Reconfigurable vehicle interior assembly

In one embodiment, a reconfigurable vehicle interior assembly is provided. The assembly includes a trim member including a plurality of first elastically deformable mating members and a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members matingly engages with at least one of the second elastically deformable mating members in order to couple the trim member to the vehicle interior carrier component. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

TECHNICAL FIELD

The present disclosure relates to a reconfigurable vehicle interior assembly.

BACKGROUND

Most vehicles, such as automobiles, include a vehicle interior assembly that defines a passenger compartment. Vehicle occupants spend most of their time in the passenger compartment. It is therefore useful to tailor the aesthetic appearance of the vehicle interior assembly in accordance with the vehicle occupant's preferences.

SUMMARY

In one embodiment, a reconfigurable vehicle interior assembly is provided. The assembly includes a trim member including a plurality of first elastically deformable mating members and a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members matingly engages with at least one of the second elastically deformable mating members in order to couple the trim member to the vehicle interior carrier component. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

In another embodiment, a vehicle is provided. The vehicle includes a trim assembly including a plurality of a trim members, each of the trim members including a plurality of first elastically deformable mating members, and a vehicle interior carrier component sub-assembly including a plurality of a vehicle interior carrier components. Each of the vehicle interior carrier components includes a plurality of second elastically deformable mating members, and each of the first elastically deformable mating members engages at least one of the second elastically deformable mating members in order to couple the trim members to the vehicle interior carrier components. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

In yet another embodiment, a method of assembling a vehicle interior assembly is provided. The method includes providing a trim member including a plurality of first elastically deformable mating members, and providing a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members is configured to deformably engage at least one of the second elastically deformable mating members. The method further includes mating the first elastically deformable mating members with the second deformable mating members in order to couple the trim member to the vehicle interior coupling member.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. For example, the embodiments shown are applicable to vehicle components, but the system disclosed herein may be used with any suitable components to provide securement and elastic averaging for precision location and alignment of all manner of mating components and component applications, including many industrial, consumer product (e.g., consumer electronics, various appliances and the like), transportation, energy and aerospace applications, and particularly including many other types of vehicular components and applications, such as various interior, exterior, electrical and under hood vehicular components and applications. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

As used herein, the term “elastically deformable” refers to components, or portions of components, including component features, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo a resiliently reversible change in its shape, size, or both, in response to application of a force. The force causing the resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or torsional force, or various combinations of these forces. The elastically deformable materials may exhibit linear elastic deformation, for example that described according to Hooke's law, or non-linear elastic deformation.

Elastic averaging provides elastic deformation of the interface(s) between mated components, wherein the average deformation provides a precise alignment, the manufacturing positional variance being minimized to Xmin, defined by Xmin=X/√N, wherein X is the manufacturing positional variance of the locating features of the mated components and N is the number of features inserted. To obtain elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that is over-constrained and provides an interference fit with a mating feature of another component and its contact surface(s). The over-constrained condition and interference fit resiliently reversibly (elastically) deforms at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components allows repeatable insertion and withdrawal of the components that facilitates their assembly and disassembly. In some embodiments, the elastically deformable component configured to have the at least one feature and associated mating feature disclosed herein may require more than one of such features, depending on the requirements of a particular embodiment. Positional variance of the components may result in varying forces being applied over regions of the contact surfaces that are over-constrained and engaged during insertion of the component in an interference condition. It is to be appreciated that a single inserted component may be elastically averaged with respect to a length of the perimeter of the component. The principles of elastic averaging are described in detail in commonly owned U.S. Pat. No. 8,695,201, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed above provide the ability to convert an existing component that is not compatible with the above-described elastic averaging principles, or that would be further aided with the inclusion of an elastic averaging system as herein disclosed, to an assembly that does facilitate elastic averaging and the benefits associated therewith.

Any suitable elastically deformable material may be used for the mating components and alignment features disclosed herein and discussed further below, particularly those materials that are elastically deformable when formed into the features described herein. This includes various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof suitable for a purpose disclosed herein. Many composite materials are envisioned, including various filled polymers, including glass, ceramic, metal and inorganic material filled polymers, particularly glass, metal, ceramic, inorganic or carbon fiber filled polymers. Any suitable filler morphology may be employed, including all shapes and sizes of particulates or fibers. More particularly any suitable type of fiber may be used, including continuous and discontinuous fibers, woven and unwoven cloths, felts or tows, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers or thermoset polymers, or composites thereof, or any other combinations thereof, including a wide variety of co-polymers and polymer blends. In one embodiment, a preferred plastic material is one having elastic properties so as to deform elastically without fracture, as for example, a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate ABS polymer blend (PC/ABS). The material may be in any form and formed or manufactured by any suitable process, including stamped or formed metal, composite or other sheets, forgings, extruded parts, pressed parts, castings, or molded parts and the like, to include the deformable features described herein. The elastically deformable alignment features and associated component may be formed in any suitable manner. For example, the elastically deformable alignment features and the associated component may be integrally formed, or they may be formed entirely separately and subsequently attached together. When integrally formed, they may be formed as a single part from a plastic injection molding machine, for example. When formed separately, they may be formed from different materials to provide a predetermined elastic response characteristic, for example. The material, or materials, may be selected to provide a predetermined elastic response characteristic of any or all of the elastically deformable alignment features, the associated component, or the mating component. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.

As used herein, the term vehicle is not limited to just an automobile, truck, van or sport utility vehicle, but includes any self-propelled or towed conveyance suitable for transporting a burden.

Referring now to the drawings, wherein the like numerals indicate corresponding parts throughout the several views,FIG. 1schematically illustrates a vehicle100including a reconfigurable vehicle interior assembly102. The vehicle interior assembly102includes a vehicle interior component carrier sub-assembly104and a plurality of instrument panel trim members or pieces106that can be coupled to different vehicle carrier components103of the vehicle interior carrier component sub-assembly104. The trim members106may be part of a trim assembly124(FIG. 2) and may also be trim panels.

The vehicle interior carrier components103may be entirely or partially disposed inside the vehicle100. In the depicted embodiment, the vehicle interior carrier component sub-assembly102includes a plurality of vehicle interior carrier components103. In the present disclosure, some of the vehicle interior carrier components103at least partially define a passenger compartment106of the vehicle100, while other vehicle interior carrier components103are devices that can be used to control the vehicle100. As non-limiting examples, the vehicle interior carrier components103may include at least one door108, a steering wheel110, an instrument panel or dashboard112, and a center floor console114. The dashboard112may include a center console116, a first lateral section118, and a second lateral section120. The first lateral section118is closer to the steering wheel110than the second lateral section120of the dashboard112. All or some of the vehicle interior carrier components103may be decorated with one or more trim members106in order to enhance the aesthetic appeal of the vehicle100.

In the present disclosure, the trim members106are removably coupled to the different vehicle interior carrier components103. The trim members106may have different colors and/or styles. Accordingly, the vehicle10may be equipped with trim members106that are specifically tailored to satisfy a vehicle occupant's preferences. Because the trim members106can be decoupled from the vehicle interior carrier components103, the vehicle interior assembly102may be reconfigured by replacing the trim members106with other trim members106.

In order to facilitate coupling the trim members106to the vehicle interior carrier components103, the vehicle interior assembly102includes elastic averaging couplings or interfaces122(seeFIGS. 5 and 7). Elastically averaged coupling is based on the principle that alignment can be obtained by using a large number of fairly compliant contacting members. Therefore, the term “elastic averaging coupling” means a passive alignment coupling, in which two parts are joined using a large number of interference-fitting contact features. When the two parts are joined, small errors in size and position of the interference-fitting contact features result in multiple elastic deformations that average to yield a precisely repeatable alignment. Unlike kinematic couplings, elastic averaging couplings are over-constraining systems in which each constraint is fairly elastic.

With reference toFIGS. 1 and 2, the trim assembly124(FIG. 2) includes a plurality of the trim members106and can be custom-made. For example, the trim members106may have different colors and styles in order to enhance the aesthetic appeal of the vehicle100. Each trim member106includes a trim member body126defining a first or outer surface130(FIG. 1) and a second or inner surface132(FIG. 2). The second surface132is opposite to the first surface130and may intersect the first surface130along an edge134. The first surface130of the trim member106faces away from a corresponding vehicle interior carrier component103, whereas the second surface132faces toward a corresponding vehicle interior carrier component103. Moreover, the first surface130may be a reflective surface.

In addition to the trim member body126, each trim member106includes at least one first elastically deformable mating member128(FIG. 2). In the depicted embodiment, each trim member106includes a plurality of first elastically deformable mating members128. At least one of the first elastically deformable mating members128may be an elastically deformable protrusion136. The elastically deformable protrusion136may also be referred to as an elastically deformable locating protrusion. In the depicted embodiment, all the first elastically deformable mating members128are elastically deformable protrusions136extending from the trim member body126. The elastically deformable protrusions136may specifically extend from the second surface132in a direction away from the first surface130. It is contemplated, however, that the first elastically deformable mating members128may alternatively be configured, for example, as cavities that extend into the trim member body126or any other suitable elastically deformable structure. Regardless of its configuration, the first elastically deformable mating members128may be arranged along the edges134of the trim member bodies126. For example, the trim members106may include first elastically deformable mating members128(e.g., elastically deformable protrusions136) along the entire edge134of the trim member body126.

As discussed above, the trim assembly124includes a plurality of trim members106. Each trim member106can be removably coupled to a specific vehicle interior carrier component103. As non-limiting examples, the trim assembly124may include one or more door trim members138A,138B, a steering wheel trim member140, a center floor console trim member144, and one or more dashboard trim members142A,142B,142C,142D. The door trim members138A,138B can be removably coupled to the door108. The steering wheel trim member140can be removably coupled to the steering wheel110. The center floor console trim member144can be removably coupled to the center floor console116, and the dashboard trim members142A,142B,142C,142D can be removably coupled to different parts of the dashboard112. The dashboard trim member142B may be referred to as a center console trim member.

With continued reference toFIGS. 1 and 2, each vehicle interior carrier component103includes at least one second elastically deformable mating member148configured to mate with a corresponding first elastically deformable mating member128. In the depicted embodiment, each vehicle interior carrier component103includes a plurality of second elastically deformable mating members148. Each second deformable mating member148can mate a corresponding first deformable mating member128in a deformation-fit manner to couple a trim member106to a corresponding vehicle interior carrier component103. In other words, each of the first elastically deformable mating members128can mate with at least one of the second elastically deformable mating members148in a deformation-fit engagement in order to couple the trim member106to the corresponding vehicle interior carrier component103. The first and second elastically deformable mating members128,148collectively form a plurality of elastic averaging couplings122(FIGS. 5 and 7). As such, the first elastically deformable mating members128or second elastically deformable mating member148(or both) elastically deform when they are coupled to each other.

Each vehicle interior carrier component103may include a coupling structure146, such as a border, rim, or raised surface, and the second elastically deformable mating members148are disposed along the coupling structure146. In the depicted embodiment, some of the coupling structures146are borders, and the second elastically deformable mating members148span the border of those vehicle interior carrier components103.

With reference toFIGS. 3-5, at least one of the first elastically deformable mating members128may be an elastically deformable protrusion136as discussed above. Each elastically deformable protrusion136extends from the trim member body126along a longitudinal axis Y. As a non-limiting example, the elastically deformable protrusion136may be a cylinder or a tube and, as such, includes a cylindrical body150defining an opening152extending into the cylindrical body150along the longitudinal axis Y. The cylindrical body150may define an outer body surface151and an inner body surface153. The inner body surface153defines the opening152. Thus, the elastically deformable protrusion136may be hollow to facilitate deformation of its cylindrical body150. Thus, the elastically deformable protrusion136may also be referred to as a compressible tube or cylinder. However, it is contemplated that the elastically deformable protrusion136may be solid and, therefore, would not include opening152. Even if the elastically deformable protrusion136is solid, it can be deformed when mated with a corresponding second elastically deformable mating member148.

With reference toFIG. 4, at least one of the second elastically deformable mating members148may be an aperture156extending into the vehicle interior carrier component103. In the depicted embodiment, the aperture156is a slot and extends into the coupling structure146of the vehicle interior carrier component103. The coupling structure146(or another part of the vehicle interior carrier component103) includes an inner mating surface158defining the aperture156. Irrespective of its location in the vehicle interior carrier component103, the aperture156is configured, shaped, and sized to receive at least one elastically deformable protrusion136(or any other type of first elastically deformable mating member128) in deformable engagement so as to form an elastic averaging coupling122(FIG. 5), thereby coupling the vehicle interior carrier component103to the trim member106.

With reference toFIG. 5, the elastically deformable protrusion136can be at least partially inserted in the aperture156in the coupling structure146in order to couple trim member106(FIG. 1) to the vehicle interior carrier component103in an elastically deformable manner. When the elastically deformable protrusion136is at least partially inserted in the aperture156, the outer body surface151is in contact with the inner mating surface158. Further, when the elastically deformable protrusion136is at least partially inserted in the aperture156, the elastically deformable protrusion136is compressed due to a force exerted by the inner mating surface158on the outer body surface151. Alternatively or additionally, when the elastically deformable protrusion136is at least partially inserted in the aperture156, the aperture156may expand due to a force exerted by the elastically deformable protrusion136on the inner mating surface156. Moreover, the vehicle interior carrier component103and the trim member106are coupled by a deformable engagement defined by the elastically deformable protrusion136and the inner mating surface158defining the aperture156.

Referring toFIG. 6, in an embodiment, at least one of the second elastically deformable mating members148may include a plurality of elastically deformable extensions160spaced apart from one another so as to define a gap161. In the depicted embodiment, each second elastically deformable mating member148includes four elastically deformable extensions160; however, each second elastically deformable mating member148may include any number of elastically deformable extensions160. The elastically deformable extensions160may be substantially cylindrical and each extends from the coupling structure146of the vehicle interior carrier component103. Each elastically deformable extension160defines an outer extension surface162. The outer extension surfaces162of the elastically deformable extensions160of each elastically deformable mating member148define the gap161. The gap161is configured, shaped, and sized to receive at least one of the elastically deformable protrusions136such that the at least one of the elastically deformable protrusions136engages the elastically deformable extensions160in the elastically deformable engagement, thereby coupling the vehicle interior carrier component103to the trim member106. Specifically, in the depicted embodiment, one elastically deformable protrusion136is at least partially inserted in the gap161such that the outer body surface151contacts the outer extension surfaces162of the elastically deformable extensions160. When the elastically deformable protrusion136is at least partially inserted in the gap161, the elastically deformable extensions160may exert a force on the outer body surface151and thereby compress the elastically deformable protrusion136. Alternatively or additionally, when the elastically deformable protrusion136is at least partially inserted in the gap161, the outer body surface151may exert a force on the outer extension surfaces162and thereby expand the gap161.

The present disclosure also relates to a method of assembling a vehicle interior assembly102. In an embodiment, the method includes providing a trim member106including a plurality of first elastically deformable mating members128as shown inFIGS. 1 and 2; providing a vehicle interior carrier component103including a plurality of second elastically deformable mating members148as shown inFIGS. 1 and 2. As discussed above, each of the first elastically deformable mating members128is configured to mate with at least one of the second elastically deformable mating members148in an elastically deformable engagement. The method further includes mating the first elastically deformable mating members128with the second deformable mating members148in order to couple the trim member106to the vehicle interior coupling member103as shown inFIGS. 5 and 7.