FASTENERS

Abstract

A fastener (1) has an elongate fastening band (2) and a buckle (10) for engagement with the band (2) to form a closed loop fastener. The buckle (10) is overmoulded on a first end region (8) of the fastening band (2). Such a design provides a fastener that has higher strength and is more compact than previously-considered designs.

Claims

1. A fastener comprising: an elongate fastening band having a longitudinal axis and first and second planar surfaces, the longitudinal axis defining a longitudinal axis of the fastener, the first surface defining a plurality of teeth arranged substantially perpendicular to the longitudinal axis, and the second surface providing an engagement surface for the fastener, wherein the elongate fastening band has a first end region, and a locking portion which is spaced apart longitudinally from the first end region, the first end region and locking portion defining respective groups of such teeth on the first surfaces thereof; and a buckle fused with the teeth of the first end region of the elongate fastening band, the buckle and elongate fastening band being arrangeable to form a closed fastener configured to compress or clamp at least one article encircled by the elongate fastening band, and the buckle comprising: a body defining an inner chamber, and having first and second end walls to respective opposite ends of the inner chamber and defining first and second passages therethrough, which passages are contiguous with the inner chamber and which are adapted for receiving the locking portion of the elongate fastening band therethrough, the body further having upper and lower walls to respective upper and lower sides of the inner chamber, the upper wall defining an access aperture therethrough such that the inner chamber is open to the upper side thereof; and a locking component located through the access aperture into the inner chamber, the locking component having at least one tooth for engaging the teeth on the first surface of the locking portion of the fastening band, the locking component being resiliently biased into the inner chamber of the body so as to engage the teeth of the fastening band when the fastener is formed in a closed loop.

2. A fastener as claimed in claim 1, wherein the buckle is fused to the teeth of the first end region of the fastening band in a moulding process.

3. A fastener as claimed in claim 1 or 2, wherein the buckle formed by overmoulding onto the first end region of the fastening band.

4. A fastener as claimed in claim 1, 2, or 3, wherein the first end region of the fastening band extends into the lower wall of the buckle, and a portion of the first end region of the fastening band at least partially overlaps the inner chamber of the body.

5. A fastener as claimed in claim 4, wherein the second passage overlaps a portion of the first end region of the fastening band.

6. A fastener as claimed in claim 1, wherein the body and the locking component are separate to one another and are of different materials, and wherein the locking component is releasably connected to the body.

7. A fastener as claimed in claim 1, wherein the elongate fastening band includes at least one reinforcing element that extends substantially parallel through the fastening band between the first and second planar surfaces thereof.

8. A fastener as claimed in claim 7, wherein the or each reinforcing element extends longitudinally through the fastening band.

9. A fastener as claimed in, claim 1 wherein the band is of a first polymer material, and the body of the buckle is of a second polymer material.

10. A fastener as claimed in claim 1, wherein the fastening band and body of the buckle are of the same polymer material.

11. A method of manufacturing a fastener comprising an elongate fastening band having a longitudinal axis and first and second planar surfaces, the longitudinal axis defining a longitudinal axis of the fastener, the first surface defining a plurality of teeth arranged substantially perpendicular to the longitudinal axis, and the second surface providing an engagement surface for the fastener, wherein the elongate fastening band has a first end region, and a locking portion which is spaced apart longitudinally from the first end region, the first end region and locking portion defining respective groups of such teeth on the first surfaces thereof; and a buckle fused to the teeth of the first end region of the elongate fastening band, the buckle and elongate fastening band being arrangeable to form a closed fastener configured to compress or clamp at least one article encircled by the elongate fastening band, and the buckle comprising a body defining an inner chamber, and having first and second end walls to respective opposite ends of the inner chamber and defining first and second passages therethrough, which passages are contiguous with the inner chamber and which are adapted for receiving the locking portion of the elongate fastening band therethrough, the body further having upper and lower walls to respective upper and lower sides of the inner chamber, the upper wall defining an access aperture therethrough such that the inner chamber is open to the upper side thereof; and a locking component located through the access aperture into the inner chamber, the locking component having at least one tooth for engaging the teeth on the first surface of the locking portion of the fastening band, the locking component being resiliently biased into the inner chamber of the body so as to engage the teeth of the fastening band when the fastener is formed in a closed loop, the method comprising the steps of: a. placing a first end region of a fastening band into a moulding tool, the moulding tool being for such a buckle; b. closing the moulding tool, thereby holding the fastening band in place therein; c. performing a moulding operation using the moulding tool, thereby to fuse the buckle to the teeth on the first end region of the fastening band; d. ejecting a partially-completed fastener from the moulding tool; e. inserting a locking component into the inner chamber of the body of the buckle through the access aperture thereof.

12. A method as claimed in claim 11, further comprising, in advance of the moulding operation, heating at least a portion of the first end region of the fastening band.

13. A method as claimed in claim 11, further comprising preparing the fastening band including the steps of: a. co-extruding a first polymer material with at least one reinforcing element to form an elongate fastening band having a longitudinal axis, first and second planar surfaces, and at least one reinforcing element extending longitudinally through the first polymer material between the first surface and the second surface; b. forming a plurality of such teeth on the first planar surface, which teeth are arranged substantially perpendicularly to the longitudinal axis, so as to form a length of fastening band; c. cutting the length of fastening band to a required length, which required length is independent on the moulding tool of the buckle moulding operation.

14. A method as claimed in claim 11, wherein the first end region of the fastening band extends into the lower wall, and a portion of the first end region at least partially overlaps the inner chamber of the body.

15. A method as claimed in claim 14, wherein the second passage overlaps a portion of the first end region of the fastening band.

16. A method as claimed claim 11, wherein the body and the locking component are separate to one another and are of different materials, and wherein the locking component is releasably connected to the body.

17. A method as claimed in claim 11, wherein the elongate fastening band includes at least one reinforcing fibre that extends substantially parallel through the fastening band between the first and second planar surfaces thereof.

18. A method as claimed in claim 17, wherein the or each reinforcing element extends longitudinally through the fastening band

19. A method as claimed in claim 11, wherein the band is of a first polymer material, and the body of the buckle is of a second polymer material.

20. A method as claimed in claim 11, wherein the fastening band and body of the buckle are of the same polymer material.

21. A method as claimed in claim 11, wherein the moulding operation is an injection moulding operation.

22. A method as claimed in claim 11, wherein, the moulding operation employs another moulding technique such as casting or makes use of PU pourable moulds.

23. A method of securing a first object to a second object, the method comprising providing a fastener as claimed in claim 1, encircling the first and second objects with the fastening band, inserting a second end of the fastening band into the first passage, passing the second end of the fastening band through the first passage, the inner chamber of the body and the second passage, causing the engagement component to engage with the engagement teeth of a portion of the second end region of the fastening band.

24. A method as claimed in claim 23, further comprising providing the fastening band with a predetermined tension.

25. A fastener having an elongate fibre-reinforced fastening band and a buckle for engagement with the band to form a closed loop fastener, the buckle being overmoulded on a first end region of the fibre-reinforced fastening band.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIGS. 1 and 2 are perspective and plan views respectively of an embodiment of the present invention;

[0032] FIG. 3 is a perspective exploded view of the embodiment of FIGS. 1 and 2;

[0033] FIG. 4 is a flowchart illustrating steps in a method of manufacture of the embodiment of the present invention;

[0034] FIGS. 5, 6 and 7 illustrate a fastening band for use in an embodiment of the present invention

[0035] FIG. 8 is a cross-sectional side view of a partially-completed embodiment of the present invention;

[0036] FIGS. 9 and 10 are perspective views of a partially-completed embodiment of the present invention; and

[0037] FIG. 11 is a plan view of a partially-completed embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] FIGS. 1 and 2 illustrate perspective and plan views respectively of an embodiment of the present invention, which provides a fastener 1 having a fastening band 2, and a buckle 10. The fastening band 2 extends from the buckle 10 in a direction illustrated by arrow X. In use, the fastening band to extends around an object and engages with the buckle 10, so as to enclose the object. In the Figures, for the sake of clarity, the fastening band 2 is shown in shortened form. It will be readily appreciated that the fastening band 2 is of sufficient length to surround circumferentially the object to which the fastener is attached.

[0039] In an embodiment of the present invention, the fastening band 2 is of elongate form and defines a longitudinal axis of the fastener 1. The fastening band 2 has a first planar surface which defines a series of engagement teeth 4. The engagement teeth 4 extend laterally across the fastening band 2, substantially perpendicular to the longitudinal axis of the fastening band 2. The fastening band 2 defines a second planar surface 6, substantially parallel to the first surface, which second surface 6 defines an engagement surface of the fastener 1. The fastening band 2 is a continuously reinforced band, having a plurality of reinforcing elements 7 that extend along the band 2 substantially parallel to the longitudinal axis of the band 2. The reinforcing elements 7 contained within the band material, for example using a co-extrusion technique, and provide increased strength for the band, compared with a band that does not make use of such reinforcement. The reinforcing elements may be of any suitable material, such as glass fibre yarn, steel wire, aramid fibres, or similar materials.

[0040] The fastening band 2 has a first end region 8 which engages with the buckle 10, as will be described in more detail below, and a second end region 9 (or locking portion), spaced apart from the first end region along the longitudinal axis of the fastening band 2. The second end region 9 of the fastening band 2 is releasably engageable with the buckle 10, thereby to form a closed loop fastener.

[0041] The buckle 10 comprises a body 12 which defines an inner chamber 14. The body 12 has a first end wall 16 and a second end wall 18, the first and second end walls 16 and 18 being spaced apart in the direction of the longitudinal axis of the fastener 1. The first end wall 16 defines a first passage 20 therethrough which extends to the inner chamber 14, such that the inner chamber 14 is accessible through the first end wall 16. The second end wall 18 defines a second passage 22 which extends to the inner chamber 14 such that the inner chamber 14 is accessible through the second end wall 18. The fastening band 2 extends from the second end wall 18 of the body 12. In use, in order to form a closed loop fastener, the fastening band 2 passes through the first and second passages 20 and 22, such that a portion of the second end region 9 of the fastening band 2 is located in the inner chamber 14 of the body 12. The fastening band 2 is held in place in the body 12 of the buckle 10, as will be described below.

[0042] The body 12 of the buckle 10 has an upper wall 24, and a lower wall 26 which provides a portion of an engagement surface of the fastener. An access aperture 28 is provided in the upper wall 24, the access aperture 28 extending through the upper wall 24 to the inner chamber 14, such that the inner chamber 14 is accessible through the upper wall 24. A locking component 30 is located within the access aperture 28 and extends into the inner chamber 14. In use, the locking component 30 engages with the engagement teeth 4 of the second end region 9 of the fastening band 2 so as to secure the fastener 1 around an object.

[0043] The lower wall 26 may have a concave curved shape to fit with an outer surface of the object being held in place.

[0044] FIG. 3 illustrates the embodiment of FIGS. 1 and 2, in exploded view, with the locking component 30 separated from the body 12 of the buckle 10. The locking component 30 comprises an engagement portion 32 which is configured to engage with the fastening band 2. A hinge portion 36 extends from the engagement portion 32, and releasably engages with a reception portion 34 located adjacent the inner chamber 14 of the body 12. The reception portion 34 is configured to receive the hinge portion 36 of the locking component 30, and includes a biasing component 38 which serves to bias the engagement portion 32 into the inner chamber 14, thereby to engage the engagement teeth 4 of the fastening band 2, when the fastener is in use. In one example, the reception portion 34 is formed integrally with the body 12. In another possible example, the reception portion 34 is inserted into the body 12 through an aperture 40 in the lower surface 26 of the body 12, and the body 12 and reception portion 34 have cooperating features of shape that serve to retain the reception portion 34 in place in the body.

[0045] In order to form a closed loop fastener, the fastening band 2 is passed around the objects being secured, and is inserted into the body 12 through the first passage 24 in the first end wall 16 of the body 12 of the buckle 10. The fastening band 2 is then moved through the inner chamber 14, and passed through the second passage 26 in the second end wall 18. The second end region 9 of the fastening band 2 is then located in the inner chamber 14, such that the engagement teeth 4 of the second end region 9 engage with the engagement portion 32 of the locking component 30. The engagement portion 32 is biased into contact with the fastening band 2, thereby retaining the fastening band 2 in the buckle 10.

[0046] In accordance with the principles of one aspect of the present invention, the embodiment shown in FIGS. 1 to 3 is manufactured using an overmoulding technique, as will now be described with reference to the flow chart of FIG. 4, and to FIGS. 5 to 11.

[0047] Firstly, the fastening band 3 is prepared (step A). The fastening band is prepared in accordance with known practice, preferably using a moulding technique, in which polymer material is moulded around the reinforcing fibres 7 to provide the required engagement teeth 4 and the elongate shape of the fastening band 2. The fastening band 2 is cut to a required length, appropriate for the application for which the fastener 1 is intended. In accordance with the principles of the present invention, the fastening band 2 may be of any length. As illustrated in FIGS. 5, 6 and 7, the first end region 8 of the fastening band 2 may include a cut out 40. The cut out 40 may be provided in order to enable the reception portion 34 to be inserted into the body 12 of the buckle 10. A cut out may be provided in order to maximise the length of the first end region 8 of the fastening band 2 located in the buckle 10. It will be readily appreciated that other configurations of the first end region 8 of the fastening band 2 may be used. For example, there may not be the need or requirement to provide the cut out 36 in the first end region 8.

[0048] The first end region 8 of the fastening band 2 is then held in place in a moulding tool, which is closed around the first end region 8 (step B). The moulding tool provides a mould for the body 12 of the buckle 10. Before moulding, the first end region 8 of the fastening band 2 may be heated (step C), for example, by the use of hot air within the moulding tool. Such heating can improve contact between the first end region 8 and the body 12. In accordance with the principles of the present invention, a single moulding tool may be used for any length of fastening band 2. The moulding technique is preferably an injection moulding technique, although other techniques such a casting, or a technique that uses PU pourable moulds, could be used for preparation of the buckle.

[0049] Since the fastening band 2 is prepared in advance of the overmoulding step, and only one end region of the band is placed in the moulding tool, the band length is not constrained by the moulding process. This is in contrast with previously-considered fastener designs in which the band and buckle are moulded in a single step, which leads to the need for specific moulding tools, or adjustable tools, for different lengths of fastening band 2, and to significant difficulties that prevent the reinforcement fibres being moulded into the band.

[0050] An injection moulding process is then performed (step D), in which a suitable polymer material is injected into the injection moulding tool, in line with well-known and understood practice. In this step, the body is formed in the mould in such a way as to engage with the teeth of the fastening band 2.

[0051] The polymer may be the same as that of the fastening band 2, may be similar to that of the fastening band 2, or may be different to that of the fastening band 2. When the polymer materials of the fastening band 2 and buckle 10 are the same or similar, then a close bond can be formed between the two parts during the injection moulding process. The injection moulding process can be carried out at a temperature that causes the polymer material of the fastening band to melt, and thereby bond with the material of the buckle 10.

[0052] The reinforcing fibres 7 of the fastening band 2 extend fully into the overmoulded buckle 10 in order to provide increased strength of the fastener.

[0053] Following the injection moulding process of step D, the body 12 is ejected from the injection moulding tool (step E), resulting in the partially-completed fastener 1 shown in FIGS. 8 to 11. FIG. 8 illustrates a side cross-sectional view of the partially-completed fastener 1, and shows the first end region 8 of the fastening band 2 integrated with the body 12 of the buckle 10. The body of the buckle is engaged with the teeth of the first end region of the band. In this example, the body is fused to the teeth by the overmoulding step. The first end region 8 extends beneath the inner chamber 14 through a lower region of the body 12, and out through the second end wall 18, below the second passage 26. FIGS. 9, 10 and 11 illustrate perspective and plan views respectively of the partially-completed fastener 1.

[0054] In order to complete the fastener 1, the reception portion 34 is inserted into the body 12, if the reception portion is not formed as an integral part of the body during the injection moulding process (step F). The locking component 30 is then inserted into the reception portion 34 (step G), thereby completing the fastener 1.

[0055] As described above, in order to form a closed loop fastener, the fastening band 2 is passed around the objects being secured, and is inserted into the body 12 through the first passage 20 in the first end wall 16 of the body 12 of the buckle 10. The fastening band 2 is then moved through the inner chamber 14, and passed through the second passage 22 in the second end wall 18. A portion of the second end region 9 of the fastening band 2 is then located in the inner chamber 14, such that the engagement teeth 4 of the second end region 9 engage with the engagement portion 32 of the locking component 30. The engagement portion 32 is biased into contact with the fastening band 2 by the biasing component 38, thereby retaining the fastening band 2 in the buckle 10.

[0056] As described above, the fastening band 2 includes a plurality of reinforcing fibres 7 (for example, glass fibre yarn, steel, or aramid fibres), moulded into a polymer material, such as nylon 6-6, nylon 11, acetal, polypropylene, or similar material. The buckle is preferably of the same polymer material as used in the fastening band, and so may be of nylon 6-6, nylon 11, acetal, polypropylene, or similar material.

[0057] A fastener embodying the present invention has improved strength with reduced size, compared to previously-considered designs, because of the integration of the first end region of the fastening band with the lower wall portion of the buckle. The fastener, therefore, only has a single locking component, which improves strength of the coupling, and reduces the size of the buckle. A reduced-size buckle enables the use of the fastener on objects having a smaller diameter, and hence tighter outer curvature, compared with previously-considered designs.

[0058] Fasteners embodying aspects of the present invention have several advantageous features, as will be apparent from the forgoing description. In particular, overmoulding the buckle onto a prepared fastening band allows the integration of a fibre-reinforced band with a buckle. Previously considered designs only enable a non-reinforced band to be integrated with a buckle, or require the use of a separate two-latch buckle with a reinforced band.

[0059] The band of a fastener embodying the principles of the present invention can be of any length. The overmoulding technique described above requires only one end of the band to be held in the moulding tool, which means that the band can be of any desired length. Previously-considered designs using integrated buckles have length limitations on the band due to restrictions on injection moulding length, and the need for a specific or adjustable tool for each length of band.

[0060] Such a fastener has higher strength compared to previously-considered designs due to the provision of a fibre reinforced fastening band with an integrated buckle at one end of the fastener. Such a design removes one locking arrangement, and replaces it with a bonded component. This higher strength is particularly useful during the installation process in which the fastening band is passed around an object or objects, passed through the buckle and tightened. The tension experienced during the installation process may be much higher than that experienced by the fastener once installed, due to the relaxation of the locking arrangement. Removing the locking arrangement from one end of the fastener provides greater strength at the one end of the fastener, and hence a larger safety margin during the installation process.

[0061] Fasteners embodying the present invention are particularly useful in harsh environments in which high strength and durability are required. For example, fasteners embodying the present invention are particularly useful for subsea and marine applications, such as in the oilfield industry where such fasteners may be used to attach cables and the like to pipelines or other structures.

[0062] It will be readily appreciated that the terms upper, lower, inner, end, below, and beneath etc are used for the sake of simplicity and clarity and are not intended to confer any particular orientation on the parts being described. It will be appreciated that the fastener embodying the principles of the present invention may be used in any orientation suitable for the application.