Abstract:
A component positioning device including at least one resilient structure that centers the component. For example, a spring that acts between a grille and a grille opening to center the grille within a grille opening. The spring generating a reaction force sufficient to self-adjust the grille within the grille opening wherein opposing springs are deployed on either side of the grill with the springs exerting a force on and moving the grill until the force exerted by the opposing springs reaches equilibrium.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not applicable 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a system for positioning a trim component or other part on a vehicle; and, more specifically, to a structure for positioning a grille on a vehicle. 
         [0004]    2. Description of Related Art 
         [0005]    Modern vehicle manufacturers incorporate a grille on the front end of the vehicle. The grille covers an opening at the front of the vehicle allowing air flow to the radiator aiding in its function of cooling the engine. Grille design integrates both functionality and style. Modern grilles include an elegant, distinctive or authentic look, giving the vehicle a distinct visual appeal that sets it apart from similar vehicle makes and models on the road. 
         [0006]    Typically, the grille attaches to the vehicle structure between the vehicle headlights. Given that fit and finish for vehicles is a key deliverable for overall craftsmanship of the vehicle, emphasis is placed on the headlight/grille margins. In some instances, front end parts and build tolerances result in uneven margin or gap between the grille and headlights. For example, a vehicle could have a tight margin on one side and a wide margin on the other. Regardless of the size of the margin, customers demand even and parallel margins on both sides of the grille. 
         [0007]    Manually adjusting the grille to center and equalizing the margin or gap on either side of the grille, after the vehicle reaches the end of the assembly line, i.e., after building the vehicle, is one way to center a grille and achieve a desired look. However, on high volume vehicles, it is not practical to manually adjust the grille as this is a labor intensive and expensive process. In some instances, assembly operators at the end of line would have to uninstall parts such as air deflectors, beauty shields, hood seals etc., to get to the grille fasteners or attachments. Further, since the grille is a decorative part, there is the potential of damage during the adjustment. 
       SUMMARY OF THE INVENTION 
       [0008]    An embodiment of the present invention provides a positioning device including resilient structures that positions the component. The resilient structures exert an equal and opposite force on respective reaction surfaces. The respective forces resulting in movement between adjacent resilient structures and reaction surfaces until the resilient structure forces reach equilibrium. For example, when the component is a grille placed between headlamps, the resilient structures may include springs that act between the grille and the headlamps to center the grille in the space between headlamps. Each spring acting against a respective reaction surface and generating a reaction force. The reaction forces operate to move the grill until the force exerted by opposing springs reaches equilibrium and correspondingly self-adjusting the grille within the grille opening or the space between headlamps. 
         [0009]    In one embodiment, the springs are integrated into the grille making the assembly process unchanged for the operator. A further embodiment includes the springs being small cantilever beams deployed from the side of the grille with some interference to the reaction surface located on or adjacent the grille opening. 
         [0010]    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 
         [0011]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0012]      FIG. 1  is a perspective view of a vehicle including a grille attachment structure according to an embodiment of the present invention 
           [0013]      FIG. 2  is a partial front perspective view of a grille and grille attachment structure according to the present invention 
           [0014]      FIG. 3  is an enlarged partial perspective view of a portion of the grille attachment structure as set forth in  FIG. 2 . 
           [0015]      FIG. 4  is an enlarged partial perspective view of the grille attachment structure engaged with a portion of the vehicle. 
           [0016]      FIG. 5A  is an enlarged schematic side view of one example of a spring-like mechanism initially engaging a reaction surface according to the present invention. 
           [0017]      FIG. 5B  is an enlarged schematic side view of one example of a spring-like mechanism engaging a reaction surface according to the present invention illustrating the interference fit between the spring-like mechanism and the reaction surface. 
           [0018]      FIG. 6  is a schematic view of the grille attachment structure illustrating the grill offset in the opening and having an uneven margin. 
           [0019]      FIG. 7  is a schematic view of the grille attachment structure illustrating the grille in equilibrium and centered in an opening. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    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. 
         [0021]      FIG. 1  illustrates a grille, seen generally at  10 , for an automotive vehicle  12 . The vehicle  12  includes a grille opening  14  located in the front end of the vehicle  12  between the headlights  16 ,  18 . This is for illustration purposes only, as the grille opening  14  may be located in various positions on the front end structure of the vehicle  12  or between various trim or body components. For example, the grille opening  14  may not extend from the first headlight  16  to the second headlight  18 . Instead, it may extend between trim components (not shown) attached to the front end structure of the vehicle and positioned adjacent the headlights  16 ,  18 . 
         [0022]    Due to the respective build tolerances in the various parts or components of the front end structure and the grille  10  there is a margin or gap  20 ,  22  between the grille  10  and the vehicle  12 , in the present example the headlights  16 ,  18 , when the grille  10  is placed in the grille opening  14 . During installation the margin or gap  20 ,  22  can become uneven causing an aesthetically unpleasing appearance. For example, the vehicle  12  could have a tight margin or small gap on one side and a wide margin or large gap on the other side. 
         [0023]      FIG. 2  illustrates the grille  10  including a grille centering structure, seen generally at  24 , the grille centering structure  24  operates to center the grill  10  in the grille opening  14  such that the margin or gaps  20 ,  22  are even and uniform. One embodiment of the grille centering structure  24  includes a resilient structure, for example a spring-like mechanism or member  26  that centers the grille  10  in the grille opening  14 . One example of a spring-like mechanism  26  is a cantilever member  28  shown attached to a structural member, including a sidewall  30  of the grille  10 . In the present example, the grille  10  includes an integrally molded cantilever member  28 ; however, either the cantilever member  28  or the spring-like mechanism  26  may be formed separate from and attached to the grille  10 . For example, the cantilevered member  28  or spring like mechanism  26  may include a clip or attachment feature used to attach it to the grille  10 . 
         [0024]    As illustrated, a proximal end  32  of the cantilever member  28  attaches to the sidewall  30  of the grille  10 . The distal or free end  34  extends outwardly and is spaced from the sidewall  30 . The distal or free end  34  includes an arcuate surface  36 . The cantilever member  28  has a spring stiffness that depends on the geometry of the member and the material stiffness of the member, with the ratio of force and deflection referred to as the stiffness of the member. In the disclosed example, the cantilevered member  28  has a generally rectangular cross-section having rounded edges. Cross sectional shape and edge style of the member  28  can play an important role in spring stiffness of the member  28 . 
         [0025]    As illustrated in  FIG. 3 , in the present example the cantilever member  28  has a first section  38  extending generally perpendicular to the sidewall  30  of the grille  10 . A second section  40  extends outwardly at an angle to the sidewall  30  of the grille  10  with an arcuate section or bend  42  located between the first section  38  and the second section  40 . Accordingly, the overall shape and configuration of the cantilever member  28  may be adjusted to vary its spring stiffness. 
         [0026]    In a further example, illustrated in  FIG. 3 , the cantilever member  28  includes a rib  44 . The rib  44  extends between the cantilever member  28  and the sidewall  30  similar to the web portion of an I-Beam. As with the shape and configuration of the cantilevered member  28 , the shape and configuration of the rib  44  adjusts to increase or decrease the spring stiffness. For example, the rib  44  may extend longitudinally along the second section  40  of the cantilevered member  28 . Instead of being an integral portion of the cantilever member  28  and sidewall  30  the rib  44  can be a separate or member connected either to the cantilever member  28  or sidewall  30 . 
         [0027]      FIG. 4  illustrates the engagement or contact of the cantilever member  28  with a support plate  46 , having a reaction surface  48 , located adjacent the grille opening  14 , typically near the headlights  16 ,  18 . The cantilever member  28  is designed with a certain amount of interference between the distal or free end  34  of the cantilever member  28  and the reaction surface  48 , see  FIGS. 5A and 5B  illustrating the interference in dotted lines. Accordingly, when the grille  10  is placed in the grille opening  14  the distal or free end  34  of the cantilever member  28  is disposed inwardly, toward the sidewall  30  generating a certain amount of reaction or spring force in the cantilever member  28 . 
         [0028]      FIGS. 4, 5A and 5B  illustrate an example of a vertically installed grille  10  wherein the grille  10  is lowered between the respective headlights  16 ,  18 . In doing so, an engagement face  50  of the cantilevered member  28  engages a beveled guide surface  52  located on the support plate  46  adjacent the reaction surface  48 . The guide surface  52  operates to move or compress the distal or free end  34  of the cantilever member  28  inwardly toward the sidewall  30 . The cantilever member  28  bows or deflects inwardly until the engagement face  50  engages the reaction surface  48  thereby generating a spring force operative to urge the grille  10  laterally in the grille opening  14  away from the headlight  16  toward the center of the grille opening  14 . 
         [0029]    As set forth below, one example of the present invention includes the grille  10  having a first and second resilient structure illustrated herein as multiple cantilevered members  28  located on an opposite sidewalls  30 . Further, the grille  10  includes first and second reaction surfaces one example thereof being multiple support plates  46  located in the grille opening  14  adjacent the respective headlights  16 ,  18 . Since the cantilever members  28  are located on opposite sidewalls  30  of the grille  10 , the interference fit between the respective cantilever members  28  and support plates  46  operates to generate a reaction force that pushes the grille  10  into the center of the opening. The amount of interference depends on the predictive variance of the headlight  16 ,  18  to grille  10  margin or gap  20 ,  22 . 
         [0030]    As set forth below, the reaction force between the spring-like mechanisms  26 , shown herein as cantilever members  28 , and the support plates  46  is such that even margins  20 ,  22  on either side of the grille  10  produce an equal amount of reaction force by the spring-like mechanisms  26 , keeping the system in equilibrium. 
         [0031]      FIG. 6  illustrates a free body schematic for a grille  10  system having a spring-like mechanism  26  operative to push the grille  10  to the center of the grille opening, the open area between the respective headlights  16 ,  18 . Depending on the size and weight of the grille  10 , there could be one or more spring-like mechanisms  26  deployed on each side of the grille  10  and acting on corresponding support plates or members located adjacent the respective headlights  16 ,  18 . As illustrated in  FIG. 6 , when the grille  10  lowered into the grille opening (not shown) between the headlights  16 ,  18  it is not centered, creating a wide margin or gap  20  adjacent headlight  16  and a narrow margin or gap  22  on the other side of the grille  10  adjacent headlight  18 . 
         [0032]    Initially, the determination of spring stiffness (k) and amount of interference (X), see  FIG. 5B  illustrating the inward deflection of the cantilever member  28  from its original position shown in a dotted lines, depends on the inertial force (F) provided by the weight of the grille  10 , where F=kX. For example, a heavier grille  10  may need both a greater amount of interference (X) to increase the spring force and in addition may require a stiffer spring. As illustrated in  FIG. 6 , when the grille  10  is off-center, there is a larger interference (X′) associated with the narrow margin  22  and a lesser interference (X) associated with the wider margin  20 . This results in an unbalanced forces F and F′ on each side of the grille  10  wherein F′=kX+kX′, where k equals the spring stiffness and kX′ is the uneven force generated due to additional compression of the spring-like mechanism  26  caused by the uneven margins  20 ,  22 , specifically the narrow margin  22 . 
         [0033]    The unbalanced forces F and F′ on each side of the grille  10  automatically adjust the position of grille  10  in the grille opening  14 . Because the force F′ is greater than the force F it acts on and shifts the grille  10  laterally until there is an equal amount of interference between the spring-like mechanisms  26  located on opposite sides of the grille  10 .  FIG. 7  shows the result of an unbalanced force centering the grille  10  between the headlights  16 ,  18 . As illustrated, the grille  10  achieves equilibrium (F″) along with even margins  20 ,  22  from the left to right hand side headlights  16 ,  18  when F″=kX+kX″ where X″=X′/2 and is the result of the unbalanced force causing the grille  10  to move laterally or slide in the grille opening  14  until equilibrium is achieved with an equal amount of interference between the opposing spring-like mechanism  26  located adjacent the respective headlights  16 ,  18 . Upon achieving equilibrium, the grille  10  can then be secured to the vehicle  12  using various known means to prevent future displacement. The even margins  20 ,  22  on either side of the grille  10  produce an equal amount of reaction force by the spring-like mechanisms  26  on either side of the grille  10 , keeping the system in equilibrium and the grille equidistant from the respective edges of the grille opening  14 . 
         [0034]    Additional embodiments of the present invention include the spring-like mechanism  26  being a molded in feature on an inner or outer surface of the grille  10 . If molded in features are not possible due to tooling condition, plastic or metal spring clips can be mechanically attached to the grille  10  to deliver the same results. 
         [0035]    The disclosed example is for a top loaded grille  10  assembly; that is, the grille  10  is inserted into the grille opening  14  in a vertical manner, from the top down. Accordingly, the spring-like mechanism  26  is oriented in a vertical direction whereby it compresses and correspondingly generates a reaction force upon installation of the grille  10 . For a horizontally loaded grille, the spring-like mechanism  26  is oriented in the horizontal direction whereby it compresses and correspondingly generates a reaction force upon installation of the grille  10 . In some cases the spring-like mechanism  26  can be part of the grille opening  14  or headlight housings with the support plate  46  and reaction surface  48  being part of the grille  10 . 
         [0036]    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.