Abstract:
An attachment system for connecting a vehicle fascia birds beak element to a vehicle front end module bolster includes a bracket having a fascia-engaging portion and a bolster-engaging portion. The bolster-engaging portion includes one or more bracket locator structures configured for engaging cooperating structures disposed on the bolster to self-orient the bracket in a predetermined orientation. The system further includes a vehicle front end module bolster having a bracket-engaging portion that includes one or more bolster locator structures configured for engaging cooperating structures disposed on the bracket to self-orient the bracket in the predetermined orientation.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates generally to brackets for motor vehicle components, and more particularly to an improved fascia securing system for connecting vehicle components such as a vehicle fascia and a front end module bolster one to another. 
       BACKGROUND 
       [0002]    It is industry practice during motor vehicle manufacture/assembly to provide various components of the vehicle in modular form. The modules are then connected one to another in the latter stages of vehicle assembly. As one non-limiting example, various components of a vehicle closest to the radiator are typically packaged into an assembly commonly called a front-end module. The front-end module includes a frame structure commonly referred to as a bolster, to which other components such as the vehicle grille assembly, etc. are secured. Typically, a fascia is also secured to some portion of the vehicle/vehicle frame in order to hide internal vehicle components, frame members, etc. to provide an aerodynamic front surface for the vehicle, and for aesthetic reasons. With reference to  FIG. 1  showing a motor vehicle V front-end module  100 , as shown a vehicle front fascia  102  is provided which borders and/or frames the vehicle hood  104 , the vehicle grille assembly  106 , and the vehicle headlamp assembly  108  (which typically includes a headlamp unit, a headlamp housing, and a headlamp cover as is known). 
         [0003]    One of the engineering challenges faced during such assembly is ensuring a tight mating, i.e. a flush margin, between various components/modules and/or adjoining panels of a vehicle during and after assembly, for reasons of safety, aesthetics, and customer satisfaction. For example, during the assembly of a vehicle front end, as shown in  FIG. 1  after assembly of the fascia  102  to the vehicle bolster (not visible in this view), seams (shown by arrows) are defined between the mating surfaces of the fascia  102  and the hood  104  and between the fascia  102  and the headlamp opening  108 . A particular flushness of margin is typically required for the seam created between those mating surfaces, and any deviation from a perfect mating surface can create a mismatch. Mismatched or uneven seams between mating surfaces create aesthetic concerns and at least a perception of reduced quality of manufacture. 
         [0004]    One area of particular difficulty in securing a fascia  102  to a vehicle V is the “birds beak” area  110  of the fascia, so named because of its configuration which resembles the shape of a birds beak. This portion of the fascia  102  must be secured to assist in providing a seam having a desired margin between the hood  104  and the headlamp assembly  108 . However, the birds beak area  110  of course cannot be secured directly to the hood  104  since the hood must be opened/closed for engine maintenance and repair. In turn, while conventionally the fascia birds beak area  110  is coupled to some portion of the headlamp assembly  108 , such coupling is difficult and results in inconsistencies in the flushness of the resulting seam. In turn, conventional methods for securing the birds beak area to the headlamp assembly, such as sonic welding, are expensive and can be caused to fail by the vibration incurred during normal vehicle operation. 
         [0005]    To satisfy this identified need in the art, the present disclosure describes a fascia attachment system for fastening a birds beak area  110  of a fascia  102  to a vehicle bolster, and to brackets and bolsters comprising the system. Advantageously, by use of the described fascia attachment system the birds beak area  110  of the fascia can be decoupled from the headlamp assembly  108  but still secured to the vehicle in a manner providing a seam having a desired flushness of margin. 
       SUMMARY 
       [0006]    In accordance with the purposes and benefits described herein, in one aspect a bracket for connecting a vehicle fascia element such as a “birds beak” portion to a vehicle front end module bolster is described, the bracket including a fascia-engaging portion and a bolster-engaging portion. The bolster-engaging portion includes one or more locator structures configured for engaging cooperating structures disposed on the bolster to self-orient the bracket in a predetermined orientation. 
         [0007]    In embodiments, the locator structures include a locator through-bore configured for engaging a cooperating pin disposed on a portion of the bolster and one or more locator tabs disposed on a bottom surface of the bracket and configured for engaging one or more cooperating structures disposed on the vehicle bolster. One or more reinforcing structures may be included in the bracket body. 
         [0008]    In another aspect, a vehicle front end module bolster is provided having a bracket-engaging portion comprising one or more locator structures configured for engaging cooperating structures disposed on a bracket to self-orient the bracket in a predetermined orientation. In embodiments, the locator structures include a locator pin configured for engaging a cooperating aperture of the bracket. One or more ribs may be included in the bracket-engaging portion, configured for restricting movement of the bracket in a Z direction. 
         [0009]    In still another aspect, an attachment system for connecting a vehicle fascia birds beak element to a vehicle front end module bolster is provided, including a bracket and a vehicle front end module bolster as described above. 
         [0010]    In the following description, there are shown and described embodiments of the disclosed fascia attachment system. As it should be realized, the system is capable of other, different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the devices and methods as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of a fascia attachment system for securing a vehicle fascia birds beak area to a vehicle bolster, and together with the description serve to explain certain principles thereof. In the drawing: 
           [0012]      FIG. 1  depicts a prior art vehicle front end module including a fascia; 
           [0013]      FIG. 2A  shows a bottom view of a passenger side bracket for use in a fascia securing system according to the present disclosure; 
           [0014]      FIG. 2B  shows a top view of the bracket of  FIG. 2A ; 
           [0015]      FIG. 2C  shows a side view of the bracket of  FIG. 2A ; 
           [0016]      FIG. 2D  shows a bottom view of a driver side bracket according to the present disclosure; 
           [0017]      FIG. 2E  shows a top view of the bracket of  FIG. 2D ; 
           [0018]      FIG. 3A  shows a bracket-receiving portion of a vehicle bolster for use in a fascia securing system according to the present disclosure, including a locator system for the disclosed bracket; 
           [0019]      FIG. 3B  shows the bracket of  FIGS. 2A-2C  positioned on the bolster bracket-receiving portion of  FIG. 3A ; and 
           [0020]      FIG. 4  shows the bracket of  FIGS. 2A-2C  attaching the bolster of  FIG. 3A  to a birds beak area of the fascia of  FIG. 1 . 
       
    
    
       [0021]    Reference will now be made in detail to embodiments of the disclosed fascia securing system, examples of which are illustrated in the accompanying drawing figures. 
       DETAILED DESCRIPTION 
       [0022]    To solve the aforementioned and other problems, the present disclosure at a high level relates to a fascia attachment system comprising at least a bracket and a vehicle bolster. A bracket is described, including various reinforcing features which provide a bracket having good load-bearing capacity. As will be described, the bracket further includes various self-location features for self-locating the bracket on corresponding features of the bolster, and in the event of full and/or partial removal of the bracket from the bolster for servicing, for allowing easy relocation of the bracket back on the proper portion of the bolster. 
         [0023]    With reference to  FIGS. 2A-2C , an embodiment of a reinforced bracket  200  is shown. Preliminarily, a number of suitable materials for manufacturing such brackets are known in the art, including polymers such as glass-filled polypropylene (30%) and others. However, any suitable material for fabricating/molding brackets according to the present description is contemplated. Accordingly, any such descriptions should not be taken to be limiting in any way. 
         [0024]    The bracket  200  includes a body  202  including a bolster-engaging portion  203  and a fascia-engaging portion  205 . Body  202  could of course be fabricated or molded to be a solid piece. However, for reasons of weight, a plurality of reinforcing features are included or molded into the body  202 . For example, as shown in  FIG. 2A , one or more reinforcing ribs may be included or molded into a bottom surface of body  202 . Likewise, reinforcing features are provided in a top surface of bracket  200 . With reference to  FIG. 2B , one such surface is a reinforced midsection  206 , provided in the depicted embodiment by a “honeycomb” structure molded into the bracket  200  top surface. Of course, alternative structures such as additional ribs are contemplated for reinforced midsection  206 . In turn, a side wall  208  is defined for body  202 , which provides further strengthening structural support for the bracket  200 . 
         [0025]    The bracket body  202  further includes various locator and retention features, provided to allow the bracket  200  to substantially self-locate on and be secured to a vehicle bolster (not shown) as will be described infra. With particular reference to  FIGS. 2A and 2B , one or more through-bores  210 ,  211  are provided in bolster-engaging portion  203  and fascia-engaging portion  205 , for receiving fasteners such as bolts, screws, etc. A locator receiver  212 , in the depicted embodiment also being a through-bore, is also provided in bolster-engaging portion  203 , the function of which will be described infra. Of course, alternative configurations for locator receiver  212  are possible and contemplated, such as an open-ended or closed-ended sleeve. In turn, a plurality of locator tabs  214  are provided on the bottom surface of body  202  (see  FIGS. 2A and 2C ), the purpose of which will also be described infra. As depicted, the locator tabs  214  are disposed offset one from another, although alternative configurations are contemplated. 
         [0026]    It is noted that in the present description reference is made to a “driver side” bracket and a “passenger side” brackets, i.e. to brackets which are secured to a left side and a right side, respectively, of a vehicle bolster (not shown in this view). The disclosed “driver side” and “passenger side” bracket are substantially similar, and thus the specific features of the brackets of  FIGS. 2D and 2E , being in the disclosed embodiment substantially mirror images of the bracket of  FIGS. 2A-2C , need not be described in detail. However, the skilled artisan will readily appreciate that the described bracket could easily be modified for use in either or both of the right and left hand side of a vehicle bolster. 
         [0027]    Turning now to  FIG. 3A , a vehicle bolster  300  is depicted therein to which brackets  200 ,  200 ′ as described above are secured. The bolster  300  a pair of bracket-receiving portions  304  for receiving brackets  200 ,  200 ′, the bracket-receiving portions  304  including various locator and retention features. 
         [0028]    A threaded aperture  306  is included in bracket-receiving portion  304 , for receiving a fastener (not shown) passing through the bracket body through-bore  210 . A variety of suitable alternative or additional structures for receiving and releasably securing a fastener are known and contemplated for use herein, for example a clip  308  as shown. In turn, optionally a second clip  309  may be associated with aperture  306 , to provide additional retention of bracket  200  (not shown in this view). As an example, this can be advantageous when it is desired to remove a fastener such as a bolt securing bracket  200  to bracket-receiving portion  304  without risking losing that bracket. Even without a fastener such as a bolt, bracket  200  is at least loosely retained on bracket-receiving portion  304  until fully removed. 
         [0029]    Bracket-receiving portion  304  also includes a locator pin  310 , in the depicted embodiment being a four-way locator. Locator pin  310  is dimensioned to engage locator receiver  212  in bracket body  202 . In turn, bracket-receiving portion  304  also includes opposed trend-setting ribs  312 ,  312 ′, being positioned in the depicted embodiment as substantially mirror images one to the other. Each trend-setting rib  312 ,  312 ′ includes a plurality of anti-locking tabs  314  for releasably engaging locator tabs  214  of a bracket body  202 ,  202 ′. As will be appreciated, a height dimension of trend-setting ribs  312 ,  312 ′ may be adjusted as needed in order to match a horizontal plane of a bracket fascia-engaging portion  205  to a horizontal plane of a fascia  102  portion secured to the fascia-engaging portion in the assembled vehicle V. 
         [0030]    Turning to  FIG. 3C , in use a bracket  200  is placed on bracket-receiving portion  304  (obscured in this view), whereby the engagement of bolster locator pin  310 /bracket locator receiver  212  and of bolster anti-locking tab  314 /bracket locator tab  214  allow bracket  200  to substantially self-position in the desired location by controlling movement of the bracket  200  in the x, y, and z (by ribs  312 ,  312 ′ tabs  314 ) directions. A suitable fastener  316  (not shown in this view, but see  FIG. 4 ) may then be passed through bracket through-bore  210  to secure the bracket to the bolster  300 . Of course, this process is repeated with a second bracket  200 ′ on the opposed side (not shown) of bolster body  302 . 
         [0031]    Turning to  FIG. 4 , as shown a birds beak area  110  of a vehicle fascia can then be secured to the bracket fascia-engaging portion  205  (not visible in this view) by any suitable fastener  316 . Again, the process is repeated with a second bracket on the opposed side (not shown) of bolster body  302  to secure the opposed birds beak area  110  of the fascia. 
         [0032]    As will be appreciated by the skilled artisan, by the foregoing described reinforced bracket  200 /bolster  300  assembly, a system is provided for securing a vehicle fascia  102  to a bolster body  302 , and in particular for securing a birds beak area  110  of the fascia in a manner providing a secure and snug fit and a desired flushness of margin for a seam defined between the fascia and the vehicle hood, and also between the fascia and the vehicle headlamp assembly. The bracket  200  is compact, robust, and easy to manufacture, and by the structural features described above provides a bracket that does not exceed a desired level of deflection in use. Still more, simply by use of a pair of brackets as described, the cost of conventional means for securing a fascia birds beak area  110 , such as sonic welding, is eliminated. 
         [0033]    Advantageously, the described system allows securing a vehicle fascia birds beak area  110  to the vehicle without any element of engaging the vehicle headlamp assembly  108 . Instead, the birds beak area  110  is secured directly to the bolster. By this expedient, any movement/shifting of the headlamp assembly  108  is isolated and independent of the fascia  102  attachment, and so headlamp  108  movement/vibration/shifting does not affect fascia  102  movement and a tighter margin is achievable. 
         [0034]    Moreover, the self-locating features of the system as described above improve ease of servicing, for example for repairs/maintenance requiring loosening or removal of the fascia. For example, a bolt  316  can be removed from the bracket bolster-engaging portion  203 , and bolt  316  can be loosened from the bracket fascia-engaging portion  205 , and bracket  200  can simply be rotated aside for repair/maintenance, for example for latch servicing. Then, by the various self-locating features as described above, the bracket  200  is easily returned to the desired position and secured in place. 
         [0035]    Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.