Vehicle component support structure

A panel of a vehicle body structure has a first slot and a second slot spaced apart from one another. A component has a mounting structure that includes a first tab and a second tab spaced apart from the first tab. A first head of the first tab is inserted through a wide second end of the first slot and the second head of the second tab is inserted through a wide second end of the second slot. The first tab and the second tab thereafter moved to a corresponding one of respective narrow first ends of the first and second slots. Consequently, the first head of the first tab rests on a first upper surface portion of a first area of the panel and the second head rests on a third upper surface portion of a second area of the panel thereby suspending the component from the panel.

BACKGROUND

1. Field of the Invention

The present invention generally relates to vehicle component support structure. More specifically, the present invention relates to horizontally oriented panel configured to temporarily support a component prior to fasteners being subsequently attached to the component to fixedly attach the component to the panel within the vehicle.

2. Background Information

During the assembling process of a vehicle, various components must be held in place adjacent to a vehicle body structure while fasteners are installed to the component and/or the vehicle body structure in order to fixedly attach the component to the vehicle body structure. During the assembly processes, a robotic apparatus can hold the component in position while the fasteners are being installed. In other assembly processes, a technician holds the component in position and either that same technician or another technician installs the fasteners.

SUMMARY

One object of the disclosure is to provide a panel of a vehicle body structure with features that temporarily retain component in a position that allows for fasteners to be installed to fix the component to the panel without the use of a separate component positioning mechanism.

In view of the state of the known technology, one aspect of the present disclosure is to provide a vehicle component support structure with a vehicle body structure and a component. The vehicle body structure includes a horizontally oriented panel rigidly supported within the vehicle body structure. The panel has an upper surface and a lower surface. A first area of the panel defines a first slot and a second area of the panel spaced apart from the first area defines a second slot. Each of the first and second slots extend from the upper surface to the lower surface of the panel. A first end of the first slot has a first width measured perpendicular to a length of the first slot and a second end of the first slot has a second width that is greater than the first width. The first end of the second slot has a third width and a second end of the second slot has a fourth width greater than the third width. The first area of the panel defines a first upper surface portion at the first end of the first slot and second upper surface portions at either side of the first slot at a location spaced apart from the first end of the first slot. The second upper surface portions are located vertically higher above the first upper surface portion. The second area of the panel defines a third upper surface portion at the first end of the second slot. The component has a main body and a mounting structure. The mounting structure includes a first tab and a second tab spaced apart from the first tab by a distance corresponding to a distance between the first slot and the second slot. The first tab includes a first shaft portion and a first head that is wider than the first shaft portion. The second tab includes a second shaft portion and a second head that is wider than the second shaft portion. The first head of the first tab is inserted through the second end of the first slot, the second head of the second tab is inserted through the second end of the second slot, the first tab and the second tab thereafter moved to a corresponding one of the first end of the first slot and the first end of the second slot. The first head of the first tab thereafter rests on the first upper surface portion of the first area and the second head thereafter rests on the third upper surface portion of the second area to suspend the component from the panel. The second upper surface portions of the first area of the panel restrict movement of the first tab away from the first end of the first slot.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring initially toFIG. 1, a vehicle body structure10is illustrated in accordance with a first embodiment. As shown inFIG. 2, a component12is installed within the vehicle body structure10defining a vehicle component support structure14that is described in greater detail below.

The vehicle body structure10includes a variety of structural elements that are welded or otherwise rigidly fixed to one another to define a basic vehicle structure, as shown inFIG. 1. Since most of the structural elements of the vehicle body structure10are conventional elements, only those structures related to the vehicle component support structure14are described herein below for the sake of brevity.

The vehicle body structure10as it relates to the vehicle component support structure14basically includes a panel20. The panel20is a generally horizontally oriented member that at least partially defines a parcel shelf located at the rear of a passenger compartment of the vehicle, rearward of the passenger seats and beneath a rear window opening22(glass is removed in the drawings). The panel20has an upper surface26and a lower surface28and is rigidly supported within the vehicle body structure10between rearward pillars (shown as C-pillars) in a conventional manner. The upper surface26faces upward and at least partially defines a rear boundary of the passenger compartment29of the vehicle body structure10. The lower surface28faces downward and at least partially defines a front and upper boundary of a storage compartment or trunk30at the rear of the vehicle body structure10.

As is described in greater detail below, the panel20is specifically modified in order to support the component12. Prior to a description of the panel20, a description of the component12is provided with specific reference toFIGS. 3 and 4. In the depicted embodiment, the component12is an electrical component such as an audio amplifier or an audio/visual processing and amplifying unit that is part of an audio system (not shown) and/or an audio/visual system (not shown) installed within the vehicle body structure10. For instance, the component12can be built to provide electronic amplification for audio signals broadcasted via audio speakers within the vehicle body structure10, or can also include image processing capability for a global positioning system and/or camera based imaging systems that provides images of areas adjacent to the vehicle body structure10during, for example, parking maneuvers. Alternatively, the component12can be an audio speaker, or can be any structure, vehicle element, or vehicle feature that is installed to the underside of a panel and can be installed by first temporarily suspending the component12prior to installation of mechanical fasteners.

As shown inFIGS. 3 and 4, the component12includes a main body40and a mounting structure42. The main body40is basically a case with heat dissipation fins with electronic circuitry and panels (not shown) disposed therein. The main body40has a lower surface40aand an upper surface40b. The mounting structure42of the component12includes a first bracket44and a second bracket46. The first bracket44and the second bracket46are fixedly attached to the main body40by, for example, mechanical fasteners F1, but can be attached to the main body40by other fastening means, such as clamps or welding.

The first bracket44includes a first tab50, a first fastener aperture52and a second fastener aperture54. The first tab50is located between the first fastener aperture52and the second fastener aperture54. The first tab50includes a first shaft portion50aand a first head50bthat is wider than the first shaft portion50a. Since the first head50bis wider than the first shaft portion50a, the first head50bincludes first contact surfaces50calong lower edges of the first head50b. The first contact surfaces50cface the main body40and provide a specific purpose and function as is explained in greater detail below. The fastener apertures52and54include machine threads for engagement with a threaded fastener, as described in greater detail below.

The second bracket46includes a second tab56, a third fastener aperture58, and a fourth fastener aperture60. The second tab56is located between the third fastener aperture58and the fourth fastener aperture60. The second tab56includes a second shaft portion56aand a second head56bthat is wider than the second shaft portion56a. Since the second head56bis wider than the second shaft portion56a, the second head56bincludes second contact surfaces56calong lower edges of the second head56b. The fastener apertures58and60also include machine threads for engagement with a threaded fastener, as described in greater detail below. The second contact surfaces56cface the main body40and provide a specific purpose and function as is explained in greater detail below.

As shown inFIG. 4, the first contact surfaces50care spaced apart from an upper surface40bof the main body40of the component12by a first distance D1and the second contact surfaces56care spaced apart from the upper surface40bof the main body40of the component by a second distance D2, the first distance D1being greater than the second distance D2. The first tab50and the second tab56are spaced apart from one another by a distance D3. As shown inFIG. 4, the first and second heads50band56bhave a width D4and the first and second shaft portions50aand56aof the first and second tabs50and56have a width D5.

The specific locations of the fastener apertures52,54,56and58, and the spacing therebetween define an attachment pattern. The positioning of the first tab50and the second tab56is related to the attachment pattern and is discussed in greater detail below

A more detailed description of the panel20is now provided with specific reference toFIGS. 5-13. The panel20is formed such that many sections of the upper surface26are co-planar. Correspondingly, there are many sections of the lower surface28of the panel20that are co-planar. However, the panel20further includes a plurality of embossed, pressed or otherwise offset sections that define at least a first area66and a second area68that includes regions that are not co-planar with the remainder of the panel20, but rather are offset from the remainder of the panel20. The panel20also includes a third area70that is located between the first area66and the second area68. The third area70is not specifically necessary for installation of the component12, but is mentioned for reference to recognition of the depictions of the panel20in the drawings. For example, inFIGS. 5-8 and 11, the third area70is clearly shown as an embossed area that is raised relative to the remainder of the upper surface26of the panel20and generally located between the first area66and the second area68, but is spaced apart from the first area66and the second area68.

The first area66defines a first slot72and the second area68of the panel20defines a second slot74. The first slot72and the second slot74are spaced apart from one another by the distance D3, the same distance between the first tab50and the second tab56of the mounting structure42of the component12, as shown inFIG. 13. Each of the first slot72and the second slot74extend completely through the panel20, from the upper surface26to the lower surface28of the panel20.

As is described in greater detail below, the first tab50and the second tab56are located relative to one another in order to align with of the first slot72and the second slot74, respectively, during installation of the component12.

As shown inFIG. 5, the first slot72has a first end72aand a second end72b. The first end72aof the first slot72has a first width W1measured perpendicular to a length of the first slot72and the second end72bof the first slot72has a second width W2that is greater than the first width W1. Similarly, the second slot74has a first end74aand a second end74b. The first end74aof the second slot74is dimensioned such that it also has the first width W1measured perpendicular to a length of the second slot74and the second end74bof the second slot74is dimensioned with the second width W2(a maximum width of the second slot74). In the depicted embodiment, the first ends72aand74ahave the same width W1and the second ends72band74bhave the same (maximum) width W2. As shown inFIG. 5, the first slot72and the second slot74have differing overall shapes. The first ends72aand74acan alternatively have the same shape, but can also be formed such that the second ends72band74bhave differing maximum widths. The first end72aof the first slot72and the first end74aof the second slot74extend in directions that are parallel to one another. Alternatively, the first ends72aand74aof the first slot72and second slot74can have differing widths and need not be identical.

The overall dimensions of the first slot72and the second slot74are directly related to the dimensions of the first tab50and the second tab56. Specifically, the first slot72is dimensioned such that the first head50bcan pass freely through the second end72bof the first slot72, but cannot pass freely through the first end72aof the first slot72. The first shaft portion50aof the first tab50can pass freely along the first end72aof the first slot72. Further, the second slot74is dimensioned such that the second head56bcan pass freely through the second end74bof the second slot74, but cannot pass freely through the first end74aof the first slot74. The second shaft portion56aof the second tab56can pass freely along the first end74aof the second slot74.

As shown inFIGS. 5-10 and 13, the first area66of the panel20defines a first upper surface portion80at the first end72aof the first slot72. Further, the first area66of the panel20defines second upper surface portions82at opposite sides of the first slot72at a location spaced apart from the first end72aof the first slot72and spaced apart from the second end72bof the first slot72. The second upper surface portions82are located adjacent to a central area of the first slot72. As shown inFIG. 13, the second upper surface portions82are located vertically higher above the first upper surface portion80. The second upper surface portions82can be formed as an embossment or deformed area such that the second upper surface portion82is raised up above the first upper surface portion80.

Similarly as shown inFIGS. 5-8 and 11-13, the second area68of the panel20defines a third upper surface portion84at the first end74aof the second slot74. The second area68also defines a fourth upper surface portion86around the second end74bof the second slot74. The fourth upper surface portion86is located vertically higher than the third upper surface portion84.

Returning toFIGS. 5 and 10, the first area66of the panel20further defines a fifth upper surface portion90and a sixth upper surface portion92that are lower than the second upper surface portion82. The fifth upper surface portion90defines a first fastener opening90aand the sixth upper surface portion92defines a second fastener opening92a. The fifth upper surface portion90and the sixth upper surface portion92are located at a height below the first upper surface portion80and below the second upper surface portion82, as shown inFIG. 10. The third upper surface portion84is at a height lower than the second upper surface portion82.

As shown inFIGS. 5, 11 and 12, the second area68of the panel20includes further features. Specifically, the third upper surface portion84defines a third fastener opening96a. The second area68includes a seventh upper surface portion98that defines a fastener slot100. The third upper surface portion84and the seventh upper surface portion98are co-planar, and are at a height lower than the fourth upper surface portion86, as shown inFIG. 12. However, it should be understood from the drawings and the description herein that the third upper surface portion84and the seventh upper surface portion98can alternatively be at differing heights (non-co-planar).

The fastener slot100has a first end100aand a second end100b. The second end100bis wider than the first end100a, as shown inFIGS. 5 and 11.

A description of a first part of the installation process of the component12to the panel20is now provided with specific reference toFIGS. 6-8 and 13. Prior to installation, a fastener F5is installed to the fourth fastener aperture60of the mounting structure42of the component12. As is explained in greater detail below, the fastener F5is not tightened but rather is only partially threaded into the fourth fastener aperture60. As shown inFIG. 6, a first step in the installation process involves positioning the component12under the panel20and lifting it up such that the first head50bof the first tab50moves upward passing through the second end72bof the first slot72. Simultaneously, the second head56bof the second tab56moves upward passing through the second end74bof the second slot74. As shown inFIG. 6, the first head50band the second head56bare positioned above the upper surface26of the panel20. Hence, the first shaft portion50aof the first tab50extends through the second end72bof the first slot72and the second shaft portion56aof the second tab50extends through the second end74bof the second slot74. With the fastener F5installed, the fastener F5also moves upward passing through the second end100bof the fastener slot100.

Thereafter, as shown inFIG. 7, the component12is moved toward the rear of the vehicle body structure10, causing the first shaft portion50ato move or slide from the second end72bof the first slot72toward the first end72aof the first slot72. Simultaneously, the second shaft portion56amoves or slides from the second end74bof the second slot74toward the first end74aof the second slot74. Further during this movement, the fastener F5is moved from the second end100bof the fastener slot100to the first end100aof the fastener slot. Since the first slot72, the second slot74and the fastener slot100extend in directions that are substantially parallel to one another, the first tab50and the second tab56are moved in the same direction while the first shaft portion50aand the second shaft portion50amove along the first slot72and the second slot74toward the first ends72aand74a, respectively.

The component installer (technician or robot) releases the component12at this point thereby lowering the component12such that the contact surfaces50cof the first tab50contact the upper surface26of the panel20at the first upper surface portion80, and the contact surfaces56cof the second tab56contact the upper surface26of the panel20at the third upper surface portion84, as shown inFIGS. 7, 13 and 14. Further, the fastener F5contacts the seventh upper surface portion98as shown inFIG. 7, with the fastener F5remaining in an untightened state, only partially threaded into the fourth fastener aperture60.

Hence, as shown inFIGS. 7 and 13, the component12rests on the panel20and temporarily hangs in place without fasteners via the contact between the contact surfaces50cand56cof the first and second tabs50and56and the upper surface26of the panel20at the first upper surface portion80and the third upper surface portion84, respectively. The component12is not fixed in position by fasteners yet (the fastener F5is not yet tightened), but movement of the component12is restricted due to arrangement of the first upper surface portion80being lower than the second upper surface portions82. Further, movement of the component12is further restricted due to the third upper surface portion84being lower than the fourth upper surface portion86. The area of the upper surface26of the panel20where the contact surface50cof the first tab50defines a first suspension surface or first suspension point. Similarly, the area of the upper surface26of the panel20where the contact surface56cof the second tab56defines a second suspension surface or second suspension point. The first and second suspension points support the component12temporarily during the installation process, as described in greater detail below.

In other words, the second upper surface portions82are higher than the first upper surface portion80such that gravity assists in the retention of the first tab50at the first end72aof the first slot72. Similarly, the fourth upper surface portion86is higher than the third upper surface portion84such that gravity assists in the retention of the second tab56at the first end74aof the second slot74. Hence, the second upper surface portion82of the panel20restricts movement of the first tab50away from the first end72aof the first slot72with the first tab50located at the first end72aof the first slot74, and the fourth upper surface portion86of the panel20restricts movement of the second tab56away from the first end74aof the second slot74with the second tab56being located at the first end74aof the second slot74.

The configuration of the surface portions of the first area66and the second area68are beneficial to the component installer of the component12for a variety of reasons. For example, the component12is installed in a location of the vehicle body structure10that is difficult and/or awkward to work in. Specifically, the component12is being installed within a forward region of the storage compartment or trunk30of the vehicle body structure10and to the underside or lower surface of the panel20. The component installer must reach deep within the trunk30to install the component12, or must climb into the space that defines the trunk30. With the arrangement of the panel12described above, the component installer can continue with the installation process without concern regarding contact with the component12and possibly bumping the component12out of position because the first and second tabs50and56resting on the upper surface26of the panel20are retained in the positions shown inFIG. 7by the second upper surface portion82and the fourth upper surface portion86.

As shown inFIG. 13, the third upper surface portion84is at a height lower than the first upper surface portion80. The first contact surfaces50ccontact the first upper surface portion80and the second contact surfaces56ccontact the third upper surface portion84. Since the first contact surfaces50care at a location that is higher than the location of the second contact surface56c(the first distance D1being greater than the second distance D2) the component12is suspended from the panel12is a generally level orientation. In other words, the relative heights of the first upper surface portion80and the third upper surface portion84correspond to the relative heights of the first contact surfaces50cof the first tab50and the second contact surfaces56cof the second tab56.

As shown inFIGS. 7, 14 and 15, the fastener F5is the first mechanical fastener installed first to the panel20and the component20. However, the fastener F5is merely hand tightened and is not fully tightened or torqued initially. Initially, the fastener F5is not tightened, but is merely threaded in such a way that the head of the fastener F5contacts the seventh upper surface portion98of the panel20. In this condition, the contact surfaces56cof the second tab56remain in contact with the upper surface26of the panel20. It should be understood, that the fastener F5can alternatively be installed to the panel20and the component12after the first and second tabs50and56are positioned to rest on the upper surface26of the panel20. However, in the depicted embodiment, the fastener F5is threaded loosely into the fourth fastener aperture60prior to installation of the first and second tabs50and56into the first and second slots72and74.

The area of contact between the fastener F5and the panel20(the seventh upper surface portion98) defines a third suspension point for the component12. The third suspension point (the seventh upper surface portion98) is important to prevent pivoting movement of the component12about a pivot axis (not shown) that extends through the first suspension point (contact between the contact surfaces50cand the panel20) and the second suspension point (contact between the contact surfaces56cand the panel20). Any such pivoting movement might cause “winking” of the fastener apertures90a,92aand96arelative to the fastener openings52,54and58during the installation of the fasteners F2, F3and F4. The “winking” referred to above is basically defined as a circumstance where any one or all of the fastener apertures90a,92aand96abecomes slightly mis-aligned with the corresponding one of the fastener openings52,54and58to a degree where installation of the fasteners F2, F3and F4is more difficult or impossible. The “winking” can also be a circumstance where any one or all of central axis of the fastener apertures90a,92aand96abecomes angularly offset from the central axis of the corresponding one of the fastener openings52,54and58to a degree where installation of the fasteners F2, F3and F4might cause cross threading.

With the head of the fastener F5resting on the upper surface26of the panel20with the fastener F5only hand tightened as shown inFIGS. 7, 14 and 15, the fastener F5and the first and second tabs50and56provide the component12with the following movement restrictions: prevent pivoting, rearward and lateral movement of the component12; the fastener F5and the first and second tabs50and56prevent downward movement of the component12; and the second upper surface portion82and the fourth upper surface portion86restrict forward movement of the component12relative to the panel12.

As is explained further below, fasteners F2, F3and F4are next installed to secure the component12to the panel20in a specific sequence, during which the fastener F5is fully tightened. However, as shown inFIG. 8, after the fasteners F2, F3, F4and F5are completely installed and torqued, the first contact surfaces50cof the first tab50and the second contact surfaces56cof the second tab56are lifted off of the upper surface26of the panel20.

A description of an installation and tightening sequence of the fasteners F2, F3, F4and F5is now provided with specific reference toFIGS. 14-18.

As shown inFIG. 14with the fastener F5removed, the spacing and relative positioning between the first fastener opening90a, the second fastener opening92a, the third fastener opening96aand the first end100aof the fastener slot100of the panel20define a first fastener pattern. Further, the spacing and relative positioning between the fastener apertures52,54,58and60, of the mounting structure42of the component12define a second fastener pattern. When the first tab50is positioned within the first end72aof the first slot72and the second tab56is positioned within the first end74aof the second slot74as shown inFIG. 14, the second fastener pattern coincides or aligns with the first fastener pattern. In other words, the second fastener pattern may not be perfectly aligned in all circumstances with the first fastener pattern, but will at least coincide therewith such that the fastening apertures52,54,58and60are substantially accessible through corresponding ones of the first fastener opening90a, the second fastener opening92a, the third fastener opening96aand the fastener slot100. More specifically, the first fastener aperture52coincides or aligns with the first fastener opening90a, the second fastener aperture54coincides or aligns with the second fastener opening92a, the third fastener aperture58coincides or aligns with the third fastener opening96aand the fourth fastener aperture58coincides or aligns with the first end100aof the fastener slot100.

As is also shown inFIG. 14, the first fastener opening90aof the panel20has a diameter that is larger than the diameter of the first fastener aperture52of the component12. Similarly, the second fastener opening92aof the panel20has a diameter that is larger than the diameter of the second fastener aperture54. In other words, the first fastener opening90aand the second fastener opening92aare oversized relative to the first and second fastener apertures52and54. The oversizing of the first fastener opening90aand the second fastener opening92arelative to the first and second fastener apertures52and54is provided to allow for engineering tolerances and because the first fastener opening90aand the second fastener opening92amight not be perfectly aligned with the fastener apertures52and54with the component12hanging from the panel20prior to installation of the fasteners F2-F5.

As shown inFIG. 14, the third fastener aperture58and the third fastener opening96ahave approximately the same diameter. Hence, the third fastener opening96ais smaller than the first and second fastener openings90aand92a. The fourth fastener aperture60has a diameter that is equal to the width of the first end100aof the fastener slot100.

As shown inFIG. 15, the fastener F5is the first mechanical fastener installed first to the panel20and the component20, installed prior to suspension of the component12to the panel20by the first and second tabs50and56. As mentioned above, the fastener F5is merely hand tightened and is not fully tightened or torqued initially. Specifically, the fastener F5is threaded such that the head of the fastener F5contacts the upper surface26of the panel20.

Next, as shown inFIG. 16, the fastener F4is installed. Specifically, the fastener F4is installed such that it extends through the third fastener opening96aand is threaded into the mechanical threads of the third fastener aperture58. The fastener F4can be fully tightened and torqued at this point pulling the component12upward such that the contact surfaces56cof the second tab56no longer contact the upper surface26of the panel20. As the fastener F4is tightened and torqued, the first tab50, the second tab56and the fastener F5prevent noticeable movement of the component12relative to the panel20.

Next, as shown inFIG. 17, the fastener F3is installed. Specifically, the fastener F3is installed such that it extends through the second fastener opening92aand is threaded into the mechanical threads of the second fastener aperture54. The fastener F3can be fully tightened and torqued at this point pulling the component12upward such that the contact surfaces50cof the first tab50no longer contact the upper surface26of the panel20. It is possible that the tightening of the fastener F4could lift up the side of the component12having the first tab50. However, once the fastener F3is tightened and torqued, the contact surfaces50cof the first tab50are definitely lifted up and no longer contact the upper surface26of the panel20. Since the second fastener opening92ais larger than the fastener aperture54of the component12, installation of the fastener F3is assured with little or no risk of mis-alignment between the second fastener opening92aand the second fastener aperture54. As the fastener F3is tightened and torqued, the first tab50, the second tab56and the fasteners F5and F4prevent movement of the component12relative to the panel20.

Next, as shown inFIG. 18, the fastener F2is installed. Specifically, the fastener F2is installed such that it extends through the first fastener opening90aand is threaded into the mechanical threads of the first fastener aperture52. The fastener F2can be fully tightened and torqued at this point fully securing the component12to the panel20. Since the first fastener opening90ais larger than the first fastener aperture52of the component12, installation of the fastener F2is assured with little or no risk of mis-alignment between the first fastener opening90aand the first fastener aperture52. As the fastener F2is tightened and torqued, the first tab50, the second tab56and the fasteners F5, F4and F3prevent movement of the component12relative to the panel20.

Finally, the fastener F5can be tightened and torqued and installation of the component12is completed.

The embossed or deformed areas of the first area66and the second area68make the installation process of the component12easier and more reliable without use of additional robotic equipment or additional technician's hands. The component12is more simply and easily installed as a result of the specific design of the panel20and the mounting structure42of the component12, described above.

The vehicle body structure10includes many conventional components that are well known in the art. Since these conventional components are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

General Interpretation of Terms