# Patent

## Title
Alignment system and method thereof

## Abstract

An alignment system for aligning components includes a first component, a second component, upstanding, elongated tabs connected to at least one of the components, each elongated tab having a tab wall, and deformable elongated tab apertures formed in at least one of the components, each deformable tab aperture comprising opposing deformable aperture walls. The apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the elongated tabs such that each elongated tab is receivable into a respective aperture and each tab has a width larger than a cross-sectional width of its respective aperture measured in a same direction. Each aperture is configured to elastically deform upon disposition of each elongated tab into its respective tab aperture at an interface between the tab wall and the aperture wall.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
This patent application claims priority to U.S. Provisional Patent Application Ser. No. 61/682,597, filed Aug. 13, 2012, which is incorporated herein by reference in its entirety.


FIELD OF THE INVENTION
The subject invention relates to an alignment system and method thereof, and more particularly to location features for alignment and attachment of components during a mating operation.
BACKGROUND
Currently, components which are to be mated together in a manufacturing process are mutually located with respect to each other by 2-way and/or 4-way male alignment features, typically upstanding bosses, which are received into corresponding female alignment features, typically apertures in the form of holes or slots. There is a clearance between the male alignment features and their respective female alignment features which is predetermined to match anticipated size and positional variation tolerances of the male and female alignment features as a result of manufacturing (or fabrication) variances. As a result, there can occur significant positional variation as between the mated first and second components which contributes to the presence of undesirably large and varying gaps and otherwise poor fit therebetween. Accordingly, it is desirable to provide an improved alignment system and method for precisely aligning components.
SUMMARY OF THE INVENTION
In one exemplary embodiment of the invention, an alignment system for aligning components to each other is disclosed. The system includes a first component and a second component. The system also includes a plurality of upstanding, elongated tabs connected to at least one of the first and second components, each elongated tab having a tab wall. The system further includes a plurality of deformable elongated tab apertures formed in at least one of the first and second components, each deformable tab aperture comprising opposing deformable aperture walls; wherein the plurality of apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the plurality of elongated tabs such that each elongated tab is receivable into a respective aperture and each tab has a width larger than a cross-sectional width of its respective aperture measured in a same direction, and, wherein each aperture is configured to elastically deform upon disposition of each tab into each respective aperture at an interface between the tab wall of each tab and the aperture wall of each respective aperture.
In another exemplary embodiment of the invention, a method for precisely aligning components of a motor vehicle during a mating operation is disclosed. The method includes providing a first vehicle component. The method also includes providing a second vehicle component, wherein either of the first and second vehicle components are provided with a plurality of upstanding elongated tabs and a plurality of deformable elongated apertures formed therein, wherein the plurality of elongated apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the plurality of elongated tabs such that each elongated tab is matingly engageable into a respective elongated aperture and each tab has a width larger than a cross-sectional width of its respective aperture measured in a same direction. The method also includes mating the first vehicle component to the second vehicle component by pressing the components together, wherein during pressing the first vehicle component is aligned to the second vehicle component by each elongated tab being received into its respective deformable elongated aperture. The method further includes elastically deforming opposing deformable walls of each of the deformable apertures upon disposition of each tab into each respective aperture at an interface between a tab wall of each tab and an aperture wall of each respective aperture, wherein elastic deformation of the deformable apertures occurs over the plurality of deformable apertures such that upon mating, a precise location of the first vehicle component to the second vehicle component is realized.
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 perspective view of one embodiment of an alignment system and component assembly incorporating the same as disclosed herein;
FIG. 2 is a partially disassembled perspective view of the system and assembly of FIG. 1;
FIG. 3 is a partially disassembled perspective view of the system and assembly of FIG. 1, further comprising a third component;
FIG. 4 is a perspective view of the system and assembly of FIG. 3 in an assembled condition, wherein the components have been aligned according to the method disclosed herein;
FIG. 5. is a cross-sectional view of a tab and aperture of FIG. 4; and
FIG. 6 is a flow chart of a method for precisely aligning components of a motor vehicle during a mating operation as disclosed herein.



DESCRIPTION OF THE EMBODIMENTS
The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
In accordance with an exemplary embodiment of the invention, a thin tri-layer door assembly utilizing deformable elastic averaging features for precision alignment is disclosed. This embodiment disposes an inner component between two mating outer components to hold the inner component and also utilizes deformable elastic averaging features for precision alignment comprising deformable fixed-fixed beams and interfacing tabs to precisely locate mating vehicle components. This approach may be used to reduce or eliminate the need for secondary attachments (e.g. heat staking) to hold the inner component in position with regard to one of the outer components during their assembly.
The embodiment uses elongated (e.g. rectangular) tabs mating with deformable elongated apertures to locate components to each other. The width of each elongated tab is larger than the width of the mating elongated aperture. As the components are assembled opposing deformable walls of the elongated apertures deform elastically. The deformable walls comprise fixed beam portions of the respective component. This creates an interference condition that eliminates the variation associated with the clearances inherent in 2-way/4-way locating schemes. Furthermore, the over constrained interface will flex the fixed-fixed beam sections on each side of the mating apertures to a position that averages each aperture's individual positional error. This will result in part-to-part misalignment equal to each of the elongated tabs positional variation X 1/√N, where N is the number of constraints. The deformation of the fixed-fixed beam sections serves to align and stiffen the interface.
Referring to the Figures, and more particularly FIGS. 1, 2 and 5, an alignment system 10 for aligning components to each other is disclosed. The system includes a first component 20 and a second component 40. The system 10 also includes a plurality of upstanding, elongated tabs 22 connected to at least one of the first component 20 and second component 40, each elongated tab having a tab wall 24. The system further includes a plurality of deformable elongated tab apertures 42 formed in at least one of the first component 20 and second component 40, each deformable tab aperture 42 comprising opposing deformable aperture walls 44; wherein the plurality of apertures 42 are geometrically distributed in coordinated relationship to a geometrical distribution of the plurality of elongated tabs 22 such that each elongated tab 22 is receivable into a respective aperture 42, and wherein when each elongated tab 22 is received into its respective tab aperture 42 an elastic deformation occurs at an interface between the tab wall 24 and the aperture wall 44, wherein the elastic deformation is responsive to each tab wall having a width larger than a cross-sectional width of its respective aperture 42; and wherein the elastic deformation is elastically averaged over the plurality of deformable aperture walls 44 such that the first component 20 is precisely located relative to the second component 40. The elastic deformation of the aperture walls 44 elastically averages positional errors of the tabs 22 relative to the apertures 42. In other words, gaps that would otherwise be present due to positional errors associated with portions or segments of the tabs 22 and apertures 42 are reduced or eliminated by offsetting the gaps with an over-constrained condition along other portions or segments of the tabs 22 and apertures 42. 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 alignment system 10 may include deformable apertures 42 wherein each of the deformable aperture walls 44 comprises a deformable fixed beam 46. In one embodiment, the deformable fixed beams 46 are defined by elongated beam apertures 48 formed proximate the deformable aperture walls 44. In an embodiment, the elongated beam aperture 48 has a length (L2) that is greater than a length (L1) of the tab aperture 42. In another embodiment, the elongated beam aperture 48 extends beyond a first end 50 and a second end 52 of the tab aperture 42. In one embodiment, the deformable fixed beam 46 has a predetermined beam width (Wa), and the predetermined beam width is selected to obtain a predetermined compliance characteristic of the deformable fixed beam 46. The beam widths Wa may be the same or different, depending on the predetermined compliance characteristics required for each beam 46.
In another embodiment, the deformable fixed beam 46 is defined by a free surface 54 of the respective component on which it is formed. In this embodiment, the deformable fixed beam 46 also has a predetermined beam width (Wc), which may be the same or different than the beam width Wa depending on the predetermined compliance characteristic required for each beam. The beam widths Wc may be the same or different, depending on the predetermined compliance characteristics required for each beam. The predetermined beam width Wa is selected to obtain a predetermined compliance characteristic of the deformable fixed beam 46.
In one embodiment, the plurality of elongated tabs 22 each have a tab wall axis 26 and a first portion of the plurality of elongated tabs 22 have tab wall axes 26 that are not-parallel to the tab wall axes 26 of a second portion of the plurality of elongated tabs 22. In another embodiment, the first portion of elongated tabs 22 have tab wall axes 26 that are substantially orthogonal to the tab wall axes of the second portion of elongated tabs.
In one embodiment, the plurality of elongated tabs 22 each have a beveled tab edge 28 proximate a top end 30 of the tab. In another embodiment, each of the plurality of elongated tab apertures 42 has a beveled aperture edge 56 proximate an entrance opening 58 of the tab aperture 42.
Referring now to FIGS. 1-5, in one embodiment, the alignment system 10 further includes an assembly 60 of the first component 20 and the second component 40, wherein each elongated tab 22 is disposed in the corresponding elongated tab aperture 42 and deforms the deformable aperture walls 44 thereof. In this embodiment (FIG. 1), each elongated tab 22 has a top end 30 that projects above a top edge 62 of the respective aperture 42. In another embodiment, the alignment system 10 may also include a third component 80, such as a door open and closure mechanism, which is attached to the assembly having a surface 82 disposed proximate the top ends 30 of the elongated tabs 22, the surface 82 having a plurality of recessed pockets 84 disposed therein that are configured to receive the top ends 30 of the elongated tabs 22. Any or all of the components may comprise a surface or surfaces having a class A finish. The alignment system 10 thus provides a system for desired alignment of the first component 20, second component 40, and third component 80 while also providing a compact and space efficient assembly of these components. In the embodiment of FIGS. 1-5, for example, the assembly has a maximum thickness that is less than the maximum thicknesses of the individual component parts 20, 40, 80. That is, the components are nested within one another to provide a compact assembly while at the same time providing for precise alignment of the components with respect to one another.
In one embodiment, the system 10 may be used to assemble an assembly 60 that comprises a motor vehicle assembly, and more particularly a door assembly for a motor vehicle.
Any suitable elastically deformable material may be used for the first component 20 and elongated tabs 22 or the second component 40 and fixed beams 46 or the third component 80, for example, 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. 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 elongated tabs 22 may be formed in any suitable manner. They may be integrally formed or manufactured with the first component 20, or they may formed together separately and attached to the first component, or they may both be formed entirely separately and attached to the first component. When formed separately, they may be formed from different materials than those of the first component 20 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 first component 20 or second component 40 or third component 80, particularly the deformable fixed beams 46. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.
Referring to FIGS. 2-4, the first component 20 or third component 80 may also include elastic tubes 90 and corresponding apertures 92 as part of the alignment system 10 and assembly 60 disclosed herein. These elastic tubes 90 and corresponding apertures 92 and their use in an alignment system are described in commonly owned, co-pending U.S. patent application Ser. No. 13/187,675.
Referring to FIG. 6, in one embodiment, a method 200 for precisely aligning components of a motor vehicle during a mating operation is disclosed. The method includes providing 210 a first vehicle component. The method also includes providing 220 a second vehicle component, wherein either of the first and second vehicle components are provided with a plurality of upstanding elongated tabs and a plurality of deformable elongated apertures formed therein, wherein the plurality of elongated apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the plurality of elongated tabs such that each elongated tab is matingly engageable into a respective elongated aperture. The method also includes mating 230 the first vehicle component to the second vehicle component by pressing the components together, wherein during pressing the first vehicle component is aligned to the second vehicle component by each elongated tab being received into its respective deformable elongated aperture. The method further includes elastically deforming 240 opposing deformable walls of each of the deformable apertures. Still further, the method includes elastically averaging 250 the elastic deformation over the plurality of deformable apertures such that upon mating, a precise location of the first vehicle component to the second vehicle component is realized.
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 alignment system for aligning components to each other, comprising:
a first component;
a second component;
a plurality of upstanding, elongated tabs connected to at least one of the first and second components, each elongated tab having a tab wall;
a plurality of deformable elongated tab apertures formed in at least one of the first and second components, each deformable tab aperture comprising opposing deformable aperture walls;
wherein the plurality of apertures are geometrically distributed in coordinated relationship to a geometrical distribution of the plurality of elongated tabs such that each elongated tab is receivable into a respective aperture and each tab has a width larger than a cross-sectional width of its respective aperture measured in a same direction;
wherein each aperture is configured to elastically deform upon disposition of each tab into each respective aperture at an interface between the tab wall of each tab and the aperture wall of each respective aperture;
an assembly of the first component and the second component, wherein each elongated tab is disposed in the corresponding elongated tab aperture and deforming the deformable aperture walls thereof, wherein each elongated tab has a top end that projects above a top edge of the respective aperture; and
a third component that is attached to the assembly having a surface disposed proximate the top ends of the elongated tabs, the surface having a plurality of recessed pockets disposed therein that are configured to receive the top ends of the elongated tabs.

2. The alignment system of claim 1, wherein each of the deformable aperture walls comprises a deformable fixed beam.

3. The alignment system of claim 2, wherein the deformable fixed beam is defined by an elongated beam aperture formed proximate the deformable aperture wall.

4. The alignment system of claim 3, wherein the elongated beam aperture has a length that is greater than a length of the tab aperture.

5. The alignment system of claim 4, wherein the elongated beam aperture extends beyond a first end and a second end of the tab aperture.

6. The alignment system of claim 2, wherein the deformable fixed beam has a predetermined beam width.

7. The alignment system of claim 6, wherein the predetermined beam width is selected to obtain a predetermined compliance characteristic of the deformable fixed beam.

8. The alignment system of claim 2, wherein the deformable fixed beam is defined by a free surface of the respective component on which it is formed.

9. The alignment system of claim 8, wherein the deformable fixed beam has a predetermined beam width.

10. The alignment system of claim 9, wherein the predetermined beam width is selected to obtain a predetermined compliance characteristic of the deformable fixed beam.

11. The alignment system of claim 1, wherein the plurality of elongated tabs each have a tab wall axis and a first portion of the plurality of elongated tabs have tab wall axes that are not-parallel to the tab wall axes of a second portion of the plurality of elongated tabs.

12. The alignment system of claim 11, wherein the first portion of the elongated tabs have tab wall axes that are substantially orthogonal to the tab wall axes of the second portion of elongated tabs.

13. The alignment system of claim 1, wherein the plurality of elongated tabs each have a beveled tab edge proximate a top end of the tab.

14. The alignment system of claim 1, wherein the plurality of elongated tab apertures have a beveled aperture edge proximate an entrance opening of the tab aperture.

15. The alignment system of claim 1 wherein the assembly comprises a motor vehicle assembly.

16. The alignment system of claim 15, wherein the motor vehicle assembly comprises a door assembly.