which defines a hole to receive the grommet end of the fastener. The metal plate is attached to the honeycomb panel using one or more potted inserts that, in turn, are mounted within the honeycomb panel. The object to be mounted is attached to the metal plate by inserting the fastener into the hole defined by the metal plate and expanding the grommet end.

Mounting an object with a fastener such as a peg to a honeycomb panel similarly requires supplemental parts to prepare the mounting surface. A sheet metal plate with a keyhole-shaped aperture is required to receive the head portion of the fastener. The keyhole aperture consists of two intersecting apertures, one larger than the other. The larger portion of the keyhole is configured to receive the wider head portion of the fastener, and the smaller portion of the keyhole is configured to retain the head in the installed position and is thus smaller than the width of the head. The object is installed by inserting the head into the larger portion of the keyhole and sliding the peg into the smaller portion. However, this requires that the honeycomb panel be cut behind both portions of the keyhole before installing the metal plate to allow enough clearance for the head to slide from one portion of the keyhole to the other.

The current method of mounting objects to such interior surfaces has several disadvantages. It requires the manufacture of multiple parts, such as the metal plates and the potted inserts. The use of multiple parts increases the manufacturing and shipping costs, the cost of labor for installing the metal plates and mounting the objects, as well as the overall weight of the structure, which is a particularly acute concern for aircraft and other vehicles. Aesthetic concerns also factor in when the object to be mounted is smaller than the metal plate used for mounting, and the choice of location of the fasteners on the object to be mounted becomes limited. These disadvantages are further magnified by the large quantities of fasteners commonly utilized on board aircraft and other structures. In addition, the fixed nature of the holes in the metal plates provides small tolerances and does not allow for minor changes in the position of the fasteners, making small miscalculations in the mounting process costly.

Thus, there is a need for a simpler, more cost effective way of mounting objects using Nylatch® or other fasteners that requires fewer, lighter parts, allows greater flexibility in placement, and provides greater mounting tolerances.

Embodiments of the present invention are directed to a receptacle for a fastener that is relatively light weight and compact, reduces the number of parts required for mounting an object to a surface, and allows greater flexibility in the placement of the object to be mounted. Additionally, a corresponding method for installing a receptacle and mounting an object is provided. As a result, embodiments of the present invention address at least some of the concerns with the use of expandable fasteners.

A receptacle of one embodiment of the present invention has an outer housing forming an internal cavity and an aperture opening into the internal cavity. The internal cavity is configured to receive at least part of a fastener, such as the latching members of a Nylatch® fastener. The outer housing has a rim extending circumferentially out from the internal cavity. In some embodiments, the rim forms one or more openings to allow the application of adhesive when installing the receptacle in or on a surface. The rim of one embodiment serves as an integral spacer having increased thickness to allow for the installation of fasteners in certain types of surfaces where the depth of the mounting surface is less than the length of the shank or latching members of the fastener, such as with shallow panels.

In another embodiment, the outer housing has two rims. The first rim may extend circumferentially out from an end of the outer housing that defines the aperture, and the second rim may extend circumferentially out from an end of the outer housing opposite the first rim. In one embodiment, the second rim is larger than and extends beyond the first rim. The larger, second rim may define one or more openings to allow for the application of adhesive during installation of the receptacle directly onto a surface. The second rim may also have a plurality of pins extending away from the aperture. These pins may be used to locate the proper positioning of the receptacle with respect to holes configured to receive the pins in the mounting surface.

In another embodiment of the present invention, the aperture of the receptacle is configured to receive and hold in place the head portion of a fastener. In this case, the aperture has a keyhole shape formed by two intersecting aperture portions in the outer housing. The first aperture portion is sized to receive the head portion of a fastener. The second aperture portion is smaller than the first aperture portion and is sized to allow the fastener, e.g., a shaft of the fastener, to be moved from the first aperture portion to the second aperture portion. As a result, the head portion of a fastener may be inserted into the first aperture portion and moved into the second aperture portion of the keyhole aperture. Positioned in the second aperture portion, the head portion of the fastener is held in place by the outer housing. To facilitate the orientation of receptacles with respect to the mounting surface and the object to be mounted, the outer housing may be marked or notched, such as by forming a flat portion in a generally circular outer housing to mark the top of the receptacle for installation purposes.

A receptacle of another embodiment of the present invention has an outer housing and a floating insert. The outer housing defines an internal cavity and forms an aperture that opens into the internal cavity. The floating insert also defines an internal cavity and forms an aperture that opens into the internal cavity of the floating insert. The floating insert is sized to be smaller than the internal cavity of the outer housing and is configured to fit within the outer housing, such that the floating insert is movable within the internal cavity of the outer housing.

The aperture of the floating insert is configured to receive at least part of a fastener, such as the latching member of a Nylatch® fastener. In one embodiment, the aperture of the floating insert is smaller than the aperture of the outer housing. However, the floating insert of one embodiment is configured such that the aperture of the floating insert is within the aperture of the outer housing in all positions. The mobility of the floating insert within the outer housing provides the ability to make minor adjustments in the position of the fastener, thereby increasing mounting tolerances.

In some embodiments of the present invention, the receptacle may include a cap which mates with the outer housing to at least partially close the internal cavity of the outer housing. The cap may be configured to be press fit around the outer wall of the outer housing, it may be configured to fit inside the internal cavity of the outer housing, or it may be bonded to a surface of the outer housing, among other options.

Another embodiment of the present invention is directed to a method of mounting an object using a receptacle. As described above, the receptacle may include an outer housing and a floating insert fitting within an internal cavity of the outer housing such that the floating insert is movable within the outer housing. The receptacle is configured to receive a fastener and may be installed on a surface, such as the interior surface of an aircraft, for mounting an object. In one embodiment, the receptacle may be installed by forming a hole in the surface, inserting the receptacle into the hole, and bonding the receptacle within the hole. In another embodiment, the receptacle may be installed by forming a hole in the surface, inserting the receptacle at least partially into the hole, bonding the receptacle within the hole, and bonding the rim to the surface, such that the receptacle in the installed position is not flush with the surface but rather extends in part beyond the surface. In yet another embodiment, the receptacle may be bonded directly to the surface.

The fastener with the object to be mounted may then be at least partially inserted into the internal cavity of the outer housing or, if the receptacle includes a floating insert, into the internal cavity of the floating insert within the outer housing. In the case of a receptacle having a floating insert, if the fastener is not aligned exactly with the internal cavity of the floating insert, the floating insert may be moved within the outer housing to allow a better fit between the fastener and the receptacle.

• Provisional Patent
• Utility Patent

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