Datum pin assembly

A system and method for assembling a door to a motor vehicle is disclosed including a bracket assembly that includes a bracket having a first pair of holes and a second pair of holes, and weld nuts welded to the bracket, the weld nuts being aligned with the first pair of holes. The system further includes an alignment piece having first and second alignment holes, the first alignment hole corresponding to a first of the second pair of holes of the bracket, the second alignment hole corresponding to a second of the second pair of holes of the bracket, datum pins inserted through the first and second alignment holes and the second pair of holes in the bracket, and a roller assembly fixedly attached to the bracket.

TECHNICAL FIELD

The embodiments described herein are directed to brackets and the assembly thereof used for doors of motor vehicles.

BACKGROUND

For sliding doors for a motor vehicle, a bracket is attached to the door to locate a center roller assembly that sits in a rail attached to the body. The bracket supports approximately 25% of the door weight. The door bracket mating structure is welded into the door to receive the roller assembly.

In the past, alignment of the roller assembly with the door bracket was achieved using a jig. The bracket was provided with datum holes for receiving alignment pins from the jig. Additional alignment pins from the jig were inserted into receptacles in the inner panel of the door to align bolt holes on the bracket with bolt holes in the inner panel. The bolt holes on the bracket were oversized to allow for proper alignment of the bracket. The bracket was then bolted to the door panel, and the jig was removed.

However, design considerations may make complicate or prohibit the use of a jig. Therefore, there is a need for an improved alignment system for installing a roller assembly to the door panel that does not require a jig.

APPLICATION SUMMARY

According to one aspect, a system for assembling a door for a motor vehicle includes a bracket assembly. The bracket assembly includes a bracket, the bracket having a first fastener hole and a second fastener hole and a first pin hole and a second pin hole, and a pair of fasteners welded to the bracket, the fasteners being aligned with the first and second fastener holes. The system further includes an alignment piece positioned on a first side of the bracket, the alignment piece having a first alignment hole and a second alignment hole corresponding to the first and second pin holes of the bracket, a first datum pin inserted through the first alignment hole and the first pin hole in the bracket, a second datum pin inserted through the second alignment hole and the second pin hole in the bracket, and a roller assembly positioned on a second side of the bracket that receives the first and second datum pins and is attached to the bracket assembly.

According to another aspect, a method for assembling a roller assembly to a door for a motor vehicle includes the steps of assembling a bracket assembly, the bracket assembly having a first fastener hole, a second fastener hole, a first pin hole, a second pin hole, and fasteners welded to the bracket assembly, the fasteners being aligned with the first and second fastener holes, assembling an alignment piece, the alignment piece having first and second alignment holes, the first alignment hole corresponding to the first pin holes of the bracket assembly, the second alignment hole corresponding to the second pin hole of the bracket assembly, inserting datum pins through the first and second alignment holes and the second pair of holes in the bracket, and attaching the roller assembly to the bracket assembly.

According to yet another aspect, a bracket assembly for a sliding door of a motor vehicle includes a door panel comprising a first side and a second side, the door panel defining a first hole and a second hole there through, a bracket including a fastener receiving member, the bracket is fixedly secured to the first side of the door panel with the fastener receiving member aligned with the second hole of the door panel to receive a roller assembly fastener installable through the second hole of the door panel from the second side of the door panel, and a datum pin movably secured to the bracket, the datum pin includes a first end that extends outward from the bracket through the first hole of the door panel to the second side of the door panel, the datum pin is movable from the second side of the door panel along the door panel with respect to the second hole of the door panel.

DETAILED DESCRIPTION

FIGS. 1 and 2show a side view of a motor vehicle100with a sliding door102.FIG. 1shows the sliding door102in a closed position, andFIG. 2shows the sliding door102in the open position, thereby providing entry to a second row of seats200.

FIG. 3shows a transparent perspective view of a sliding door102. The sliding door102includes a roller assembly300that is fixedly attached to the sliding door102and rolls within a slide rail302located in the rear side panel104of the motor vehicle.FIG. 4illustrates a close-up view of the roller assembly300. The roller assembly300includes a generally L-shaped roller bracket400. A first surface402of the roller bracket400is fixedly attached to the sliding door102by two fasteners404, preferably bolts, or any other suitable fasteners, including, but not limited to rivets, screws, and the like. Extending from a second surface406of the roller bracket400are rollers408that permit longitudinal movement of the roller bracket400within the slide rail302as the sliding door102moves from a closed position to an open position, and from the open position to the closed position.

With regards toFIGS. 5-10, the system and method for attaching the roller assembly300to the sliding door102are discussed below.

FIG. 5shows an outer side502of a door panel500of the sliding door102with the outer body sheet metal106removed. The roller assembly300is fixedly attached to the inner side602of the door panel500of the sliding door102, which is illustrated inFIG. 6prior to assembly of the roller assembly300. The door panel500includes one pair of weld nut holes604and one pair of datum pin holes606.

With continuing reference toFIG. 5, a bracket assembly504is attached to the outer side502of the door panel500. The bracket assembly504is attached to the outer side502of the door panel500by welding, mechanical fasteners, adhesives, or by any other suitable method known to one skilled in the art. The bracket assembly504includes a pair of bracket weld nut holes704, shown in the exploded view illustrated inFIG. 7, that correspond with the weld nut holes604of the door panel500. Further, the bracket assembly504includes a pair of bracket datum pin holes706that correspond with the pair of datum pin holes606in the door panel500. The bracket datum pin holes706are each located in an embossed region710. The bracket assembly504does not contact the outer side502of the door panel500in the embossed region710. In the embodiments described herein, as illustrated inFIG. 13, the bracket datum pin holes706are substantially square-shaped to manage the adjustment of the datum pins800, illustrated and discussed in further detail with respect toFIG. 8.

The bracket assembly504also includes a pair of fasteners708, such as weld nuts, that correspond with the weld nut holes604and bracket weld nut holes704. The fasteners708are attached to the bracket assembly504by welding or any other suitable method, which may include physical attachment, being integrated within the bracket assembly504, adhesives, or any other suitable method known to one skilled in the art.

FIG. 8shows an exploded view of the bracket assembly504and the installation of a pair of datum pins800and an alignment piece802for receiving the datum pins800. The alignment piece802is substantially flat and dogbone-shaped, with two rounded ends804located on opposite ends of a central portion805. The alignment piece802includes a pair of alignment datum holes806, each of which includes a receiver808for receiving one of the datum pins800. The bracket assembly504include a number of raised ridges820of varying

As illustrated inFIGS. 8-9 and 11, the pair of datum pins800include a flange810that extends radially outward from a central portion812of each of the datum pins800. A first end814of each of the datum pins800is designed to be received by each of the receivers808of the alignment piece802. The first end814of each of the datum pins800may be threaded for insertion, from the inner side602of the door panel500, through the datum pin holes606, the bracket datum pin holes706, and the alignment datum holes806into one of the receivers808, which also includes an internally threaded hole818. In the embodiment illustrated inFIG. 11, The first end814of each the datum pins, adjacent the flange810, has a threaded region1100, which has a diameter d1and a no thread region1102, which has a diameter d2that is less than diameter d1. The reduced diameter d2of the no thread region1102ensures that the no thread region1102freely rotates within the receiver808.

In a further embodiment, illustrated inFIG. 11-12, each of the datum pins800may include a clip region1200, located in the no thread region1102of the first end814of each of the datum pins800. The clip region has a diameter d3, which is less than diameter d2. A clip1202, such as a so-called E-clip, may be located in the clip region as illustrated in theFIG. 11. The clip1202is generally semi-circular in shape with a central rib1204, which abuts the clip region1200. The clip1202is fixedly secured to the clip region1200by an interference fit caused by the ends1206,1208being spread apart as the clip1202is inserted around the clip region1200and returning to a resting position upon completion of the installation process. In the installed position, the clip1202has a diameter d4greater than diameter d5of each of the threaded holes818of the receivers808.

A second end816of each of the datum pins800has a hexagonal or six-lobe wrench portion820, which enables the datum pins800to be rotated by a socket-type tool (not shown), and a datum portion822, for holding the roller assembly300during installation.

The flange810has a diameter d6that is less than the diameter d7of the datum pin holes606, and thus passes on to the outer side502of the door panel500. The diameter d6is, however, greater than either the heighth h1or width w1of the bracket datum pin holes706ensuring that the flange810of the datum pins800will remain in the area1210between the outer side502of the door panel500and the embossed region710of the bracket assembly504when the datum pins800are inserted into and engaged with the receivers808of the alignment piece802, which are located on the outside502of the door panel500.

As illustrated inFIG. 9, with the flange810preventing datum pins800inserted into the receivers808of the alignment piece802from passing completely through the datum pin holes606, the datum pins800may be moved in either the x or y directions, as depicted inFIG. 9. The alignment piece802, into which the datum pins800are inserted, ensure the datum pins800maintain a constant distance x1from one another. While the datum pins800are tightened when inserted into the receivers808, they are preferably not tightened completely to allow freedom of the movement of the datum pins800and the alignment piece802until the final position of the datum pins800is determined, at which point they may be tightened to create a friction fit that prevents motion of the datum pins800. The final position of the datum pins800may be determined using a jig during the assembly process, or by any other method known to those skilled in the art.

FIG. 10is an exploded view illustrating the assembly of the first surface402of the roller bracket400of the roller assembly300to the inside602of the door panel500. Datum pin alignment holes1000in the first surface402corresponding with each of the datum pins800are aligned, and the first surface402of the roller bracket is moved into engagement with the inner surface602of the door panel500. The datum pins800are inserted into datum pin alignment holes1000. Weld nut bracket holes1004are aligned with the weld nut holes604in the door panel500. The final step of installation is to insert fasteners404through the weld nut bracket holes1004, the weld nut holes604, the bracket weld nut holes704, and into the fasteners708. The fasteners404illustrated inFIG. 10are bolts, but other types of mechanical fasteners may be used such as rivets, screws, and the like. The fasteners404are tightened to complete installation.

In addition, the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the embodiments is intended to be illustrative, but not limiting, of the scope of the embodiments, which is set forth in the claims.

While particular embodiments and applications have been illustrated and described herein, it is to be understood that the embodiments are not limited to the precise construction and components disclosed herein and that various modifications, changes, and variations may be made in the arrangement, operation, and details of the methods and apparatuses of the embodiments without departing from the spirit and scope of the embodiments as defined in the appended claims.