Abstract:
A structure for a vehicle may include first and second spaced-apart members, first and second internally-threaded members, a module, first and second connecting members, and first and second fasteners. The first and second internally-threaded members may be connected to the first and second members, respectively. The module is positioned between the first and second members for a predetermined alignment relative thereto. The first and second connecting members include an outer surface having external threads and an inner surface having internal threads. The outer surface may engage a corresponding one of the internally-threaded members. The external and internal threads have opposite thread-handedness. The first and second fasteners engage the internal threads of the first and second connecting members, respectively. The first and second fasteners may move the first and second connecting members toward the module to clamp the module relative to the first and second members and maintain alignment therebetween.

Description:
FIELD 
     The present disclosure relates to vehicle structure and a method for assembling the structure, and more particularly to structure and a method for assembly a front-end module to a vehicle frame in a manner that maintains predetermined alignment therebetween. 
     BACKGROUND 
     Vehicle manufacturing may include a modular approach to vehicle assembly whereby individual components are preassembled into subassemblies or modules prior to integration into a vehicle body. Such an approach may increase manufacturing efficiency and throughput. For example, a preassembled front-end module may include a front fascia, a grille, exterior lighting units (i.e., headlights, turn signals, and/or fog lights), a front bumper, and structural members supporting such components. The front-end module may be assembled as a unit onto the vehicle chassis or frame. The front-end module can optionally be installed onto the vehicle chassis or frame after an engine, motor or other source of rotary power is installed into the vehicle to provide improved access to an engine or motor compartment during installation of the engine or motor. 
     SUMMARY 
     In one form, the present disclosure provides a structure for a vehicle that may include first and second members, first and second internally-threaded members, a module, first and second connecting members, and first and second fasteners. The first and second members may be spaced apart from each other. The first and second internally-threaded members may be connected to the first and second members, respectively. The module may be positioned between the first and second members for a predetermined alignment relative to the first and second members. The first and second connecting members may each include an outer circumferential surface having external threads and an inner circumferential surface having internal threads. The outer circumferential surface may threadably engage a corresponding one of the first and second internally-threaded members. The external threads and the internal threads may have opposite thread-handedness. The first and second fasteners may threadably engage the internal threads of the first and second connecting members, respectively. The first and second fasteners may be configured to move the first and second connecting members toward the module to clamp the module relative to the first and second members and maintain the predetermined alignment between the module and the first and second members. 
     In another form, the present disclosure provides a method of assembling a vehicle that may include providing first and second rails and first and second internally-threaded members connected to the first and second rails, respectively. First and second connecting members may be provided that each includes internal threads and external threads. A module may be provided that may include first and second portions. The external threads of the first and second connecting members may be engaged with the first and second internally-threaded members, respectively. An alignment of said module relative to said first and second rails may be established. A first fastener associated with the first portion may be engaged with the internal threads of the first connecting member. The first fastener may be rotated in a first direction to cause the first connecting member to rotate relative to the first internally-threaded member such that the first connecting member moves away from the first internally-threaded member to secure the module relative to first connecting member. The first fastener may be further rotated in the first direction such that the first fastener moves toward the module to threadably tighten the first fastener relative to the first connecting member to secure the module relative to the first rail. 
     Further area of applicability of the present disclosure will become apparent from the detailed description and claims provided hereinafter. It should be understood that the detailed description, including disclosed embodiments and drawings, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the invention, its application or use. Thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partially exploded perspective view of a vehicle including a frame having a front-end module according to the principles of the present disclosure; 
         FIG. 2  is a perspective view of a front-end module mounted to first and second rails; 
         FIG. 3  is a partial perspective view of the frame according to the principles of the present disclosure; 
         FIG. 4  is a partial perspective view of the frame including structure for mounting the front-end module to one of the rails; 
         FIG. 5  is a partial perspective view of the rail according to the principles of the present disclosure; 
         FIG. 6  is a perspective view of the structure of  FIG. 4 ; 
         FIG. 7  is a partial perspective view of the structure in a first position relative to the front-end module and the rail; 
         FIG. 8  is a partial perspective view of the structure in a second position relative to the front-end module and the rail; 
         FIG. 9  is a partial cross-sectional view of the front-end module, rail and mounting structure; and 
         FIG. 10  is a schematic representation of a partial side view of the front-end module, rail and mounting structure according to the principles of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Disclosed herein are exemplary embodiments of assembly of vehicle structure, including modular portions, so as to maintain predetermined alignment therebetween. With reference to  FIGS. 1-10 , a vehicle frame  10  is provided that may include a first rail  12 , a second rail  14 , and a front-end module  16 . The vehicle frame  10  may support a body  18 , suspension (not shown), and drivetrain (not shown) of a vehicle  20 . The first and second rails  12 ,  14  may be disposed adjacent to corresponding first and second front quarter panels  22 ,  24  of the body  18  and may cooperate with the front-end module  16  to define an engine or motor compartment  26 . The front-end module  16  may be installed onto the remainder of the vehicle  20  independently from the remainder of the vehicle frame  10 . It should be appreciated that the vehicle  20  could be any type of vehicle such as a car, sport-utility vehicle, crossover vehicle, pickup truck, van, recreational vehicle, commercial or industrial truck or equipment, or a military vehicle, for example. The vehicle  20  can be powered by an internal combustion engine and/or an electric motor, for example, and/or any other power source. 
     The first and second rails  12 ,  14  may be elongated members extending generally toward a front-end of the vehicle  20 . Each of the first and second rails  12 ,  14  may include an outer portion  27 , a first portion  28 , a second portion  30  ( FIG. 5 ), first and second pipe nuts  32 ,  34 , and first and second T-nuts  36 ,  38 . The first and second portions  28 ,  30  may extend generally inwardly from the outer portion  27 . The first portion  28  may include an aperture or slot  40  extending therethrough, and the second portion  30  may include a slot or aperture  42  extending therethrough. 
     The first and second pipe nuts  32 ,  34  may be welded or otherwise fixedly secured to the first and second portions  28 ,  30 , respectively. The pipe nuts  32 ,  34  may be generally elongated members having a threaded aperture  44  extending at least partially therethrough. The threaded apertures  44  of the first and second pipe nuts  32 ,  34  may be substantially aligned with the slot  40  and aperture  42 , respectively. The threaded apertures  44  may include left-handed threads. In another embodiment, the spaced apart first and second rails (members) may include the threaded apertures ( 44 ) where the threads are formed in the respective structural member rather than joining another portion having the apertures (e.g. pipe nuts  32 ,  34 ) to the spaced apart members. 
     The first and second T-nuts  36 ,  38  may movably engage the threaded apertures  44  of the first and second pipe nuts  32 ,  34 , respectively. As shown in  FIG. 9 , each of the T-nuts  36 ,  38  may include a shaft  50  and a head  52 . The shaft  50  may include left-handed external threads  54 . A threaded aperture  56  including right-handed threads may extend through the shaft  50  and the head  52 . The shaft  50  of the T-nuts  36 ,  38  may extend through the slot  40  and aperture  42 , respectively, in the corresponding rail  12 ,  14  and threadably engage the threaded aperture  42  of the corresponding pipe nut  32 ,  34 . 
     Each of the first and second rails  12 ,  14  may include a mounting bracket  53  having first and second legs  55 ,  57  forming a generally L-shaped cross section. The first leg  55  of each bracket  53  may include a plurality of first apertures  58  and the second leg  57  may include a plurality of second apertures  59 . Each of the first apertures  58  may be substantially aligned with one of the slots  40  and apertures  42  in the rails  12 ,  14 . As shown in  FIG. 9 , the first leg  55  may be disposed between the pipe nuts  32 ,  34  and the heads  52  of the T-nuts  36 ,  38 . The second leg  57  may extend laterally outward from the rails  12 ,  14 . The mounting brackets  53  may be welded or otherwise fixed to the first and second rails  12 ,  14 . In some embodiments, the mounting brackets  53  could be integrally formed with the first and second rails  12 ,  14 . 
     As shown in  FIGS. 1 and 2 , the front-end module  16  may include an upper cross member  60 , a lower cross member  62 , a first support member  64 , a second support member  66 , a first laterally-extending member  68 , and a second laterally-extending member  70 . The first and second support members  64 ,  66  may extend between and interconnect the upper and lower cross members  60 ,  62 . The first and second laterally-extending members  68 ,  70  may extend outwardly from the first and second support members  64 ,  66 , respectively. 
     The front-end module  16  may support a front-end fascia  72  and one or more cosmetic and/or functional accessories, such as exterior lighting units  74 , a grille  76 , a bumper  78 , and a radiator (not shown), for example. The upper and lower cross members  60 ,  62  and the first and second support members  64 ,  66  may cooperate to define a frame supporting the radiator and/or the grille  76 . The first and second laterally-extending members  68 ,  70  may cooperate with the upper cross member  60  and corresponding support members  64 ,  66  to house the exterior lighting units  74 . The lower cross member  62  may support the bumper  78 . 
     The lower cross member  62  may include a generally U-shaped cross member  80  having a generally square or rectangular hollow cross section defining an interior volume  81  ( FIGS. 9 and 10 ). The U-shaped cross member  80  may include a pair of vertically-extending members  82  disposed on opposing ends of a horizontal beam  86 . The vertically-extending members  82  may include a plurality of first apertures  90  ( FIG. 9 ) and a plurality of second apertures  92  ( FIGS. 4 and 9 ) extending therethrough. The plurality of first apertures  90  may be generally perpendicular to the plurality of second apertures  92 . Each of the first and second apertures  90 ,  92  may engage a corresponding sheath  94  that spans the interior volume  81  of a corresponding one of the vertically-extending members  82 . 
     Each of the first and second support members  64 ,  66  may include a sleeve  96  having a generally U-shaped cross section that at least partially receives a corresponding one of the vertically-extending members  82  ( FIGS. 3 ,  4 , and  6 ). The sleeve  96  may include a plurality of first apertures  98  and a plurality of second apertures  100 . Each of the first and second apertures  98 ,  100  may be aligned with a corresponding one of the first and second apertures  90 ,  92 , respectively. 
     Each of a plurality of first threaded fasteners  102  may extend through a corresponding one of the first apertures  90  in the U-shaped cross member  80 , the corresponding sheath  94 , and the first aperture  98  and threadably engage the threaded aperture  56  in the T-nuts  36 ,  38 . The first fasteners  102  may include heads  103  and right-handed external threads  108 . A distal end portion  110  of the external threads  108  may include a film or patch  112  formed from a relatively thin polymeric or metallic material. The patch  112  is sufficiently thin so that the external threads  108  that are covered by the patch  112  may still engage the threaded aperture  56  through the patch  112 , but thick enough to provide substantial friction therebetween. In an exemplary embodiment, the patch  112  may be formed from nylon. The patch  112  may be a strip of material that is wrapped onto the threads  108  or the patch  112  may be material that is sprayed onto or otherwise coated on the threads  108 , for example. It will be appreciated that other materials and/or methods of applying the patch  112  may be utilized. 
     Each of a plurality of second threaded fasteners  104  may extend through a corresponding one of the second apertures  92  in the U-shaped cross member  80 , the corresponding sheath  94 , the second aperture  100  in the sleeve  96 , and the second aperture  59  in the mounting bracket  53 . Nuts  106  may engage the second fasteners  104  to secure the U-shaped cross member  80  and the support members  64 ,  66  to the second leg  57  of the mounting brackets  53 . 
     A locating pin  114  may extend from the sleeve  96  of each of the first and second support members  64 ,  66  and may engage the second leg  57  of the mounting bracket  53 . The locating pins  114  may be integrally formed with the first and second support members  64 ,  66 , or alternatively, the locating pins  114  may be discrete components that are inserted through locating or centering apertures in the sleeves  96  and vertically-extending members  82 . 
     With continued reference to  FIGS. 1-10 , a method of installing the front-end module  16  onto the first and second rails  12 ,  14  will be described. As described above, the front-end module  16  may be installed onto the remainder of the vehicle  20  after installation of the first and second rails  12 ,  14 . In some embodiments, an engine, motor, and/or other source of rotary power may be installed in the compartment  26  prior to installation of the front-end module  16 . The front-end module  16  may be installed with a predetermined alignment relative to the first and second rails  12 ,  14 . For example, the front-end module  16  may be substantially centered in a horizontal direction (relative to the view shown in  FIG. 1 ) relative to the first and second rails  12 ,  14 . 
     Prior to installation of the front-end module  16 , the pipe nuts  32 ,  34  and the mounting brackets  53  may be welded or otherwise secured to the first and second rails  12 ,  14 . The T-nuts  36 ,  38  may then be threadably installed into the corresponding pipe nuts  32 ,  34  such that the heads  52  of the T-nuts  36 ,  38  are contacting or nearly contacting the first leg  55  of the mounting brackets  53  or the outer portions  27  of the corresponding rails  12 ,  14 . As described above, the external threads  54  of the T-nuts  36 ,  38  and the threaded apertures  44  of the pipe nuts  32 ,  34  may include left-handed threads, such that turning the T-nuts  36 ,  38  in a counterclockwise direction relative to the pipe nuts  32 ,  34  increases the threaded engagement between the pipe nuts  32 ,  34  and the T-nuts  36 ,  38 , respectively. Stated another way, counterclockwise rotation of the T-nuts  36 ,  38  moves the heads  52  of the T-nuts  36 ,  38  closer to the pipe nuts  32 ,  34 . 
     Next, the alignment between the front-end module  16  and the first and second rails  12 ,  14  may be established. For example, a distance between the first and second rails  12 ,  14  and/or a distance between the sleeves  96  of the first and second support member  64 ,  66  may be measured or otherwise determined. Such measurements may be acquired using known manual and/or automated methods and means, such as a laser measuring device or coordinate measuring machine (CMM), for example. Based on such measurements, a position of the front-end module  16  relative to the first and second rails  12 ,  14  may be determined at which the front-end module  16  is horizontally centered relative to the first and second rails  12 ,  14 . Next, the front-end module  16  may be moved into the centered position, and the pins  114  may be inserted into punched or pierced locating or centering apertures, for example, through the second leg  57  of the mounting brackets  53  of the first and second rails  12 ,  14 , thereby establishing the alignment of the front-end module  16  relative to the first and second rails  12 ,  14 . 
     Next, the plurality of fasteners  102  may be inserted through the vertically-extending members  82  and the sleeve  96  and threadably engaged with the threaded apertures  56  of the T-nuts  36 ,  38  ( FIGS. 8 and 9 ). Because the threaded apertures  56  and the external threads  108  of the fasteners  102  include right-handed threads, clockwise rotation of the fasteners  102  relative to the T-nuts  36 ,  38  increases the threaded engagement therebetween. 
     As described above, the distal end  110  of the fasteners  102  may include the patch  112 , which increases the friction between the threads of the fasteners  102  and the threaded aperture  56  of the T-nuts  36 ,  38 . Clockwise rotation of the fasteners  102  may cause corresponding clockwise rotation of the T-nuts  36 ,  38  relative to the pipe nuts  32 ,  34 , which causes the heads  52  of the T-nuts  36 ,  38  to move outwardly away from the pipe nuts  32 ,  34  and towards the sleeve  96 . This is because the friction between the threads of the fasteners  102  and the threaded aperture  56  is greater than the friction between the threaded apertures  44  of the pipe nuts  32 ,  34  and the external threads  54  of the T-nuts  36 ,  38 . Accordingly, as long as the friction between the fasteners  102  and the T-nuts  36 ,  38  is greater than the friction between the T-nuts  36 ,  38  and the pipe nuts  32 ,  34 , rotation of the fasteners  102  does not result in relative rotation between the fasteners  102  and the T-nuts  36 ,  38 , but rather, the result is relative rotation between the T-nuts  36 ,  38  and the pipe nuts  32 ,  34 . Furthermore, because the threaded apertures  56  and the fasteners  102  include right-handed threads, and the threaded apertures  44  of the pipe nuts  32 ,  34  and the external threads  54  of the T-nuts  36 ,  38  include left-handed threads, clockwise rotation of the fasteners  102  (and hence clockwise rotation of the T-nuts  36 ,  38  relative to the pipe nuts  32 ,  34 ) causes the T-nuts  36 ,  38  to move outwardly toward the sleeves  96  from a first position ( FIGS. 7 and 9 ) to a second position ( FIGS. 8 and 10 ). 
     Continued clockwise rotation of the fasteners  102  may cause the T-nuts  36 ,  38  to move outwardly until the T-nuts  36 ,  38  contact the sleeves  96  with enough force to generate more friction counteracting clockwise rotation of the T-nuts  36 ,  38  relative to the pipe nuts  32 ,  34  that the friction counteracting relative rotation between the fasteners  102  and the T-nuts  36 ,  38 . Once such relative levels of friction are reached, continued clockwise rotation of the fasteners  102  will cause the fasteners  102  to move inwardly relative to the T-nuts  36 ,  38  (i.e., increasing threaded engagement between the fasteners  102  and the T-nuts  36 ,  38 ). The fasteners  102  may be rotated in such a manner until a sufficiently secure clamping force is achieved between the heads  103  of the fasteners  102  and the heads  52  of the T-nuts  36 ,  38  to secure the support members  64 ,  66  and the U-shaped cross member  80  relative to the rails  12 ,  14  (see  FIG. 10 ). 
     In this manner, the first threaded fasteners  102  may secure the U-shaped cross member  80  and the first and second support members  64 ,  66  to the T-nuts  36 ,  38 , which in turn may be secured to the pipe nuts  32 ,  34 , which in turn may be secured to the first and second rails  12 ,  14 . As described above, the heads  52  of the T-nuts  36 ,  38  provide a surface against which the U-shaped cross member  80  and first and second support members  64 ,  66  may be mounted. Securing the U-shaped cross member  80  and the first and second support members  64 ,  66  to the T-nuts  36 ,  38  in this manner allows for dimensioning of the front-end module  16  relative to the rails  12 ,  14  such that horizontally-extending gaps  120  exist between the rails  12 ,  14  and the sleeves  96  of the first and second support members  64 ,  66  ( FIG. 10 ). Because the T-nuts  36 ,  38  are threadably adjustable relative to the pipe nuts  32 ,  34  such that the heads  52  of the T-nuts  36 ,  38  are horizontally movable relative to the rails  12 ,  14 , the T-nuts  36 ,  38  are able to span the gaps  120  and still provide a secure mounting surface for the U-shaped cross member  80  and the first and second support members  64 ,  66 . Such an arrangement allows for manufacturing tolerances to be relaxed (i.e., made larger), while maintaining the relative alignment between the front-end module  16  and the rails  12 ,  14 . That is, the mounting arrangement described above reduces or eliminates movement of the front-end module  16  relative to the rails  12 ,  14  while the front-end module  16  is fastened to the rails  12 ,  14 , thereby maintaining accurate centering of the front-end module  16 . 
     In some embodiments, a sequence in which each of the fasteners  102  are tightened may be a factor in maintaining the alignment between the front-end module  16  and the rails  12 ,  14 . In an exemplary embodiment, the upper fastener  102  (relative to the view shown in  FIG. 10 ) on each side of the vehicle  20  may be tightened to a predetermined torque first, and then the bottom fasteners  102  on each side of the vehicle  20  may be tightened to a predetermined torque. In other embodiments, the torque sequence described above may be performed in the reverse order (i.e., bottom fasteners  102  tightened first). In still other embodiments, it may be beneficial to tighten the plurality of fasteners  102  in some other sequence. 
     Once the plurality of first fasteners  102  are tightened to the predetermined torque, the plurality of second fasteners  104  may be inserted through the vertically-extending members  82 , the sleeves  96  and the second leg  57  of the mounting brackets  53 . Nuts  106  may be tightened onto the second fasteners  104  to a predetermined torque to more securely retain the front-end module  16  relative to the rails  12 ,  14 . 
     While the threaded apertures  56  and the fasteners  102  are described above as including right-handed threads, and the threaded apertures  44  of the pipe nuts  32 ,  34  and the external threads  54  of the T-nuts  36 ,  38  are described above as including left-handed threads, it will be appreciated that the handedness of these threads may be reversed. That is, the threaded apertures  56  and the fasteners  102  may include left-handed threads, and the threaded apertures  44  of the pipe nuts  32 ,  34  and the external threads  54  of the T-nuts  36 ,  38  may include right-handed threads. 
     While the pipe nuts  32 ,  34 , T-nuts  36 ,  38  and fasteners  102  are described above as cooperating to secure the front-end module  16  to the first and second rails  12 ,  14  while maintaining the relative alignment therebetween, it will be appreciated that in some embodiments, the pipe nuts  32 ,  34 , T-nuts  36 ,  38  and fasteners  102  could be configured to cooperate to secure another component and/or module of a vehicle frame, body, chassis and/or accessory, for example, to any other component and/or module (or spaced apart pair of components and/or modules) of a vehicle frame, body, chassis and/or accessory and maintain a relative alignment therebetween.