Abstract:
A composite applique assembly for a vehicle interior trim piece includes a flexible receiver element and a flexible insert connected to the flexible receiver element by a sliding joint. An end of the flexible receiver element is fixedly connected to a vehicle door element. An end of the flexible insert opposite to the flexible receiver element end is fixedly connected to a vehicle door element. The flexible receiver element defines an internal channel configured for slidingly receiving the flexible insert therein. The flexible receiver element further defines at least a partial-length slot providing fluid communication with the internal channel.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates generally to vehicle trim pieces and trim packages. In particular, the disclosure relates to a composite applique piece for a vehicle trim piece which resolves separation issues in the event of a side impact, especially side-pole impact. 
       BACKGROUND 
       [0002]    Certain regulatory, industry, and manufacturer standards have been established regarding post-impact interior component separation. For example, European regulations relating to side impacts specify that “no interior device or component shall become detached in such a way as noticeably to increase the risk of injury to the occupant from sharp projections or jagged edges.” Likewise, certain manufacturer side impact standards require “no interior aggressive edges to be present post impact.” Various controlled impact tests have been developed to evaluate compliance with such regulatory, industry, and manufacturer standards. A representative example of a regulatory side-pole test is the FMVSS 214 Vehicle-to-Pole test, wherein a laterally moving vehicle impacts a rigid pole at 20 miles per hour. In this test, the vehicle is propelled laterally so that its line of forward motion forms an angle of 75 degrees with the longitudinal centerline of the vehicle. 
         [0003]    Interior trim pieces such as decorative applique pieces pose a particular concern because such trim pieces, not being integral with other vehicle interior components, may break and/or detach post-impact and present sharp projections/jagged edges. There is accordingly a need in the art for interior applique pieces which reduce or eliminate this risk. 
         [0004]    To address this identified need, the present disclosure relates to a composite applique assembly for vehicle interior trim. Advantageously, the described applique assembly defines a sliding joint which reduces or eliminates the tendency of the applique piece to fracture on impact. This likewise reduces or eliminates the tendency of the applique piece to present a sharp edge or jagged projection post-impact. 
       SUMMARY 
       [0005]    In accordance with the purposes and benefits described herein, in one aspect a composite applique assembly for a vehicle interior trim piece is provided, comprising a flexible receiver element and a flexible insert connected to the flexible receiver element by a sliding joint. In use, an end of the flexible receiver element is fixedly connected to a vehicle door element. Likewise, an end of the flexible insert opposite to the flexible receiver element end is fixedly connected to a vehicle door element. Optionally, one or more frangible fasteners may releasably connect the flexible receiver element and the flexible insert. The flexible receiver element defines an internal channel configured for slidingly receiving the flexible insert therein. The flexible receiver element further defines one or more slots defined along a longitudinal axis thereof. 
         [0006]    In embodiments, the sliding joint comprises a sliding mechanical fastener attached to the flexible insert and engaging the one or more slots. In embodiments, the sliding joint comprises a flexible insert flange slidingly engaging the one or more slots. 
         [0007]    In another aspect, an interior trim assembly for a vehicle is described, comprising a vehicle interior substrate and a composite applique assembly substantially as described above. 
         [0008]    In the following description, there are shown and described embodiments of the disclosed composite applique assembly and of trim piece packages including the applique assembly. As it should be realized, the device is capable of other, different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the devices as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the disclosed composite applique assembly, and together with the description serve to explain certain principles thereof. In the drawings: 
           [0010]      FIG. 1  shows a side view of a composite applique assembly according to the present disclosure; 
           [0011]      FIG. 2A  shows the top view composite applique assembly of  FIG. 1  prior to a side-pole impact; 
           [0012]      FIG. 2B  shows the composite applique assembly of  FIG. 2A  after a side-pole impact; 
           [0013]      FIG. 2C  shows a prior art applique assembly after side-pole impact; 
           [0014]      FIG. 3A  shows a side cross-sectional view of an embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0015]      FIG. 3B  shows a side cross-sectional view of an alternative embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0016]      FIG. 3C  shows a side cross-sectional view of another alternative embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0017]      FIG. 3D  shows a side cross-sectional view of yet another alternative embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0018]      FIG. 3E  shows a side cross-sectional view of still another alternative embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0019]      FIG. 3F  shows a side cross-sectional view of still yet another alternative embodiment of a sliding joint for a composite applique assembly according to the present disclosure; 
           [0020]      FIG. 4A  shows a side view of an alternative embodiment of a composite applique assembly according to the present disclosure; 
           [0021]      FIG. 4B  shows a side cross-sectional view of a stopped sliding joint for the composite applique assembly of  FIG. 4A ; 
           [0022]      FIG. 4C  shows the composite applique assembly of  FIG. 4A  prior to a side-pole impact; and 
           [0023]      FIG. 4D  shows the composite applique assembly of  FIG. 4A  after a side-pole impact. 
       
    
    
       [0024]    Reference will now be made in detail to embodiments of the disclosed composite applique assembly and trim pieces incorporating same, examples of which are illustrated in the accompanying drawing figures. 
       DETAILED DESCRIPTION 
       [0025]    Preliminarily, the present disclosure describes a composite applique assembly primarily in the context of application to a vehicle door interior trim piece, intended to reduce a tendency of conventional applique pieces to produce sharp edges/jagged projections on side impact as summarized above. However, the skilled artisan will appreciate that the disclosed sliding-joint applique piece and interior trim pieces incorporating same are readily adaptable to other interior trim locations and impact locations. Accordingly, the present descriptions should not be taken as limiting in that regard. 
         [0026]    As summarized above, interior trim pieces such as decorative applique pieces pose a particular concern because such trim pieces, not being integral with other vehicle interior components, may break and/or detach post-impact and present sharp projections/jagged edges. As an example, consider the case of an applique piece attached to a door trim top-roll by conventional fasteners such as heat stakes, PALNUTs® (which as is known are locking devices including a series of barbs for locking a nut in place on a bolt), or other such fasteners. On receiving an exterior side impact to the door the applique bends. As the impacting device (for example a pole) continues to intrude into the vehicle door structure, the applique undergoes bending and tensile stresses. Eventually, tensile and shear stresses cause the fasteners to break, releasing the applique piece and potentially allowing an end of the applique to protrude into the vehicle passenger cabin. 
         [0027]    Prior art means to overcome this applique separation phenomenon include additional fastening means such as end-mounted hooks to try to prevent applique separation. However, it has been shown that side impact tests such as the vehicle-to-pole side impact test, which as summarized above provides a 20 mph oblique side impact, are too severe for such fasteners and so applique separation still occurs. Other attempts to overcome applique separation include providing predefined weakenings of the applique structure, for example one or more v-grooves or semicircular grooves defined in a portion of the material of the applique that is not within a vehicle occupant zone. Such predefined weakenings are intended to encourage breakage/separation of the applique in a defined and controlled manner away from the occupant zone post-impact. However, because these solutions still allow breakage of the applique, the potential still exists for sharp/jagged edges protruding into the vehicle passenger cabin post-impact. Thus, a need exists for a more robust solution. 
         [0028]    To solve this and other problems, with reference to  FIG. 1  there is provided a composite applique assembly  100  comprising a flexible receiver element  102  and a flexible insert  104 . In embodiments, each of the flexible receiver element  102  and flexible insert  104  are manufactured of a suitably flexible material, for example a ductile plastic, wood and metal such as aluminum and stainless steel and any other interior decorative appliques. As will be appreciated, by fabricating each of the flexible receiver element  102  and flexible insert  104  of a flexible material such as ductile plastic, on receipt of an impact the composite applique assembly  100  will bend and flex rather than breaking, reducing the likelihood of producing sharp, jagged edges post-impact. 
         [0029]    The flexible receiver element  102  and flexible insert  104  are each secured to a vehicle element  106 , for example to a vehicle door trim piece, by suitable mechanical fasteners  108 . As shown the flexible receiver element  102  is secured to the vehicle element  106  on an end  110  thereof. In turn, the flexible insert  104  is secured to the vehicle element  106  on an end  112  thereof. As shown, ends  110  and  112  are opposite to one another. 
         [0030]    Optionally, one or more frangible fasteners  114  disposed between the ends  110 ,  112  may secure the flexible receiver element  102  to the flexible insert  104 . This beneficially reduces issues of noise, such as rattling of the flexible insert  104  within the flexible receiver element  102  during vehicle operation. The frangible fasteners  114  may be shear pins of substantially conventional construction. It will be appreciated that the need or desirability of such frangible fasteners  114  may be determined by various physical properties of the applique assembly  100 . For example, applique assemblies  100  defining a short longitudinal length may not require such additional fastening. Likewise, flexible receiver elements  102  and/or flexible inserts  104  that are fabricated of very soft, malleable materials may not create issues of noise even without additional fastening. 
         [0031]    As will be appreciated, the above-described arrangement allows a sliding relationship between the flexible receiver element  102  and the flexible insert  104 . With reference to  FIGS. 2A-2B , the applique assembly  100  is shown attached to a substrate  108 , being a door trim piece attached to a vehicle door structure  116  disposed between a vehicle A pillar  118  and a B-pillar  120 . As shown, the flexible receiver element  102  and flexible insert  104  are strongly and separately attached to the substrate  108  but are otherwise either separate from one another or at most releasably attached to one another by frangible fasteners  114 . On receipt of an oblique side impact from a pole  122 , as the pole intrudes into the door  116  structure the flexible receiver element  102  and flexible insert  104  displace in opposite directions relative to one another (arrows A, B). If present, the optional frangible fasteners  114  will break on application of sufficient tensile and shear stress. Thus, a sliding joint is provided between the flexible receiver element  102  and flexible insert  104 , allowing sufficient relative movement between the two to prevent a break but also preventing separation of the two. 
         [0032]    Contrast this to a prior art applique  124  comprising a bezel  126  and applique plate  128  ( FIG. 2C ). As shown, because the bezel  126  and applique plate  128  are neither flexible nor slidable relative to one another, as the side impacting pole  122  intrudes into the door  116  structure, the applique plate  128  separates from the bezel  126 , presenting a sharp applique plate corner. 
         [0033]    A number of embodiments of sliding joints slidingly connecting the flexible receiver element  102  and the flexible insert  104  are contemplated. With reference to  FIG. 3A-3F , in embodiments the flexible receiver element  102  defines an interior channel  300  within which a substantially planar flexible insert  104  is received. A window  302  is defined in a portion of the flexible receiver element  102  through which the flexible insert  102  may be visualized. The flexible insert  102  is retained by flexible receiver element flanges  304 . 
         [0034]    In an alternative embodiment (see  FIG. 3B ), a flexible insert  104  is provided defining a substantially C-shaped cross-section and including flanges  306  which slidingly engage opposed cooperating flexible receiver element  102  longitudinal slots  308 . 
         [0035]    In another alternative embodiment (see  FIG. 3C ) a flexible insert  104  is provided including a flange  312  defining a substantially T-shaped cross-section which slidingly engages a cooperating flexible receiver element  102  longitudinal slot  310 . 
         [0036]    In yet another alternative embodiment (see  FIG. 3D ) a flexible insert  104  is provided including a flange  312  defining a substantially L- or hook-shaped cross-section which slidingly engages the cooperating flexible receiver element  102  longitudinal slot  310 . The flange  312  may be oriented vehicle-downwardly ( FIG. 3D ) or vehicle-upwardly ( FIG. 3E ). 
         [0037]    In still yet another alternative embodiment (see  FIG. 3F ) a sliding joint is provided by slidably securing a flexible insert  104  to a flexible receiver element  102  by a mechanical fastener  316  which slidingly engages the cooperating flexible receiver element  102  longitudinal slot  310 . Use of any suitable fastener providing a sliding joint arrangement as described is contemplated, including without intending any limitation a nut and bolt, a nut, bolt, and washer, a PALNUT®, a nut, bolt, and lockwasher, a locknut and bolt, and others. 
         [0038]    In yet another alternative embodiment, it is contemplated to provide a composite applique assembly which comprises a sliding joint element, but which also is configured to allow a controlled separation of the flexible receiver element and the flexible insert at need. With reference to  FIGS. 4A-4D , in this embodiment a composite applique assembly  400  comprises a flexible receiver element  402  and a flexible insert  404 . In embodiments, each of the flexible receiver element  402  and flexible insert  404  are manufactured of a suitably flexible material, for example a ductile plastic, wood and metal such as aluminum and stainless steel and any other interior decorative appliques. As will be appreciated, by fabricating each of the flexible receiver element  402  and flexible insert  404  of a flexible material such as ductile plastic, on receipt of an impact the composite applique assembly  400  will bend and flex rather than breaking, reducing the likelihood of producing sharp, jagged edges post-impact. 
         [0039]    The flexible receiver element  402  and flexible insert  404  are each secured to a vehicle element  406 , for example to a vehicle door trim piece, by suitable mechanical fasteners  408 . As shown the flexible receiver element  402  is secured to the vehicle element  406  on an end  410  thereof. In turn, the flexible insert  404  is secured to the vehicle element  406  on an end  412  thereof. As shown, ends  410  and  412  are opposite to one another. Optionally, one or more frangible fasteners (not shown) disposed between the ends  410 ,  412  may secure the flexible receiver element  402  to the flexible insert  404 . As for other embodiments discussed above, the above-described arrangement allows a sliding relationship between the flexible receiver element  402  and the flexible insert  404 . In this embodiment, the sliding joint is defined as a stopped sliding joint by providing a key slot  414  comprising a first slot portion  416  and a second slot portion  418 . As shown, the second slot portion  418  defines a width dimension that is less than a width dimension of the first slot portion  416 . 
         [0040]    As shown in  FIG. 4B , the flexible insert  404  includes a flange  420  which slidingly engages the second slot portion  418 . The depicted embodiment illustrates a flange  420  defining a substantially T-shaped cross-section which slidingly engages the second slot portion  418 . However, it will be appreciated that any suitable flange configuration as described above, including the L-shaped flange embodiments, the C-shaped flange embodiments, and the mechanical fasteners discussed above will serve. 
         [0041]    As shown, the flange  420  is dimensioned to slidingly engage the second slot portion  418  but defines a lesser width dimension than the first slot portion  416 . Accordingly, on separation of the flexible insert  404  and flexible receiver element  402  in opposite directions the flange  420  will retain the sliding joint arrangement as described until the flange reaches the first slot portion  416  of the key slot  414 . At that point, the sliding joint engagement of the flexible receiver element  402  and flexible insert  404  will disengage, and a portion of the flexible insert  404  may separate from the flexible receiver element  402  through the first slot portion  416 . 
         [0042]    Advantageously, this occurs in a controlled manner whereby: a) the risk of the flexible insert  404  having a jagged or sharp edge is minimized because the flexible insert has not been broken along any portion of its length; and b) the separation of the flexible insert from the flexible receiver element  402  is controlled. This is illustrated in  FIGS. 4C-4D  showing the applique assembly  400  attached to a substrate  108 , again being a door trim piece attached to a vehicle door structure  116  disposed between a vehicle A pillar  118  and a B-pillar  120 . As shown ( FIG. 4C ), the flexible receiver element  402  and flexible insert  404  are strongly and separately attached to the substrate  108  but are otherwise either separate from one another or at most releasably attached to one another by frangible fasteners. 
         [0043]    On receipt of an oblique side impact from a pole  122  ( FIG. 4D ), as the pole intrudes into the door  116  structure the flexible receiver element  402  and flexible insert  404  displace in opposite directions relative to one another. When the flexible insert flange  420  reaches the first slot portion  416  as described above (not shown for convenience) a controlled separation of the flexible receiver element  402  and flexible insert  404  is effected, with the separated end  422  being oriented away from a vehicle occupant zone. Moreover, because the flexible insert  404  is sufficiently flexible to separate in a controlled manner rather than breaking due to the impact, the separated end  422  is unlikely to include a sharp or jagged edge. Thus, a stopped sliding joint is provided between the flexible receiver element  402  and flexible insert  404 , allowing sufficient relative sliding movement between the two to assist in preventing a break and, for a sufficiently severe impact, providing for a controlled separation of the two. 
         [0044]    Thus, by the above-described structures and mechanisms, composite applique assemblies for interior vehicle trim and interior trim pieces incorporating such assemblies are provided. The composite applique assemblies are robust, flexible, and meet applicable regulatory, industry, and manufacturer standards for impacts such as the side-pole impact. Advantageously, by the sliding relationship provided by the described sliding joints, the tendency of the applique pieces to present sharp, jagged edges is minimized. The assemblies are easily serviceable, easily adaptable to any vehicle configuration, and provide a high degree of tenability to accommodate various vehicle trim designs. Still more, the assemblies are simple and cost-efficient to manufacture. 
         [0045]    Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.