Vehicle components including rib receiving channels for receiving alignment ribs of vehicle panels

A method of installing a vehicle component to a vehicle panel is provided. The method includes aligning a rib receiving channel of the vehicle component with an alignment rib that is formed integrally with the vehicle panel while also aligning a fastening opening of the vehicle component with a fastening opening through the vehicle panel. The alignment rib is inserted into the rib receiving channel. A fastener is inserted through the fastening openings of the vehicle component and the vehicle panel. The fastener is tightened while the alignment rib and rib receiving channel inhibit rotation of the vehicle component.

TECHNICAL FIELD

The present specification generally relates to installation of vehicle components on vehicle panels, and more specifically, installation of vehicle components that include rib receiving channels for receiving alignment ribs of vehicle panels for inhibiting rotation of the vehicle components during an installation operation.

BACKGROUND

Vehicles have a number of components that are attached to vehicle panels during assembly of the vehicles. For example, brackets may be connected to a shut face panel of a vehicle door assembly. These brackets may be used to align the vehicle door assemblies as the vehicle door assemblies are moved from an open position to a closed position. Installation of these brackets can be somewhat cumbersome, particularly for brackets that have multiple fastening locations. In some installation operations, for example, the installer may loosely tighten one fastener at one installation location, leave that installation location and move to a next installation location to tighten another fastener, only to return to the first fastener to complete tightening. The first fastening location is left loose so that the second fastening location can be aligned to the desired location of the shut face panel.

Accordingly, a need exists for vehicle components that include rib receiving channels for receiving alignment ribs of vehicle panels for inhibiting rotation of the vehicle components during an installation operation.

SUMMARY

In one embodiment, a method of installing a vehicle component to a vehicle panel is provided. The method includes aligning a rib receiving channel of the vehicle component with an alignment rib that is formed integrally with the vehicle panel while also aligning a fastening opening of the vehicle component with a fastening opening through the vehicle panel. The alignment rib is inserted into the rib receiving channel. A fastener is inserted through the fastening openings of the vehicle component and the vehicle panel. The fastener is tightened while the alignment rib and rib receiving channel inhibit rotation of the vehicle component.

In another embodiment, a vehicle includes a vehicle door assembly including an outer panel and an inner panel connected to the outer panel. A shut face panel spans a gap between the outer panel and the inner panel. The shut face panel includes an alignment rib that is formed integrally with the shut face panel. A stopper component is mounted to the shut face panel using a fastening opening that extends through the shut face panel. The stopper component includes a fastening opening that is aligned with the fastening opening of the shut face panel. The stopper component comprising a rib receiving channel receiving the alignment rib.

DETAILED DESCRIPTION

Vehicles according to the present specification include vehicle panels that include integrally formed alignment ribs that inhibit rotation of vehicle components when fastened to the vehicle panels. The alignment ribs may be formed of material that forms the vehicle panel, such as by integrally molding the alignment ribs during formation of the vehicle panels. The alignment ribs can be formed to be received within rib receiving channels that are provided within the vehicle components. The rib receiving channels may be provided on a panel facing side of the vehicle components. The rib receiving channels and the alignment ribs can be used to inhibit rotation of the vehicle components during fastening of the vehicle components to the vehicle panels. The rib receiving channels and the alignment ribs can also be used to align the vehicle components in a desired orientation during the installation operation and reduce a number of steps needed to complete installation of the vehicle components.

As used herein, the term “vehicle longitudinal direction” refers to the forward-rearward direction of the vehicle (i.e., in the +/−vehicle X-direction depicted inFIG. 1). The term “vehicle lateral direction” refers to the cross-vehicle direction (i.e., in the +/− vehicle Y-direction depicted inFIG. 1), and is transverse to the vehicle longitudinal direction. The term “vehicle vertical direction” refers to the upward-downward direction of the vehicle (i.e., in the +/− vehicle Z-direction depicted inFIG. 1). Further, the terms “inboard,” “inward,” “outboard” and “outward” are used to describe the relative positioning of various components of the vehicle. Because the vehicle structures may be generally symmetrical about the vehicle centerline, the direction to which use of terms “inboard,” “inward,” “outboard” and “outward” refer may be mirrored about the vehicle centerline when evaluating components positioned along opposite sides of the vehicle10.

The vehicle10includes a vehicle body12including a body framework and having a front16, a rear18and sides20that extend between the front16and the rear18. The vehicle10includes a rear end assembly22at the rear18of the vehicle body12. The rear end assembly22includes a vehicle door assembly24that is rotatably connected to the vehicle body12using hinges26.

Motor vehicles that incorporate elements according to the present disclosure may include a variety of construction methodologies that are conventionally known, including a unibody construction methodology as well as a body-on-frame construction methodology. Furthermore, the Figures may only show one side of the vehicle. Descriptions of the other side of the vehicle may be omitted because both sides of the vehicle may be laterally symmetrical and substantially the same.

Referring also toFIG. 2, the vehicle door assembly24includes an outer panel28and an inner panel30that is spaced from the outer panel28in the vehicle longitudinal direction with the vehicle door assembly24in a closed position. A shut face panel32extends between the outer panel28and the inner panel30at a side34of the vehicle door assembly24. The shut face panel32may be a monolithic and integrally formed part of the inner panel30and may be formed of a plastic material, such as by molding the shut face panel32.

Referring toFIG. 3, a stopper component34includes a stopper body36and flanges38and40that extend outward from the stopper body36at opposite sides42and44. In some embodiments, the stopper body36may be formed of an elastic material, such as a plastic or rubber. The flanges38and40may be formed of a different material, such as a metal and have fastening openings46and48extending therethrough to provide fastening locations where the stopper component34can be fastened to the shut face panel32. In some embodiments, the flanges38and40are provided by a bracket50having a somewhat curved body52onto which the stopper body36is provided. For example, the stopper body36may be overmolded onto the curved body52. In other embodiments, the stopper body36may be adhered onto the curved body52. As can be seen the stopper body36provides the stopper component34with an increased thickness that mates with a corresponding stopper component54located on a shut face panel56of the vehicle body12(FIG. 1). The stopper body36provides alignment of the vehicle door assembly24as it returns to a closed position, while also providing damping to reduce shock as the vehicle door assembly24closes against the vehicle body12.

Referring toFIG. 4, an alignment rib60is provided on the shut face panel32. In particular, the alignment rib60is integrally formed with the shut face panel32such that the alignment rib60extends outwardly from a surface62of the shut face panel32in the vehicle lateral direction. In the illustrated embodiment, the alignment rib60is box-shaped having opposite ends64and66, sides68and70and a face72that extends between the opposite ends64and66. While the alignment rib60is illustrated as being box-shaped, the alignment rib may have other profiles, such as rounded. Further, the alignment rib60is illustrated as having a length L that is of a greater dimension than a width W of the alignment rib60providing an elongated shape that extends between edges74and76of the shut face panel32. In some embodiments, the alignment rib60could be formed with a connector feature that can be used to connect other components, such as cross rib.

Referring toFIG. 5, the stopper component34includes the stopper body36having an outboard side75facing away from the shut face panel32and an inboard side77that faces toward the shut face panel32. In the example ofFIG. 5, the stopper body36is generally hollow and includes side walls84and86and end walls88and90. Support walls92and94extend between the side walls84and86and are located within the stopper body36. Each support wall92and94includes a respective notch96and98forming a rib receiving channel100. While multiple notches96and98are illustrated, a single, elongated notch may form the rib receiving channel. The rib receiving channel100is sized and arranged to receive the alignment rib60in both the notches96and98and orients the stopper component34including the fastening openings46and48with fastening openings80and82(FIG. 4). The sectional shape of the notches96and98can correspond to the sectional shape of the alignment rib60. In other embodiments, the sectional shape of the notches may be different than the sectional shape of the alignment rib. In some embodiments, the stopper body36may be formed from a single piece of material, such as by molding, and the notches may be formed during that process or by a different process such as by machining the notches96and98into the support walls92and94.

Referring toFIG. 6, during an installation operation, the rib receiving channel100is aligned with the alignment rib60such that the notches96and98receive the alignment rib60at step102. By aligning the rib receiving channel100with the alignment rib60, the fastening openings46and48of the flanges38and40are also aligned with fastening openings80and82formed through the shut face panel32at step104. A first fastener may be inserted through the fastening openings46and80at step106. At step108, the orientation of the stopper component34is supported by the alignment rib60as the first fastener is completely tightened. A second fastener may then be inserted through the fastening openings48and82at step110and completely tightened thereby installing the stopper component34to the shut face panel32.

The above-described vehicle panels with integrally formed alignment ribs can provide a datum location for positioning of a vehicle component as the vehicle component is being installed to the vehicle panels. The alignment ribs may be formed as a monolithic part of the vehicle panels, which can little cost and mass to the vehicle panels. In some embodiments, the alignment ribs have a thickness that is substantially the same as the surrounding vehicle panel thickness (i.e., the alignment rib may be hollow), which can provide the reduced mass compared to a solid alignment rib. The vehicle component receives the alignment rib within a rib receiving channel so that the alignment rib inhibits rotation of the vehicle component as a fastener is being tightened. The alignment rib and rib receiving channel can reduce a number of steps to install the vehicle component, particularly when there is multiple fastening locations. While two fastening openings are illustrated, there may be only one fastening opening.