Abstract:
A method of attaching a vehicle accessory, such as a running board, to an attachment bracket and/or a vehicle, wherein the attachment method requires no additional discrete fasteners. Furthermore, the positioning of the accessory relative to the vehicle or bracket is precisely controlled by means of datum references, set on the accessory, vehicle, and or bracket.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to the method of attaching a vehicle accessory such as a running board, to an attachment bracket and/or a vehicle. Specifically, requiring no additional fasteners and precisely positioning the accessory in reference to a datum on the accessory bracket and/or vehicle.  
       BACKGROUND OF THE INVENTION  
       [0002]     The accurate locating of a vehicle accessory to a vehicle is often made difficult because of vehicle and part variation. Presently known accessories are joined to a vehicle by discrete fasteners that screw through holes or slots in the joining surface that are larger than the fastener itself. Thus a degree of positional adjustment can be made between the accessory, its mounting bracket system and/or the vehicle prior to tightening the fasteners.  
         [0003]     Also, presently known in the art are accessories that are mounted to their respective bracket system and/or vehicle by snap-together means. Here also, however, due to the mean of manufacturing such components, snap-together joints have limited adjustability to accommodate for accessory, bracket or vehicle variation and/or adjustment during attachment.  
         [0004]     It is therefore advantageous to have vehicular accessories that can be manufactured and assembled quickly, easily and without the need for discrete fasteners or hardware, thereby driving down production costs and installation time, while still maintaining a secure and strong assembly with a precise fit and finish.  
       SUMMARY OF THE INVENTION  
       [0005]     It is therefore an object of the present invention to provide a method of installing an accessory to a vehicle in a precise manner without the use of discrete fasteners and without the need for adjustability.  
         [0006]     It is another object of the present invention to provide a method of installing an accessory to a vehicle in a precise manner that can compensate for individual vehicle and part variations.  
         [0007]     A further object of the present invention is to provide for a method of aligning an accessory with a vehicle or mounting bracket prior to assembly which provides for a precise and accurate attachment thereof.  
         [0008]     These and other objects are achieved in a vehicle accessory mounting method disclosed in the following embodiments which comprises both a secure, fastenerless joining method and a precise locating method, providing for cost-effective, simple attachment.  
         [0009]     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 embodiments 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  
       [0010]     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0011]      FIG. 1  is a partial cross-sectional view of first embodiment of an accessory joining zone prior to joining with the vehicle or bracket;  
         [0012]      FIG. 2  is a cross sectional view of the accessory joining zone of  FIG. 1  after the joint has been secured, wherein the accessory&#39;s protrusion has been formed so as to lock the accessory to the bracket or vehicle;  
         [0013]      FIG. 3  is a partial cross-sectional view of a second embodiment of an accessory joining zone prior to joining with the vehicle or bracket;  
         [0014]      FIG. 4  is a cross-sectional view of the accessory joining zone of  FIG. 3  showing the joint after being secured, wherein the ferrous media has been induction heated;  
         [0015]      FIG. 5  is a partial cross-sectional view of a third embodiment of an accessory joining zone prior to joining with the vehicle or bracket;  
         [0016]      FIG. 6  is a cross-sectional view of the accessory joining zone illustrated in  FIG. 5 , after the joint has been secured, wherein an adhesive or solvent has bonded the parts together;  
         [0017]      FIG. 7  is a partial cross-sectional view of a fourth embodiment of an accessory joining zone prior to joining with the vehicle or bracket;  
         [0018]      FIG. 8  is a cross-sectional view of the accessory joining zone illustrated in  FIG. 7 , after the joint has been secured, wherein an adhesive tape has bonded the parts together;  
         [0019]      FIG. 9  is a partial cross-sectional view of a fifth embodiment of an accessory joining zone prior to joining with the vehicle or bracket;  
         [0020]      FIG. 10  is a cross-sectional view of the accessory joining zone illustrated in  FIG. 9  after the joint has been secured;  
         [0021]      FIG. 11  is a partial perspective view of a sixth embodiment of an accessory joining zone prior to joining with the vehicle or bracket; and  
         [0022]      FIG. 12  is a partial cross-sectional view of the accessory joining zone illustrated in  FIG. 11  after the joint has been secured. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0024]     Referring to  FIG. 1 , a first embodiment of the present invention is shown, illustrating a vehicle accessory  10  such as a running board, positioned for attachment to a vehicle or bracket member  12 . The accessory  10  has a generally planar area proximal the joining zone, and comprises one or more spacers  16  molded therein for positioning the bracket off the vehicle/bracket  12  surface. Datum locators  14  are utilized on both the vehicle/bracket  12  and the accessory  10 , to allow precise positioning of the two components prior to joining.  
         [0025]     To join the accessory  10  to the vehicle/bracket  12  as shown in  FIG. 2 , the accessory is positioned via the datum locators  14 , so as to align the pre-formed protrusions  18  on the accessory  10  through a corresponding receiving aperture  13  located on the vehicle/bracket. A support means  20  holds the accessory  10  in position while applying an opposing forming tool  22 , to the protrusions  18  creating a locking flare on the bottom side of the vehicle/bracket  12 , securing the accessory  10  in position. The forming operation can use heat and/or force to plastically deform the protrusion  18  about the vehicle/bracket  12 . During the forming process the relative location of the accessory  10 , or vehicle/bracket  12  is defined by one or more datum locations  14  and fixtured thus to prevent any post-joining movement. Any of six degrees of freedom can be located and locked into place by this method.  
         [0026]     In a second embodiment, illustrated in  FIG. 3 , a plastic accessory  10  is joined to the vehicle/bracket  12  by means of a weld. A ferrous media  30  is applied to mounting locations on the accessory  10 . The accessory  10  is then positioned proximal its mounting location, utilizing the datum locators  14  and the support tools  20  and  36 . Once the accessory  10  is abutted to the vehicle/bracket  12 , a series of induction heating coils  34  secures the accessory  12  by supplying sufficient induction heat to the ferrous media, which locally melts the accessory  10  and vehicle/bracket  12  after which they are pressed and welded together as illustrated in  FIG. 4 . During the pressing and welding process the relative location of the accessory  10 , or vehicle/bracket  12  is defined by one or more datum locations and fixtured thus to prevent any post-joining movement. Any of six degrees of freedom can be located and locked into place by this method.  
         [0027]     Referring now to  FIGS. 5 and 6  illustrating a further embodiment, an accessory  10  is joined to the vehicle/bracket  12  by means of an applied adhesive or solvent  40  in between the accessory  10  and the vehicle/bracket  12 . Prior to joining, the adhesive or solvent  40  is applied to mounting locations on the accessory  10 , at which time the accessory  10  is subsequently pressed and bonded to the vehicle/bracket  12 . During the pressing and bonding process the relative location of the accessory  10  and vehicle/bracket  12  is defined by one or more datum locations  14  and fixtures thus to prevent any post-curing movement. Any of six degrees of freedom can be located and locked into place by this method.  
         [0028]      FIGS. 7 and 8  illustrate a further embodiment, wherein an accessory  10  is joined to the vehicle/bracket  12  by means of an applied adhesive tape  46  in between the accessory  10  and the vehicle/bracket  12 . Prior to joining, the adhesive tape  46  is applied to mounting locations on the accessory  10 , at which time the accessory  10  is subsequently pressed and bonded to the vehicle/bracket  12 . During the pressing and bonding process the relative location of the accessory  10  and vehicle/bracket  12  is defined by one or more datum locations  14  and fixtures thus to prevent any post-curing movement. Any of six degrees of freedom can be located and locked into place by this method as well.  
         [0029]      FIG. 9  illustrates a further embodiment, wherein an accessory  10  is joined to the vehicle/bracket  12  by means of a series of barbs  50  or suchlike sharp protrusions that are strong enough to penetrate the communicating joint area  52  located on the surface of the vehicle/bracket  12 , or in the alternative on the accessory  10  itself, when applied by force.  
         [0030]     Referring now to  FIG. 10 , showing the accessory joining zone of  FIG. 9  after the joint has been secured, wherein the sharp protrusions  50  have penetrated the communicating part  52  and by friction or barb orientation within the communicating part have joined the parts together. During the mechanical joining process the relative location of the accessory  10 , vehicle/bracket  12  is defined by one or more datum locations  14  and fixtures thus to prevent any post-joining movement. Any of six degrees of freedom can be located and locked into place by this method.  
         [0031]      FIGS. 11 and 12  illustrate another alternative embodiment to the present invention, illustrating a partial perspective view of an accessory joining zone prior to joining wherein the accessory  10 , or vehicle/bracket  12  has at least one area with one or more tapered protrusions  60 , sized such that an interference fit can be obtained with the communicating joint area receptacles  62 . The communicating joint area receptacles  62  are sized such that any one of the receptacles may be used as a joint location.  
         [0032]     After the tapered protrusions  60  have penetrated the communicating part  62  the friction between the communicating parts forms the mechanism by which the parts are joined together. During the mechanical joining process the relative location of the accessory  10  or vehicle/bracket  12  is defined by one or more datum locations  14  and fixtures thus to prevent any post-joining movement. Any of six degrees of freedom can be located and locked into place by this method.  
         [0033]     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.