Abstract:
A The present invention is a support system for a panel having a carrier member to which a component support structure is attached, at least one component support structure to which a first externally visible component and the contoured finish panel require attachment, a first attachment structure for providing fixed position attachment of the first externally visible component, and a support member having a contoured surface for supported the contoured finished panel in a fixed position. The present invention also includes a second attachment structure which provides adjustable positioning of the support member to the support structure such that a close tolerance fit can be facilitated between the first externally visible component and the contoured finish panel by selecting the position of the support member.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to support assemblies which are used in the front end of an automobile; more particularly, the present invention relates to a support member which is used for supporting a front fascia or top cap in an automobile, as well as controlling the relative positioning between a headlamp assembly and the front fascia or top cap in an automobile. 
       BACKGROUND OF THE INVENTION 
       [0002]    Fascias or top caps are generally known and used throughout various types of automobiles. The fascia or top cap is a portion of the body which is typically positioned near, or below the headlights and grille, and is used for providing an aesthetically pleasing appearance. However, typical fascias, as well as top caps, are lacking in support in an area below the headlights and in front of the grill of the automobile. These fascias and top caps are typically made of a composite material which can be difficult to dimension, as well as position relative to the headlights such that the correct dimensions are achieved. 
         [0003]    Often during assembly, due to tolerances and other manufacturing causes, the position of the headlight relative to the fascia or top cap is too large, leaving a gap between the headlight and the fascia or top cap, which detracts from the appearance of the automobile. It is desired to have a minimal gap between the headlight and front fascia or top cap of the automobile. 
         [0004]    Accordingly, there exists a need for an improved way of controlling the dimensions between the headlight and the front fascia or top cap, as well as providing support for the front fascia or top cap. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention is a support system for a panel having a carrier member to which a component support structure is attached, at least one component support structure to which a first externally visible component and the contoured finish panel require attachment, a first attachment structure for providing fixed position attachment of the first externally visible component, and a support member having a contoured surface for support of the contoured finished panel in a fixed position. 
         [0006]    The present invention also includes a second attachment structure which provides adjustable positioning of the support member to the support structure such that a close tolerance fit can be facilitated between the first externally visible component and the contoured finish panel by selecting the position of the support member. 
         [0007]    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 
         [0008]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0009]      FIG. 1  is a perspective view of a front end assembly support system for a top cap, according to the present invention; 
           [0010]      FIG. 2  is a perspective view of a front end assembly support system for a top cap with the headlamp removed, according to the present invention; 
           [0011]      FIG. 3  is an enlarged perspective view of a support system used for a top cap, according to the present invention; 
           [0012]      FIG. 4  is an enlarged front view of a support system for a top cap, according to the present invention; 
           [0013]      FIG. 5  is an enlarged perspective rear view of a support system for a front fascia or top cap, according to the present invention; 
           [0014]      FIG. 6  is a perspective view of a support system for a top cap with the top cap attached, according to the present invention; 
           [0015]      FIG. 7  is an enlarged perspective rear view of a support system with the top cap attached, according to the present invention; and 
           [0016]      FIG. 8  is a perspective rear view of a bracket headlamp carrier used in a support system, according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0017]    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. 
         [0018]    Referring to the Figures, a support system for a contoured finish panel, more specifically a top cap or a fascia is shown generally at  10 . The system  10  includes a carrier member, which in this embodiment is a carrier  12  which is used for supporting various vehicle components, such as a radiator, hood, fan, fan shroud, windshield washer fluid container, various hoses, and the like. Attached on each side of the carrier  12  are lamp supports  14 . The lamp supports  14  are attached through the use of an adhesive bond and rivets  16 . The adhesive bond is placed between the carrier  12  and the lamp supports  14 , the rivets  16  are then attached and hold the carrier  12  and lamp supports  16  together until the adhesive bond cures. 
         [0019]    Attached to each of the lamp supports  14  is a bracket headlamp carrier  18 , and a support member  20 . The bracket headlamp carrier  18  is attached to the carrier  12  through the use of fasteners, shown as bolts  22  in  FIGS. 6 and 7 , and the lamp supports  14  along with the bracket headlamp carrier  18  forms a component support structure. Also attached to each of the headlamp supports  14  is a center support  24 . The support member  20  and the center support  24  are used for supporting a contoured finish panel of the body of a vehicle, which in this embodiment is a top cap  26 . The top cap  26  is used to provide an aesthetically pleasing appearance and is typically the same color as the remaining body components. 
         [0020]    During assembly, a first externally visible component, which in this embodiment is a lamp assembly in the form of a headlamp  27 , is attached to the bracket headlamp carrier  18  using an aperture  28  and tab  30 . The tab  30  is received in a slot  32  in the bracket headlamp carrier  18 . The tab  30  has a corresponding aperture  34  such that when the aperture  28  and corresponding aperture  34  are aligned, the aperture  28  and corresponding aperture  34  will receive a protrusion from the headlamp  27 . Once inserted, the tab  30  is moved in the slot  32  so as to offset the aperture  28  and the aperture  34  of the tab  30 , and engage the protrusion of the headlamp  27 , securing the headlamp  27  to the bracket headlamp carrier  18 . The headlamp  27  also includes a ball which is received in a socket  36 . The socket  36  allows for the position of the headlamp  27  to be changed, and compensates for various tolerances. 
         [0021]    The support member  20  is connected to the bracket headlamp carrier  18  through the use of an extension  38  which is connected to a bracket  40 ; the support member  20  is also connected to the lamp support  14  through the use of fastener, such as a screw (not shown) inserted through a slot  42  in a flange  44  and through a corresponding aperture  46  in the lamp support  14 . The support member  20  also includes snaps  48 , the function of which will be described later, and a contoured surface  50  for supporting the top cap  26 . 
         [0022]    The headlamp  27  is also attached to the lamp supports  14  through the use of an upper connector  52  and a lower connector  54 . The upper connector  52 , lower connector  54 , the slot  32  and tab  30 , and the ball and socket  36  form a first attachment structure for connecting the headlamp  27  to the lamp support  14  and bracket headlamp carrier  18 . The flange  44  and the slot  42 , and the corresponding aperture  46  form a first attachment point; the extension  38  and bracket  40  form a second attachment point. Both the first attachment point and second attachment point form a second attachment structure for attaching the support member  20  to the lamp support  14  and the bracket headlamp carrier  18 . 
         [0023]    Once the headlamp  27  is attached to the lamp support  14 , and the bracket headlamp carrier  18 , the position of the support member  20  can be adjusted using the extension  38  and bracket  40 , along with the fastener inserted through the slot  42  and aperture  46 . The slot  42  is shaped so as to allow the position of the support member  20  to be adjusted during assembly relative to the lamp support  14 . Adjusting the position of the support member  20  relative to the lamp support  14  secures the position of the support member  20 , and therefore secures the position of the top cap  26  relative to the headlamp  27 , allowing for control over the amount of space between the headlamp  27  and top cap  26 . The space between the headlamp  27  and top cap  26  is shown as a gap generally at  29  in  FIG. 1 . 
         [0024]    Referring to  FIGS. 6 and 7 , the top cap  26  includes a set of extensions  56  having an angled tab  57  and a contact surface  59  which are received into the snaps  48  of the support member  20 . The snaps  48  have a frame member  61  and an aperture  63 . The angled tab  57  is inserted through the aperture  63  until the contact surface  59  contacts the frame member  61 . The contoured surface  50  of the support member  20  provides support for the top cap  26 . 
         [0025]    The center support  24  also includes a contoured surface  58 , which also provides support for the top cap  26 . The center support  24  includes a centering aperture  60 , a series of grille snaps  62  having an aperture  66 , and top snaps  64  having an aperture  68 . A second externally visible member, which in this embodiment is an exterior body component in the form of a grille (not shown), is attached to the center support  24  through the use of the grille snaps  62 . The grille has extensions (not shown) which include angled tabs and contact surfaces, and are inserted into the grille snaps  62  in the same manner as the extensions  56  of the top cap  26  are inserted into the snaps  48 . The grille is properly aligned with the center support  24  by using the centering aperture  60 . After the grille is attached, the top cap  26  is attached using a set of extensions (not shown) having an angled tab and contact surface, which are similar to the extensions  56  inserted into the snaps  48 , and are inserted into the top snaps  64  in a similar manner that the extensions  56  are inserted into the snaps  48 . 
         [0026]    The center support  24  is formed such that once the grille and the top cap  26  are both attached to the center support  24 , the desired distance between the grille and top cap  26  is achieved to provide an aesthetically pleasing appearance. The top snaps  62 , and extensions of the top cap  26  form a first attachment assembly for connecting the top cap  26  to the center support  24 , and the grille snaps  62  along with the extensions of the grille form a second attachment assembly for connecting the grille to the center support  24 . 
         [0027]    It should be noted that the top cap  26  could also be replaced with a fascia. The fascia would also have extensions which would be received by the snaps  48  of the support member  20  and the top snaps  64  of the center support  24 , and supported by the contoured surface  50  of the support member  20  and the contoured surface  58  of the center support  24  in the same manner as the top cap  26 . 
         [0028]    While it has been shown that the support member  20  has been used with the carrier  12  and lamp supports  14 , the support member  20  is made through a forming process, such as injection molding, and can be made to fit any type of vehicle having any type of top cap  26  or front fascia. 
         [0029]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence 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.