Reinforced vehicle component cover

Methods and systems are provided for a vehicle component cover. In one example, a vehicle component cover may be adapted to conceal vehicle components within an engine compartment, and the cover may include an embedded support structure having a plurality of lock orifices positioned to align with a plurality of openings of a solid encasement. The plurality of lock orifices are adapted to couple in locking engagement with a plurality of extensions of an emblem of the cover.

FIELD

The present description relates generally to methods and systems for a cover for a component of a vehicle.

A motorized vehicle often includes one or more vehicle component covers shaped to couple with components of the vehicle in order to increase an aesthetic quality of the components and/or reduce an amount of noise generated by the vehicle. An engine compartment of a vehicle, for example, may include a cover positioned to obscure one or more sections of the engine and/or to display a make and/or model of the engine to a viewer.

One example approach towards an engine cover is shown by Kondo et al. in U.S. Publication 2015/0075482. Therein, an engine cover has a cover body made of urethane foam, a skin layer disposed on a surface of the cover body, and an attachment member made of an elastic body and integrally molded with the cover body. The attachment member has a recess into which an attachment pin provided to project from an engine member is fitted.

However, the inventors herein have recognized potential issues with such systems. As one example, an engine cover such as the cover described by the '482 publication may not be configured to couple with components separately from the engine, such as an emblem displaying a make and/or model of the vehicle and/or engine. Often, an emblem is coupled to an engine cover via one or more fasteners such as bolts, increasing an assembly time and cost of the engine cover due to the increased amount of parts to couple the emblem to the engine cover.

In one example, the issues described above may be addressed by a vehicle component cover, comprising: a solid encasement including a plurality of passages; and a support structure embedded within the encasement and including a plurality of lock orifices, with each lock orifice of the plurality of lock orifices positioned to intersect a corresponding passage of the plurality of passages. In this way, the plurality of lock orifices is configured to couple in locking engagement with a separate component, such as an emblem of the vehicle.

As one example, the emblem includes a plurality of extensions arranged to slide through the plurality of lock orifices during conditions in which the emblem is coupled to the solid encasement. The extensions may slide through the plurality of lock orifices in a first direction and may not slide through the lock orifices in an opposite, second direction. In this way, the emblem is locked to the vehicle component cover and a position of the emblem relative to the solid encasement and support structure is maintained.

DETAILED DESCRIPTION

The following description relates to systems and methods for a vehicle component cover. A vehicle, such as the vehicle shown byFIG. 1, may include an engine having a plurality of combustion chambers capped by a cylinder head. The cylinder head and other vehicle components positioned at a top end of the engine may be concealed by an engine cover, such as the engine cover shown byFIG. 2. The engine cover includes a support structure (as shown byFIG. 3) embedded within a solid encasement, as shown byFIG. 6. In some examples, the support structure may include a plurality of lock orifices positioned to align with a corresponding plurality of openings of the encasement, as shown byFIG. 4. The plurality of lock orifices are adapted to couple in locking engagement with a plurality of extensions of an emblem of the cover. In some examples, the support structure may include a plurality of notched sections adapted to increase an energy absorption quality of the support structure, as shown byFIGS. 5A-5B. In some examples, one or more of the notched sections may be angled differently relative to each other notched section, as shown byFIGS. 7-8. By configuring the engine cover to include the support structure embedded within the encasement, a durability of the engine cover may be increased and an amount of noise, vibration, and/or harshness of the engine may be decreased. Additionally, by configuring the support structure to include the plurality of lock orifices, the emblem may be coupled to the cover without additional fasteners.

FIG. 1depicts an example of a combustion chamber or cylinder of internal combustion engine10. Engine10may be controlled at least partially by a control system including controller12and by input from a vehicle operator130via an input device132. In this example, input device132includes an accelerator pedal and a pedal position sensor134for generating a proportional pedal position signal PP. Cylinder (herein also “combustion chamber”)14of engine10may include combustion chamber walls136with piston138positioned therein. Piston138may be coupled to crankshaft140so that reciprocating motion of the piston is translated into rotational motion of the crankshaft. Crankshaft140may be coupled to at least one drive wheel of the passenger vehicle via a transmission system. Further, a starter motor (not shown) may be coupled to crankshaft140via a flywheel to enable a starting operation of engine10.

Cylinder14can receive intake air via a series of intake air passages142,144, and146. Intake air passage146can communicate with other cylinders of engine10in addition to cylinder14. In some examples, intake air passage146may be one of a plurality of intake air passages fluidly coupled to the intake passage144. The plurality of intake air passages may be referred to herein collectively as an intake manifold. Each passage of the intake manifold may be coupled to a different cylinder of the engine, for example, and intake air may flow to each cylinder from the intake air passage144and through the intake manifold. In some examples, one or more of the intake passages may include a boosting device such as a turbocharger or a supercharger. For example,FIG. 1shows engine10configured with a turbocharger including a compressor174arranged between intake passages142and144, and an exhaust turbine176arranged along exhaust passage148. Compressor174may be at least partially powered by exhaust turbine176via a shaft180where the boosting device is configured as a turbocharger. However, in other examples, such as where engine10is provided with a supercharger, exhaust turbine176may be optionally omitted, where compressor174may be powered by mechanical input from a motor or the engine. A throttle162including a throttle plate164may be provided along an intake passage of the engine for varying the flow rate and/or pressure of intake air provided to the engine cylinders. For example, throttle162may be positioned downstream of compressor174as shown inFIG. 1, or alternatively may be provided upstream of compressor174.

Exhaust passage148can receive exhaust gases from other cylinders of engine10in addition to cylinder14. Exhaust gas sensor128is shown coupled to exhaust passage148upstream of emission control device178. Sensor128may be selected from among various suitable sensors for providing an indication of exhaust gas air/fuel ratio such as a linear oxygen sensor or UEGO (universal or wide-range exhaust gas oxygen), a two-state oxygen sensor or EGO (as depicted), a HEGO (heated EGO), a NOx, HC, or CO sensor, for example. Emission control device178may be a three way catalyst (TWC), NOx trap, various other emission control devices, or combinations thereof.

Each cylinder of engine10may include one or more intake valves and one or more exhaust valves. For example, cylinder14is shown including at least one intake poppet valve150and at least one exhaust poppet valve156located at an upper region of cylinder14. In some examples, each cylinder of engine10, including cylinder14, may include at least two intake poppet valves and at least two exhaust poppet valves located at an upper region of the cylinder.

Intake valve150may be controlled by controller12via actuator152. Similarly, exhaust valve156may be controlled by controller12via actuator154. During some conditions, controller12may vary the signals provided to actuators152and154to control the opening and closing of the respective intake and exhaust valves. The position of intake valve150and exhaust valve156may be determined by respective valve position sensors (not shown). The valve actuators may be of the electric valve actuation type or cam actuation type, or a combination thereof. The intake and exhaust valve timing may be controlled concurrently or any of a possibility of variable intake cam timing, variable exhaust cam timing, dual independent variable cam timing or fixed cam timing may be used. Each cam actuation system may include one or more cams and may utilize one or more of cam profile switching (CPS), variable cam timing (VCT), variable valve timing (VVT) and/or variable valve lift (VVL) systems that may be operated by controller12to vary valve operation. For example, cylinder14may alternatively include an intake valve controlled via electric valve actuation and an exhaust valve controlled via cam actuation including CPS and/or VCT. In other examples, the intake and exhaust valves may be controlled by a common valve actuator or actuation system, or a variable valve timing actuator or actuation system.

In some examples, each cylinder of engine10may be configured with one or more fuel injectors for providing fuel thereto. As a non-limiting example, cylinder14is shown including two fuel injectors166and170. Fuel injectors166and170may be configured to deliver fuel received from fuel system8. As elaborated with reference toFIGS. 2-3, fuel system8may include one or more fuel tanks, fuel pumps, and fuel rails. Fuel injector166is shown coupled directly to cylinder14for injecting fuel directly therein in proportion to the pulse width of signal FPW-1 received from controller12via electronic driver168. In this manner, fuel injector166provides what is known as direct injection (hereafter referred to as “DI”) of fuel into combustion cylinder14. WhileFIG. 1shows injector166positioned to one side of cylinder14, it may alternatively be located overhead of the piston, such as near the position of spark plug192. Such a position may improve mixing and combustion when operating the engine with an alcohol-based fuel due to the lower volatility of some alcohol-based fuels. Alternatively, the injector may be located overhead and near the intake valve to improve mixing. Fuel may be delivered to fuel injector166from a fuel tank of fuel system8via a high pressure fuel pump, and a fuel rail. Further, the fuel tank may have a pressure transducer providing a signal to controller12.

Fuel injector170is shown arranged in intake passage146, rather than in cylinder14, in a configuration that provides what is known as port injection of fuel (hereafter referred to as “PFI”) into the intake port upstream of cylinder14. Fuel injector170may inject fuel, received from fuel system8, in proportion to the pulse width of signal FPW-2 received from controller12via electronic driver171. Note that a single driver168or171may be used for both fuel injection systems, or multiple drivers, for example driver168for fuel injector166and driver171for fuel injector170, may be used, as depicted.

In an alternate example, each of fuel injectors166and170may be configured as direct fuel injectors for injecting fuel directly into cylinder14. In still another example, each of fuel injectors166and170may be configured as port fuel injectors for injecting fuel upstream of intake valve150. In yet other examples, cylinder14may include only a single fuel injector that is configured to receive different fuels from the fuel systems in varying relative amounts as a fuel mixture, and is further configured to inject this fuel mixture either directly into the cylinder as a direct fuel injector or upstream of the intake valves as a port fuel injector. As such, it should be appreciated that the fuel systems described herein should not be limited by the particular fuel injector configurations described herein by way of example.

Fuel may be delivered by both injectors to the cylinder during a single cycle of the cylinder. For example, each injector may deliver a portion of a total fuel injection that is combusted in cylinder14. Further, the distribution and/or relative amount of fuel delivered from each injector may vary with operating conditions, such as engine load, knock, and exhaust temperature, such as described herein below. The port injected fuel may be delivered during an open intake valve event, closed intake valve event (e.g., substantially before the intake stroke), as well as during both open and closed intake valve operation. Similarly, directly injected fuel may be delivered during an intake stroke, as well as partly during a previous exhaust stroke, during the intake stroke, and partly during the compression stroke, for example. As such, even for a single combustion event, injected fuel may be injected at different timings from the port and direct injector. Furthermore, for a single combustion event, multiple injections of the delivered fuel may be performed per cycle. The multiple injections may be performed during the compression stroke, intake stroke, or any appropriate combination thereof.

Fuel injectors166and170may have different characteristics. These include differences in size, for example, one injector may have a larger injection hole than the other. Other differences include, but are not limited to, different spray angles, different operating temperatures, different targeting, different injection timing, different spray characteristics, different locations etc. Moreover, depending on the distribution ratio of injected fuel among injectors170and166, different effects may be achieved.

Fuel tanks in fuel system8may hold fuels of different fuel types, such as fuels with different fuel qualities and different fuel compositions. The differences may include different alcohol content, different water content, different octane, different heats of vaporization, different fuel blends, and/or combinations thereof etc. One example of fuels with different heats of vaporization could include gasoline as a first fuel type with a lower heat of vaporization and ethanol as a second fuel type with a greater heat of vaporization. In another example, the engine may use gasoline as a first fuel type and an alcohol containing fuel blend such as E85 (which is approximately 85% ethanol and 15% gasoline) or M85 (which is approximately 85% methanol and 15% gasoline) as a second fuel type. Other feasible substances include water, methanol, a mixture of alcohol and water, a mixture of water and methanol, a mixture of alcohols, etc.

In still another example, both fuels may be alcohol blends with varying alcohol composition wherein the first fuel type may be a gasoline alcohol blend with a lower concentration of alcohol, such as E10 (which is approximately 10% ethanol), while the second fuel type may be a gasoline alcohol blend with a greater concentration of alcohol, such as E85 (which is approximately 85% ethanol). Additionally, the first and second fuels may also differ in other fuel qualities such as a difference in temperature, viscosity, octane number, etc. Moreover, fuel characteristics of one or both fuel tanks may vary frequently, for example, due to day to day variations in tank refilling.

Controller12is shown inFIG. 1as a microcomputer, including microprocessor unit106, input/output ports108, an electronic storage medium for executable programs and calibration values shown as non-transitory read only memory chip110in this particular example for storing executable instructions, random access memory112, keep alive memory114, and a data bus. The controller12receives signals from the various sensors ofFIG. 1and employs the various actuators ofFIG. 1to adjust engine operation based on the received signals and instructions stored on a memory of the controller. For example, controller12may receive various signals from sensors coupled to engine10, in addition to those signals previously discussed, including measurement of inducted mass air flow (MAF) from mass air flow sensor122; engine coolant temperature (ECT) from temperature sensor116coupled to cooling sleeve118; a profile ignition pickup signal (PIP) from Hall effect sensor120(or other type) coupled to crankshaft140; throttle position (TP) from a throttle position sensor; and absolute manifold pressure signal (MAP) from sensor124. Engine speed signal, RPM, may be generated by controller12from signal PIP. Manifold pressure signal MAP from a manifold pressure sensor may be used to provide an indication of vacuum, or pressure, in the intake manifold. Controller12may infer an engine temperature based on an engine coolant temperature. In one example, the controller12may adjust an opening amount and/or timing of intake valve150by adjusting an actuator of the intake valve150(e.g., actuator152, a described above) to adjust the opening amount and/or timing.

As described above,FIG. 1shows only one cylinder of a multi-cylinder engine. As such, each cylinder may similarly include its own set of intake/exhaust valves, fuel injector(s), spark plug, etc. It will be appreciated that engine10may include any suitable number of cylinders, including 2, 3, 4, 5, 6, 8, 10, 12, or more cylinders. Further, each of these cylinders can include some or all of the various components described and depicted byFIG. 1with reference to cylinder14.

In some examples, vehicle5may be a hybrid vehicle with multiple sources of torque available to one or more vehicle wheels55. In other examples, vehicle5is a conventional vehicle with only an engine, or an electric vehicle with only electric machine(s). In the example shown, vehicle5includes engine10and an electric machine52. Electric machine52may be a motor or a motor/generator. Crankshaft140of engine10and electric machine52are connected via a transmission54to vehicle wheels55when one or more clutches56are engaged. In the depicted example, a first clutch56is provided between crankshaft140and electric machine52, and a second clutch56is provided between electric machine52and transmission54. Controller12may send a signal to an actuator of each clutch56to engage or disengage the clutch, so as to connect or disconnect crankshaft140from electric machine52and the components connected thereto, and/or connect or disconnect electric machine52from transmission54and the components connected thereto. Transmission54may be a gearbox, a planetary gear system, or another type of transmission. The powertrain may be configured in various manners including as a parallel, a series, or a series-parallel hybrid vehicle.

Electric machine52receives electrical power from a traction battery58to provide torque to vehicle wheels55. Electric machine52may also be operated as a generator to provide electrical power to charge battery58, for example during a braking operation.

The vehicle5includes a vehicle component cover (similar to the examples described below with reference toFIGS. 2-8) that may be positioned to obscure one or more vehicle components within a compartment of the vehicle (e.g., an engine compartment housing the engine10). For example, the vehicle component cover (which may be referred to herein as an engine cover) may be positioned to partially or entirely obscure (e.g., visually block) engine10. The vehicle component cover may additionally be configured to reduce a noise and/or vibration of the engine10via a solid encasement of the vehicle component cover, as described below.

FIGS. 2-8show various views of a vehicle component cover200(and/or one or more components of the vehicle component cover200). In one example, the vehicle component cover200may be the vehicle component cover described above with reference toFIG. 1. Reference axes299are included by each ofFIGS. 2-8for comparison of the views shown.

FIG. 2shows a perspective view of a vehicle component cover200(which may be referred to herein as an engine cover). The engine cover200is configured to couple to an engine of a vehicle (e.g., engine10of vehicle5described above with reference toFIG. 1) in order to visually block (e.g., obscure) one or more sections of the engine from view. For example, during conditions in which the engine cover200is coupled to the engine and a hood of the vehicle is in an opened position (e.g., a position in which the hood is pivoted away from the engine and an engine compartment of the vehicle is visually exposed from an exterior of the vehicle), the engine cover200may block an intake manifold of the engine from view (e.g., the intake manifold described above with reference toFIG. 1). Specifically, the engine cover200includes a top end202and a bottom end214, and during conditions in which the engine cover200is coupled to the engine (e.g., the bottom end214of the engine cover200is positioned in face-sharing contact with one or more components positioned at an upper end of the engine, such as the intake manifold) and the engine compartment is opened (e.g., the hood is pivoted to an opened position), the top end202of the engine cover200is visually unblocked.

The engine cover200includes a solid encasement212. The encasement212forms exterior surfaces of the engine cover200, such as top surface216positioned at the top end202and away from the bottom end214. The encasement212is formed of a compressible material. In one example, the compressible material (e.g., foam, rubber, etc.) may be an elastic material capable of temporarily compressing (e.g., deforming) in response to a force applied to the encasement212. During conditions in which the force is not applied to the encasement212, the elastic material may return to its initial, uncompressed shape. The compressible material may additionally include increased sound damping characteristics relative to other types of materials (e.g., metal, rigid plastic, etc.) and may reduce an amount of noise and/or vibration produced by the engine. In some examples, the encasement212may be formed of polyurethane foam (e.g., polyurethane foam with a density of eight pounds per cubic foot, or polyurethane foam having a different density).

The encasement212is a solid (e.g., not hollow) component of the cover200formed as a single piece. For example, encasement212may be formed via injection-molding. The encasement212does not include cavities, voids, etc. positioned within an interior630of the encasement212(as shown byFIG. 6). Specifically, the encasement212is not formed as a shell (e.g. a housing having an interior cavity) and is not separable into two or more pieces. However, encasement212is molded around a support structure300(shown byFIGS. 3-6and described below), and the encasement212and support structure300together form a single unit. Specifically, support structure300is embedded within the encasement212and is surrounded by the encasement212. Because the support structure300and encasement212are formed together as a single unit, the support structure300and encasement212are not separable from each other. The support structure300is described in further detail below with reference toFIGS. 3-6.

As shown byFIG. 2, the encasement212includes an open-ended recess206positioned at the top end202and formed by the top surface216of the encasement212. The recess206is a depression in the top surface216that extends from the top surface216in a direction of the z-axis toward the bottom end214. As shown byFIG. 4, the recess206includes a lower surface406joined to the top surface216via a plurality of sidewalls404. The recess206is open at the top surface216and closed at the lower surface406. The lower surface406is offset from the top surface216in a direction toward the bottom end214, and the plurality of sidewalls404extend in a direction from the top end202toward the bottom end214. In this way, the recess206only extends partially through the encasement212. In one example, the sidewalls404may be positioned perpendicular to the lower surface406. In other examples, the sidewalls404may be positioned at an angle relative to the lower surface406. For example, a perimeter of the recess206at the top surface216may be larger than a perimeter of the recess at the lower surface406, and the sidewalls404may taper from the top surface216to the lower surface406.

The recess206is shaped to seat (e.g., house) an emblem204(which may be referred to herein as a badge), as shown byFIG. 2. In some examples, the emblem204may include ornamentation indicating a make, model, brand, type, etc. of a vehicle and/or engine. For example, emblem204may include ornamentation displaying a make of an engine configured to couple with the engine cover200. In another example, emblem204may include ornamentation displaying a model of a vehicle having an engine compartment configured to house the engine cover200. In yet another example, emblem204may include ornamentation displaying a model (e.g., a name) and/or manufacturer of the engine cover200.

The ornamentation described above is positioned at an outer surface218of the emblem204, and the outer surface218and ornamentation are visually unblocked during conditions in which the emblem204is coupled to the encasement212(e.g., seated within the recess206). For example, as shown by the cross-sectional view ofFIG. 6, the emblem204includes a bottom surface608positioned in face-sharing contact with the lower surface406of the recess206during conditions in which the emblem204is coupled to the encasement212, and the outer surface218of the emblem204is positioned at the top end202of the engine cover200. In other examples, the encasement212may not include the recess206and the emblem204may instead couple directly to the top surface216.

In one example, emblem204may be formed of a material different than the material of the encasement212. For example, emblem204may be formed of a rigid material such as plastic, metal, etc. In other examples, the emblem204may be formed of one or more different materials. Emblem204is separably coupled to the encasement212(e.g., via a plurality of extensions of the emblem204, as described below with reference toFIG. 6). The emblem204may be decoupled (e.g., removed) from the encasement212for replacement, adjustment, etc.

In the example shown byFIG. 2, the encasement212includes a main aperture210(e.g., hole) having a perimeter220shaped to surround one or more components of the engine (e.g., engine10described above with reference toFIG. 1) during conditions in which the engine cover200is coupled to the engine. In one example, the perimeter220of the main aperture210may surround an oil inlet of the engine (e.g., an oil port sealed by a removable cap). An axis208positioned at a center of the main aperture210(e.g., centered within the perimeter220of the main aperture210) extends in a direction from the top end202to the bottom end214. Similarly, main aperture210extends entirely through the engine cover200from the top end202to the bottom end214.

As described above, the support structure300(shown as a separate piece relative to the encasement212byFIG. 3) is embedded within the encasement212. The support structure300is formed of a rigid material (e.g., plastic, metal, etc.) and increases a durability of the encasement212(e.g., reinforces the encasement212). For example, as described above, the encasement212is formed of a compressible material. The support structure300is formed of a stiffer material (e.g., a substantially less compressible material than the material of the encasement212) in order to increase a rigidity of the engine cover200. Thus, the support structure300may have increased stiffness relative to the encasement212. Additionally, the support structure300may include a plurality of arms configured to enable the support structure300to be coupled to the engine (e.g., via fasteners, such as bolts). By embedding the support structure300within the encasement212, the encasement212may be formed of a more compressible material having increased noise reduction and energy absorption characteristics, and the support structure300may be formed of stiffer, less compressible material (e.g., non-compressible material) to increase the rigidity and durability of the engine cover200(e.g., by reinforcing the surrounding encasement212).

The support structure300includes a front end395and an opposing back end397. During conditions in which the cover200is coupled to the engine, the front end395is positioned at a front end of the engine and the back end397is positioned toward a back end of the engine (e.g., away from the front end). The support structure300may include an annular opening334having a perimeter350shaped to surround (e.g., encircle) the perimeter220of the main aperture210of the encasement212. The support structure300may be embedded within the encasement212in a position in which no portion of the support structure300extends into the main aperture210. In other examples, the encasement212may not include the main aperture210and/or the support structure300may not include the annular opening334.

The support structure300includes a main section352having a substantially flat, planar profile (as shown by the cross-sectional view ofFIG. 6). For example, as shown byFIGS. 3-6, the main section352of the support structure300extends substantially in the directions of the x-axis and y-axis of reference axes299. Support structure300includes a plurality of arms (e.g., first arm326, second arm328, third arm330, and fourth arm332) joined to the main section352and extending in directions away from the main section352. For example, as shown byFIG. 3, each of the arms extends in a perpendicular direction relative to the main section352(e.g., in a direction of the z-axis of reference axes299, and in a radial direction relative to axis316) and away from the top end202of the encasement212. Each arm may include a tab positioned away from the main section352. For example, first arm326includes a first tab336, second arm328includes a second tab338, third arm330includes a third tab342, and fourth arm332includes a fourth tab340). Each of the tabs may be substantially flat (e.g., planar) and, in some examples, each of the tabs may extend in a perpendicular direction relative to the arms (e.g., in a direction of the x-axis and y-axis of the reference axes299and parallel to the main section352). The plurality of arms may further provide reinforcement for the encasement212and increase a durability and rigidity of the encasement212.

In some examples, one or more of the tabs (e.g., first tab336, second tab338, third tab342, and/or fourth tab340) may include an aperture or slot shaped to receive a fastener (e.g., a bolt). For example, as shown byFIG. 3, first tab336includes first slot360, second tab338includes second slot362, third tab342includes third slot366, and fourth tab340includes aperture364. In some examples, one or more arms of the plurality of arms may extend outward from the encasement212to an exterior of the encasement212. For example, a first portion of an arm of the plurality of arms may be partially embedded within the encasement212, and a second portion of the arm may extend outward from the encasement212to a location external to the encasement212(e.g., to a mounting bracket included by the engine). During conditions in which the tabs are coupled to the engine via fasteners, the fasteners may press against surfaces of the tabs in order to retain a position of the engine cover200relative to the engine. For example, a fastener inserted into the first slot360of the first tab336may press the surfaces of the first tab336into engagement (e.g., into face-sharing contact) with one or more surfaces of the engine, a component of the engine (e.g., intake manifold), and/or other vehicle component (e.g., a frame of the vehicle). Because the support structure300is embedded within the encasement212, and because the encasement212and support structure300are formed together as a single unit, coupling the arms of the support structure300to the vehicle in this way secures (e.g., maintains) the position of the engine cover200within the engine compartment (e.g., maintains the position of the engine cover200relative to the engine). In some examples, first slot360, second slot362, and third slot366may each include a corresponding ball stud grommet (not shown), and each ball stud grommet may be coupled to a corresponding ball stud of the engine. For example, first slot360may include a first ball stud grommet adapted to couple to a first ball stud protruding from the engine at a first location, second slot362may include a second ball stud grommet adapted to couple to a second ball stud protruding from the engine at a second location, and third slot366may include a third ball stud grommet adapted to couple to a third ball stud protruding from the engine at a third location.

In some examples (e.g., as shown byFIGS. 3-6), the support structure300may include a plurality of notched sections324(which may be referred to herein as notched tabs) positioned along the main section352. In the example described herein, the support structure300includes eight notched sections324. In other examples, the support structure300may include a different number and/or arrangement of notched sections (e.g., four, five, ten, etc.). In some examples, the front end395of the support structure300(e.g., front end of main section352) may include a greater number of notched sections324than the back end397of the support structure300(e.g., back end of main section352), or vice versa. Each notched section324may extend across a width507of the main section352(as shown byFIG. 5B). For example, as shown byFIG. 3, two notched sections324are positioned along axis370and extend in a direction of the axis370along the main section352, with axis370being arranged in a normal direction relative to the surfaces of the support structure300intersected by the axis370. Similarly, two notched sections324are positioned along axis372and extend in a direction of the axis372along the main section352, two notched sections324are positioned along axis374and extend in a direction of the axis374along the main section352, one notched section324is positioned along axis376and extends in a direction of the axis376along the main section352, and one notched section324is positioned along axis378and extends in a direction of the axis378along the main section352. The axes372,374,376, and378are each arranged in normal directions relative to the surfaces of the support structure300that they intersect (e.g., edges of the support structure300positioned at an outer perimeter of the main section352). In some examples, one or more the notched sections324(e.g., notched sections surrounding annular opening334) may extend in a radial direction relative to axis208positioned at the center of the main aperture210(shown byFIG. 2). For example, the support structure300may be embedded within the encasement212such that the annular opening334surrounds the main aperture210, and the notched sections positioned at the portion of the main section352surrounding the main aperture210may be arranged radially relative to the axis208.

A thickness642of each notched section324is less than a thickness644of the main section352in a direction of the z-axis of reference axes299(e.g., a normal direction relative to an outer surface351of the main section352, and a direction of the axis208). Each notched section324extends partway into the thickness644of the main section352(e.g., by an amount corresponding to a difference between the thickness642of each notched section324and the thickness644of the main section352). As shown by the enlarged view641of inset640inFIG. 6, each notched section324includes a notch681formed by a first angled surface646and a second angled surface648, with the first angled surface646and second angled surface648being angled relative to the outer surface351of the main section352. The first angled surface646and the second angled surface648may be angled relative to the outer surface351of the main section352in opposing directions by a same amount of angle. For example, first angled surface646may be angled by 45 degrees in a first direction relative to the outer surface351, and the second angled surface648may be angled by 45 degrees in a second direction relative to the outer surface351, with the first direction being opposite to the second direction. As shown byFIG. 5A, each notched section is positioned at a different, corresponding location of a plurality of locations along the main section352. In some examples, a length505of each notched section is the same as a width507of the main section352at each location, with the length505being in a same direction as the width507.

In other examples (such as the examples shown byFIGS. 7-8), the support structure may include notched sections positioned in a different arrangement relative to the example shown byFIG. 3and described above. For example,FIG. 7shows a support structure700andFIG. 8shows a support structure800, with the support structure700and support structure800each being similar to the support structure300described above with reference toFIG. 3. The support structure700and support structure800include parts similar to those described above with reference to support structure300(e.g., main section352, annular opening334, first arm326, second arm328, third arm330, fourth arm332, etc.). Similar parts may be labeled similarly and not re-introduced. The support structure700and support structure800are each configured to be embedded within a solid encasement of a vehicle component cover (e.g. encasement212of engine cover200described above).

Support structure700shown byFIG. 7includes notched sections724. Notched sections724are similar to the notched sections324described above with reference toFIG. 3. However, the notched sections724are positioned at an angle relative to the notched sections324across the width of the main section352. For example,FIG. 7shows axis725positioned at an angle relative to axis370and axis372. One or more of the notched sections724may extend across the main section352in a direction parallel to the axis725(e.g., at an angle726relative to the axis370). Similarly, support structure800shown byFIG. 8includes notched sections824(similar to the notched sections724), with the notched sections824being positioned at an angle relative to the notched sections324across the width of the main section352. In the example shown byFIG. 8, the notched sections824intersect with each other along the main section352. For example, a first notched section826positioned along axis806and extending in a direction of the axis806intersects with a second notched section828positioned along axis808and extending in a direction of the axis808. Axis806is positioned at an angle802relative to the axis370, and axis808is positioned at an angle804relative to the axis372, with the axis370and axis372being parallel to each other, and with the axis806and axis808being not parallel to each other. In one example, axis806and axis808may be positioned perpendicular to each other.

By configuring a support structure embedded within a solid encasement of a vehicle component cover (e.g., encasement212of engine cover200) to include the notched sections as described above (e.g., support structure300including notched sections324, support structure700including notched sections724, or support structure800including notched sections824), an energy absorption characteristic of the support structure may be increased. For example, in response to an impact (for example), the support structure300may deform (e.g., bend, fold, etc.) and/or separate into a plurality of sections at the notched sections324in order to absorb a greater amount of mechanical energy from the impact. In one example, the support structure300may deform along axes positioned parallel to one or more of the notched sections324(e.g., axis370, axis372, axis374, etc.). In the example of the support structure700shown byFIG. 7and described above, the support structure700may deform along axes positioned parallel to one or more of the notched sections724(e.g., axis725).

In the example of the support structure800shown byFIG. 8and described above, the support structure800may deform along axes positioned parallel to one or more of the notched sections824(e.g., axis806parallel to first notched section826, and/or axis808parallel to second notched section828). In other examples, the notched sections may have a different relative arrangement and the support structure may deform along different axes corresponding to the direction of extension of the notched sections. Each notched section324may separate the main section352into a plurality of breakaway sections, as shown by first breakaway section391and second breakaway section393ofFIG. 3. In response to an impact, the first breakaway section391and second breakaway section393may separate from each other at the notched section324, enabling the support structure300to absorb an increased amount of mechanical energy from the impact. The main section352is configured such that, for each breakaway section of the plurality of breakaway sections, a corresponding notched section of the plurality of notched sections joins the breakaway section to an adjacent, corresponding breakaway section of the plurality of breakaway sections. For example, the first breakaway section391is joined to the second breakaway section393by the notched section324, with the second breakaway section393and first breakaway section391being positioned adjacent to each other.

In this way, the number and relative arrangement of the notched sections determines the energy absorption characteristics (e.g., deforming characteristics) of the support structure (e.g., the axes along which the support structure may deform). For example, because the support structure300includes notched sections324positioned along the axis374, the support structure300may have an increased likelihood to deform along axis374in response to an impact relative to the support structure800(which does not include notched sections positioned along the axis374). Similarly, because the support structure800includes notched sections824positioned along the axes806and808, the support structure800may have an increased likelihood to deform along axis806and/or axis808in response to an impact relative to the support structure300. In each example, during conditions in which the support structure (e.g., support structure300, support structure700, and support structure800) is not deformed (e.g., the support structure has not absorbed mechanical energy from an impact), the support structure increases a rigidity and durability of the engine cover.

In some examples, the support structure300(and similarly, support structure700and/or support structure800) may include a plurality of lock orifices positioned along the main section352. For example,FIG. 3shows a first lock orifice318, a second lock orifice320, and a third lock orifice322aligned with each other along axis316(e.g., positioned along axis316, with axis316intersecting a midpoint of each lock orifice). In other examples, the support structure may include a different number of lock orifices (e.g., two, five, etc.) and/or a different arrangement of lock orifices (e.g., with one or more of the first lock orifice318, second lock orifice320, and/or third lock orifice322being positioned along a different axis than each other lock orifice).

The emblem204includes a plurality of extensions (e.g., first extension306, second extension304, and third extension302) positioned to couple with (e.g., slide into locking engagement with) the plurality of lock orifices during conditions in which the emblem204is seated within the recess206of the encasement212(as shown byFIG. 2and described above). In the example shown byFIG. 3, the plurality of extensions are aligned with each other along axis314, similar to the alignment of the plurality of lock orifices along the axis316. For example, a distance380from the first lock orifice318to the second lock orifice320in a direction of the axis316(e.g., the distance380from axis312to axis310in the direction of axis316, with the axes312and310each being perpendicular to the axis316, and with the axis312intersecting a midpoint of the first lock orifice318and the axis310intersecting the midpoint of the second lock orifice320) is the same as the distance between the first extension306and the second extension304in a direction of the axis314(with the axis314being parallel to the axis316and positioned along the axis316during conditions in which the emblem204is coupled to the support structure300by coupling the plurality of extensions to the plurality of lock orifices). Similarly, a distance382from the second lock orifice320to the third lock orifice322in a direction of the axis316(e.g., the distance380from axis310to axis308in the direction of axis316, with the axes310and308each being perpendicular to the axis316, and with the axis310intersecting a midpoint of the second lock orifice320and the axis308intersecting the midpoint of the third lock orifice322) is the same as the distance between the second extension304and the third extension302in a direction of the axis314.

As shown byFIG. 4, the recess206of the encasement212includes a plurality of openings (e.g., first opening400and second opening402) positioned to align with the plurality of lock orifices of the support structure300. Specifically, a separate, corresponding opening of the plurality of openings is positioned to align with each lock orifice of the support structure300. For example, the first opening400is positioned to align with the third lock orifice322in a direction from the bottom end214to the top end202(with the bottom end214and top end202being shown byFIG. 2), and the second opening402is positioned to align with the second lock orifice320in the direction from the bottom end214to the top end202(e.g., in a direction of the z-axis of reference axes299).

In the example shown byFIG. 4, the plurality of openings are aligned with each other along axis316(which may be referred to herein as a lateral axis of the cover), similar to the alignment of the plurality of lock orifices along the axis316. For example, a distance450from the first opening400to the second opening402in the direction of the axis316is the same as the distance382(shown byFIG. 3and described above) from the second lock orifice320to the third lock orifice322in the direction of the axis316. Similarly, a third opening (not shown) of the plurality of openings of the recess206positioned away from the second opening402and first opening400by a same distance from the second opening402in the direction of the axis316as the distance380from the first lock orifice318to the second lock orifice320. In one example, each opening of the plurality of openings is positioned at an end of a separate passage open at both the top end202and the bottom end214of the encasement212, with the passage extending entirely through the encasement212in the direction from the top end202to the bottom end214. For example, the passage622shown byFIG. 6forms the first opening400, and the passage620shown byFIG. 6forms the second opening402. The support structure is embedded within the encasement in a position such that each passage (e.g., passage622and passage620) is intersected by a corresponding lock orifice of the plurality of lock orifices. For example, passage622is intersected by second lock orifice320, and passage620is intersected by third lock orifice322. In other examples, each passage may be open at the top end202and closed at the bottom end214of the encasement212and may extend partially through the encasement212in the direction from the top end202to the bottom end214. In yet other examples, one or more of the passages may be opened at both the top end202and the bottom end214, and one or more of the openings may be opened at the top end202and closed at the bottom end214. In some examples, each passage of the plurality of passages tapers from a larger, first diameter at the recess206to a smaller, second diameter in a direction from the top end202to the bottom end214. Additionally, each extension of the plurality of extensions may taper from a third diameter to a smaller, fourth diameter, similar to the tapering of the passages described above.

Although the openings of the plurality of openings of the recess206are aligned with each other in the direction of the axis316in the example described herein, in other examples the openings may be positioned differently (e.g., not aligned with each other). However, in each example, each opening of the plurality of openings is aligned with a corresponding lock orifice of the plurality of lock orifices in the direction from the top end202to the bottom end214(e.g., in the direction of the z-axis of reference axes299). For example, in examples in which the lock orifices positioned in a different arrangement relative to the example shown byFIG. 3(e.g., examples in which the lock orifices are not positioned aligned along a same axis), the openings of the recess206are positioned in a similar arrangement so that each opening of the recess206(and each corresponding passage forming the openings) is aligned with a corresponding lock orifice of the support structure300. In yet other examples which do not include the recess206, the openings of the plurality of openings (e.g., first opening400, second opening402, etc.) may instead be positioned at the top surface216and each passage forming the openings (e.g., passage620, passage622, etc.) may extend from the top surface216toward the bottom end214, with each opening being aligned with a corresponding lock orifice of the support structure300in the direction from the top surface216toward the bottom end214(e.g., the direction of the z-axis of reference axes299).

Each of the lock orifices (e.g., first lock orifice318, second lock orifice320, and third lock orifice322) may be a self-locking orifice shaped to engage with a corresponding extension of the plurality of extensions of the emblem204in order to couple the emblem204to the encasement212(e.g., lock the emblem204into the recess206). As an example,FIG. 5Bshows an enlarged view of an area520surrounding the third lock orifice322, the area520being shown byFIG. 5A. Although the third lock orifice322is shown as an example, each other lock orifice (e.g., first lock orifice318and second lock orifice320) may include a similar configuration.

The third lock orifice322includes a first notched tab500and a second notched tab502(which may each be referred to herein as notched sections), as shown byFIG. 5B. Each notched tab (e.g., first notched tab500and second notched tab502) is adapted to hold a corresponding extension of the plurality of extensions in place. As an example of the intersection of each lock orifice with each corresponding passage of the encasement212, the support structure may be embedded within the encasement212in a position in which the first notched tab500and second notched tab502are positioned partially or entirely within the passage620. Each other lock orifice (e.g., first lock orifice318and second lock orifice320) includes notched tabs similar to the first notched tab500and second notched tab502, and the notched tabs of the lock orifices may be positioned partially or entirely within (e.g., partially or entirely intersecting) the corresponding passages of the encasement. For example, notched tabs of the second lock orifice320may be positioned partially or entirely within passage622, and notched tabs of the first lock orifice318may be positioned partially or entirely within a passage (not shown) forming the third opening at the recess206. During conditions in which a corresponding extension of the plurality of extensions of the emblem204(e.g., third extension302) is inserted (e.g., slides) through the third lock orifice322, the first notched tab500and second notched tab502are pressed away from the extension and may temporarily bend in a direction away from the emblem204.

In some examples, the first notched tab500and second notched tab502may be formed of a same material as the support structure300(e.g., metal, plastic, etc.) and may have spring-like characteristics. For example, during conditions in which the third extension302is not inserted into the third lock orifice322, a width504of the third lock orifice322between the first notched tab500and the second notched tab502is less than a diameter of the third extension302, and a length506of the third lock orifice322is greater than the diameter of the third extension302. However, during conditions in which the third extension302is inserted into the third lock orifice322, the first notched tab500and second notched tab502are pivoted away from each other by the third extension302, increasing the width504between the first notched tab500and the second notched tab502. As the third extension302slides through the third lock orifice322, the first notched tab500and second notched tab502may resist pivoting by the third extension302and may press against the third extension302to lock the third extension302into engagement with the third lock orifice322. In this way, the notched tabs of the third lock orifice322enable the third extension302of the emblem204to slide through the third lock orifice322in a first direction (e.g., the direction from the top end202to the bottom end214) but do not enable the third extension302to slide through the third lock orifice322in a second direction opposite to the first direction (e.g., from the bottom end214to the top end202). Locking the third extension302to the third lock orifice322in this way restrains (e.g. locks) the third extension302from sliding in the opposite, second direction.

Coupling the emblem204to the engine cover200as described above includes sliding the plurality of extensions of the emblem204(e.g., first extension306, second extension304, and third extension302) into locking engagement with the plurality of lock orifices of the support structure (e.g., support structure300, support structure700, or support structure800) embedded within the solid encasement212of the cover200. For example, first extension306slides into locking engagement with the first lock orifice318, second extension304slides into locking engagement with the second lock orifice320, and third extension302slides into locking engagement with the third lock orifice322. The plurality of extensions are locked into engagement with the plurality of lock orifices only by sliding the plurality of extensions through the plurality of lock orifices. For example, the plurality of extensions may slide through the plurality of passages (e.g., passage620, passage622, etc.) forming the plurality of openings (e.g., first opening400, second opening402, etc.), with the plurality of openings being positioned at the recess206. For each extension of the plurality of extensions, the extension presses against self-locking section of a corresponding lock orifice of the plurality of lock orifices. In one example, the self-locking section may be one or more notched tabs, similar to the first notched tab500and second notched tab502of third lock orifice322described above with reference toFIG. 5B. Pressing the extension against the self-locking section of the corresponding lock orifice may include pivoting the self-locking section in a direction away from the extension. For example, as the third extension302slides through the passage620and presses against the third lock orifice322, the first notched tab500and second notched tab502may be pivoted in a direction away from the third extension302by the third extension302. In addition to coupling the emblem204to the cover200, the cover200may be coupled to the engine (e.g., engine10) by inserting a fastener (e.g., bolt) through an opening of an arm of the support structure300(e.g.,360of336of326,362of338of328,364of340of332, and/or366of342of330) and into a corresponding opening of the engine, vehicle component, or component of the engine.

FIG. 6shows a cross-sectional view of the emblem204coupled to the encasement212. Specifically, the emblem204is seated within the recess206, the third extension302is inserted through the third lock orifice322via first opening400, and the second extension304is inserted through the second lock orifice320via second opening402. Although not shown byFIG. 6, the first extension306is inserted through the first lock orifice318via the third opening (not shown) of the plurality of openings of the recess206, with the third opening being formed by a passage extending through the encasement212(e.g., similar to passage620and passage622). In the configuration shown byFIG. 6, the third extension302is locked into engagement with the third lock orifice322, the second extension304is locked into engagement with the second lock orifice320, and the first extension306is locked into engagement with the first lock orifice318(e.g., via pivoting of notched tabs of each locked orifice, as described in the example above with reference to first notched tab500and second notched tab502of third lock orifice322).

In this configuration, the emblem204may be coupled to the encasement212without additional fasteners (e.g., bolts, nuts, clips, etc.). For example, as shown byFIG. 6, no additional fasteners are coupled to the extensions of the emblem204at the bottom end214of the engine cover200. The emblem204is locked into position within the recess206by the engagement of the lock orifices of the support structure300with the plurality of extensions of the emblem204. By configuring the emblem204to lock to the support structure300without fasteners, an assembly time and/or cost of the engine cover200may be reduced (e.g., by reducing an amount of components to couple the emblem204to the support structure300and encasement212).

In this way, the support structure embedded within the solid encasement of the vehicle component cover increases the rigidity of the vehicle component cover. The support structure may additionally increase the energy absorption characteristic and/or an ease of assembly of the vehicle component cover. By including the plurality of notched sections positioned across the main section of the support structure, the support structure may deform in order to absorb an increased amount of mechanical energy (e.g., from an impact to the vehicle component cover). By configuring the support structure to include the plurality of lock orifices, the lock orifices may engage (e.g., couple) with the extensions of the emblem in order to enable the emblem to be coupled to the engine cover without fasteners and to retain the position of the emblem relative to the encasement and support structure. The technical effect of sliding the extensions of the emblem through the lock orifices is to lock the emblem against the surfaces of the encasement. The technical effect of enabling the support structure to deform via the plurality of notched sections is to increase the energy absorption characteristic of the engine cover.

In one embodiment, a vehicle component cover comprises: a solid encasement including a plurality of passages; and a support structure embedded within the encasement and including a plurality of lock orifices, with each lock orifice of the plurality of lock orifices positioned to intersect a corresponding passage of the plurality of passages. In a first example of the cover, the cover further comprises an emblem including a plurality of extensions, with each extension of the plurality of extensions aligning with a corresponding passage of the plurality of passages. A second example of the cover optionally includes the first example, and further includes a recess positioned at a top end of the cover, the recess including a plurality of sidewalls and a lower surface offset from a top surface of the cover, wherein the emblem is shaped to seat against the lower surface and the plurality of sidewalls. A third example of the cover optionally includes one or both of the first and second examples, and further includes wherein each extension of the plurality of extensions is shaped to engage with a corresponding lock orifice of the plurality of lock orifices. A fourth example of the cover optionally includes one or more or each of the first through third examples, and further includes wherein each extension of the plurality of extensions is slideable through the corresponding lock orifice in a first direction and not in an opposing, second direction, and wherein each corresponding lock orifice includes a notched tab adapted to hold a corresponding extension of the plurality of extensions in place. A fifth example of the cover optionally includes one or more or each of the first through fourth examples, and further includes wherein each passage of the plurality of passages extends from a top surface of the cover to a bottom surface of the cover, the top surface and bottom surface arranged opposite one another. A sixth example of the cover optionally includes one or more or each of the first through fifth examples, and further includes wherein each passage of the plurality of passages is aligned with each other passage of the plurality of passages along a lateral axis of the cover, the lateral axis intersecting a midpoint of each lock orifice of the plurality of lock orifices. A seventh example of the cover optionally includes one or more or each of the first through sixth examples, and further includes wherein the plurality of passages forms a plurality of openings at a top end of the cover. An eighth example of the cover optionally includes one or more or each of the first through seventh examples, and further includes wherein the plurality of openings are positioned at a lower surface of a recess, the lower surface being offset from a top surface of the cover. A ninth example of the cover optionally includes one or more or each of the first through eighth examples, and further includes a plurality of arms joined to a flat, planar main section of the support structure and extending through the encasement away from the main section. A tenth example of the cover optionally includes one or more or each of the first through ninth examples, and further includes wherein each arm of the plurality of arms extends away from the main section in a radial direction relative to a lateral axis of the cover, the lateral axis intersecting a midpoint of each lock orifice of the plurality of lock orifices, and wherein an arm of the plurality of arms includes an end adapted to receive a fastener. An eleventh example of the cover optionally includes one or more or each of the first through tenth examples, and further includes wherein an entirety of the main section is positioned within an interior of the encasement, and wherein the plurality of arms extends outward from the encasement to an exterior of the encasement. A twelfth example of the cover optionally includes one or more or each of the first through eleventh examples, and further includes wherein the encasement is formed of an elastic, compressible material, and wherein the support structure is formed of a rigid, non-compressible material.

In one embodiment, a method comprises: coupling an emblem to a vehicle component cover by sliding a plurality of extensions of the emblem into locking engagement with a plurality of lock orifices of a support structure embedded within a solid encasement of the cover, the plurality of extensions being locked into engagement with the plurality of lock orifices only by sliding the plurality of extensions through the plurality of lock orifices. In a first example of the method, coupling the emblem to the vehicle component cover includes: sliding the plurality of extensions of the emblem through a plurality of passages formed by the encasement. A second example of the method optionally includes the first example, and further includes wherein sliding the plurality of extensions through the plurality of lock orifices includes, for each extension of the plurality of extensions, sliding the extension in a first direction through a corresponding lock orifice of the plurality of lock orifices to lock the extension to the corresponding lock orifice, where locking the extension to the corresponding lock orifice restrains the extension from sliding in an opposite, second direction. A third example of the method optionally includes one or both of the first and second examples, and further includes wherein locking the extension to the corresponding lock orifice includes pressing the extension against a self-locking section of the corresponding lock orifice to pivot the self-locking section in a direction away from the extension. A fourth example of the method optionally includes one or more or each of the first through third examples, and further includes coupling the vehicle component cover to a vehicle component by inserting a fastener through an opening of an arm of the support structure and into a corresponding opening of the vehicle component.

In one embodiment, a vehicle comprises: an engine compartment having an engine disposed therein; and a vehicle component cover coupled to the engine, the cover including: a solid elastic encasement having a plurality of passages formed therein; a rigid support structure embedded within the encasement, the support structure including a plurality of lock orifices positioned to align with the plurality of passages; and an emblem including a plurality of extensions shaped to seat within the plurality of passages and couple in locking engagement with the plurality of lock orifices. In a first example of the vehicle, the encasement includes a main aperture adapted to encircle a component of the engine, and wherein the support structure includes an annular section shaped to encircle the main aperture within an interior of the encasement.

In another representation, a vehicle comprises: an engine compartment having an engine disposed therein; a vehicle component cover coupled to the engine, the cover including: a solid encasement including a plurality of passages; and a support structure embedded within the encasement and including a plurality of lock orifices, with each lock orifice of the plurality of lock orifices positioned to intersect a corresponding passage of the plurality of passages; a transmission; and an electric machine selectably coupleable to the transmission via one or more clutches, the electric machine adapted to drive the transmission.