Patent Publication Number: US-2013249230-A1

Title: Trim panels for mounting to support structures of automotive vehicles by rention clips

Description:
TECHNICAL FIELD 
     The present specification generally relates to trim panels for mounting to support structures of automotive vehicles utilizing a retention clip and, more specifically, to trim panels for mounting to support structures of automotive vehicles having housings which accommodate retention clips in a pre-installation clip position and a separate installed clip position. 
     BACKGROUND 
     Many automobiles utilize trim panels to improve the appearance of the interior passenger compartment of the vehicle. The trim panels are attached to support structures of the vehicle using a plurality of retention clips located at various positions on the outer surface of the trim panel. The retention clips have a body portion for attaching to an opening in the support structure and a head portion for attaching to housings on the trim panel. Oftentimes, the retention clips are installed in the housings on the trim panels in advance of the installation of the trim panel to the support structure. To install the trim panel to the support structure, the body portions of the retention clips are inserted into mounting apertures located on the support structure. The easiest and most efficient way to insert the retention clips is in a direction normal to the support structure. 
     However, problems arise when trim panels are configured in such a manner that the retention clips are not installed normal to the mounting apertures. As an example of this, in some cases a bottom edge of the trim panel is first installed and held in a stationary position, and the top edge of the trim panel is then rotated into the installed position. In this instance, the retention clips are not installed normal to the mounting apertures. However, those retention clips closer to the top edge of the trim panel are oriented close enough to normal such that the body portion of the retention clip is still easily inserted into the mounting aperture. This is not the case for retention clips located nearer the bottom edge of the trim panel. In some cases, the body portions of the retention clips may be deformed during installation thereby damaging the clips or even causing a mis-installation of the trim panel with the support structure. Such mis-installations increase production losses and/or warranty costs thereby increasing vehicle production costs. 
     Accordingly, a need exists for alternative trim panels which facilitate mounting a trim panel to a support structure of an automotive vehicle with a retention clip that cannot be installed substantially normal the support structure. 
     SUMMARY 
     In one embodiment, a trim panel for mounting to a support structure of an automotive vehicle by a retention clip may include an inner surface facing an interior of the vehicle and an outer surface facing the support structure, and a two-stage retention clip housing extending from the outer surface. The two-stage retention clip housing may include a top surface and at least one sidewall coupling the top surface of the two-stage retention clip housing to the outer surface of the trim panel such that the top surface is spaced apart from the outer surface. The top surface may include a first aperture defining a pre-installation clip position for receiving a head of the retention clip, a second aperture defining an installed clip position for receiving a head of the retention clip, a first channel extending from an edge of the top surface to the first aperture, and a second channel extending from the first aperture to the second aperture. Furthermore, the first channel extends through the edge of the top surface and opens into the first aperture; and the second channel opens into the first aperture and the second aperture. 
     In another embodiment, a trim panel assembly for mounting to a support structure of an automotive vehicle may include: a retention clip having a body portion and a head portion, the head portion having a head flange spaced apart from a body flange; a trim panel including an inner surface facing an interior of the vehicle and an outer surface facing the support structure; and a two-stage retention clip housing extending from the outer surface. The two-stage retention clip housing may include a top surface and at least one sidewall coupling the top surface of the two-stage retention clip housing to the outer surface of the trim panel such that the top surface is spaced apart from the outer surface. The top surface may include a first aperture, the first aperture defining a pre-installation clip position, a second aperture extending through the thickness of the top surface, the second aperture defining an installed clip position, a first channel extending from an edge of the top surface to the first aperture, wherein the first channel opens into the first aperture, and a second channel extending from the first aperture to the second aperture, wherein the second channel opens into the first aperture and the second aperture. Furthermore, the head portion of the retention clip is slidably engaged with the two-stage retention clip housing in the pre-installation clip position such that the retention clip is slidable from the pre-installation clip position to the installed clip position through the second channel upon attachment of the trim panel assembly to the support structure. 
     In yet another embodiment, a trim panel assembly for mounting to a support structure of an automotive vehicle may include a retention clip having a body portion and ahead portion, a trim panel having an inner surface facing an interior of the vehicle and an outer surface facing the support structure, and a two-stage retention clip housing extending from the outer surface of the trim panel. The two-stage retention clip housing may include a top surface with a pre-installation clip position, an installed clip position, and a channel extending between the pre-installation clip position and the installed clip position. The head portion of the retention clip is slidably engaged with the two-stage retention clip housing in the pre-installation clip position such that the retention clip is slidable from the pre-installation clip position to the installed clip position through the second channel upon attachment of the trim panel assembly to the support structure. 
     These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which: 
         FIG. 1  schematically depicts the outside surface of a trim panel according to one or more embodiments shown and described herein; 
         FIG. 2  schematically depicts the inside surface of a trim panel according to one or more embodiments shown and described herein; 
         FIG. 3  schematically depicts a two-stage retention clip housing for receiving a retention clip according to one or more embodiments shown and described herein; 
         FIG. 4  schematically depicts a cross section of a retention clip for securing a trim panel to an attachment structure according to one or more embodiments shown and described herein; 
         FIG. 5  schematically depicts the retention clip of  FIG. 4  positioned in a pre-installation clip position of the two-stage retention clip housing of  FIG. 3 ; 
         FIG. 6A  schematically depicts a trim panel positioned for installation on a support structure of a vehicle according to one or more embodiments shown and described herein; 
         FIG. 6B  schematically depicts a trim panel installed on a support structure of a vehicle according to one or more embodiments shown and described herein; 
         FIG. 7A  schematically depicts a retention clip in the pre-installation position of a two-stage retention clip housing prior to engagement with a mounting aperture of a support structure of a vehicle; and 
         FIG. 7B  schematically depicts a retention clip in the installed position of a two-stage retention clip housing after engagement with a mounting aperture of a support structure of a vehicle. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  generally depict a trim panel for mounting to a support structure of an automotive vehicle using retention clips. The trim panel generally includes an inner surface facing an interior of the vehicle, an outer surface facing the support structure, and at least one two-stage retention clip housing for receiving a retention clip extending from the outer surface. The at least one two-stage retention clip housing includes a top surface and at least one sidewall coupling the top surface of the two-stage retention clip housing to the outer surface of the trim panel such that the top surface is spaced apart from the outer surface. The top surface of the at least one two-stage retention clip housing includes a first aperture defining a pre-installation clip position for receiving a head of a retention clip, a second aperture defining an installed clip position for receiving a head of the retention clip, a first channel extending from an edge of the top surface to the first aperture, and a second channel extending from the first aperture to the second aperture. Various embodiments of trim panels will be described in more detail herein with specific reference to the appended drawings. 
     Referring now to  FIGS. 1 and 2 , the inner surface  102  and outer surface  104  of a trim panel  100  are schematically depicted. In at least one embodiment, the trim panel  100  is a garnish for a C-pillar of an automotive vehicle. However, it should be understood that alternative embodiments of the trim panel may take the form of A-pillar garnishes, B-pillar garnishes, or any other trim panel for attachment to the interior or exterior of an automotive vehicle. 
     In the embodiments described herein, the trim panel  100  is formed from moldable polymeric material. Non-limiting examples of such materials include various types of structural plastics such as engineered polymeric materials of which polypropylene is but one example. Other suitable materials include, without limitation, thermoplastic olefin, acrylonitrile butadiene styrene, styrene maleic anhydride, polycarbonate/acrylonitrile butadiene styrene alloy, or other materials suitable for molding a rigid structure. In some embodiments, the trim panel  100  may also include a cover layer formed from vinyl, thermoplastic elastomer, PVC, or other suitable materials for molding flexible cover layers. Alternatively, cover layers may be formed form fabric or leather. 
     The trim panel  100  may be formed by an injection molding process. Other suitable methods may be used for forming the trim panel  100 , including, without limitation, industrial blow molding, reaction injection molding, rotational molding, thermoforming, thermoplastic compression molding, and twin-sheet forming. 
     The trim panel  100  may have a unitary body structure that includes an inner surface  102  and an outer surface  104 . The trim panel  100  is at least partially defined by an upper edge  106 , a lower edge  107 , a leading side edge  108 , and a trailing side edge  109 . The trim panel  100  may also include one or more openings  112  in the body for windows and the like. The trim panel  100  is configured such that the upper edge  106  can be positioned proximate the roof of the vehicle when the trim panel  100  is installed in the vehicle. The leading side edge  108  may be positioned proximate the passenger compartment when the trim panel  100  is in the installed condition. The trailing side edge  109  may be positioned aft of the passenger compartment when the trim panel  100  is in the installed position. In the embodiment of the trim panel  100  depicted in  FIGS. 1 and 2 , the lower edge  107  includes one or more protruding attachment guides  110 . The attachment guides  110  are sized and shaped to penetrate and be retained in openings, such as slotted openings, formed in the support structure to which the trim panel is attached. 
     Referring to  FIG. 2 , the trim panel  100  includes an inner surface  102  exposed to the passenger compartment of the vehicle. The inner surface  102  typically includes a decorative or aesthetically appealing design. For example, in some embodiments, the inner surface  102  may be formed with a variety of colors and/or patterns. In other embodiments, the entire trim panel may be formed from a single color. In some embodiments of the trim panels described herein, an additional cover layer of material, such as a decorative fabric or a similar sheet material, may be molded or otherwise secured to the inner surface  102 . In other embodiments, the inner surface  102  of the trim panel may have a smooth surface or a textured surface. 
     Referring to  FIG. 1 , the trim panel  100  also includes an outer surface  104  opposite the inner surface  102 . The outer surface  104  faces the support structure  170  of the vehicle to which the trim panel is attached. The outer surface  104  includes at least one two-stage retention clip housing  120  integrally formed with the outer surface  104  of the trim panel  100 . The outer surface  104  may also include reinforcement members  114 , for example, without limitation, connection reinforcement projections integrally molded to the outer surface  104 . As depicted in  FIG. 1 , the outer surface  104  includes a plurality of reinforcement projections configured as a series of ribs positioned at a spaced distance along at least a portion of the outer surface  104  of the trim panel  100 . In this embodiment, the reinforcement projections are integrally molded to the outer surface  104 . Alternatively, the reinforcement projections may be separately formed and attached to the outer surface  104 . 
     Referring now to  FIGS. 1 and 3 , one embodiment of a two-stage retention clip housing  120  is schematically depicted. The two-stage retention clip housing projects from the outer surface  104  of the trim panel  100  toward the support structure to which the trim panel is attached. The two-stage retention clip housing  120  generally includes at least one sidewall which couples the housing to the instrument panel. For example, in one embodiment, the two-stage retention clip housing  120  includes a top surface  122 , a first sidewall  124 , and a second sidewall  126 . The first sidewall  124  and second sidewall  126  couple the top surface  122  of the two-stage retention clip housing  120  to the outer surface  104  of the trim panel  100  such that the top surface  122  is spaced apart from the outer surface  104 . In some embodiments, the two-stage retention clip housing  120  may also include a plurality of support ribs  128  to increase the structural strength and stability of the two-stage retention clip housing  120  as depicted in  FIGS. 1 and 3 . 
     Still referring to  FIGS. 1 and 3 , the top surface  122  of the two-stage retention clip housing  120  includes a first aperture  130 , a second aperture  134 , a first channel  138 , and a second channel  140 . While the first aperture  130  and the second aperture  134  are depicted as circular in  FIGS. 1 ,  3  and  4 , it should be understood that apertures of other geometrical cross sections are also contemplated including, without limitation, ovals, squares, irregular geometric shapes and the like. The first aperture  130  generally defines a pre-installation clip position  132  for receiving a head portion  152  of a retention clip  150 . The second aperture  134  generally defines an installed clip position  136  for receiving a head portion  152  of a retention clip  150 . The first aperture  130  generally has a diameter D 1  and the second aperture  134  has a diameter D 2 . In the embodiments of the two-stage retention clip housing  120  depicted in  FIG. 3 , the diameter D 1  and the diameter D 2  are the same. However, in alternative embodiments (not shown) the diameter D 1  and the diameter D 2  may be different. For example, in some embodiments, the diameter D 1  may be larger than the diameter D 2 . In this embodiment, the larger diameter D 1  of the first aperture  130  may facilitate quickly and easily positioning a retention clip in the pre-installation clip position  132  while the smaller diameter D of the second aperture  134  may firmly secure the retention clip  150  in the installed clip position  136  by forming a tight interference fit between the retention clip  150  and the second aperture  134 . 
     Still referring to  FIG. 3 , the first channel  138  generally has a width W 1  and extends from an edge  142  of the top surface  122  to the first aperture  130 . The first channel  138  extends through the edge  142  of the top surface  122  and opens into the first aperture  130 . Forming the first channel  138  such that it extends through the edge  142  of the top surface  122  and opens into the first aperture  130  facilitates the installation of a retention clip (not shown) through the first channel  138  and into the pre-installation clip position  132  defined by the first aperture  130 . 
     The second channel  140  generally has a width W 2  and extends from the first aperture  130  to the second aperture  134 . The second channel  140  may also open into the first aperture  130  and the second aperture  134 . Forming the second channel  140  such that the second channel  140  opens into both the first aperture  130  and the second aperture  134  facilitates sliding a retention clip through the second channel  140  from the pre-installation clip position  132  of defined by the first aperture  130  to the installed clip position  136  defined by the second aperture  134 . 
     In the embodiments described herein, the width W 1  of the first channel  138  and the width W 2  of the second channel  140  are substantially equal. However, in some other embodiments, the widths W 1 , W 2  need not be equal. In general, the widths W 1  and W 2  are slightly less than the diameter of a corresponding retention clip to facilitate an interference fit between the retention clip and the channels. In some embodiments, the widths W 1  and W 2  are less than the diameter D 1  of the first aperture  130  and less than the diameter D 2  of the second aperture  134 . 
     In one exemplary embodiment, the first aperture  130  and the second aperture  134  each have a radius of approximately 9 millimeters while the first channel  138  and the second channel  140  each have a width of approximately 5.8 millimeters. However, it should be understood that other dimensions for the first aperture  130 , the second aperture  134 , the first channel  138  and the second channel  140  are contemplated. 
     In the embodiment of the two-stage retention clip housing  120  depicted in  FIGS. 1 and 3 , the first channel  138  and the second channel  140  do not lie along a common diameter of the first circular aperture (i.e., the smallest angle between the first channel  138  and the second channel  140  is less than 180 degrees). However in other embodiments, the first channel  138  and the second channel  140  may lie along a common diameter of the first circular aperture (i.e., the angle between the first channel  138  and the second channel  140  is 180 degrees). 
     Referring again to  FIG. 1 , the trim panel  100  may also include one or more conventional retention clip housings  220 . 
     Unlike the two-stage retention clip housing  120 , the conventional retention clip housing  220  does not include a second aperture and a second channel. The first aperture  230  generally defines an installed clip position for receiving a head of a retention clip. 
     Referring now to  FIG. 4 , a retention clip  150  includes a head portion  152 , a body portion  154 , a head flange  156 , a body flange  158 , and a standoff flange  160 . In alternative embodiments, the retention clip may not include a standoff flange. Generally, the head portion  152  attaches to a two-stage retention clip housing  120  and the body portion  154  of the retention clip  150  attaches to a mounting aperture formed in the support structure to which the trim panel is attached. The head portion  152  includes a radially extending head flange  156  at one end of the head portion  152  and a radially extending body flange  158  spaced apart from the head flange  156 . A standoff flange  160  is optionally provided adjacent the body flange  158 . 
     As depicted in  FIG. 4 , the diameter of the head portion  152  of the clip  150  may differ from the diameter of the body portion  154 . Furthermore, the diameter of the head flange  156  and the diameter of the body flange  158  are both larger than the diameter of the head portion  152  and body portion  154 . In one exemplary embodiment, the diameter of the head portion  152  between the head flange  156  and the body flange  158  is approximately 6.0 millimeters. However, it should be understood that other dimensions for the head portion are contemplated. 
     The retention clip  150  can be formed from any suitable material such as metal or a polymeric material. Semi-rigid polymeric materials, such as, but not limited to, polyethylene, polypropylene, or polyamides such as nylon are preferred. The retention clip can be formed by conventional extrusion process or injection molding process. 
     Referring to  FIG. 5 , the retention clip  150  is shown engaged with the two-stage retention clip housing  120  of the trim panel  100  in a pre-installation clip position  132 . The head portion  152  of the clip  150  engages the first aperture  130  of the two-stage retention clip housing  120 . To snap fit with the first aperture  130 , the head portion  152  is slidably engaged through the first channel  138  and into the first aperture  130 . Because the diameter of the head portion is greater than the width of the first channel  138 , the head portion  152  of the clip  150  deforms upon installation. When engaged in the first aperture  130 , the body flange  158  is positioned above the top surface  122  of the housing  120  and generally covers the first aperture  130 . The head flange  156  is positioned under the top surface  122 . 
     Because the head portion  152  is greater in diameter than the width of the second channel  140 , the retention clip  150  will not slide into the second channel  140  unless the clip  150  is slightly deformed. Accordingly, if a force great enough to cause deformation of the clip  150  is applied in the direction of the second channel  140 , the retention clip  150  will slide through the second channel  140  and into engagement with the second aperture  134  and into the installed clip position  136 . 
     Referring to  FIGS. 6A and 6B  a trim panel  100  being installed on to a corresponding support structure  170  is schematically depicted. The trim panel  100  is installed on the support structure  170  by inserting the body portion  154  of one or more retention clips  150  into corresponding mounting apertures  172  on the support structure  170 . More specifically, the trim panel  100  is first positioned proximate the final installation position such that the attachment guides (not shown) of the trim panel are inserted into slotted openings on the support structure  170  which prevents the lower edge of the trim panel  100  from moving, but allows the rest of the trim panel  100  to rotate with respect to the lower edge of the trim panel, thus defining a locus of rotation. The trim panel  100  may then be rotated about the locus of rotation toward the installed position as indicated by arrow  173  in  FIG. 6A. 100411  Referring to  FIGS. 6A and 7A , the trim panel  100  is shown in a pre-installed position and the retention clip  150  is shown in profile in a pre-installation clip position  132  within the two-stage retention clip housing  120 . The body portion  154  of the retention clip  150  is generally aligned for insertion into a mounting aperture  172  on the support structure  170 . The installed clip position  136  is also depicted. A retention clip  150  positioned in the installed clip position  136  would not be properly aligned for insertion into the mounting aperture  172 . Once the clip  150  in the pre-installation clip position  132  is aligned and partially inserted into the mounting aperture  172 , a force is applied to the trim panel  100  causing the head portion  152  of the retention clip  150  to slide through the second channel  140  and into the second aperture  134  and assume the installed clip position  136 , as shown in  FIGS. 6B and 7B . 
     Referring to  FIGS. 6B and 7B , the trim panel  100  is shown in an installed position and the retention clip  150  is shown in profile in an installed clip position  136  within the two-stage retention clip housing  120 . 
     It should be understood that a retention clip positioned beyond a threshold distance from the locus of rotation will not require a two-stage retention clip housing while a retention clip positioned within the threshold distance will require a two-stage retention clip housing otherwise the retention clip will not properly seat in the corresponding mounting aperture and/or will be damaged during installation, each of which potentially results in a mis-installation of the trim panel on the mounting structure. This threshold distance is a function of the size of the mounting aperture  172 , the length of the body portion  154  of the retention clip  150 , and the properties of the material forming the retention clip  150 . 
     It should now be understood that the trim panels with two-stage retention clip housings are beneficial when the trim panels are attached by rotating the trim panel into place on the mounting structure. Particularly, utilizing trim panels with two-stage retention clip housings facilitates rotating the trim panel into the installation position without damaging the retention clip and/or causing a costly mis-installation of the trim panel on the mounting structure. In particular, trim panels with two-stage retention clip housings are most useful for supporting retention clips that are installed near the locus of rotation of the trim panel. 
     It is noted that the terms “substantially” and “about” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. 
       100461  While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.