Abstract:
A system for attaching a component to a substrate, such as a vehicle. The system comprises a bracket. At least one fastener is coupled to the bracket and is engageable to the vehicle. A component is assembled to the bracket such that a lip of the component contacts a tab of the bracket, and the bracket at least partially engages a gap defined by the lip and an interior surface of the component. The component is attached to the vehicle when the fastener is engaged with the vehicle. A method employs the system.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a system for attaching components to a vehicle, in particular a system for attaching components to the exterior of the vehicle. 
     BACKGROUND 
     Vehicle exteriors typically include components attached thereto that aid to form the shape of the body or accentuate the styling of the vehicle. Example components include fender flares, cladding, panels, ground effects, scoops and trim pieces, among others. These components are typically made from a plastic material and thus are lighter than their metal counterparts. Plastic components are also less susceptible to environmental degradation and damage from minor impacts. 
     Attaching plastic components to metal substrates of the vehicle, such as body panels, poses several problems. First, plastic and metal are incompatible for welding. Consequently, the components must be secured to the substrate with adhesives or mechanical fasteners. However, mounting a component in this way can be problematic due to inherent differences in the rates of thermal expansion for plastic and metal, which can cause deformation of the component if it is rigidly attached to the metal substrate. Such distortion is easily visible to an observer and detracts from the esthetics of the vehicle. 
     Another drawback of using plastic body components is the need to include molded-in mounting structures such as recesses or “doghouses” that accommodate common fasteners for attaching the component to the vehicle. These attachment structures can cause slide marks, sink marks, recesses, dimples and other visible imperfections on the exterior surface of the component. These flaws, which are inherent to molded components having complex geometries, detract from the esthetics of the vehicle. 
     There is a need for a way to attach components to the exterior of a vehicle without the need for a molded-in fastener attachment feature that can cause visible surface imperfections. There is a further need for a way to attach components that provides for thermal expansion of the components. 
     SUMMARY 
     A system for attaching components to a vehicle is disclosed. The system overcomes the limitations of the prior art by allowing the components to be attached to the vehicle without the use of molded-in attachment structures. The system also allows for lateral movement of the components to compensate for thermal expansion and contraction. The system utilizes a component design having a lip that engages a bracket and rests upon tabs extending from the bracket. The bracket includes fasteners for attaching the component to the vehicle. The component&#39;s movement is then restricted in all directions except laterally, due to interference between the component, the bracket and the vehicle. 
     An aspect of the present invention is a system for attaching a component to a substrate. The system comprises a bracket. At least one fastener is coupled to the bracket and is engageable to the substrate. A component is assembled to the bracket such that a lip of the component contacts a tab of the bracket, and the bracket at least partially engages a gap defined by the lip and an interior surface of the component. The component is attached to the substrate when the fastener is engaged with the substrate. 
     Another aspect of the invention is a method for attaching a component to a substrate. The method comprises the steps of selecting a bracket, coupling at least one fastener to the bracket, and assembling a component to the bracket such that a lip of the component contacts a tab of the bracket and the bracket at least partially engages a gap defined by the lip and an interior surface of the component. Finally, the fastener is engaged to a receptacle of the substrate such that the component is attached to the substrate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features of the inventive embodiments will become apparent to those skilled in the art to which the embodiments relate from reading the specification and claims with reference to the accompanying drawings, in which: 
         FIG. 1  is a view in section of a prior art component attached to a metal substrate; 
         FIG. 2  is an exploded view of the assembly of a component to a bracket according to an embodiment of the present invention; 
         FIG. 3  depicts the component and bracket of  FIG. 2  in an assembled condition; 
         FIG. 4  is an elevational view of the assembled component and metal substrate of  FIG. 3 ; 
         FIG. 5  is a view in section  5 - 5  of  FIG. 3  showing details of the component, the bracket and a fastener; and 
         FIG. 6  is a view in section  6 - 6  of  FIG. 3  showing details of the component, the bracket and a tab portion of the bracket. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a view in section of a prior art plastic component  10 , such as cladding, assembled to a body panel  12  of a vehicle. Component  10  includes a molded-in fastener housing  14  having a fastener aperture  16 , into which a fastener  18  is installed. Fastener  18  is coupled to a mounting aperture  20  of body panel  12 , thus securing component  10  to the body panel. This assembly system suffers from several shortcomings. First, as can be seen in  FIG. 1 , the molding process utilized to form the fastener housing  14  often results in depressions or irregularities such as sink marks  22 . The sink marks  22  are caused by variations in the flow of molten plastic material in the mold used to form component  10 , and by uneven heating and cooling in the mold. These flaws often appear on an exterior surface  24  of component  10 , detracting from the esthetics of the component. 
     Another drawback of the assembly of  FIG. 1  is that the component  10  is rigidly attached to body panel  12  by fastener  18 . Since plastic component  18  and metal body panel  12  have different rates of thermal expansion, the component is subject to distortion and warping that can detract from the esthetics of the vehicle. 
     A system for attaching components to a substrate according to an embodiment of the present invention is shown in  FIGS. 2 through 6 . The general arrangement of the system is shown in  FIGS. 2 ,  3  and  4  wherein a component  30  is assembled to a metal bracket  32 . Bracket  32  includes one or more fasteners  34  coupled thereto for attaching the assembled component and metal bracket assembly to a substrate such as a vehicle body  36 . 
     Component  30  may be any type of component suitable for assembly to a vehicle. Examples include, without limitation, fender flares, cladding, scoops, panels, ground effects and trim pieces attached to a vehicle or other suitable structure. Component  30  may further include one or more alignment apertures  44  and one or more lips  40 , as shown in  FIGS. 2-6 . Component  30  may be made from any suitable type of lightweight material, such as plastic, and may be finished with a decorative coating such as paint and/or clear-coating. Component  30  may also be molded from plastic having a desired color. In some embodiments component  30  may be made from other materials such as carbon fiber composites or metal. 
     With continued reference to  FIGS. 2-6  viewed in combination, bracket  32  is a generally planar strip extending longitudinally and having a length generally corresponding to the length of component  30 . Bracket  32  further includes one or more tabs  42 , alignment elements  38  and flanges  46 . Tabs  42  extend generally perpendicularly from bracket  32  toward vehicle body  36 , while flanges  46  are generally parallel to the bracket. Bracket  32  further includes at least one fastener aperture  48  to which fastener  34  is coupled. Bracket  32  is generally formed from metal, such as steel, but may be produced from any other suitable material including, without limitation, other metals and alloys thereof, as well as plastics, composites or other non-metallic materials. Bracket  32  may be finished by any suitable coating or plating process to protect it from the environmental elements. 
     Fastener  34  may be any conventional type of fastener suitable for use with component  10 , bracket  32  and vehicle body  36 . Examples include, without limitation, plastic or metal clips, push-in fasteners, rivets, bolts, screws and lugs. 
     With reference to  FIGS. 2-4 , component  30  is coupled to bracket  32  by first attaching fasteners  34  to fastener apertures  48  such that the fasteners extend generally perpendicular to the bracket. Component  30  and bracket  32  are then assembled together by engaging alignment elements  38  with corresponding alignment apertures  44  and then sliding the bracket underneath lip  40 . In this position flanges  46  are proximate component  30  and the flanges are in contact with the component, effectively wedging a portion of the bracket into a gap  50  formed by the component and lip  40 . 
     Referring now to  FIGS. 5 and 6 , the assembled component  30  and bracket  32  are attached to vehicle  36  by first aligning fasteners  34  with corresponding mounting receptacles  52  on the vehicle and then engaging the fasteners to the receptacles. Component  30  is then pressed into place such that it moves downwardly in relation to bracket  32 , causing the alignment elements  38  to disengage from alignment apertures  44  by moving away from the apertures and allowing lip  40  to come into contact with tabs  42 . In the installed condition tabs  42  support the weight of component  30 , which rests thereupon. 
     Once alignment elements  38  are disengaged from alignment apertures  44  lip  40  is able to move longitudinally along corresponding tab  42 , thereby allowing component  30  to expand and contract with changes in temperature without binding or distorting the component&#39;s shape or surface. Likewise, interior surface  54  of component  30  is able to slide longitudinally along flanges  46 . Despite this freedom of movement, component  30  is otherwise rigidly attached to vehicle body  36  by bracket  32  and fasteners  34 . 
     A friction reducing element  56  may optionally be attached to flanges  46  to aid in decreasing friction between bracket  30  and component  32  as well as protecting the component from deformation caused by contact with the bracket. A contact area  58  between component  30  and bracket  32  may also include a friction reducing element  56  to assist in reducing friction and wear between the component and the bracket. Friction reducing element  56  may be made from felt, fabric, plastic, rubber or other materials, and may be provided in forms such as tape, pads, or bumpers, among others. 
     As can be seen, the present invention requires no attachment structures, such as recesses or “doghouses” for inserting fasteners to attach a component to a vehicle body. Attachment of component  30  to vehicle body  36  is accomplished entirely through the use of bracket  32  and interference to movement of the component via the bracket and the vehicle body after installation. Accordingly, component  30  may have a superior exterior surface without the undesirable slide marks or sink marks. The present invention also provides for a rigid attachment of component  30  to vehicle body  36  while allowing movement for thermal expansion and contraction of the panel material, thus preventing warping or deformation of the component. 
     In an alternate embodiment of the present invention a plurality of brackets  32  may be used in connection with a component  30 . Likewise, a plurality of components  30  may be assembled to a single bracket  32  and a plurality of components may be assembled with a plurality of brackets. In still other embodiments bracket  32  may comprise one or more curved portions, such as to correspond to contours of vehicle body  36  instead of, or in addition to, a straight design as is depicted in the figures. 
     While this invention has been shown and described with respect to a detailed embodiment thereof, it will be understood by those skilled in the art that changes in form and detail thereof may be made without departing from the scope of the claims of the invention. For example, the present invention may be employed in other contexts such as attaching siding to a house or building, or retaining signage on a support structure, among others.