Abstract:
A trim panel cover tether and method for use with interior trim cover panels or audio speakers grilles. A deformable tether strap is engaged with the trim panel substrate and the cover panel to deter undesirable rattles of the speaker grille and to prevent complete detachment of the cover panel from the trim panel substrate in the event the cover panel is dislodged from the substrate.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to tethers used to secure automotive trim panel covers, for example audio speaker grilles, to trim panels preventing undesired rattling of the grilles and complete detachment of the grilles from the trim panels on dislodgement of the cover. 
       BACKGROUND 
       [0002]    Automotive interior trim panels cover for concealing the sheet metal body structures, wires and other components from view are common in today vehicles. With the ever increasing demand of additional accessories, for example, increased numbers of audio speakers for premium sound systems, additional speaker grilles and other closure panels are required to cover such speakers and accessories. 
         [0003]    Most luxury automobiles include six or more audio speakers which are typically recessed and concealed behind a trim panel through a speaker grille or other closure panel. The speakers are typically recessed in concave cavities molded into the trim panel or are placed in holes through the trim panel and attached to the body structure or other speaker mounting brackets. The speaker grilles typically include locking tabs that snap into the trim panel recesses or other fasteners to keep the speaker grilles in place. 
         [0004]    Due to manufacturing and assembly variances, speaker grilles often, either initially or after vehicle use, have a tendency to rattle or make noise due to the lack of firm and engaging contact with the enjoining trim panel. It may also occur in the assembly or use that one or more of the speaker grille locking tabs may break off or fatigue under heat and stress further allowing the speaker grille to rattle or make other unwanted noises. To deter unwanted squeaks and rattles, pieces of foam tape are currently used between the grille and trim panel which adds cost, assembly time and are of limited effectiveness and duration. 
         [0005]    It is also common that auto manufacturers will use the same basic trim panel for their luxury models as their economy models to reduce the number of different panels to be designed and manufactured. When using the same trim panel in an economy model, it is common for one or more of the speakers included in the luxury models to not be used in an economy model. As the same trim panel is used, the same speaker grille or other closure panel must be used to cover the cavity or hole although an actual speaker is not present. The lack of a physical speaker or other concealed accessory may further add to the tendency of the speaker grille or closure panel to rattle or squeak on initial installation or at some point during the long life of the vehicle. 
         [0006]    In addition, with the ever growing need of safety features in vehicles, auto manufacturers strive to ensure that snap on accessories and covers, for example, speaker grilles and other closure panels remain in place during vehicle impacts or deployment of safety airbags to prevent them from entering the passenger compartment. 
       SUMMARY 
       [0007]    It would be desirable to provide a trim panel cover tether which reduces the likelihood of the trim closure panels or covers from rattling and squeaking during the life of a vehicle. It is further desirable to provide a trim panel cover tether that prevents complete detachment of the closure panel from the trim panel in the event of an impact or other event that may dislodge the closure panel from the trim panel. It is further desirable to provide a tether which accomplishes both the above objectives which is inexpensive, easy to install and is durable in use. 
         [0008]    In one embodiment of the invention, a tether strap is used to secure a closure panel to a trim panel substrate. The tether includes a flexible, deformable strap having a first end attached to a trim panel substrate, a second end attached to a closure panel and a middle portion between the ends. On installation of the closure panel to the substrate, the strap is deformed in one or more bends in the middle portion. On complete installation of the closure panel to the substrate, the deformed and compressed strap exerts a compressive force against the closure panel thereby resisting movement of the closure panel with respect to the substrate. In the event that the closure panel is dislodged from the substrate, the tether on dissipation of the bends in the middle portion is stretched and exerts a tension force toward the substrate preventing the closure panel from completely detaching from the substrate and thereby entering the passenger compartment. 
         [0009]    In an alternate embodiment, the strap is, semi-rigid and integrally molded into the closure panel and engages the substrate providing the compressive force against the closure panel resisting relative movement. 
         [0010]    In an alternate embodiment, the flexible, deformable strap is compressed through several bends in the middle portion of the strap about rotational axes between the first and second ends to provide the compressive force desired and to accommodate the available space between the closure panel and the substrate. 
         [0011]    Other applications of the present invention will become apparent to those skilled in the field when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The description herein makes reference to the accompanying drawing wherein like reference numerals refer to like parts throughout the several views and wherein: 
           [0013]      FIG. 1  is an isometric view of the tether in an uninstalled and underformed state; 
           [0014]      FIG. 2  is a schematic sectional view showing the tether installed with a closure panel in a trim panel cavity; 
           [0015]      FIG. 3  is schematic sectional view of another embodiment of the installed tether deformed in two bends; 
           [0016]      FIG. 4  is a schematic sectional view of another embodiment showing the tether installed in a closure panel having a through hole; 
           [0017]      FIG. 5  is a schematic sectional view of another embodiment showing the tether installed with a closure panel with the strap engaged to a side wall of the substrate; 
           [0018]      FIG. 6  is schematic sectional view of another embodiment of the tether installed with an alternate closure panel in a substrate cavity; 
           [0019]      FIG. 7  is a schematic sectional view of an alternate embodiment of the tether as a semi-rigid part of the closure panel; and 
           [0020]      FIG. 8  is a schematic sectional view of the installed tether in a non-deformed state when the closure panel is dislodged from the substrate. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Referring to  FIGS. 1-8 , several embodiments of the trim panel tether and method are illustrated. The tether is useful in securing a trim closure panel, for example an automotive speaker grille, to an automotive trim panel or other vehicle structure. The tether is particularly useful in deterring the speaker grille or other closure panel from rattling or squeaking in use. The tether is further useful in preventing complete detachment of the speaker grille from the trim panel. 
         [0022]    Referring to  FIG. 1 , tether  10  includes elongate strap  20  having a first end  22 , a second end  24  and a middle portion  30  positioned between the first  22  and second  24  ends. In a preferred embodiment, strap  20 , first end  22  and second end  24  are generally rounded as shown in  FIG. 1  and include a first hole  32  and a second hole  34  positioned adjacent the respective ends. Strap  20  includes a first linear length  36  generally defined between the center lines of first hole  32  and second hole  34 . In a preferred embodiment, the first linear length is approximately 2½ inches (63.5 mm) and approximately 1/16 inches (1.5875 mm) in thickness. Tether strap  12  may be manufactured from a flexible elastomer, a polymer such as polypropylene, other polymers, thin metal and other materials known by those skilled in the art. It is understood that other sizes, shapes thicknesses and configurations may be used without deviating from the present invention. 
         [0023]    Strap  20  is engaged with trim panel substrate  14  generally shown in  FIGS. 2-8 . In a preferred embodiment, trim panel substrate  14  includes a cavity  16  defined by side walls  26  and a lower wall  28  whereby strap  20  first end  22  engages substrate  14  at lower wall  28 . In a preferred embodiment, first end  22  is mechanically fastened to substrate  14  by a fastener  38 . In a preferred embodiment, fastener  38  is integrally molded into substrate  14  and engages strap  20  through hole  32 . In an alternate embodiment, for example as shown in  FIG. 8 , conventional fasteners such as screws, plastic push clips and other fasteners known by those skilled in the art may be used with deviating from the invention. 
         [0024]    Strap  20  second end  24  is similarly engaged with a trim closure panel  12 , for example, an automotive audio speaker grille, as generally shown  FIG. 2-8 . In a preferred embodiment, strap  20  is mechanically secured to closure panel  12  through a fastener  38  as described for the first end  22 . It is understood that the methods of engaging the first end  22  and second end  24  may vary from each other depending on the application. 
         [0025]    Referring to  FIGS. 2-8 , following attachment of strap  20  to substrate  14  and closure panel  12 , during installation of trim closure panel  12  to substrate  14 , tether strap  20  is compressed and deformed into a generally “U” or reverse “C” shape as generally shown in  FIG. 2 . Through such physical compression and deformation of strap  20  and the flexible and elastic properties of strap  20 , a compressive force C in the general direction along a first linear axis  46 , is exerted by strap  20  against closure panel  12 . When closure panel  12  is in the installed position, for example as shown abutting substrate  14 , closure panel  12  is removeably secured by screws, clips or other devices (not shown). In a typical installation, integral closure panel tabs  62  are used as generally shown in  FIG. 6 . 
         [0026]    The compressive force C produced by strap  20  in an outward direction generally along the first linear axis  46  places a substantially constant outward force on closure panel  12  thereby resisting relative movement of closure panel  12  with respect to substrate  14  thereby reducing squeaks, rattles and other unwanted noise or vibration caused by a loose or loosened condition of the closure panel  12  from substrate  14 . 
         [0027]    In an alternate embodiment to the “U” or reverse “C” shape of strap  12  in  FIG. 2 ,  FIGS. 3-6  show different configurations for the installed strap  20 . In these different configurations, strap  20  linear length  36  is of length such that strap  20  maybe deformed and compressed into a generally “Z” configuration. In these embodiments, a first bend  40  and an opposing second bend  50  are imparted to middle portion  30  generally about a first rotational axis  42  and second rotational axis  52  respectively. As also shown in  FIG. 6 , closure panel  12  may include locking tabs  62  extending from closure panel  12  including first locking members  66  at distal ends thereof On installation of closure panel  12  to substrate  14 , locking tab  62  and first locking member  66  on installation, lockingly engage second locking members  70  and substrate  14  as generally shown. On installation of closure panel  12 , strap  20  similarly exerts a compressive force C against a first surface  60  of closure panel  12  forcing first locking member  66  into contact with second locking member  70  or in the alternative, provides an increasing engagement force if already in contact, to resist relative movement between closure panel  12  and trim panel  14  reducing or eliminating squeaks, rattles and other unwanted noises and vibrations. 
         [0028]    Referring to  FIG. 4 , in an alternate embodiment, panel substrate  14  does not include a closed cavity  16  having a bottom wall  28 . In this embodiment, there is a through hole in trim panel  14  with sidewalls  26 . In this embodiment, strap  20  first end  22  is engaged with vehicle body structure  18 , for example, vehicle body sheet metal, other adjacent trim substrate or brackets. Similar to the other embodiments, first end  22  is preferably mechanically secured by a integral locking fastener  38  or traditional mechanical fasteners such as screws, clips and other fasteners known to those skilled in the art. It is understood that side walls  26  could also be removed leaving an unflanged opening in substrate  14 . 
         [0029]    Referring to  FIG. 5 , in an alternate embodiment, substrate  14  does not include a closed cavity  16  as previously described, but includes a through hole having side walls  26  as generally shown. First end  22  is similarly engaged with a sidewall  26  as previously described and illustrated. 
         [0030]    Referring to  FIG. 7 , an alternate embodiment of tether  10  is illustrated. In this embodiment, strap  20  is a semi-rigid strap extending from the first surface  60  of closure panel  12  down to first end  22 . On engagement of strap  20  to substrate  14  and installation of closure panel  12  to substrate  14 , compressive force C is generated in upward direction against closure panel  12  to resist relative movement between closure panel  12  and substrate  14  as previously described. In a preferred aspect of this embodiment, strap  20  is integrally molded into closure panel  12  as shown. It is understood that a separate strap  20  can be engaged or attached to closure panel  12  and substrate  14  as previously described. It is further understood that different shapes and configurations of strap  20  may be used other than a generally straight, diagonal shape as shown without departing from the invention. It is further understood that the various details and configurations shown in  FIGS. 2-7  can be interchanged and used without deviating from the invention. 
         [0031]    Referring to  FIG. 8 , on dislodgement or separation of closure panel  12  from substrate  14 , closure panel  12  would typically fall away or project from its normally engaged position adjacent to substrate  14 . This is particularly the case if a significant impact in the area adjacent the closure panel  12  forceably dislodges and projects closure panel  12  away from substrate  14 . As shown, as closure panel  12  is displaced or projected in a direction generally along first linear axis  46  generally away from substrate  14 , strap  20  begins to elongate across middle portion  30  dissipating or removing the bend or bends and potential energy as closure panel  12  moves away from substrate  14 . When middle portion  30  reaches its first linear length  36  as a straight line as illustrated, and attempts to move beyond first linear length  36 , tether strap  20  exerts a tension force T in the general direction shown toward first end  22  to prevent further linear displacement of closure panel  12  away from substrate  14 . This tethered or restrained condition of closure panel  12  relative to substrate  1   4  prevents complete detachment and unwanted displacement or projection of closure panel  12  into the passenger compartment or another undesirable area. Continued attachment of closure panel  12  to substrate  14  further provides ease in re-engaging closure panel  12  to substrate  14  as closure panel  12  remains in close proximity to its original engagement position to cover cavity  16 . 
         [0032]    A method of securing the closure panel  12  to trim panel substrate  14  using the inventive tether  10  proceeds as follows. An elongate deformable tether strap  20  as previously described having a first end  22 , a second end  24  and a middle portion  30  is provided. In a preferred method of use, tether strap  20  is positioned in cavity  16  formed in a trim panel substrate  14 . First end  22  is engaged with substrate  14  and second end  24  is engaged with surface  60  on the underside of closure panel  12 . On approaching the installed or removable locking position of closure panel  12  to substrate  14 , strap  20  middle portion  30  is deformed and compressed producing one or more bends or curvatures in middle portion  30 . The physical deformation and compression configuration of strap  20 , and the resilent and elastic properties of the strap  20  produce a compressive force C in a direction generally away from first end  22  along first linear axis  46  against closure panel  12 . In the installed position of closure panel  12  to substrate  14 , compressive force C exerts a substantially constant compressive force thereby resisting relative movement of closure panel  12  with respect to substrate  14  to deter or eliminate squeaks, rattles or other undesirable vibrations between closure panel  12  and substrate  14 . 
         [0033]    On dislodgement of closure panel  12  from its installed position in substrate  14 , as closure panel  12  moves away from substrate  14 , strap  20  extends to its first linear length  36 . Any further movement of closure panel  12  away from substrate  14  beyond first linear length  36  produces a tension force T in a general direction toward first end  22  thereby preventing complete detachment of closure panel  12  from substrate  14 . 
         [0034]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the preferred embodiment but, on the contrary, it intended to cover various embodiments, modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures.