Abstract:
The present invention is a tolerance adjusting attachment which is part of a bracket member used for providing proper alignment between more than one externally visible component. The tolerance adjusting attachment has a support aperture formed as a portion of the bracket member, and an adjuster core at least partially extending through the support aperture, the adjuster core operably associated with at least one structural member for providing proper positioning of the bracket member in relation to the structural member. The present invention also includes an adjuster clip at least partially extending through and movable through a portion of the bracket member such that the position of the adjuster core is secured relative to the bracket member.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/126,376, filed on May 2, 2008. The disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a tolerance adjusting attachment which compensates for variations in the dimensions of two adjoining components. 
     BACKGROUND OF THE INVENTION 
     Variation in the assembly of parts for an automobile is generally known, and is considered undesirable. Many different attempts have been made to compensate for the variation in dimensions of parts which occurs during various manufacturing processes. Often, reducing the variation in part dimensions increases the cost of manufacturing the part, regardless of what type of part is being manufactured, or what manufacturing process is being used. 
     One application where compensation for variation in part dimensions is very difficult is in the production of body panels used for automobiles. An increased amount of emphasis is placed on compensating for variation in part dimensions in body panels because body panels having a large variation in their dimensions will reduce the aesthetic appeal of the vehicle. There is space, or various “gaps,” between the different body panel components, such as the doors, hood, and trunk. It is considered desirable to have the gaps of a consistent width between the hood and fenders, between the door and fenders, between components such as the trunk and rear fenders, or between other various body panels. Variation in part dimension can cause the gaps between these components to be inconsistent, as well as have an effect on how the parts are assembled. 
     Additionally, ensuring that the body panels are in proper alignment may have an effect on how the parts are connected to the vehicle. There are various frame members or other types of structures which the body panels are connected to, and due to variations in the dimensions of the part, providing proper alignment of the body panels may not allow the body panels to then be connected to the various frame members or other structures. 
     Accordingly, there exists a need for a part which can be used to compensate for the various tolerances in body panels of automobiles, and provide for consistent spacing between the panels, as well as allow for the panels to be properly aligned and connect to various structures used for supporting the body panels. 
     SUMMARY OF THE INVENTION 
     The present invention is a tolerance adjusting attachment which is part of a bracket member used for providing proper alignment between more than one externally visible component, such as two body panels for an automobile. The tolerance adjusting attachment has a support aperture formed as a portion of the bracket member, and an adjuster core at least partially extending through the support aperture, the adjuster core operably associated with at least one structural member for providing proper positioning of the bracket member in relation to the structural member. The present invention also includes an adjuster clip at least partially extending through and movable through a portion of the bracket member such that the position of the adjuster core is secured relative to the bracket member. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is an exploded view of a bracket member having a tolerance adjusting attachment, according to the present invention; 
         FIG. 2  is a perspective view of a bracket attached to a structural member using a tolerance adjusting attachment, according to the present invention; 
         FIG. 3  is a second exploded view of a bracket member having a tolerance adjusting attachment, according to the present invention; 
         FIG. 4  is a perspective view of an adjuster core used for a tolerance adjusting attachment, according to the present invention; 
         FIG. 5  is a perspective view of an adjuster clip used for a tolerance adjusting attachment, according to the present invention; 
         FIG. 6  is a perspective view of a tolerance adjusting attachment having an adjuster clip in a first position, according to the present invention; 
         FIG. 7  is a rear view of a tolerance adjusting attachment having an adjuster clip in a first position, according to the present invention; 
         FIG. 8  is a side view of a tolerance adjusting attachment having an adjuster clip in a first position, according to the present invention; 
         FIG. 9A  is a sectional side view of a tolerance adjusting attachment having an adjuster clip in a first position, according to the present invention; 
         FIG. 9B  is an enlarged view of the circled portion of  FIG. 9A ; 
         FIG. 10A  is a side view of a fastener aligned with the aperture of a structural member and a tolerance adjuster having an adjuster clip in a first position, according to the present invention; 
         FIG. 10B  is a side view of a fastener partially inserted into the aperture of a structural member and a tolerance adjuster having an adjuster clip in a first position, according to the present invention; 
         FIG. 10C  is a side view of a fastener further inserted into the aperture of a structural member and a tolerance adjuster having an adjuster clip in a first position, according to the present invention; 
         FIG. 10D  is a side view of a fastener fully inserted through the aperture of a structural member such that the adjuster core is partially drawn out of the bracket member, according to the present invention; 
         FIG. 10E  is a side view of a fastener fully inserted into the aperture of a structural member such that the adjuster core of a tolerance adjusting attachment is in contact with the frame member, according to the present invention; 
         FIG. 10F  is a perspective view of a fastener fully inserted into the aperture of a structural member such that the adjuster core of a tolerance adjusting attachment is in contact with the frame member, with an adjuster clip being further inserted through a bracket member, according to the present invention; 
         FIG. 11  is a first sectional perspective view of a tolerance adjusting attachment having the adjuster clip in a second position, according to the present invention; 
         FIG. 12  is a sectional side view of a tolerance adjusting attachment having the adjuster clip in a second position, according to the present invention; 
         FIG. 13  is a second sectional perspective view of a tolerance adjusting attachment having the adjuster clip in a second position, according to the present invention; and 
         FIG. 14  is a sectional top view of a tolerance adjusting attachment having the adjuster clip in a second position, according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring to  FIG. 1 , an exploded view of a tolerance adjusting attachment for a bracket member used for compensating for variation in alignment between a series of externally visible components is shown generally at  10 . The bracket member  10  connects to more than one externally visible component, such as a fender (not shown) or a fascia (also not shown). 
     The bracket member  10  includes a first slot  12 , which is formed as part of the bracket member  10 , and a second slot (not shown). The slot  12  is made by a first substantially flat portion  14  which is offset from a second substantially flat portion  16  and an extension  18 . The first flat portion  14  has an aperture  20  which is selectively in alignment with a corresponding aperture  22  formed on a tab  24 . The apertures  20 , 22  are used along with a socket  26  for allowing one of the externally visible components mentioned above, which in this embodiment is a headlamp (not shown), to be attached to the bracket member  10 . When the apertures  20 , 22  are aligned, the aperture  20  and corresponding aperture  22  will receive a protrusion having a detent (not shown) from the headlamp. Once inserted, the tab  24  is moved in the slot  12  so as to offset the aperture  20  from the corresponding aperture  22  of the tab  24 . When the tab  24  is moved in the slot  12 , the aperture  22  becomes offset from the aperture  20 , and the aperture  22  has a narrow portion  28  which engages the detent of the headlamp. The headlamp also includes a ball (not shown) which is inserted into the socket  26 , allowing for the position of the headlamp to be changed, and compensate for various tolerances. Once the protrusion is inserted through the apertures  20 , 22 , and the ball is inserted into the socket  26 , headlamp is secured to the bracket member  10 . 
     The bracket member  10  is attached to other components used for supporting various body panels through the use of fasteners, such as bolts, screws, rivets, or the like, inserted through a set of apertures  36  formed as part of the bracket member  10 . 
     Other components used for supporting the front fascia or the fender are connected to the bracket member  10  through the use of a lower bracket  38  through the use of a snap-fit connection, which allows for pivoting about the bracket  38 . 
     Referring to the Figures generally, the bracket member  10  also includes a tolerance adjusting attachment, generally shown at  40 . The adjustment attachment  40  includes a support aperture  42  formed as a portion of the bracket member  10 . The support aperture  42  is part of a first wall portion  44 , which is substantially perpendicular to a second wall portion  46  and a third wall portion  48 . The second and third wall portions are also referred to as side wall portions  46 , 48 . Perpendicular to both the side wall portions  46 , 48  and the first wall portion  44  are an upper wall portion  50 , and a lower wall portion  52 . The side wall portions  46 , 48 , upper wall portion  50 , and lower wall portion  52  form a box member, generally shown at  54 . The second wall portion  46  and third wall portion  48  include upper and lower slots  56 , 58  respectively, which are formed as part of the second wall portion  46 , and the third wall portion  48 , respectively. 
     The adjustment attachment  40  also includes an adjuster core, generally shown at  60  and an adjuster clip, generally shown at  62 . The adjuster core  60  includes a first box section  64  having rack features  66 , and a second box section, generally shown at  68 . The adjuster core  60  also includes a core aperture  70  which is optionally threaded and extends through both the first box section  64  and the second box section  68 , as shown in  FIGS. 1 ,  3 ,  4 ,  9 A, and  11 - 12 , allowing for a fastener  72 , such as a bolt or screw, to be inserted therethrough. The first box section  64  includes two side wall portions  74 , 76  which are connected to two more side wall portions  78 , 80  upon which the rack features  66  are mounted. The first box section  64  also includes a limit stop  82  which limits the movement of the adjuster core  60  through the support aperture  42  when the adjuster clip  62  is used, the function of which will be described later. 
     The second box section  68  includes a first wall member  84  connected to the first box section  64 , a second wall member  86 , a third wall member  88 , and a fourth wall member  90 . There is space between the wall members  84 , 86 , 88 , 90  such that a box aperture  92  is formed. 
     The adjuster clip  62  includes a generally U-shaped body portion  94  which has a first leg  96  and a second leg  98 . Both the first leg  96  and the second leg  98  have inner surfaces  100 , 102  which include rack features  104  which correspond to the rack features  66  of the adjuster core  60  when the adjuster clip  62  slides into the slots  56 , 58 . The leg  96  has a first pair of attachment fingers  106 , and the other leg  98  has a second pair of attachment fingers  108 . Each pair of fingers  106 , 108  also includes a set of snap features  110  and a set of engagement tabs  112  which prevent the adjuster clip  62  from easily becoming detached from the bracket member  10  when the adjuster clip  62  is inserted through the first and second sets of slots  56 , 58 . The adjuster clip  62  also includes a preliminary engagement member, or small tooth  114  which initially engages the rack feature  66  of the adjuster core  60  when the adjuster clip  62  is inserted into the first and second slot  56 , 58 . Also included as part of the adjuster core  60  are a pair of protrusions  116  which support the adjuster clip  62  as the adjuster clip  62  slides into the first and second sets of slots  56 , 58 . 
     During assembly, the tolerance adjusting attachment  40  is used for attaching the bracket member  10  to a structural member, such as a frame member  120  having an aperture  122 . The adjuster core  60  is inserted through the support aperture  42 , and is free to move within the support aperture  42 . Once this occurs, the adjuster clip  62  is inserted through the upper and lower slots  56 , 58  to a first position, shown in  FIGS. 6-7 , and  10 A- 10 D, such that the first leg  96  and attachment fingers  106  are inserted through the upper slots  56 , and the second leg  98  and attachment fingers  108  are inserted through the lower slots  58 . However, in the first position, the first leg  96  and second leg  98  are only inserted through the slots  56 , 58  until the engagement tabs  112  contact the outside of the second wall portion  46 , and only the small tooth  114  is engaged with the rack feature  66  of the adjuster core  60 , as best seen in  FIGS. 9A and 9B . 
     As shown in  FIGS. 10A-10D , there is a gap, shown generally at  124 , which is located between the adjuster core  60  and the frame member  120 . The bolt, screw or other suitable fastener  72  is then inserted through the aperture  122  of the frame member  120  and the core aperture  70  of the adjuster core  60 . As the bolt  72  is rotated in the core aperture  70 , the adjuster core  60  will move in the support aperture  42  toward the frame member  120  such that the second box section  68  of the adjuster core  60  contacts the frame member  120 , as shown in  FIGS. 10E-14 . The bolt or fastener  72  will then be tightened. The engagement between the small tooth  114  and the rack feature  66  will provide enough resistance to keep the adjuster core  60  secured while in transit toward the frame member  120 , but will allow the adjuster core  60  to move in the support aperture  42  such that the gap  124  is eliminated. It should be noted that the limit stop  82  will only allow the adjuster core  60  to be moved so far in the support aperture  42  before the limit stop  82  will contact the adjuster clip  62 , preventing further movement of the adjuster core  60 . This can best be seen in FIGS.  9 A and  11 - 13 . 
     Once the fastener  72  is tightened, the attachment fingers  106 , 108  are further inserted through the slots  56 , 58  such that the snap features  110  contact the outside of the second wall portion  46 , thereby retaining the adjuster clip  62  in place, and placing the adjuster clip  62  in a second position. Also, as the adjuster clip  62  is inserted through the upper and lower slots  56 , 58  such that the rack features  104  of the adjuster clip  62  engage with the rack features  66  of the adjuster core  60 , the adjuster core  60  is prevented from moving relative to the rest of the bracket member  10 , best seen in  FIGS. 11-14 . 
     While one specific configuration of the bracket member  10  and tolerance adjusting attachment  40  has been shown, the bracket member  10  and the tolerance adjusting attachment  40  are made through a forming process, such as injection molding, and can be made to fit any type of vehicle having any type of fascia or top cap. 
     The tolerance adjusting attachment  40  can also optionally include a U-nut  126 , which is partially inserted into the box aperture  92  of the adjuster core  60 . The U-nut  126  will also include a threaded surface that is used with the fastener  72  as the fastener  72  is inserted into the core aperture  70 . 
     Furthermore, as the tolerance adjusting attachment  40  is assembled and the adjuster core  60  is secured to the frame member  120 , torque is generated by the fastener  72  being rotated in the core aperture  70 . The adjuster core  60  includes a set of ribs  128 . Each of the side wall portions  74 , 76  includes a rib  128 , and there is also a corresponding groove  130  formed as part of the second wall portion  46  and third wall portion  48 , respectively. When the adjuster core  60  is disposed in the support aperture  42 , the ribs  128  will be located in the corresponding grooves  130 , and will allow the adjuster core  60  to move within the aperture  42  toward the frame member  120  as described above. As the fastener  72  is tightened, the ribs  128  and the grooves  130  will help to absorb the torque applied to the core  60 , and help to reduce the torque the rack features  66  on the adjuster core  60  apply to the rack features  104  on the surfaces  100 , 102  of the clip  62 . 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.