System for attaching components to a vehicle

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.

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'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.

DETAILED DESCRIPTION

FIG. 1shows a view in section of a prior art plastic component10, such as cladding, assembled to a body panel12of a vehicle. Component10includes a molded-in fastener housing14having a fastener aperture16, into which a fastener18is installed. Fastener18is coupled to a mounting aperture20of body panel12, thus securing component10to the body panel. This assembly system suffers from several shortcomings. First, as can be seen inFIG. 1, the molding process utilized to form the fastener housing14often results in depressions or irregularities such as sink marks22. The sink marks22are caused by variations in the flow of molten plastic material in the mold used to form component10, and by uneven heating and cooling in the mold. These flaws often appear on an exterior surface24of component10, detracting from the esthetics of the component.

Another drawback of the assembly ofFIG. 1is that the component10is rigidly attached to body panel12by fastener18. Since plastic component18and metal body panel12have 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 inFIGS. 2 through 6. The general arrangement of the system is shown inFIGS. 2,3and4wherein a component30is assembled to a metal bracket32. Bracket32includes one or more fasteners34coupled thereto for attaching the assembled component and metal bracket assembly to a substrate such as a vehicle body36.

Component30may 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. Component30may further include one or more alignment apertures44and one or more lips40, as shown inFIGS. 2-6. Component30may 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. Component30may also be molded from plastic having a desired color. In some embodiments component30may be made from other materials such as carbon fiber composites or metal.

With continued reference toFIGS. 2-6viewed in combination, bracket32is a generally planar strip extending longitudinally and having a length generally corresponding to the length of component30. Bracket32further includes one or more tabs42, alignment elements38and flanges46. Tabs42extend generally perpendicularly from bracket32toward vehicle body36, while flanges46are generally parallel to the bracket. Bracket32further includes at least one fastener aperture48to which fastener34is coupled. Bracket32is 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. Bracket32may be finished by any suitable coating or plating process to protect it from the environmental elements.

Fastener34may be any conventional type of fastener suitable for use with component10, bracket32and vehicle body36. Examples include, without limitation, plastic or metal clips, push-in fasteners, rivets, bolts, screws and lugs.

With reference toFIGS. 2-4, component30is coupled to bracket32by first attaching fasteners34to fastener apertures48such that the fasteners extend generally perpendicular to the bracket. Component30and bracket32are then assembled together by engaging alignment elements38with corresponding alignment apertures44and then sliding the bracket underneath lip40. In this position flanges46are proximate component30and the flanges are in contact with the component, effectively wedging a portion of the bracket into a gap50formed by the component and lip40.

Referring now toFIGS. 5 and 6, the assembled component30and bracket32are attached to vehicle36by first aligning fasteners34with corresponding mounting receptacles52on the vehicle and then engaging the fasteners to the receptacles. Component30is then pressed into place such that it moves downwardly in relation to bracket32, causing the alignment elements38to disengage from alignment apertures44by moving away from the apertures and allowing lip40to come into contact with tabs42. In the installed condition tabs42support the weight of component30, which rests thereupon.

Once alignment elements38are disengaged from alignment apertures44lip40is able to move longitudinally along corresponding tab42, thereby allowing component30to expand and contract with changes in temperature without binding or distorting the component's shape or surface. Likewise, interior surface54of component30is able to slide longitudinally along flanges46. Despite this freedom of movement, component30is otherwise rigidly attached to vehicle body36by bracket32and fasteners34.

A friction reducing element56may optionally be attached to flanges46to aid in decreasing friction between bracket30and component32as well as protecting the component from deformation caused by contact with the bracket. A contact area58between component30and bracket32may also include a friction reducing element56to assist in reducing friction and wear between the component and the bracket. Friction reducing element56may 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 component30to vehicle body36is accomplished entirely through the use of bracket32and interference to movement of the component via the bracket and the vehicle body after installation. Accordingly, component30may have a superior exterior surface without the undesirable slide marks or sink marks. The present invention also provides for a rigid attachment of component30to vehicle body36while 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 brackets32may be used in connection with a component30. Likewise, a plurality of components30may be assembled to a single bracket32and a plurality of components may be assembled with a plurality of brackets. In still other embodiments bracket32may comprise one or more curved portions, such as to correspond to contours of vehicle body36instead 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.