Abstract:
A mounting system for aligning and suspending an HVAC module onto a cross car beam is provided. The mounting system may include a first mounting feature attached to the HVAC module and a second mounting feature attached to the cross car beam such that the second mounting feature is inserted into the first mounting feature to align the HVAC module with the cross car beam and to suspend the HVAC module from the cross car beam.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/718,864 filed Oct. 26, 2012. The entire disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to HVAC modules and, more particularly, to a mounting feature for attaching an HVAC module to a vehicle cross car beam or structure. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     The dashboard assembly of a vehicle is a complex structure constructed from many components. The dashboard assembly may include dashboard components such as a cross car beam, an HVAC module, a crashpad assembly, climate controls, a radio head unit, a glove compartment, airbags, switchgear, vehicle instruments and associated wiring to and from each component. 
     Typically, in a vehicle production environment, each dashboard assembly is pre-assembled at a workstation prior to installation within a vehicle. Assembly may begin with a cross car beam mounted upon a support structure, such as a carrier. The dashboard components may be attached to the cross car beam until the dashboard assembly is fully constructed. 
     The workstation and carrier may be ergonomically designed to provide the user with supplies such as hand-tools and/or fasteners to assemble the dashboard assembly. In addition, the workstation may include quantities of each dashboard component to ensure that the user is equipped to assemble the dashboard assembly efficiently. 
     The workstation and carrier may also be ergonomically designed to improve safety and reduce the likelihood of injury. The carrier may suspend the dashboard assembly at a height convenient for the user in order to minimize stress, strain and fatigue due to bending of the knees and/or back. Further, the carrier may also rotate along the length of the dashboard assembly to provide the user with convenient access to all sides of the dashboard assembly. 
     Despite the ergonomic advantages that the workstation and carrier provide, the construction of the dashboard assembly may be a physically demanding and cumbersome process. Heavy dashboard components must be lifted, aligned and fastened to the cross car beam. For example, when attaching an HVAC module to the cross car beam, the HVAC module must first be lifted onto the cross car beam. The HVAC module must then be held in alignment with the cross car beam in order to fasten the HVAC module to the cross car beam. Typically, a lift-assist tool and/or additional staff are required to help lift, align and fasten the HVAC module. Either option, however, requires additional investment. 
     A need, therefore, exists for a mounting feature to allow a user to mount and fasten an HVAC module to a cross car beam without the assistance of a lift-assist tool and/or additional staff. More specifically, a need exists for a mounting feature which may allow a user to suspend an HVAC module from a cross car beam such that the hands of the user may be free to fasten the HVAC module to the cross car beam. Additionally, a need exists for a mounting feature which may self-align an HVAC module with a cross car beam such that the HVAC module may be quickly fastened to the cross car beam. 
     SUMMARY 
     The present teaching provide for a mounting system for suspending an HVAC module onto a cross car beam. The mounting system may include a first mounting feature attached to the HVAC module and a second mounting feature attached to the cross car beam such that the second mounting feature is inserted into the first mounting feature to suspend the HVAC module from the cross car beam. 
     The present teaching provides for an additional mounting system for aligning an HVAC module mounted on a cross car beam. The mounting system may include a first mounting feature attached to the HVAC module and a second mounting feature attached to the cross car beam such that the second mounting feature may be inserted into the first mounting feature to align the HVAC module with the cross car beam. 
     The present teaching provides for a method for aligning an HVAC module to a cross car beam. The method may entail inserting the cross car beam into the HVAC module and utilizing the force of gravity to rotate the HVAC module relative to the cross car beam such that the HVAC module is in alignment with the cross car beam. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
         FIG. 1  is a perspective view of an automotive vehicle showing a passenger space with an exemplary cross car beam and an exemplary HVAC module according to the present teachings; 
         FIG. 2A  is a perspective view of the cross car beam and the HVAC module attached to a carrier at an HVAC assembly workstation; 
         FIG. 2B  is an exploded perspective view of the HVAC module and the cross car beam attached to the carrier of the HVAC assembly workstation; 
         FIG. 3  is a top view of the cross car beam and HVAC module; 
         FIG. 4  is an enlarged perspective view of a bracket referenced in  FIG. 2A ; 
         FIG. 5  is a cross-sectional view of the HVAC module along line  5 - 5  of  FIG. 3 ; 
         FIG. 6  is an enlarged perspective view of a bracket referenced in  FIG. 2A ; 
         FIG. 7  is a cross-sectional view of the HVAC module along line  7 - 7  of  FIG. 3 ; 
         FIG. 8  is an enlarged perspective view of a bracket referenced in  FIG. 2A ; 
         FIG. 9  is a cross-sectional view of the HVAC module along line  9 - 9  of  FIG. 3 ; 
         FIG. 10A  is a cross-sectional view of the HVAC module along line  7 - 7  of  FIG. 3  depicting the bracket entering the notch as the HVAC module is mounted onto the cross car beam; 
         FIG. 10B  is a cross-sectional view of the HVAC module along line  7 - 7  of  FIG. 3  depicting the bracket sliding into the notch as the HVAC module is mounted onto the cross car beam; 
         FIG. 10C  is a cross-sectional view of the HVAC module along line  7 - 7  of  FIG. 3  depicting the bracket and the notch as the HVAC module is suspended from the cross car beam; and 
         FIG. 10D  is a cross-sectional view of the HVAC module along line  7 - 7  of  FIG. 3  depicting the HVAC module fastened to the cross car beam. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     Referring  FIG. 1 , an automotive vehicle  10  with a dashboard assembly  12  according to the present teachings is illustrated. The dashboard assembly  12  may include an HVAC module  14  attached to a cross car beam  16 . The dashboard assembly  12  may be attached to the vehicle  10  by fastening the cross car beam  16  to a driver-side hinge pillar (not shown) and a passenger-side hinge pillar (not shown). The HVAC module  14  may be formed from injection molded thermoplastic. The cross car beam  16  may be formed from hydroformed metal in conjunction with other suitable metal forming methods, such as bending and/or welding. The invention is not limited to a cross car beam constructed from metal and may include composite cross car beams of any material or construction including composite materials and/or laminate construction. 
     As shown in  FIG. 2A , the dashboard assembly  12  may be pre-assembled at a workstation having a carrier  20 . Pre-assembly may begin with the cross car beam  16  initially mounted upon the carrier  20 . Individual dashboard components may be attached to the cross car beam  16  until the dashboard assembly  12  is fully assembled and ready for installation into the vehicle  10 . 
     The HVAC module  14  and the cross car beam  16  may be mounted to the carrier  20  such that the HVAC module  14  and the cross car beam  16  may be positioned at a convenient height for a user to assemble the dashboard assembly  12 . The carrier  20  may also allow the HVAC module  14  and the cross car beam  16  to rotate along the length of the cross car beam  16 . The carrier  20  may have a handle  22  to allow a user to control the rotation of the HVAC module  14  and the cross car beam  16 . Allowing rotation of the HVAC module  14  and the cross car beam  16  may provide a user with access to the rear and underside of the HVAC module  14  and the cross car beam  16 . In addition, the cross car beam  16  may be rotated and held at any convenient angle for installing a dashboard component. 
     As illustrated in  FIG. 2B , the cross car beam  16  may have brackets  30 ,  32 ,  34  which may be attached to and spaced along the length of the cross car beam  16 . The brackets  30 ,  32 ,  34  may have a base  36  attached to the cross car beam  16  and a tip  38  positioned opposite the cross car beam  16 . The base  36  and the tip  38  may be connected by a bend  40 . The base  36  may be welded to the cross car beam  16 . The brackets  30 ,  32 ,  34  may have a top surface  42  and a bottom surface  44 . The brackets  30 ,  32 ,  34  may have a hole  46  through the top surface  42  and the bottom surface  44  for receiving fasteners  28 . 
     As shown in  FIG. 3 , the HVAC module  14  may have notches  50 ,  52 ,  54  spaced along the length of the HVAC module  14 . The notches  50 ,  52  may be positioned at the outer extents of the HVAC module  14  and the notch  54  may be positioned between notches  50 ,  52 . The notches  50 ,  52 ,  54  may be integrally formed with the HVAC module  14 . 
     Referring back to  FIG. 2B , the notches  50 ,  52 ,  54  may have a control surface  56  which may engage the bottom surface  44  of the brackets  30 ,  32 ,  34  when the HVAC module  14  is mounted to the cross car beam  16 . The control surface  56  may include a recess  58  and a hole  48  positioned within the recess  58 . A clip-on nut  80  may be inserted into the recess  58  by clipping the clip-on nut  80  onto the HVAC module  14  and within the recess  58 . The clip-on nut  80  may be a J-nut as is well known in the art. The clip-on nut  80  may be positioned within the recess  58  such that the clip-on nut  80  may be aligned with the hole  48 . In addition, the clip-on nut  80  may have a thickness similar to the depth of the recess  58  such that the top surface of the clip-on nut  80  may be flush with the control surfaces  56 . The hole  48  may be positioned within the recess  58  such that the fastener  28  may be inserted into the hole  48  and threadingly engage the clip-on nut  80 . 
       FIGS. 4 through 7  depict the notches  50 ,  52 . The notches  50 ,  52  may have a tapered opening  60  and a side opening  62  to provide a larger opening through which the tip  38  of the brackets  30 ,  32  may be inserted into the notches  50 ,  52 . The larger opening may ease the burden of mounting the HVAC module  14  onto the cross car beam  16  by allowing the tip  38  to be inserted into the notches  50 ,  52  at a broad range of angles. 
     As illustrated in  FIGS. 5 and 7 , the tapered opening  60  may be defined by a tapered surface  64 , a load-bearing surface  66 , a base surface  68 , a sidewall  70 , the side opening  62  and the control surface  56 . The tapered surface  64  may be positioned opposite to the control surface  56  and adjacent to the load-bearing surface  66 . The tapered surface  64  and the load-bearing surface  66  may be connected by a ridge  74 . The load-bearing surface  66  may be positioned opposite to the control surface  56  and connected to the base surface  68 . The base surface  68  maybe connected to the control surface  56  and the sidewall  70 . The sidewall  70  may be positioned opposite to the side opening  62 . 
     The sidewall  70  may provide lateral support and aid in the lateral alignment of the HVAC module  14  with the cross car beam  16 . The sidewall  70  may be positioned on the side of the notches  50 ,  52  adjacent to the notch  54 . When initially inserting the tip  38  of the brackets  30 ,  32  into the notches  50 ,  52 , the sidewall  70  may abut the tip  38  to align the HVAC module  14  with the cross car beam  16 . 
       FIGS. 8 and 9  depict the notch  54 . The notch  54  may have an alignment slot  90  such that the notch  54  may laterally align the HVAC module  14  with the cross car beam  16  when inserting the tip  38  into the notch  54 . The alignment slot  90  may be defined by a load-bearing surface  92 , guide walls  94 , and the control surface  56 . The load-bearing surface  92  may be positioned opposite to the control surface  56  and adjacent to the guide walls  94 . The guide walls  94  may be spaced at a distance apart which is slightly greater than the width of the tip  38 . When the tip  38  of the bracket  34  is inserted into the alignment slot  90 , the guide walls  94  may be in sliding contact with the tip  38  such that the guide walls  94  may guide the tip  38  into the alignment slot  90 . As a result, the guiding of the tip  38  into the alignment slot  90  may laterally align the HVAC module  14  with the cross car beam  16 . 
     As illustrated in  FIGS. 10A through 10D , the HVAC module  14  may rotate relative to the cross car beam  16  when the HVAC module  14  is initially mounted to the cross car beam  16 . The rotation may cause the HVAC module  14  to self-align with the cross car beam  16  such that the holes  46 ,  48  may move into alignment. The rotation may also allow the HVAC module  14  to be suspended by the cross car beam  16  such that the user may insert the fasteners  28  into the holes  46 ,  48  and fasten the HVAC module  14  to the cross car beam  16 . 
     The tip  38  and the tapered opening  60  may be shaped to utilize the center of mass CM of the HVAC module  14  to facilitate the rotation of the HVAC module  14  relative to the cross car beam  16 . The tip  38  may have the bend  40  to create a rotational axis about which the HVAC module  14  may rotate. In addition, the ridge  74  of the tapered opening  60  may also create a rotational axis about which the HVAC module  14  may rotate. When the tip  38  is inserted into the tapered opening  60 , the center of mass CM of the HVAC module  14  may be located a distance from the axes of rotation A, B. The center of mass CM being offset from the axes of rotation may create a rotating moment about the axes of rotation. 
     In operation, the construction of the dashboard assembly may begin with the HVAC module  14  being lifted by the user onto the cross car beam  16 . The user may rotate the handle  22  of the carrier  20  such that the cross car beam  16  may be oriented with the brackets  30 ,  32 ,  34  pointing upwards and away from the ground (not shown). The HVAC module  14  may be lifted onto the cross car beam  16  such that the tip  38  of the brackets  30 ,  32 ,  34  are inserted into the tapered openings  60  and the alignment slot  90 . 
     As shown in  FIG. 10A , as the tip  38  of the brackets  30 ,  32  enter the tapered opening  60  of notches  50 ,  52 , the top surface  42  of the tip  38  may contact and slide against the tapered surface  64 . The tip  38  will slide further into the tapered opening  60  as the HVAC module  14  slides onto the cross car beam  16 . Further, as the tip  38  of the bracket  34  enters the alignment slot  90  of notch  54 , the guide walls  94  may contact and guide the tip  38  such that the HVAC module  14  may be laterally aligned with the cross car beam  16 . 
     As illustrated in  FIG. 10B , the tip  38  of the brackets  30 ,  32  may slide within the tapered opening  60  until the tip  38  contacts the base surface  68 . When the tip  38  contacts the base surface  68 , the HVAC module  14  may begin to rotate about the bend  40  and/or the ridge  74  due to the rotating moment caused by the offset center of mass CM of the HVAC module  14 . The bend  40  and the ridge  74  may both provide a rotational axis around which the HVAC module  14  may rotate. 
     Referring to  FIG. 10C , the HVAC module  14  may rotate about the bend  40  and/or the ridge  74  until the bottom surface  44  contacts the control surface  56 . Rotating the control surface  56  into contact with the bottom surface  44  may align the holes  46 ,  48  such that the fasteners  28  may be inserted into the holes  46 ,  48 . 
     Also illustrated in  FIG. 10C , the rotating moment may press and hold the HVAC module  14  against the cross car beam  16  such that the HVAC module  14  may be suspended by the brackets  30 ,  32 . The rotating moment may hold the control surface  56  against the bottom surface  44  and the top surface  42  against the load-bearing surface  66 . As a result, the hands of the user may be free to insert fasteners  28  within holes  46 ,  48  and tighten fasteners  28  to secure the HVAC module  14  to the cross car beam  16 . Suspending the HVAC module  14  from the cross car beam  16  may eliminate the need for a lift-tool and/or additional staff to hold and/or adjust the alignment of the HVAC module  14  relative to the cross car beam  16  while the user inserts and tightens the fasteners  28 . As shown in  FIG. 10D , the fasteners  28  may be inserted into the holes  46 ,  48  and threadingly engage clip-on nuts  80  to secure the HVAC module  14  to the cross car beam  16 . 
     The notches  50 ,  52 ,  54  may have reinforcing ribs  96  integrally formed along the exterior surfaces of the notches  50 ,  52 ,  54 . The reinforcing ribs  96  may increase the strength and stiffness of the notches  50 ,  52 ,  54  to ensure that the notches  50 ,  52 ,  54  may support the weight of the HVAC module  14  while suspended from the cross car beam  16 . In addition, the brackets  30 ,  32 ,  34  may have reinforcing members  98  such that the brackets  30 ,  32 ,  34  may support the weight of the HVAC module  14 . 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.