# Patent

## Title
Elastic mating assembly and method of elastically assembling matable components

## Abstract

An elastic mating assembly includes a first component comprising a substantially rigid material and an aperture defined by an aperture wall. The assembly also includes an elastically deformable second component having a cutout portion. The elastically deformable second component also includes a second component outer wall removably engaged with the aperture wall, wherein the second component is disposed substantially within the aperture. The elastic mating assembly further includes a third component removably engaged with the cutout portion of the elastically deformable second component, wherein the elastically deformable second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component.

## Background
FIELD OF THE INVENTION
The present invention relates to matable components, and more particularly to an elastic mating assembly, as well as a method of elastically assembling such components.
BACKGROUND
Currently, components which are to be mated together in a manufacturing process are subject to positional variation based on the mating arrangements between the components. One common arrangement includes components mutually located with respect to each other by 2-way and/or 4-way male alignment features; typically undersized structures which are received into corresponding oversized female alignment features such as apertures in the form of openings and/or slots. Alternatively, double-sided tape, adhesives or welding processes may be employed to mate parts. Irrespective of the precise mating arrangement, there is a clearance between at least a portion of the alignment features which is predetermined to match anticipated size and positional variation tolerances of the mating features as a result of manufacturing (or fabrication) variances. As a result, occurrence of significant positional variation between the mated components is possible, which may contribute to the presence of undesirably large and varying gaps and otherwise poor fit. The clearance between the aligning and attaching features may lead to relative motion between mated components, which contributes to poor perceived quality. Additional undesirable effects include squeaking and rattling of the mated components, for example.
SUMMARY OF THE INVENTION
In one exemplary embodiment, an elastic mating assembly includes a first component comprising a substantially rigid material and an aperture defined by an aperture wall. The assembly also includes an elastically deformable second component having a cutout portion. The elastically deformable second component also includes a second component outer wall removably engaged with the aperture wall, wherein the second component is disposed substantially within the aperture. The elastic mating assembly further includes a third component removably engaged with the cutout portion of the elastically deformable second component, wherein the elastically deformable second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component.
In another exemplary embodiment, a method of elastically assembling matable components is provided. The method includes engaging a first component comprising a substantially rigid material with an elastically deformable second component comprising an elastically deformable material proximate an aperture wall of the first component. The method also includes inserting a third component into a cutout portion of the elastically deformable second component, wherein the elastically deformable second component and third component form a contact interference proximate an outer surface of the third component and a cutout portion edge of the cutout portion. The method further includes elastically deforming the elastically deformable second component proximate the cutout portion edge of the cutout portion upon contact with the outer surface of the third component.
The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:
FIG. 1 is a plan view of an elastic mating assembly;
FIG. 2 is a cross-sectional view taken along line 2-2, illustrating engagement between a first component and a second component of the elastic mating assembly;
FIG. 3 is a perspective view of engagement between the second component and a third component of the elastic mating assembly;
FIG. 3A is a perspective view of the third component of the elastic mating assembly according to another aspect of the disclosure;
FIG. 4 is a plan view of engagement between the second component and the third component according to another aspect of the invention; and
FIG. 5 is a flow diagram illustrating a method of elastically assembling matable components of the elastic mating assembly.



DESCRIPTION OF THE EMBODIMENTS
Referring to FIGS. 1 and 2, an elastic mating assembly 10 is illustrated. The elastic mating assembly 10 comprises matable components, such as a first component 12 and an elastically deformable second component 14 that are configured to be engaged with each other. In one embodiment, the elastic mating assembly 10 is employed in a vehicle application. However, it is to be understood that the components may be associated with numerous other applications and industries, such as home appliance and aerospace applications, for example.
The first component 12 is formed of a substantially rigid material, such as sheet metal, for example, while the elastically deformable second component 14 is at least partially formed of an elastically deformable material, which will be described in detail below. The elastically deformable nature of the elastically deformable second component 14 provides an insert having a compliant interface for components to indirectly mate or couple with the first component 12.
In an engaged position, the elastically deformable second component 14 is substantially disposed within an aperture 16 of the first component 12 that is defined by an aperture wall 18. The elastically deformable second component 14 includes a second component outer wall 20 that engages the first component 12 proximate the aperture wall 18. Engagement between the first component 12 and the elastically deformable second component 14 may be facilitated by numerous contemplated coupling structures that provide removable engagement between the components. One such structure includes a tongue-and-groove arrangement. As shown in FIG. 2, the second component outer wall 20 includes a perimeter notch 22 extending around the second component outer wall 20, with the perimeter notch 22 configured to fittingly receive the aperture wall 18 therein. Alternatively, the aperture wall 18 of the first component 12 may include a notch configured to fittingly receive at least a portion of the second component outer wall 20 therein. Either arrangement, or a combination thereof, provides a “snap-fit” engagement between the first component 12 and the elastically deformable second component 14. As noted above, it is contemplated that the elastically deformable second component 14 is removably engaged within the aperture 16 of the first component 12, thereby providing interchangeable flexibility between inserted elastically deformable second components, as well as providing the ability to incorporate the elastically deformable second component 14 into existing first components as an add-on feature.
Referring to FIG. 3, the elastically deformable second component 14 is employed as an intermediary between the first component 12 (FIG. 1) and a third component 24 that is to be mated and aligned with the first component 12. More specifically, the third component 24 is a male portion that may extend from countless structures or components (not illustrated) that are to be mated and aligned with the first component 12.
The elastically deformable second component 14 includes a cutout portion 26 defined by a cutout portion edge 28. The cutout portion 26 is configured to engage and receive the third component 24. More particularly, the cutout portion edge 28 engages an outer surface 30 of the third component 24 upon insertion of the third component 24 into the cutout portion 26 of the elastically deformable second component 14. The cutout portion 26 may be formed in numerous shapes and at various positions of the elastically deformable second component 14. In the illustrated embodiment, the cutout portion 26 comprises a neck section 32 and at least one outer bulb section 34. The neck section 32 is narrower than the at least one outer bulb section 34 and includes a neck section width 36 (FIG. 4).
The third component 24 may be formed in numerous geometries and in the illustrated embodiment comprises a substantially tubular member that may be solid or may include a hollow portion therein. Irrespective of the precise geometry of the third component 24, the third component 24 includes an outer surface width 38 that is greater than the neck section width 36. Although a single elastically deformable second component and a single third component are referenced, embodiments of the elastic mating assembly 10 include a plurality of elastically deformable second components and a plurality of third components, as will be described in detail below.
As will be apparent from the description herein, the elastically deformable nature of the elastically deformable second component, in combination with the particular orientations described above, facilitates precise alignment of the third component 24 (and any structures or components attached thereto) relative to the first component 12 by accounting for positional variation of the retaining and/or locating features of the first component 12 and/or the third component 24 that are inherently present due to manufacturing processes. The self-aligning benefits associated with the elastic mating assembly 10 will be described in detail below.
The third component 24 is positioned and engaged with the cutout portion 26 of the elastically deformable second component 14 upon translation of the third component 24 toward the elastically deformable second component 14, as well as the first component 12. More particularly, the outer surface 30 of the third component 24 engages the cutout portion edge 28 proximate the neck section 32. Subsequent translation results in an elastic deformation of the elastically deformable second component 14. Specifically, as noted above, the neck section width 36 is smaller than the outer surface width 38, thereby ensuring contact between the third component 24 and the neck section 28 of the elastically deformable second component 14.
In another embodiment (FIG. 4), the third component 24 is also at least partially formed of an elastically deformable material. In such an embodiment, the third component 24 is configured to elastically deform upon contact with the cutout portion 26 of the elastically deformable second component 14.
Any suitable elastically deformable material may be used for the elastically deformable second component 14, as well as the third component 24 in an elastically deformable embodiment. 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 elastically deformable second component 14 and the third component 24, if elastically deformable. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.
The precise position where engagement between the outer surface 30 and the cutout portion 26 occurs will vary depending on positional variance imposed by manufacturing factors. Due to the elastically deformable properties of the elastic material comprising the elastically deformable second component 14, the criticality of the initial location of engagement is reduced. Further insertion of the third component 24 into the cutout portion 26 ultimately leads to a fully engaged position of the third component 24. In the fully engaged position, a tight, fitted engagement between the third component 24 and the first component 12 is achieved by contact interference between the outer surface 30 and the cutout portion edge 28. Such a condition is ensured by sizing the outer surface width 38 to be larger than the neck section width 36. The interference between the third component 24 and the cutout portion 26 causes elastic deformation proximate cutout portion 26 and the third component 24, whether the third component 24 is comprised of an elastically deformable material or not. The malleability of the materials reduces issues associated with positional variance.
In one embodiment, the first component 12 may include a plurality of apertures configured to receive a plurality of elastically deformable second components. Additionally, a plurality of third components may be included. The plurality of third components may be removably engaged within a single cutout portion of a single elastically deformable second component and/or may be removably engaged within distinct cutout portions of the plurality of elastically deformable second components. The elastic deformation of the plurality of elastically deformable second components elastically averages any positional errors of the first component 12 and the third component 24. In other words, gaps and/or misalignment that would otherwise be present due to positional errors associated with portions or segments of the first component 12 and the third component 24, particularly locating and retaining features. Specifically, the positional variance of each third component 24 is offset by the remaining third components to average in aggregate the positional variance of each component. 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 above provide the ability to convert an existing component that is not compatible with the above-described elastic averaging principles to an assembly that does facilitate elastic averaging and the benefits associated therewith.
A method of elastically assembling matable components 100 is also provided, as illustrated in FIG. 5, and with reference to FIGS. 1-4. The elastic mating assembly 10, and more specifically the elastically deformable nature of the elastically deformable second component 14, has been previously described and specific structural components need not be described in further detail. The method 100 includes engaging 102 the first component 12 with the elastically deformable second component 14 proximate the aperture wall 18 of the first component 12. The method 100 also includes inserting 104 the third component 24 into the cutout portion 26 of the elastically deformable second component 14, wherein the elastically deformable second component 14 and the third component 24 form a contact interference proximate the outer surface 30 of the third component 24 and the cutout portion edge 28. The method 100 further includes elastically deforming 106 the elastically deformable second component 14 proximate the cutout portion edge 28 of the cutout portion 26 upon contact with the outer surface 30 of the third component 24.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application.

## Claims

1. An elastic mating assembly comprising:
a first component comprising a substantially rigid material and an aperture defined by an aperture wall;
an elastically deformable second component comprising:
a cutout portion extending in an elongated manner, the cutout portion including a neck section, a first bulb section located at a first end of the cutout portion and a second bulb section located at a second end of the cutout portion, wherein the neck section comprises a neck section width and the first and second bulb sections include bulb section widths greater than the neck section width; and
a second component outer wall forming a perimeter of the second component, the second component outer wall removably engaged with the aperture wall, wherein the elastically deformable second component is disposed within the aperture based on engagement about the entire perimeter of the second component with the aperture wall; and

a third component removably engaged with the cutout portion of the elastically deformable second component, wherein the elastically deformable second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component, wherein the third component comprises an elastically deformable material configured to elastically deform upon contact with the cutout portion of the elastically deformable second component, the third component having an outer surface width, wherein the outer surface width is greater than the neck section width of the cutout portion of the second component.

2. The elastic mating assembly of claim 1, wherein the second component outer wall comprises a perimeter notch configured to fittingly receive the aperture wall therein.

3. The elastic mating assembly of claim 1, wherein the aperture wall of the first component comprises a notch configured to fittingly receive the second component outer wall therein.

4. The elastic mating assembly of claim 1, wherein the substantially rigid material comprises a sheet metal.

5. The elastic mating assembly of claim 1, wherein the third component comprises a solid member.

6. The elastic mating assembly of claim 1, wherein the third component comprises a hollow tubular member.

7. The elastic mating assembly of claim 1, further comprising a contact interference condition proximate an interface between the outer surface of the third component and the neck section of the cutout portion of the elastically deformable second component.

8. The elastic mating assembly of claim 1, further comprising a plurality of third components removably engaged with the cutout portion of the elastically deformable second component.

9. The elastic mating assembly of claim 1, further comprising a plurality of elastically deformable second components removably engaged with the first component.

10. The elastic mating assembly of claim 9, wherein the plurality of elastically deformable second components are removably engaged with a plurality of apertures of the first component.

11. The elastic mating assembly of claim 10, further comprising a plurality of third components removably engaged with a corresponding cutout portion defined by each of the plurality of elastically deformable second components.

12. The elastic mating assembly of claim 11, further comprising a fully engaged position of the plurality of the third components, wherein the fully engaged position comprises contact interference between the outer surface of each of the plurality of third components and the cutout portion of the plurality of elastically deformable second components, wherein respective positional deviations from respective nominal alignment positions of the first component, the second component and the third component is averaged.

13. A method of elastically assembling matable components comprising:
engaging a first component comprising a substantially rigid material with an elastically deformable second component comprising an elastically deformable material proximate an aperture wall of the first component about an entire perimeter of the second component;
inserting a third component that is formed of an elastically deformable material into a cutout portion of the elastically deformable second component, wherein the elastically deformable second component and the elastically deformable third component form a contact interference proximate an outer surface of the third component and a cutout portion edge of the cutout portion; and
elastically deforming the elastically deformable second component proximate the cutout portion edge of the cutout portion upon contact with the outer surface of the third component extending in an elongated manner, the cutout portion including a neck section, a first bulb section located at a first end of the cutout portion and a second bulb section located at a second end of the cutout portion, wherein the neck section comprises a neck section width and the first and second bulb sections include bulb section widths greater than the neck section width, the bulb sections providing additional flexibility for the neck section to deform.

14. The method of claim 13, further comprising performing an elastic averaging of the elastic deformation over a plurality of elastically deformable second components, wherein upon reaching a fully engaged position of a plurality of third components a fitted alignment between the third component and the first component is established.

15. The method of claim 13, wherein engaging the first component with the elastically deformable second component comprises fittingly engaging the aperture wall within a perimeter notch formed in the elastically deformable second component.

16. The method of claim 13, wherein engaging the first component with the elastically deformable second component comprises fittingly engaging a second component outer wall within a notch formed in the aperture wall.