Elastic averaging alignment member

Abstract

An elastic averaging alignment member includes a base portion, a first elastic averaging member including a first end portion extending substantially perpendicularly from the base portion to a second end portion and a second elastic averaging member spaced from the first elastic averaging member. The second elastic averaging member includes a first end section extending substantially perpendicularly from the base portion to a second end section. At least one elastic averaging element arranged between the first and second elastic averaging members. At least one of the first and second elastic averaging members and the at least one elastic averaging element is configured and disposed to deform when the elastic averaging alignment member is passed into an alignment member receiver to establish an elastically average position of one component to another component.

Description

FIELD OF THE INVENTION

The subject invention relates to fastening devices and, more particularly, to an elastic averaging alignment member.

BACKGROUND

Currently, components which are to be mated together in a manufacturing process are mutually located with respect to each other by 2-way and/or 4-way male alignment features, typically upstanding bosses, which are received into corresponding female alignment features, typically apertures in the form of holes or slots. There is a clearance between the male alignment features and their respective female alignment features which is predetermined to match anticipated size and positional variation tolerances of the male and female alignment features as a result of manufacturing (or fabrication) variances. As a result, there can occur significant positional variation as between the mated first and second components which may contribute to the presence of undesirably large and varying gaps and otherwise poor fit. Additional undesirable effects including squeaking, rattling and overall poor quality perception based on relative motion of the mated components.

SUMMARY OF THE INVENTION

In accordance with an exemplary embodiment, an elastic averaging alignment member includes a base portion, a first elastic averaging member including a first end portion extending substantially perpendicularly from the base portion to a second end portion and a second elastic averaging member spaced from the first elastic averaging member. The second elastic averaging member includes a first end section extending substantially perpendicularly from the base portion to a second end section. At least one elastic averaging element is arranged between the first and second elastic averaging members. At least one of the first and second elastic averaging members and the at least one elastic averaging element is configured and disposed to deform when the elastic averaging alignment member is passed into an alignment member receiver to establish an elastically average position of one component to another component.

In accordance with another exemplary embodiment, a method of aligning a first substrate to a second substrate with an elastic averaging alignment member includes positioning a first substrate including a plurality of elastic averaging alignment members each having at least two elastic averaging members joined by at least one elastic averaging element relative to a second substrate including a plurality of alignment member receivers, establishing an initial alignment of the plurality of elastic averaging alignment members with respective ones of the alignment member receivers, inserting the at least two elastic averaging members into respective one of the alignment member receivers, and deforming at least one of the at least two elastic averaging members and the at least one elastic averaging element of each of the elastic averaging alignment members to establish a desired final alignment of the first substrate relative to the second substrate.

In yet another exemplary embodiment of the invention, a motor vehicle includes a body having a trim component receiving zone provided with a plurality of alignment member receivers, and a trim component having a base portion provided with a plurality of elastic averaging alignment members. Each of the elastic averaging alignment members include a first elastic averaging member including a first end portion extending substantially perpendicularly from the trim component to a second end portion and a second elastic averaging member spaced from the first elastic averaging member. The second elastic averaging member includes a first end section extending substantially perpendicularly from the trim component to a second end section. At least one elastic averaging element is arranged between the first and second elastic averaging members. At least one of the first and second elastic averaging members and the at least one elastic averaging element is configured and disposed to deform when each of the plurality of elastic averaging alignment members is passed into a corresponding one of the plurality of alignment member receivers to establish an elastically averaged position of the trim component relative to the body.

The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:

FIG. 1 is a perspective view of an elastic averaging alignment member having a plurality of elastic averaging elements in accordance with an exemplary embodiment;

FIG. 2 is a perspective view of the elastic averaging alignment member of FIG. 1 illustrating the plurality of elastic averaging elements in a compressed configuration;

FIG. 3 is a plan view of the elastic averaging alignment member of FIG. 1 engaged with an alignment member receiver;

FIG. 4 is a perspective view of an elastic averaging alignment member in accordance with another aspect of the exemplary embodiment;

FIG. 5 is a perspective view of the elastic averaging alignment member of FIG. 4 engaged with an alignment member receiver;

FIG. 6 is a perspective view of an elastic averaging alignment member in accordance with another aspect of the exemplary embodiment;

FIG. 7 is a plan view of the elastic averaging alignment member of FIG. 6 entering into an alignment member receiver;

FIG. 8 is a plan view of the elastic averaging alignment member of FIG. 7 passing into the alignment member receiver;

FIG. 9 is a plan view of the elastic averaging alignment member of FIG. 8 seated within the alignment member receiver;

FIG. 10 is a partial perspective disassembled view of a motor vehicle and trim component including an elastic averaging alignment member in accordance with the exemplary embodiment; and

FIG. 11 is a partial perspective view of the motor vehicle of FIG. 8 illustrating the trim component joined to a trim component receiving portion through the elastic averaging alignment member in accordance with the exemplary embodiment.

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

DESCRIPTION OF THE EMBODIMENTS

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

An elastic averaging alignment member in accordance with an exemplary embodiment is indicated generally at 2 in FIG. 1. As used herein, elastic averaging provides elastic deformation of the interface(s) between mated components, wherein the average deformation provides a precise alignment, the manufacturing positional variance being minimized to X_min, defined by X_min=X/√N, wherein X is the manufacturing positional variance of the locating features of the mated components and N is the number of features inserted. To obtain elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that is over-constrained and provides an interference fit with a mating feature of another component and its contact surface(s). The over-constrained condition and interference fit resiliently reversibly (elastically) deforms at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components allows repeatable insertion and withdrawal of the components that facilitates their assembly and disassembly. Positional variance of the components may result in varying forces being applied over regions of the contact surfaces that are over-constrained and engaged during insertion of the component in an interference condition. It is to be appreciated that a single inserted component may be elastically averaged with respect to a length of the perimeter of the component. The principles of elastic averaging are described in detail in commonly owned, co-pending U.S. Patent Application No. 2013/0019455, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed herein provide the ability to convert an existing component that is not compatible with the described elastic averaging principles to an assembly that does facilitate elastic averaging and the benefits associated therewith.

Any suitable elastically deformable material may be used. The term “elastically deformable” refers to components, or portions of components, including component features, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo a resiliently reversible change in its shape, size, or both, in response to application of a force. The force causing the resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or torsional force, or various combinations of these forces. The elastically deformable materials may exhibit linear elastic deformation, for example that described according to Hooke's law, or non-linear elastic deformation.

Numerous examples of materials that may at least partially form the components include various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof. Many composite materials are envisioned, including various filled polymers, including glass, ceramic, metal and inorganic material filled polymers, particularly glass, metal, ceramic, inorganic or carbon fiber filled polymers. Any suitable filler morphology may be employed, including all shapes and sizes of particulates or fibers. More particularly any suitable type of fiber may be used, including continuous and discontinuous fibers, woven and unwoven cloths, felts or tows, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers or thermoset polymers, or composites thereof, or any other combinations thereof, including a wide variety of co-polymers and polymer blends. In one embodiment, a preferred plastic material is one having elastic properties so as to deform elastically without fracture, as for example, a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate ABS polymer blend (PC/ABS), such as an ABS acrylic. The material may be in any form and formed or manufactured by any suitable process, including stamped or formed metal, composite or other sheets, forgings, extruded parts, pressed parts, castings, or molded parts and the like, to include the deformable features described herein. The material, or materials, may be selected to provide a predetermined elastic response characteristic. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.

Elastic averaging alignment member 2 includes a base portion 4 that supports a first elastic averaging member 6 and a second elastic averaging member 8. First elastic averaging member 6 extends from a first end portion 12 to a second end portion 13 through an intermediate portion 14. Second end portion 13 includes a lead-in angle section 15. First elastic averaging member 6 extends substantially perpendicularly from base portion 4 and includes a first or exterior surface 16 and an opposing second or interior surface 17. Similarly, second elastic averaging member 8 extends from a first end portion 22 to a second end portion 23 through an intermediate portion 24. Second end portion 23 includes a lead-in angle section 25. Lead-in angle sections 15 and 25 facilitate insertion of elastic averaging alignment member 2 into an alignment member receiver as will be detailed more fully below. Second elastic averaging member 8 extends substantially perpendicularly from base portion 4 and is spaced from, and generally parallel to, first elastic averaging member 6. Second elastic averaging member 8 includes a first or exterior surface 26 and a second or interior surface 27.

In accordance with an exemplary embodiment, a web 34 extends between interior surface 17 of first elastic averaging member 6 and interior surface 27 of second elastic averaging member 8. Web 34 includes a first end 35 and a second end 36. In the exemplary embodiment shown, first end 35 is joined with base portion 4. However, it should be understood that first end 35 may also be spaced from base portion 4. Web 34 includes a plurality of elastic averaging elements, one of which is indicated at 38. Elastic averaging elements 38 are defined by a plurality of openings or gaps 41 that extend from second end 36 toward first end 35. In accordance with the exemplary aspect shown, openings 41 take the form of V-shaped notches 43 that terminate in a strain relief section 46. However it is understood that the notches could be shapes other than V-shaped and could, for example, be U-shaped. Strain relief section 46 substantially prevents openings 41 from extending completely through web 34 to first end 35.

As shown in FIGS. 2 and 3, when elastic averaging alignment member 2 is placed within an alignment member receiver 47, elastic averaging elements 38 are compressed. More specifically, alignment member receiver 47 takes the form of an opening 48 defined by a plurality of edge or side portions 50, which are indicated in FIG. 3. Two opposing side portions 50 interact with first and second elastic averaging members 6 and 8 causing elastic averaging elements 38 to come together. At this point, elastic averaging elements 38 exert an outward force on first and second elastic averaging members 6 and 8 causing an inter-engagement of elastic averaging alignment member 2 and alignment member receiver 47. In addition to an elastic deformation in elastic averaging element 38, first and second elastic averaging members 6 and 8 may also elastically deform to contribute to establishing an elastically averaged position of one component to another component. More specifically, the compression of elastic averaging element 38 and/or first and second elastic averaging members 6 and 8, when combined with compression of elastic averaging elements and/or members associated with additional elastic averaging alignment members, allows for components to be aligned or positioned. More specifically, each elastic averaging element and/or elastic averaging member may compress differently and also allow for further manipulation so that components that may be misaligned without elastic averaging, may now be aligned to one another to establish a desired fit and finish.

Reference will now follow to FIGS. 4 and 5 in describing an elastic averaging alignment member 60 in accordance with another aspect of the exemplary embodiment. Elastic averaging alignment member 60 includes a base portion 62 that supports a first elastic averaging member 64 and a second elastic averaging member 66. First elastic averaging member 64 extends from a first end portion 70 to a second end portion 71 through an intermediate portion 72. Second end portion 71 includes a lead-in angle section 73. First elastic averaging member 64 extends substantially perpendicularly from base portion 62 and includes a first or exterior surface 74 and an opposing second or interior surface 75. Similarly, second elastic averaging member 66 extends from a first end portion 80 to a second end portion 81 through an intermediate portion 82. Second end portion 81 includes a lead-in angle section 83. Lead-in angle sections 73 and 83 facilitate insertion of elastic averaging alignment member 60 into a mating component. Second elastic averaging member 66 extends substantially perpendicularly from base portion 62 and is spaced from, and generally parallel to, first elastic averaging member 64. Second elastic averaging member 66 includes a first or exterior surface 84 and a second or interior surface 85.

In accordance with the exemplary aspect shown, a web 88 extends between interior surface 75 of first elastic averaging member 64 and interior surface 85 of second elastic averaging member 66. Web 88 includes a first end 89 and a second end 90. In the exemplary embodiment shown, first end 89 is joined with base portion 62. However, it should be understood that first end 89 may also be spaced from base portion 62. Web 88 includes a plurality of elastic averaging elements, one of which is indicated at 92. Elastic averaging elements 92 are defined by a plurality of openings 94 that extend along web 88 between first end 89 and second end 90. In accordance with the exemplary aspect shown, openings 94 include a generally rectangular shape.

When elastic averaging alignment member 60 is placed within an alignment member receiver 96, openings 94 facilitate a bending moment of elastic averaging elements 92. More specifically, alignment member receiver 96 takes the form of an opening 98 defined by a plurality of edge or side portions, one of which is indicated at 100. Two opposing side portions 100 interact with first and second elastic averaging members 64 and 66 causing web 88 to compress inward. At this point, web 88 exerts an outward force on first and second elastic averaging members 64 and 66 causing an inter-engagement of elastic averaging alignment member 60 and alignment member receiver 96. First and second elastic averaging members 64 and 66 may also elastically deform. The compression of web 88 and/or elastic averaging members 64 and 66, when combined with compression/bending/deflection of webs and/or elastic averaging members associated with additional elastic averaging alignment members, allows for components to be aligned with much better precision. More specifically, each elastic averaging element may compress/bend/deflect differently and also allow for further manipulation so that components that may have poor alignment and fit prior to elastic averaging may now be aligned to establish a desired fit and finish.

Reference will now follow to FIGS. 6 and 7 in describing an elastic averaging alignment member 120 in accordance with another aspect of the exemplary embodiment. Elastic averaging alignment member 120 includes a base portion 122 that supports a first elastic averaging member 124 and a second elastic averaging member 126. First elastic averaging member 124 extends from a first end portion 130 to a second end portion 131 through an intermediate portion 132. Second end portion 131 includes a distal section 133. First elastic averaging member 124 extends substantially perpendicularly from base portion 122 and includes a first or exterior surface 134 and an opposing second or interior surface 135. Exterior surface 134 includes a first rib 136 and a second rib 137. First and second ribs 136 and 137 taper inwardly from first end portion 130 toward second end portion 131 to act as a lead-in. Similarly, second elastic averaging member 126 extends from a first end portion 139 to a second end portion 140 through an intermediate portion 141. Second end portion 131 includes a distal section 143. Second elastic averaging member 126 extends substantially perpendicularly from base portion 122 and is spaced from, and generally parallel to, first elastic averaging member 124. Second elastic averaging member 126 includes a first or exterior surface 144 and a second or interior surface 145. Exterior surface 144 includes a first rib 147 and a second rib 148. Ribs 147 and 148 taper inwardly from first end portion 139 toward second end portion 140 to act as a lead-in. The lead-ins provided by the first and second ribs 136, 147 and 137, 148 facilitate insertion of elastic averaging alignment member 120 into an alignment member receiver 165.

In accordance with the exemplary aspect shown, an elastic averaging element 153, shown in the form of a web 154, extends between interior surface 135 of first elastic averaging member 124 and interior surface 145 of second elastic averaging member 126. Web 154 includes a first end 155 and a second end 156. As discussed above, first end 155 is illustrated as being joined with base portion 122. However, it should be understood that first end 155 may also be spaced from base portion 122. A retaining clip 160 is positioned upon web 154.

The retaining clip 160 includes a clip member 163 and a spring member 1600 configured and disposed to engage with a portion 1601 of the alignment member receiver 165. The portion 1601 of the alignment member receiver 165 includes a tab 166 and a flange 167, which interferes with the tab 166 to thereby establish retention capability for elastic averaging alignment member 120.

As shown in FIG. 7, lead-ins provided by the first and second ribs 136, 147 and 137, 148 (see FIG. 6) facilitate insertion of elastic averaging alignment member 120 into the alignment member receiver 165, which is defined by a plurality of walls 168-171. As elastic averaging alignment member 120 is passed into alignment member receiver 165, ribs 136 and 137 engage with wall 171 and ribs 147 and 148 engage with wall 169 as shown in FIG. 8. As elastic averaging alignment member 120 continues to pass into alignment member receiver 165, ribs 135, 136 and 147, 148 cause first and second elastic averaging members 124 and 126 to deflect or bend around element 153 as shown in FIG. 9. The bending of first and second elastic averaging members 124 and 126 facilitates an elastically averaged alignment of components. The interference between the tab 166 and the flange 167 establish a mechanical stop for any attempt at continued insertion beyond the point of contact between the tab 166 and the flange 167. In addition, the spring member 1600 engages with the portion 1601 of the alignment member receiver 165 to establish retention capability.

Elastic averaging alignment members, as described above, may be employed in a wide range of configurations to facilitate a desired alignment of components to achieve a desired fit and finish. For example, as shown in FIGS. 10 and 11, a motor vehicle 190 includes a body 192 having a trim component receiving portion 195. Trim component receiving portion 195 is provided as a second component with a plurality of alignment member receivers, one of which is illustrated at 198. A trim component, such as shown at 203, is provided as a first component and includes a base portion 205 from which extend elastic averaging alignment members 208. Elastic averaging alignment members 208 are initially and roughly aligned with and then inter-engaged with alignment member receivers 198 to position and align trim component 203 to body 192 at trim component receiving portion 195. The use of elastic averaging alignment members allows for a much more desirable alignment then prior methods with manufactured clearances that established misalignments that would have previously resulted in a less than desirable fit and finish.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application.

Claims

1. An elastic averaging alignment member comprising: a base portion;a first elastic averaging member including a first end portion extending substantially perpendicularly from the base portion to a second end portion;a second elastic averaging member spaced from the first elastic averaging member, the second elastic averaging member including a first end section extending substantially perpendicularly from the base portion to a second end section; andat least one elastic averaging element arranged between the first and second elastic averaging members,wherein, when the elastic averaging alignment member is passed into an alignment member receiver to establish an elastically averaged position of one component to another component, at least one of the first and second elastic averaging members deforms toward the other of the first and second elastic averaging members and the at least one elastic averaging element deforms within a plane thereof.

2. The elastic averaging alignment member according to claim 1, wherein the at least one elastic averaging element defines a web extending between the first and second elastic averaging members, the web including a first end arranged at the base portion that extends to a second end.

3. The elastic averaging alignment member according to claim 2, further comprising a retaining clip operably disposed on the web.

4. The elastic averaging alignment member according to claim 2, wherein web is formed to define a plurality of openings.

5. The elastic averaging alignment member according to claim 4, wherein the plurality of openings extend between the first end and the second end of the web.

6. The elastic averaging alignment member according to claim 4, wherein each of the plurality of openings is substantially rectangular.

7. The elastic averaging alignment member according to claim 4, wherein each of the plurality of openings extends along the web through the second end to define at least one strain relief section and at least one V-shaped notch terminating at the strain relief section.

8. The elastic averaging alignment member according to claim 1, wherein the first elastic averaging member includes a first surface and an opposing second surface, the first surface including at least two ribs defining lead-ins facilitating insertion of the first and second elastic averaging alignment members into the alignment member receiver.

9. The elastic averaging alignment member according to claim 8, wherein each of the at least two ribs extends substantially perpendicularly from the first surface.

10. The elastic averaging alignment member according to claim 9, wherein each of the at least two ribs includes a first rib extending substantially perpendicularly from the first surface and a second rib extending substantially perpendicularly from the first surface and being spaced from the first rib.

11. A method of aligning a first substrate to a second substrate with elastic averaging alignment members, the method comprising: positioning the first substrate including a plurality of elastic averaging alignment members having at least two elastic averaging members joined by at least one elastic averaging element relative to the second substrate including a plurality of alignment member receivers;initially aligning the plurality of elastic averaging alignment members with respective ones of the plurality of alignment member receivers;inserting the at least two elastic averaging members into one of the alignment member receivers; anddeforming at least one of the at least two elastic averaging members the other of the at least two elastic averaging members and the at least one elastic averaging element within a plane thereof to establish a desired final alignment of the first substrate relative to the second substrate.

12. The method of claim 11, wherein deforming at least one of the at least two elastic averaging members and the at least one elastic averaging element comprises compressing at least one of elastic averaging elements to close at least one of notches formed in a web extending between first and second elastic averaging members.

13. The method of claim 11, wherein deforming at least one of the at least two elastic averaging members and the at least one elastic averaging element comprises compressing a plurality of elastic averaging elements to close a plurality of openings having a generally rectangular cross-section formed in a web extending between first and second elastic averaging members.

14. The method of claim 11, wherein inserting the plurality of elastic averaging alignment members into one of the plurality of alignment member receivers includes bending the at least two elastic averaging members about the at least one elastic averaging element.

15. A motor vehicle comprising: a body having a trim component receiving portion provided with a plurality of alignment member receivers; anda trim component having a base portion provided with a plurality of elastically averaging alignment members; each of the plurality of elastic averaging alignment members comprising:a first elastic averaging member including a first end portion extending substantially perpendicularly from the base portion to a second end portion;a second elastic averaging member spaced from the first elastic averaging member, the second elastic averaging member including a first end portion extending substantially perpendicularly from the base portion to a second end portion; andat least one elastic averaging element arranged between the first and second elastic averaging members,wherein, when each of the plurality of alignment members are passed into corresponding ones of the plurality of alignment member receivers to establish an elastically average position of the trim component relative to the body, at least one of the first and second elastic averaging members deforms toward the other of the first and second elastic averaging members and the at least one elastic averaging element deforms within a plane thereof.

16. The motor vehicle according to claim 15, wherein the at least one elastic averaging element defines a web extending between the first and second elastic averaging members, the web including a first end coupled to the base portion that extends to a second end.

17. The motor vehicle according to claim 16, wherein the at least one elastic averaging element comprises a plurality of elastic averaging elements defined by a plurality of openings formed in the web, the plurality of openings extending between the first end and the second end of the web.

18. The motor vehicle according to claim 17, wherein the plurality of openings are substantially rectangular.

19. The motor vehicle according to claim 17, wherein the plurality of openings extend along the web through the second end to define a plurality of strain relief sections and a plurality of V-shaped notches terminating at the plurality of strain relief sections.

20. The motor vehicle according to claim 15, wherein the first elastic averaging member includes a first surface and an opposing second surface coupled to the at least one elastic averaging element, the first surface including a lead-in defining first rib extending substantially perpendicularly from a first end of the first surface and a lead-in defining second rib extending substantially perpendicularly from a second, opposing end of the first surface.