Patent Document

BACKGROUND 
     FIELD OF THE INVENTION 
       [0001]    This invention relates to grill assemblies and methods for assembling the same. More specifically, the invention relates to an apparatus capable of fixing grill assembly panels in position relative to each other. The invention has numerous applications in fields including, but not limited to, vehicle grills, ventilation grills, and pipe guard grills. 
       BACKGROUND OF THE INVENTION 
       [0002]    In their various forms, grills are often produced in high quantities. This is especially true of vehicle grills, which are used to both allow airflow into components within the body of the car, especially a radiator or other heat exchanger. These grills sometimes—serve additional purposes, such as directing airflow, protecting vehicle components, and adding aesthetic appeal to the vehicle as a whole. In other fields, grills may be used to direct airflow and filter large debris in air vents and ducts, liquid passageways, or ventilation systems. 
         [0003]    In the aforementioned typical grill applications, grills are manufactured in very high quantity (especially for commercial vehicle applications), or are manufactured in preset sizes to fit certain standard ducts, vents, or passages. Often production of grills at high quantities involves manufacturing processes that may have a high initial tooling cost that becomes cost-effective over a long production period. These manufacturing processes also often involve high rates of production. In addition, grills in all applications often have members designed to interface with another body, but do not often incorporate additional interfaces for different assemblies. This is especially true of lightweight vehicle grills, which are often mass-produced using materials and dimensions not suitable for bearing the additional load of outside assemblies. Thus there is a need in the art for grill assemblies which are rigid enough to support other assemblies, have mounting interfaces for other assemblies, and which can be manufactured at lower production rates in a cost-effective manner. 
       SUMMARY 
       [0004]    This invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available systems and methods. Accordingly, improved systems and methods have been developed to assemble and install grill assemblies. Features and advantages of different embodiments of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter. 
         [0005]    Consistent with the foregoing, a front vehicle grill assembly, rear vehicle grill assembly, and ventilation grill assembly are disclosed. In one embodiment, grill panels are secured relative to each other using one deformable wall at each intersection of panels. In another embodiment, grill panels are secured relative to each other using two deformable walls at each intersection of panels. Mounting interfaces are provided that allow the grill assemblies to be rigidly attached to separate structural frame members. Mounting interfaces that allow other assemblies to be rigidly attached to the grill assemblies are also provided. A corresponding method for arranging and fixing the position of grill panels in the assemblies is also disclosed and claimed herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which: 
           [0007]      FIG. 1  is a perspective view of a vehicle front grill assembly utilizing an embodiment of the invention; 
           [0008]      FIG. 2  is a front view of the vehicle front grill assembly shown in  FIG. 1 ; 
           [0009]      FIG. 3  is a top view of the vehicle front grill assembly shown in  FIG. 1 ; 
           [0010]      FIG. 4A  is a perspective view of a partially assembled vehicle front grill assembly like the front vehicle grill shown in  FIG. 1 ; 
           [0011]      FIG. 4B  is a close-up view of first and second panels used in the partially assembled vehicle front grill assembly of  FIG. 4A ; 
           [0012]      FIG. 5A  is a perspective view of the rear side of the partially assembled vehicle front grill assembly of  FIG. 4A ; 
           [0013]      FIG. 5B  is a close-up view of the intersection of a first and second panel utilizing one embodiment of the invention in the partially assembled vehicle front grill assembly of  FIG. 5A ; 
           [0014]      FIG. 6A  is a side view of a second panel used in the vehicle front grill assembly of  FIGS. 1-5 ; 
           [0015]      FIG. 6B  is a close-up view of a third slot, fourth slot, and first deformable wall of the second panel shown in  FIG. 6A ; 
           [0016]      FIG. 6C  is a close-up view of a fourth slot and a first groove shown in the close-up view of  FIG. 6B ; 
           [0017]      FIG. 7A  is a close-up view of a first embodiment of the invention in its pre-assembly state; 
           [0018]      FIG. 7B  is a close-up view of the first embodiment of the invention in its post-assembly state; 
           [0019]      FIG. 8A  is a close-up view of a second embodiment of the invention in its pre-assembly state; 
           [0020]      FIG. 8B  is a close-up view of the second embodiment of the invention in its post-assembly state; 
           [0021]      FIG. 9  is a perspective view of a vehicle rear grill assembly utilizing an embodiment of the invention; 
           [0022]      FIG. 10A  is a side view of a second panel used in the vehicle rear grill assembly of  FIG. 9 ; 
           [0023]      FIG. 10B  is a close-up view of a third slot, fourth slot, and first deformable wall of the second panel of  FIG. 10A ; 
           [0024]      FIG. 10C  is a close-up view of the fourth slot and a first groove of the fourth slot of  FIG. 10B ; 
           [0025]      FIG. 11A  shows a perspective view of a ventilation grill assembly utilizing an embodiment of the present invention; 
           [0026]      FIG. 11B  shows a top-down view of the ventilation grill assembly of  FIG. 11A ; 
           [0027]      FIG. 12  shows a partially assembled ventilation grill assembly; 
           [0028]      FIG. 13  shows a side view of a first panel of the ventilation grill assembly of  FIG. 11A ; 
           [0029]      FIG. 14A  shows a side view of a second panel of the ventilation grill assembly of  FIG. 11A ; 
           [0030]      FIG. 14B  shows a close-up view of a third slot, fourth slot, and first deformable wall of the second panel of  FIG. 14A ; 
           [0031]      FIG. 14C  shows a close-up view of a first groove of the fourth slot of  FIG. 14B ; 
           [0032]      FIG. 15A  shows a perspective view of a ventilation grill assembly utilizing an embodiment of the present invention; and 
           [0033]      FIG. 15B  shows a close-up view of an intersection of first and second slots of the ventilation grill assembly of  FIG. 15A . 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. 
         [0035]    Referring to  FIG. 1 , a perspective view showing of a vehicle front grill assembly utilizing one embodiment of the present invention is shown. The vehicle front grill assembly comprises a plurality of first panels and a plurality of second panels. The plurality of first panels further comprise different shapes and sizes of panels all utilizing a plurality of first slots and a plurality of second slots extending inwards from opposed sides, the plurality of first slots having a different depth than the depth of the plurality of second slots. Furthermore, the plurality of first slots and the plurality of second slots share an inline longitudinal axis, as shown in  FIG. 4A . First panels of full length  102  span the entire width of the assembly and utilize first slots to interface with other assembly members as will be shown in  FIG. 4A . A lower first panel  104  is used to interface with vehicle structural frame members and exists at the bottom of the vehicle front grill assembly to allow rigid attachment of the assembly through use of first though-holes  106 . An upper first panel  120  likewise utilizes through-holes to interface with vehicle structural frame members in a manner detailed in  FIG. 3 . A first mid-section first panel  118  spans the width of space between vehicle headlight assembly housings  122 , which contain vehicle headlight assemblies  124  and act as an intermediary interface between vehicle front grill assembly panels and vehicle headlight assemblies  124 . A second mid-section first panel  116  is of smaller length than the first mid-section first panel  114 . A third mid-section first panel  114  is of smaller length than the second mid-section first panel  116 . A fourth mid-section first panel  112  is of greater length than the third mid-section first panel  114  and the second mid-section first panel  116  but smaller length than the first mid-section first panel  118 . Small first panels  110  utilize just one first slot and one second slot extending inwards from opposed sides, the first slot and the second slot having a different depth and sharing an inline longitudinal axis. A long first panel  108  is slightly smaller in length than the first panels of full length  102  which span the entire width of the assembly. The various aforementioned first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120  are configured such that each are parallel to each other and spaced evenly such that the distance between sides of any two consecutive parallel first panels is equal. The plurality of second panels further comprise different shapes and sizes of panels all utilizing an embodiment of the present invention. Second panels of full length  126  span the full height of the vehicle front grill assembly and interface with first panels  102 ,  104 ,  108 ,  112 ,  114 ,  116 ,  118 ,  120  in an interlocking, perpendicular manner. Two second panels of full length for interfacing  128  are of the same length as the second panels of full length  126 , but also incorporate second through-holes  130  to interface with the vehicle headlight assembly housings  122 . Smaller second panels for interfacing  134  are of smaller length than the second panels of full length for interfacing  128  but also incorporate second through-holes  130  to interface with the vehicle headlight assembly housings  122 . Mid-sized second panels  132  are of smaller length than second panels of full length  126  sufficient to accommodate space for vehicle headlight assemblies  124  and vehicle headlight assembly housings  122  in the vehicle front grill assembly. Small second panels  138  incorporate only one set of slots of an embodiment of the present invention. Two second panels of a second shape  136  utilize sets of slots of an embodiment of the present invention in the same manner as all other second panels  126 ,  128 ,  132 ,  134 ,  138  but utilize a panel shape that is different in that one side of the panel is more sharply curved than the others. The various aforementioned second panels  126 ,  128 ,  132 ,  134 ,  136 ,  138  are configured such that each are parallel to each other and spaced evenly with that the distance between sides of any two consecutive parallel second panels is equal. 
         [0036]      FIG. 2  shows a front view of the vehicle front grill assembly of  FIG. 1 . As explained previously, first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120  are configured parallel relative to each other and perpendicular relative to second panels  126 ,  128 ,  132 ,  134 ,  136 ,  138  which are configured parallel relative to each other. First panels are evenly spaced from each other and second panels are spaced evenly from each other. The vehicle light assemblies  124  are interfaced with vehicle light assembly housings  122 . Vehicle light assembly housings  122  are interfaced with small first panels  110 , the upper first panel  112 , the first mid-section first panel  118 , the second mid-section first panel  116 , the third mid-section first panel  114 , the fourth mid-section first panel  112 , second panels of full length for interfacing  128 , smaller second panels for interfacing  134 , mid-sized second panels  132 , and small second panels  138 . Vehicle light assembly housings further comprise first interfacing extensions  202 , which may interface with other assemblies or with vehicle structural frame members. 
         [0037]      FIG. 3  shows a top-down view of the vehicle front grill assembly of  FIG. 1 . First panels  104 ,  102 ,  110 ,  120  have a generally curved shape such that when assembled, the entire grill takes on a generally curved shape. Second panels  126 ,  136  also have a generally curved shape such that when assembled, the entire grill takes on a generally curved shape. The upper first panel  120  comprises third through-holes  302  which may interface with vehicle structural frame members. The first interfacing extensions  202  comprise through-holes  304  which may interface with vehicle structural frame members. 
         [0038]      FIG. 4A  shows a perspective view of a partially assembled vehicle front grill assembly. First panels  102 ,  104 ,  108 ,  112 ,  114 ,  116 ,  118 ,  120  comprise first slots  402  and second slots  404  extending inwards from opposed sides and sharing an inline longitudinal axis. First slots and second slots are evenly spaced along first panels  102 ,  104 ,  108 ,  112 ,  116 ,  118 ,  120  such that second panels  126  can intersect with said first slots  402  and remain parallel relative to each other and perpendicular relative to first panels  102 ,  104 ,  108 ,  112 ,  114 ,  116 ,  118 ,  120 . First panels  102 ,  104 ,  108 ,  112 ,  116 ,  118 ,  120  intersect with second panels  126  by inserting third slots of second panels shown hereafter in  FIG. 6A  into first slots  402  of first panels  102 ,  104 ,  118 ,  112 ,  114 ,  116 ,  118 ,  120 . A partially assembled vehicle front grill assembly is required to expose first slots  402  and second slots  404  and visually describe the interfacing of first panels  102 ,  104 ,  108 ,  112 ,  114 ,  116 ,  118 ,  120  and second panels  126 . First slots  402  and second slots  404  should be understood to also be incorporated in first panels  110  not shown in this figure. The interfacing of second panels is likewise represented by second panels  126  but should be understood to also be incorporated in second panels  128 ,  132 ,  134 ,  136 ,  138  not shown in this figure. 
         [0039]      FIG. 4B  shows a close-up view of the partially assembled vehicle front grill assembly of  FIG. 4A . First panels  114 ,  116 ,  118 ,  120  intersect with second panels  126  by means of first slots. Second panels  126  intersect with first panels  114 ,  116 ,  118 ,  120  in such a manner that they protrude from the grill assembly. The protrusion of second panels  126  is representative of all second panels including second panels  128 ,  132 ,  134 ,  136 ,  138  not shown in this figure, and it should be understood that second panels  128 ,  132 ,  134 ,  136 ,  138  may likewise protrude from the vehicle front grill assembly. 
         [0040]      FIG. 5A  shows a perspective view of the rear side of a partially assembled vehicle front grill assembly.  FIG. 5B  shows a close-up view of the rear side of the partially assembled vehicle front grill assembly of  FIG. 5A . The second mid-section first panel  116  is shown intersected with the second panel of full length  126 . Specifically, the third slot  520  of the second panel of full length  126  is inserted into the first slot (shown in  FIG. 4A ) of the second mid-section first panel  116 . A fourth slot  510  of the second panel of full length  126  is also shown. The third slot  520  and fourth slot  510  are separated by a distance such that a first deformable wall  530  is formed. The intersection of the second mid-section first panel  116  and the second panel of full length  126  depicted in  FIG. 5B  is representative of all other intersections of first slots  402  of all first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120  with third slots  520  of all second panels  126 ,  128 ,  132 ,  134 ,  136 ,  138  and all other intersections of second slots  404  of all first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120 , with third slots  520  of all second panels  126 ,  128 ,  132 ,  134 ,  136 ,  138 . As such, it is to be understood that the scope of this intersection of first slots  402  with third slots  520  is not limited only to the second mid-section first slot  116  and the second panel of full length  126 , but may include all other intersections between first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120  and second panels  126 ,  128 ,  132 ,  134 ,  136 ,  138 . 
         [0041]      FIG. 6A  shows a side view of a single second panel of full length  126 . The second panel of full length  126  comprises third slots  520  and fourth slots  510 .  FIG. 6B  shows a close-up view of a third slot  520  and fourth slot  510  forming a first deformable wall  530  between them.  FIG. 6C  further magnifies the view of  FIG. 6B  and shows that fourth slots  510  comprise a first groove  610  at their base. The first groove  610  facilitates deformation of the first deformable wall  530  by acting as a stress concentrator and causing the deformable wall to bend on an axis formed between the first groove  610  and third slot  520 . The first groove  610  of the fourth slot  510  of the second panel of full length  126  depicted herein is representative of first grooves that may be incorporated into all fourth slots of any first panel. As such, it is to be understood that all first panels  102 ,  104 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120  may comprise fourth slots  510  with a first groove  610  at the base of each fourth slot  510 . 
         [0042]      FIG. 7A  shows a side view of a first embodiment of the present invention used in the vehicle front grill assembly of  FIGS. 1-6  in its pre-assembly or undeformed state. What is shown is a third slot  520  and a fourth slot  510  of a second panel, the slots forming a first deformable wall  530  between them. After insertion of a first panel into a second panel at intersections of first and third slots respectively, first and second panels are not yet rigidly fixed in position relative to each other. 
         [0043]      FIG. 7B  shows the same view of the first embodiment of the present invention as  FIG. 7A  in its post-assembly or deformed state. Once first slots of first panels are inserted into third slots of second panels, the first deformable wall  530  is deformed  710  into the third slot  520 . The first deformable wall  530  fills a void created by an intersection of third slots  520  and second slots  404 . Once the first deformable wall  530  is in its deformed  710  state, the first and second panels are fixed in position relative to each other at this intersection. The first embodiment of the present invention may be incorporated at any intersection of second and third slots of first and second panels throughout the entire grill assembly. The first embodiment of the present invention may also be used on any grill utilizing a first and second panel and is not limited in scope to a vehicle front grill assembly. 
         [0044]      FIG. 8A  shows a side view of a second embodiment of the present invention used in the vehicle front grill assembly of  FIGS. 1-6  in its pre-assembly or undeformed state. What is shown is a second panel comprising a fifth slot  804  extending from the third slot  520  such that a second deformable wall  806  is formed between the fifth slot  804  and the edge of the panel. A second groove  808  is incorporated into the fifth slot  804  to promote bending of the second deformable wall. The first deformable wall  530  comprises a chamfer  802  at its corner closes to the fourth slot  510 . After insertion of a first panel into a second panel at intersections of first and third slots respectively, first and second panels are not yet rigidly fixed in position relative to each other. 
         [0045]      FIG. 8B  shows the same view of the second embodiment of the present invention as  FIG. 8A  in its post-assembly or deformed state. Once first slots of first panels are inserted into third slots of second panels, the first deformable wall  530  is deformed  810  into the fifth slot  804 . The first deformable wall  530  fills a void created by an intersection of the third slots  520  and second slots  404 . Once the first deformable wall  530  is in its deformed  810  state, the second deformable wall  806  is deformed  820  such that the second deformable wall  806  comes into contact with the chamfer  802 . Once the second deformable wall  806  is in its deformed  820  state, the first and second panels are fixed in position relative to each other at this intersection. The first embodiment of the present invention may be incorporated at any intersection of second and third slots of first and second panels throughout the entire grill assembly. The first embodiment of the present invention may also be used on any grill utilizing a first and second panel and is not limited in scope to a vehicle front grill assembly. 
         [0046]      FIG. 9A  shows a perspective view of a vehicle rear grill assembly which comprises an upper grill assembly  900  and a lower grill assembly  960 . The upper grill assembly  900  further comprises first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916 ,  918 ,  920 ,  922 ,  924 ,  926 ,  928 ,  930  and second panels  934 ,  935 ,  936 ,  938 ,  940 ,  942 ,  944 ,  946 ,  948 ,  950 ,  952 ,  954 ,  956 . A first upper grill assembly first panel  902  is a first panel comprising first slots and second slots extending inwards from opposed sides. A second upper grill assembly first panel  904  is a first panel comprising the same features as the first upper grill assembly first panel  902 , but having a greater length than the first upper grill assembly first panel  902  and comprising a portion of decreased width  905  in order to interface with a separate assembly, in this case a mounting plate  933 . A third upper grill assembly first panel  906  comprises the same features as the first upper grill assembly first panel  902  but further comprises a portion of decreased width  905  to interface with the mounting plate  933 . The third upper grill assembly first panel  906  is partially blocked from view in this Figure, but is one continuous piece extending underneath the mounting plate  933  by means of a portion of decreased width  905 . A fourth upper grill assembly first panel  908  is a first panel of lesser length than the first upper grill assembly first panel  902  and the second upper grill assembly first panel  904 . The fifth upper grill assembly first panel  910  is a first panel of lesser length than the fourth upper grill assembly first panel  908  and comprises a portion of lesser width than the rest of the fifth upper grill assembly first panel  910 . A sixth upper grill assembly first panel  912  is a first panel of lesser length than the fifth upper grill assembly first panel  910 , and comprises a portion of lesser width than the rest of the sixth upper grill assembly first panel  912  to interface with a separate assembly member, in this case a brake light assembly  932 . A seventh upper grill assembly first panel  914  is a first panel of lesser length than the sixth upper grill assembly first panel  912  and comprises a portion of lesser width than the rest of the seventh upper grill assembly first panel  914 . An eighth upper grill assembly first panel  916  is a first panel of greater length than the seventh upper grill assembly first panel  914  and lesser length than the sixth upper grill assembly first panel  912 . The eighth upper grill assembly first panel  916  further comprises first through holes  917  used to interface the upper grill assembly  900  with vehicle structural frame members. A ninth upper grill assembly first panel  918  is a first panel comprising the same features as the seventh upper grill assembly first panel  914  and additionally comprising a second portion of lesser panel width. A tenth upper grill assembly first panel  920  is a first panel comprising the same features as the sixth upper grill assembly first panel  912  but further comprising a second portion of lesser panel width. An eleventh upper grill assembly first panel  922  is a first panel comprising the same features as the fifth upper grill assembly first panel  910 . A twelfth upper grill assembly first panel  924  is a first panel comprising the same features as the fourth upper grill assembly first panel  908 . A thirteenth upper grill assembly first panel  926  is a first panel comprising the same features as the twelfth upper grill assembly first panel  924  but having the same length as the third upper grill assembly first panel  906 . A fourteenth upper grill assembly first panel  928  is a first panel comprising the same features as the thirteenth upper grill assembly first panel  926  but having the same length as the second upper grill assembly first panel  904 . TA fifteenth upper grill assembly first panel  930  is a first panel comprising the same features as the fourteenth upper grill assembly first panel  928  but having the same length as the first upper grill assembly first panel  902 . The relative width of first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916 ,  918 ,  920 ,  922 ,  924 ,  926 ,  928 ,  930  generally increases as the vertical position of the panel increases, making the upper grill assembly of a generally curved shape. A first upper grill assembly second panel  934  intersects with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912  by means of a third slot shown hereafter in  FIG. 10A . A pair of second upper grill assembly second panels  935  intersect with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  916  on one side of the upper grill assembly  900  and with first panels  916 ,  920 ,  922 ,  924 ,  926 ,  928 ,  930  on the other side of the upper grill assembly  900 . The second upper grill assembly second panels  935  are greater in length than the first upper grill assembly second panel  934  and further comprise portions of greater width than the first upper grill assembly second panel  934  and portions of lesser width than the first upper grill assembly second panel  934  in order to interface with a vehicle brake light assembly  932  and to interface with the mounting plate  933 . A third upper grill assembly second panel  936  intersects with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916 . The third upper grill assembly second panel  936  is of greater length than the second upper grill assembly second panels  935  and further comprises a portion of lesser width to interface with the mounting plate  933  and a generally pointed acute corner. A fourth upper grill assembly second panel  938  intersects with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916  and is of greater length than length than the third upper grill assembly second panel  936 . The fourth upper grill assembly second panel  938  further comprises a portion of lesser width to interface with the mounting plate  933  and a generally pointed acute corner. A fifth upper grill assembly second panel  940  is of greater length than the second upper grill assembly second panels  935  but lesser length than the third upper grill assembly second panel  936 . The fifth upper grill assembly second panel  940  further comprises a generally pointed acute corner. A sixth upper grill assembly second panel  942  intersects with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916  and further comprises bent interfaces  958  which may be used to interface with other assemblies or vehicle structural frame members. A seventh upper grill assembly second panel  944  intersects with first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916 . An eighth upper grill assembly second panel  946  does not intersect directly with other panels in this figure, but shows the general configuration of third slots and fourth slots which will be shown in greater detail hereafter in  FIG. 10A . A ninth upper grill assembly second panel  948  comprises features identical to that of the seventh upper grill assembly second panel  944 . A tenth upper grill assembly second panel  950  comprises features identical to that of the sixth upper grill assembly second panel  942  except that bent interfaces  958  are bent in the opposite direction. An eleventh upper grill assembly second panel  952  comprises features identical to that of the fifth upper grill assembly second panel  940 . A twelfth upper grill assembly second panel  954  comprises features identical to that of the fourth upper grill assembly second panel  938  except that it has no portion which interfaces with the mounting plate  933  or any other assembly. A thirteenth upper grill assembly second panel  956  comprises features identical to the third upper grill assembly second panel  936  except that it has no portion which interfaces with the mounting plate  933 . The second panels  934 ,  935 ,  936 ,  938 ,  940 ,  942 ,  944 ,  946 ,  948 ,  950 ,  952 ,  954 ,  956  are generally curved and generally increase in width along increasing height of the assembly such that the upper grill assembly  900  takes on a generally curved shape. The lower grill assembly  960  is much smaller than the upper grill assembly  900  and comprises fewer panels. A lower first panel  962  is of length that spans the entire lower grill assembly  960  and comprises mounting interfaces  968  to fix the lower grill assembly  960  to vehicle structural frame members by using second through-holes  970 . A middle first panel  964  is of length that spans the entire lower grill assembly  960  and is of a generally rectangular shape with a lesser width than that of the lower first panel  962 . An upper first panel  966  is of length that spans the entire lower grill assembly  960  and is of a generally rectangular shape with a lesser width than that of the middle first panel  964 . The upper first panel  966  is of lesser length than the middle first panel  964 . Lower assembly second panels  972  intersect with lower assembly first panels  962 ,  964 ,  966  and have a generally triangular shape with a generally curved hypotenuse. Lower assembly second panels  972  are spaced evenly along the length of lower assembly first panels  962 ,  964 ,  966  excepting a space in the middle of the lower grill assembly  960  where the space between lower assembly second panels  972  is larger than at any other portion of the lower grill assembly  960 . 
         [0047]      FIG. 10A  shows a side view of the seventh upper grill assembly second panel  944  shown in  FIG. 9 . The features of the seventh upper grill assembly second panel  944  shown and described in  FIG. 10A ,  FIG. 10B , and  FIG. 10C  are representative of features utilized on all second panels in  FIG. 9 , and as such are understood to not be limited in scope to only the seventh upper grill assembly second panel  944 . The seventh upper grill assembly second panel  944  comprises third slots  1010  and fourth slots  1020 , which form a first deformable wall  1030  between them.  FIG. 10B  shows a close-up view of a third slot  1010 , fourth slot  1020 , and a first deformable wall  1030  formed between on the seventh upper grill assembly second panel  944  of  FIG. 10A .  FIG. 10C  shows a close-up view of the base of a fourth slot  1020 , which comprises a first groove  1040 . The third slot  1010 , fourth slot  1020 , first deformable wall  1030 , and first groove  1040  are the same features as those found in the first embodiment of the invention in  FIG. 7A , which shows the third slot  520 , fourth slot  510 , first deformable wall  530 , and first groove  610 . As such, in reference to  FIG. 9 , first panels  902 ,  904 ,  906 ,  908 ,  910 ,  912 ,  914 ,  916 ,  918 ,  920 ,  922 ,  924 ,  926 ,  928 ,  930  and second panels  934 ,  935 ,  936 ,  938 ,  940 ,  942 ,  944 ,  946 ,  948 ,  950 ,  952 ,  954 ,  956  are understood to intersect by the same embodiments and methods described heretofore and depicted in  FIGS. 7A, 7B, 8A, and 8B . 
         [0048]      FIG. 11A  shows a perspective view of a ventilation grill assembly utilizing the present invention. The ventilation grill assembly comprises of first panels  1102 ,  1104  and second panels  1110 . Outer first panels  1102  are rectangular in shape and have a length that spans the entire length of the ventilation grill assembly. The outer first panels  1102  each additionally comprise first slots and second slots extending inwards from opposed sides of the panels and sharing an inline longitudinal axis, as well as bent mounting extensions  1106  which protrude perpendicularly from the side of the outer first panels  1102 . The bent mounting extensions  1106  further comprise mounting through-holes  1108  which may be used to rigidly attach the ventilation grill assembly to a vent opening. Inner first panels  1104  are identical to the outer first panels  1102  except they do not comprise bent mounting extensions  1106 . In the ventilation grill assembly depicted in  FIG. 11A , only one shape and size of second panel  1110  is utilized. The first panels  1102 ,  1104  are intersected with second panels in a manner more fully illustrated and described hereafter. 
         [0049]      FIG. 11B  shows a top-down view of the ventilation grill assembly of  FIG. 11A . This view shows that the ventilation grill assembly comprises first panels  1102 ,  1104  and second panels  1110  intersected in a perpendicular manner with like panels being spaced evenly relative to one another throughout the ventilation grill assembly. 
         [0050]      FIG. 12  shows a perspective exploded view of the ventilation grill assembly of  FIG. 11A  with only one second panel  1110 . The first panels  1102 ,  1104  are comprised of first slots  1210  and second slots  1212  extending inward from opposed sides. The second panels  1110  are comprised of third slots  1220  and fourth slots  1230 . As shown hereafter in  FIG. 15B , intersections of first panels  1102 ,  1104  and second panels  1110  comprise the insertion of first slots  1210  into third slots  1220 . 
         [0051]      FIG. 13  shows a side view of an inner first panel  1104 . The first slots  1210  and second slots  1212  extend inward from opposed sides of the inner first panel  1104  and share an inline longitudinal axis. In addition, first slots  1210  and second slots  1212  are spaced evenly such that the completed ventilation grill assembly takes on an evenly spaced appearance. First slots  1210  and second slots  1212  share an inline longitudinal axis  1300 . 
         [0052]      FIG. 14A  shows a side view of the second panel  1110 . The second panel  1110  is comprised of third slots  1220  and fourth slots  1230 , which form a first deformable wall  1410  between them.  FIG. 14B  shows a close-up view of the third slots  1220 , fourth slots  1230 , and first deformable wall  1410  of  FIG. 14A .  FIG. 14C  shows a close-up view of the fourth slot  1230  shown in  FIG. 14B  and shows that fourth slots  1230  further comprise a first groove  1420  at the base of the fourth slot  1230 . The first groove  1420  facilitates deformation of the first deformable as depicted in  FIGS. 7A and 7B . It should be understood that although  FIGS. 14A, 14B, and 14C  show second panels  1110  utilizing the first embodiment of the invention as shown in  FIGS. 7A and 7B , other embodiments, such as the one shown in  FIGS. 8A and 8B  are possible and may also be utilized on second panels  1110  of this or any other grill assembly. 
         [0053]      FIG. 15A  shows a perspective view of the bottom of the ventilation grill assembly of  FIG. 11A .  FIG. 15B  shows a close-up view of an intersection of an inner first panel  1104  and a second panel  1110 . After insertion of the first slot  1210  of the inner first panel  1104  into the third slot  1220  of the second panel  1110 , an empty void is formed at the intersection of the second slot  1212  and the third slot  1220 . This void is of equal width to the first deformable wall  1410 . Upon deformation of the first deformable wall as depicted in  FIG. 7B , the first deformable wall  1410  fits into and fills the void  1212 ,  1220  by bending at the first groove  1420 . The filling of this void  1212 ,  1220  by the first deformable wall causes the inner first panel  1104  and the second panel  1110  to become fixed in position relative to each other at this intersection. Each intersection of first panels  1102 ,  1104  and second panels  1110  throughout the ventilation grill assembly should be understood to have the same features as the one depicted in  FIG. 15B , and the filling of all voids  1212 ,  1220  in the entire ventilation grill assembly rigidly fixes first panels  1102 ,  1104  and second panels  1110  in their positions relative to each other.

Technology Category: 2