ELASTICALLY DEFORMABLE RETAINING HOOK FOR COMPONENTS TO BE MATED TOGETHER AND METHOD OF ASSEMBLING

An elastically deformable retaining hook for matable components includes a first component having a body portion extending from a first end to a second end. Also included is a second component extending from a first end to a second end. Further included is a slot disposed in the first end of the second component and defined by a first, second, third, and fourth slot wall. Yet further included is a hook portion disposed proximate the first end of the body portion. The hook portion includes a first segment extending angularly from the body portion. The hook portion also includes a second segment extending angularly from the first segment and configured to fittingly engage the slot of the second component, wherein the second segment is formed of an elastically deformable material and configured to elastically deform upon engagement with the first slot wall and the second slot wall.

DESCRIPTION OF THE EMBODIMENTS

Referring toFIG. 1, a retaining assembly10is illustrated. The retaining assembly10comprises components configured to be engaged or mated with each other, such as a first component12and a second component14. The retaining assembly10may be associated with numerous applications and industries, such as home appliance and aerospace applications, for example. In one embodiment, the retaining assembly10is employed in a vehicle, such as an automobile. In an automobile embodiment, the retaining assembly10may comprise a door handle assembly including a door handle and a handle insert. As will be appreciated from the description herein, embodiments of the retaining assembly10may be used in any application that benefits from a reduction or elimination of gaps that may result in vibration and noise or poor appearance.

The first component12includes a body portion16extending from a first end18to a second end20in a substantially longitudinal direction22. It is to be appreciated that the geometry of the body portion16typically includes slight curvature that deviates from the substantially longitudinal direction22. Irrespective of the precise degree of curvature, or lack thereof, a first engagement surface24is located along the body portion16and is configured to engage the second component14along a second engagement surface26of the second component14. Similar to the first component12, the second component14extends along the substantially longitudinal direction22, but may include slight curvature, with the second component14extending between respective ends. Specifically, the second component14extends from a first end28to a second end30. The first component12may include one or more auxiliary locating features32that assist with location and retention of the first component12relative to the second component14. The auxiliary locating features32may engage one or more apertures34of the second component14. The auxiliary locating features32may be formed of an elastically deformable material, with such materials being described in detail below. However, it is contemplated that location and retention of the first component12to the second component14may be facilitated with the embodiments described below, without the need for the auxiliary locating features32.

Referring toFIG. 2, proximate the first end28of the second component14is a slot36formed therein. As will be described in detail herein, the slot36comprises a receiving feature that is configured to fittingly engage a retaining member of the first component12. The second component14includes a first slot wall56, a second slot wall58, a third slot wall60and a fourth slot wall62. In conjunction, the slot walls56,58,60,62define the slot36.

Referring now toFIG. 3, the first component12is shown to better illustrate the first engagement surface24, as well as the retaining member referenced above. Specifically, a hook portion38is disposed proximate the first end18of the body portion16of the first component12. The hook portion38includes a first segment40extending angularly away from the first engagement surface24of the body portion16. In one embodiment, the first segment40is positioned at an angle of about 90° from the body portion16in a substantially orthogonal relationship. The first segment40, and more generally the hook portion38, may be operatively coupled to, or integrally formed with, the body portion16of the first component12. The hook portion38also includes a second segment42extending angularly away from the first segment40of the hook portion38. In one embodiment, the second segment42is positioned at an angle of about 90° from the first segment40in a substantially orthogonal relationship. The second segment42is configured to be inserted into the slot36and is formed of an elastically deformable material that facilitates precise alignment and fitted engagement of the first component12with the second component14. In other embodiments, the entire hook portion38is formed of an elastically deformable material. In yet another embodiment, the entire first component12is formed of an elastically deformable material.

Any suitable elastically deformable material may be used for the second segment42. 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.

Numerous examples of materials that may at least partially form the components include various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof. 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), such as an ABS acrylic. 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 material, or materials, may be selected to provide a predetermined elastic response characteristic of the second segment42of the hook portion38. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.

Referring now toFIG. 4, a cross-sectional view, taken along lines4A-4A and4B-4B ofFIGS. 2 and 3, illustrates engagement of the second segment42of the hook portion38with the second component14, and more particularly insertion of the second segment42within the slot36. The second segment42comprises a main portion44, with a first tab46, a second tab48and a third tab50extending therefrom. The first tab46and the second tab48are formed by a first recess52and a second recess54. The first recess52is present between the first tab46and the third tab50, while the second recess54is present between the second tab48and the third tab50.

As shown, the first slot wall56includes a first tapered portion64and the second slot wall58includes a second tapered portion68. The first tapered portion64and the second tapered portion68angle inwardly from an outer edge70of the second component14toward respective inner ends72. In the illustrated embodiment, the entireties of the first slot wall56and the second slot wall58are tapered in an angular manner, however, it is to be appreciated that only a portion of the first slot wall56and/or the second slot wall58may be tapered in alternative embodiments.

In the illustrated embodiment, the first tab46and the second tab48are positioned inwardly from respective side surfaces74of the second segment42, thereby exposing a first abutment surface76and a second abutment surface78. Upon full insertion of the second segment42into the slot36, the first abutment surface76and the second abutment surface78may engage the outer edge70of the second component14. The outer surfaces80of the first tab46and the second tab48define a hook width82. A slot width84is defined by the distance between the respective inner ends72of the first tapered portion64and the second tapered portion68of slot walls56,58. The hook width82is greater than the slot width84, such that insertion of the second segment42into the slot36results in engagement of the first tab46and the second tab48with the first slot wall56and the second slot wall58, respectively. Subsequent to initial engagement of the tabs and the slot walls, further insertion of the second segment42results in deformation of the first tab46and the second tab48. As described in detail above, deformation may occur in various forms, including bending and compression, for example. In the illustrated embodiment, the first tab46and the second tab48are shown in a deformed condition. The tabs are shown to be deflected inwardly to ensure engagement between the second segment42and the slot walls, thereby resulting in a tight, fitted engagement between the first component12and the second component14. In one embodiment, the hook portion38provides a “snap-fit” engagement with the slot36.

The elastic deformation of the second segment42averages any positional errors of the first component12and the second component14. In other words, gaps and/or misalignment that would otherwise be present due to positional errors associated with portions or segments of the first component12and the second component14, particularly locating and retaining features, are reduced or eliminated. Specifically, the positional variance of the hook portion38, including the first segment40and/or second segment42, is accounted for by deformation of the first tab46and the second tab48being averaged in aggregate.

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. 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, co-pending U.S. patent application Ser. No. 13/187,675, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed herein provide the ability to convert an existing component that is not compatible with the described elastic averaging principles to an assembly that does facilitate elastic averaging and the benefits associated therewith.

A method of assembling an automobile door handle100is also provided, as illustrated inFIG. 5, and with reference toFIGS. 1-4. The retaining assembly10, and more specifically the elastically deformable nature of the hook portion38, has been previously described and specific structural components need not be described in further detail. The method100includes positioning102a handle insert12into close proximity with a door handle14. A retaining segment38extending from a first end18of the handle insert12is engaged104into the slot36disposed in an end of the door handle14. The retaining segment38is elastically deformed106upon engagement104with the first slot wall56and the second slot wall58.