Tolerance compensation device

Abstract

The invention provides a'tolerance compensation device '. An assembly includes a housing having an inner bore defined by a bore surface; and the fastening piece can be inserted into the inner hole. The receiving portion is located within the vehicle body structure and has an opening aligned with the inner bore. The fastener includes a thread that cuts into the bore surface as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving portion, or the fastener cooperates with an insert positioned within the inner bore to secure the housing to the vehicle body structure via the receiving portion.

Description

Technical Field

[0001] The present disclosure generally relates to a tolerance compensation device, and more particularly to a tolerance compensation device for attaching various components to a vehicle body structure. Background Art

[0002] Tolerance compensation devices can be used to mount components (such as, for example, headlamps) to a vehicle body structure. The tolerance compensation device adjusts the tolerance stack-up on the vehicle body and ensures a good fit between parts. Summary of the Invention

[0003] An assembly according to an exemplary aspect of the present disclosure particularly includes: a housing having an inner bore defined by a bore surface; a fastener insertable into the inner bore; a receiving portion within the vehicle body structure having an opening aligned with the inner bore; and wherein the fastener includes threads that cut into the bore surface as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving portion, or wherein the fastener cooperates with an insert positioned within the inner bore to secure the housing to the vehicle body structure via the receiving portion.

[0004] In a further non-limiting embodiment of the foregoing assembly, the inner bore includes a threaded hole, and wherein the insert includes a threaded outer surface that threadedly engages the threaded hole via a threaded interface such that rotation of the fastener causes the insert to rotate until the head of the insert abuts the vehicle body structure.

[0005] In a further non-limiting embodiment of any of the foregoing assemblies, the insert includes an inner surface that defines an insert hole extending from the head to the distal end of the insert, and wherein the insert includes a plurality of thread grippers that extend radially inwardly from the inner surface to engage the external threads on the fastener.

[0006] In a further non-limiting embodiment of any of the foregoing assemblies, the head of the insert is in an initial position spaced apart from the vehicle body structure by a certain gap, and wherein the fastener engages the plurality of thread grippers, thereby causing the insert to rotate via the threaded interface between the insert and the housing to move the insert to a final position where the gap is eliminated and the head of the insert abuts the vehicle body structure.

[0007] In a further non - limiting embodiment of any of the foregoing assemblies, the receiving portion includes a receiving fastener, and wherein when the insert is in the final position, the fastener rotates through the insert such that the distal end of the fastener is received within the opening of the receiving fastener to secure the housing to the body structure.

[0008] In a further non - limiting embodiment of any of the foregoing assemblies, the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein the fastener includes a self - tapping fastener that cuts into the inner surface to rotate the insert relative to the housing.

[0009] In a further non - limiting embodiment of any of the foregoing assemblies, the receiving portion includes a receiving fastener, and wherein the head of the insert is in an initial position spaced apart from the body structure by a clearance, and wherein the self - tapping fastener rotates the insert to a final position at which the clearance is eliminated and the head of the insert abuts the body structure, and wherein the fastener rotates through the insert such that the distal end of the fastener extends beyond the insert.

[0010] In a further non - limiting embodiment of any of the foregoing assemblies, the insert includes a first anti - rotation feature that mates with a second anti - rotation feature on the housing to prevent the insert from rotating out of the housing in a first condition, and wherein in a second condition, the rotational force of the fastener within the insert overrides the first and second anti - rotation features to attach the housing to the body structure.

[0011] In a further non - limiting embodiment of any of the foregoing assemblies, the fastener can be selected between a first fastener having at least a first size and a second fastener having a second size different from the first size, and wherein the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein the insert bore includes a first internal feature for receiving the first fastener and a second internal feature for receiving the second fastener.

[0012] In a further non - limiting embodiment of any of the foregoing assemblies, the fastener includes threads that cut into the bore surface.

[0013] In a further non-limiting embodiment of any of the foregoing assemblies, the fastener extends from a head to a distal end, and wherein the fastener includes a first body portion extending from the head and a second body portion extending from the first body portion to the distal end, wherein the first body portion is defined by a first diameter and the second body portion is defined by a second diameter less than the first diameter, and wherein the threads include a first set of threads formed on the first body portion and a second set of threads formed on the second body portion.

[0014] In a further non-limiting embodiment of any of the foregoing assemblies, the receiving portion includes a receiving fastener, and wherein as the fastener rotates within the bore, the first set of threads cut into the bore surface and the second set of threads threadedly engage the opening in the receiving fastener.

[0015] In a further non-limiting embodiment of any of the foregoing assemblies, the fastener includes a shoulder between the first body portion and the second body portion, and wherein the fastener rotates from an initial position in which the shoulder is spaced from the body structure by a gap to a final position in which the shoulder abuts the body structure to eliminate the gap.

[0016] In a further non-limiting embodiment of any of the foregoing assemblies, the fastener includes a first fastener and the threads include external threads, and wherein the first fastener includes a bore extending from the head of the first fastener to the distal end of the first fastener, and wherein the bore includes internal threads for mating with a second fastener.

[0017] In a further non-limiting embodiment of any of the foregoing assemblies, the second fastener extends from a head to a distal end, and wherein the second fastener is screwed into the bore of the first fastener until the head of the second fastener abuts the head of the first fastener, and wherein the first fastener and the second fastener are then rotated together such that the external threads cut into the bore surface of the housing.

[0018] In a further non-limiting embodiment of any of the foregoing assemblies, the receiving portion includes a receiving fastener, and wherein the first fastener and the second fastener are rotated together until the distal end of the second fastener is received within the opening of the receiving fastener and the distal end of the first fastener engages the body structure.

[0019] A method according to another exemplary aspect of the present disclosure particularly includes: inserting a fastener into an inner hole in a housing, where the inner hole is defined by a hole surface; providing a receiving portion for a vehicle body structure such that an opening in the receiving portion is aligned with the inner hole; and cutting into the hole surface with external threads on the fastener as the fastener rotates relative to the housing to fix the housing to the vehicle body structure via the receiving portion, or positioning an insert within the inner hole to cooperate with the fastener so as to fix the housing to the vehicle body structure via the receiving portion.

[0020] In a further non - limiting embodiment of the foregoing method, the method includes positioning the insert within the inner hole, and where the inner hole includes a threaded hole, and where the insert includes a threaded outer surface that threadedly engages the threaded hole via a threaded interface, and the method includes rotating the fastener to cause the insert to rotate until the head of the insert abuts the vehicle body structure.

[0021] In a further non - limiting embodiment of any of the foregoing methods, the insert includes an inner surface that defines an insert hole extending from the head to the distal end of the insert, and the insert includes a plurality of thread grippers that radially extend inwardly from the inner surface to engage external threads on the fastener, or the fastener includes a self - tapping fastener.

[0022] In a further non - limiting embodiment of any of the foregoing methods, the receiving portion includes a receiving fastener, and the method includes cutting into the hole surface with external threads on the fastener as the fastener rotates relative to the housing to fix the housing to the vehicle body structure via the receiving fastener.

[0023] The embodiments, examples, and alternatives of the foregoing paragraphs, claims, or the following description and drawings may be employed independently or in any combination, including any one of their various aspects or corresponding individual features. Features described in connection with one embodiment apply to all embodiments unless such features are incompatible. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In accordance with the detailed description, the various features and advantages of the disclosed examples will become apparent to those skilled in the art. The drawings accompanying the detailed description can be briefly described as follows:

[0025] Figure 1 is a perspective view of a vehicle body portion having a housing for mounting a component to a vehicle body structure.

[0026] Figure 2Exploded view of an example of a tolerance compensation device.

[0027] Figure 3A Is Figure 2 Perspective view of an insert of a tolerance compensation device.

[0028] Figure 3B Is Figure 3A End view of a tolerance compensation device.

[0029] Figure 4 Is for receiving Figure 3A Perspective view of a housing hole of a tolerance compensation device.

[0030] Figure 5 Is an insert installed in Figure 4 Perspective view of an insert in a housing.

[0031] Figure 6A Is Figure 2 The first installation position of a tolerance compensation device.

[0032] Figure 6B Is Figure 2 Subsequent installation position of a tolerance compensation device.

[0033] Figure 6C Is Figure 2 The final installation position of a tolerance compensation device.

[0034] Figure 7A Is the first installation position of another example of a tolerance compensation device.

[0035] Figure 7B Is Figure 7A Subsequent installation position of a tolerance compensation device.

[0036] Figure 7C Is Figure 7B Subsequent installation position of a tolerance compensation device.

[0037] Figure 7D Is Figure 7C The final installation position of a tolerance compensation device.

[0038] Figure 7E Is Figure 7D Cross-sectional view of the final installation position.

[0039] Figure 8A Is a cross-sectional view of another example of an insert for a tolerance compensation device.

[0040] Figure 8B Shows a first type of fastener installed in Figure 8A The insert.

[0041] Figure 8CShows a second type of fastener installed in the insert of Figure 8A .

[0042] Figure 9 Is an exploded view of another example of a tolerance compensation device.

[0043] Figure 10 Is an end view of a fastener of a tolerance compensation device installed in a housing from Figure 9 .

[0044] Figure 11A Is Figure 9 The first installation position of another example of a tolerance compensation device of

[0045] Figure 11B Is Figure 11A The subsequent installation position of a tolerance compensation device of

[0046] Figure 11C Is Figure 11B The subsequent installation position of a tolerance compensation device of

[0047] Figure 11D Is Figure 11C The final installation position of a tolerance compensation device of

[0048] Figure 12 Is an exploded view of another example of a tolerance compensation device.

[0049] Figure 13A Is Figure 12 The first installation position of a tolerance compensation device of

[0050] Figure 13B Is Figure 12 The subsequent installation position of a tolerance compensation device of

[0051] Figure 13C Is Figure 12 The final installation position of a tolerance compensation device of

[0052] Figure 14A Is a cross-sectional view of a split tab in a first condition.

[0053] Figure 14B Is a cross-sectional view of a split tab in a second condition. DETAILED DESCRIPTION

[0054] The present disclosure details a tolerance compensation device for attaching various components to a vehicle body structure. For example, the tolerance compensation device can be used to attach headlights, sensor brackets, fenders, trim pieces, etc. to the vehicle body structure. The tolerance compensation device adjusts the tolerance stack-up on the vehicle body and ensures good fit and alignment between parts.

[0055] Refer toFigure 1 , the vehicle body 10 includes a vehicle body structure 12 for mounting various components to the vehicle body 10. In one example, a component housing 14 is mounted to the vehicle body structure 12. In Figure 1 the example shown, the housing 14 includes a headlight housing; however, the housing 14 may include a housing for another type of vehicle component or may include, for example, a bracket.

[0056] The component housing 14 has an inner bore 16 defined by a bore surface 18. The component housing 14 is attached to the vehicle body structure 12 using any of a variety of known attachment interfaces. In Figure 1 one example shown, the tolerance compensation device 20 includes the component housing 14, an insert 22 that can be inserted into the inner bore 16, and a receiving fastener 24 supported by the vehicle body structure 12. The receiving fastener 24 has an opening 26 that aligns with the inner bore 16. In this example, a fastener 28 ( Figures 6A to 6C ) cooperates with the insert 22 positioned within the inner bore 16 to secure the housing 14 to the vehicle body structure 12 via the receiving fastener 24. In one example, the receiving fastener 24 includes a threaded fastener such as a J / U split nut, a weld nut, or any type of fastener with an integrated thread. In one example, the fastener 28 includes a standard threaded fastener such as, for example, a bolt.

[0057] In Figures 3A to 3B the insert 22 is shown in more detail, and in Figure 4 the inner bore 16 of the housing is shown in more detail. In one example, the inner bore 16 includes a threaded hole having threads 30. In one example, the threaded inner bore 16 includes threads 30 that are integrated into the housing itself via a molding process. In one example, the insert 22 includes a threaded outer surface 32 that threadedly engages the threads 30 of the threaded hole 16 via a threaded interface such that rotation of the fastener 28 causes the insert 22 to rotate relative to the housing 14. In one example, the insert 22 includes an inner surface 34 that defines an insert bore 36 extending from the head 38 of the insert 22 to the distal end 40. As Figure 3B shown, in one example, the insert 22 includes a plurality of thread grippers 42 that radially inwardly extend from the inner surface to engage the external threads 44 on the fastener 28. The thread grippers 42 are discrete members or fingers that are circumferentially spaced from each other around the bore surface 18. In one example, the threaded outer surface 32 and the thread grippers 42 are integrally formed on the insert 22.

[0058] In one example, the insert 22 includes a first anti-rotation feature 46 that engages a second anti-rotation feature 48 on the housing 14 ( Figure 4)to cooperate to prevent the insert 22 from rotating out of the housing 14 in a first condition. For example, the first condition may include a shipping condition, in which the first anti-rotation feature 46 and the second anti-rotation feature 48 cooperate with each other ( Figure 5 )to prevent the insert 22 from exiting during shipping. Thus, the insert 22 can be pre-installed within the housing 14 to facilitate subsequent installation of the tolerance compensation device 20 on the vehicle. During a second condition (e.g., an installation condition), the rotational force of the fastener 28 within the insert 22 overrides the first anti-rotation feature 46 and the second anti-rotation feature 48 to attach the housing 14 to the body structure 12.

[0059] In one example, the first anti-rotation feature 46 is integrally formed with the insert 22, and the second anti-rotation feature 48 is integrally formed with the housing 14. In one example, the head 28 includes a flat portion 50 to facilitate installation, and the body includes a flat portion 52 to facilitate injection molding, while also forming a recessed area within the housing 14 to make it easier to screw the insert 22 into the housing 14 and prevent binding.

[0060] Figures 6A to 6C The installation process of the tolerance compensation device 20 is shown. As Figure 6A shown, the joint between the housing 14 and the body structure 12 is intentionally configured with a gap 54 to account for tolerance stack-up. The insert 22 is pre-installed in the housing 14 by screwing it into engagement with the threads 30 of the inner bore 16 of the housing 14. In this pre-installed position, the head 38 of the insert 22 is in an initial position spaced apart from the body structure 12 by the gap 54. The fastener 28 is inserted into the insert hole 36 and engages a plurality of thread grippers 42, which causes the insert 22 to rotate via the threaded interface between the insert 22 and the housing 14, causing the insert 22 to move along a linear path to a final position, at which the gap 54 is closed / eliminated and the head 38 of the insert 22 abuts the body structure 12, as Figure 6B shown. Once the gap 54 is closed, the fastener 28 travels in the remaining threads along the body of the fastener 28 and is twisted to form a joint as Figure 6C shown. When the insert 22 is in this final installed position, the distal end 56 of the fastener 28 is received within the opening 26 that receives the fastener 24 to secure the housing 14 to the body structure 12 via the joint. In the example Figures 6A to 6C shown, the receiving fastener 24 is a U-shaped nut having a first leg and a second leg 58, the first leg and the second leg having aligned openings 26 and threaded portions 60 that engage the distal end 56 of the fastener 28. As shown in FIG. 6, in the final installed position, the head 62 of the fastener 28 abuts the distal end 40 of the insert 22.

[0061] Figures 7A to 7EAnother example of a tolerance compensation device 20' is shown. In this example, the fastener includes a self-tapping fastener 28'. In this example, this is a reverse stack, where the fastener 28' is installed through the body structure 12 before entering the insert 22 in the housing 14. Regarding the interface between the insert 22 and the housing 14, it remains the same as the interface in Figures 6A to 6C , but the integral threads on the insert 22 and the housing hole 16 are changed to reverse threads. All other features on the housing 14 and the insert 22 remain the same and function in the same manner as described above.

[0062] In this example, the thread gripper 42 is sized for a simple through-hole for the self-tapping fastener 28' instead.

[0063] As Figure 7A shown, the joint between the housing 14 and the body structure 12 is intentionally configured with a gap 54 to accommodate tolerance stack-up. The insert 22 is pre-installed in the housing 14 by screwing it into engagement with the threads 30 of the inner hole 16 of the housing 14. In this pre-installed position, the head 38 of the insert 22 is in an initial position spaced apart from the body structure 12 by the gap 54. The insert 22 includes an inner surface 64 ( Figure 7E ), such as a smooth surface, which defines an insert hole 66 extending from the head 38 of the insert 22 to the distal end 40. The fastener 28' includes a self-tapping fastener having threads 44', which cut into the inner surface 64 to rotate the insert 22 relative to the housing 14, as Figure 7B shown. The head 38 of the insert 22 is in an initial position spaced apart from the body structure 12 by the gap 54, and the self-tapping fastener 28' rotates the insert 22 to a final position where the gap 54 is eliminated and the head 38 of the insert 22 abuts the body structure 12, as Figure 7C shown. Then, the fastener 28' continues to rotate through the insert 22 such that the head 62' of the fastener 28' abuts the body structure 12 and the distal end 56' of the fastener 28' extends beyond the insert 22, as Figure 7D shown. Thus, once the gap 54 is closed, the fastener 28 self-taps through the insert hole 66 and is twisted to form a joint as Figure 7E shown.

[0064] Figures 8A to 8C An example of an insert configuration is shown, where the insert 68 includes two sets of thread grippers 70a, 70b. The thread grippers 70a, 70b have holes 72a, 72b for receiving the fastener 28. The holes 72a, 72b can be smooth for self-tapping fasteners or threaded for standard fasteners. As Figure 8AAs shown, the first hole 72a for the threaded gripper 70a is defined by a diameter that is greater than the diameter of the second hole 72b in the other threaded gripper 70b. This allows the insert 68 to accept configurations with fasteners of different sizes.

[0065] For example, Figure 8B A body side mount is shown, where the shorter fastener 28 is installed in the first hole 72a. The shorter fastener 28 has a larger diameter and more threads so that it does not bottom out on the other set of threaded grippers 70b.

[0066] Figure 8C A component side mount configuration is shown, where the longer fastener 28 is installed in the second hole 72b. The fastener 28 is smaller / thinner so that it can easily extend through the other set of threaded grippers 70a.

[0067] Accordingly, the insert 68 includes a configuration in which the fastener 68 can be selected between a first fastener 28 having at least a first size and a second fastener 28 having a second size different from the first size. The insert 68 includes an inner surface that defines an insert hole 74 extending from the head of the insert 68 to the distal end, and the insert hole 74 includes a first internal feature (e.g., the first threaded gripper 70a) for receiving the first fastener and a second internal feature (e.g., the second threaded gripper 70b) for receiving the second fastener.

[0068] [[ID=1 / 5]]In any of the disclosed configurations, the insert includes a molded plastic part that can be used for many different types of connection interfaces on a vehicle, such as, for example, lighting applications, fender flares, brackets, interior / exterior trim. This type of one-piece part eliminates corrosion problems of multiple metal parts, eliminates metal-to-metal interfaces of fasteners, adjusters, and bodies, and reduces the chance of galvanic corrosion. <_{_}

[0069] In one example, the body structure 12 includes a metal (steel / aluminum) body component or a plastic (e.g., polypropylene) material. In one example, the receiving fastener 24 includes a U-shaped nut made of steel. In one example, the housing 14 includes a plastic (e.g., polypropylene) material. In one example, the insert includes a plastic (e.g., polypropylene) material, a polybutylene terephthalate material, a cast / machined aluminum material, or a cast / machined steel material.

[0070] Figure 9 Another example of a tolerance compensation device 80 is shown, where the fastener 82 includes threads that cut into the hole surface 84 of the housing 14 as the fastener 82 rotates relative to the housing 14 ( Figure 10)The housing 14 can be fixed to the vehicle body structure 12. In one example, the fastener 82 extends from a head 86 to a distal end 88 and further includes a first body portion 90 extending from the head 86 and a second body portion 92 extending from the first body portion 90 to the distal end 88. The first body portion 90 is defined by a first diameter, and the second body portion 92 is defined by a second diameter smaller than the first diameter. In one example, the threads of the fastener 82 include a first set of threads 94 formed on the first body portion 90 and a second set of threads 96 formed on the second body portion 92. In one example, the first set of threads 94 are self-tapping threads, and the second set of threads 96 include machined threads. In one example, the pitches of the two sets of threads 94, 96 are the same, such that the fastener 82 is screwed into the two joints at the same rate. Optionally, the second set of threads 96 can also be self-tapping.

[0071] In one example, the first body portion 90 includes one or more relief cuts 98, such as flat areas, that reduce friction during installation. These cuts 98 also provide cavities 100 ( Figure 10 ) within the housing 14 that collect any chips generated by the housing or the fastener to reduce any binding effects.

[0072] In one example, as the fastener 82 rotates within the inner bore of the housing 14, the first set of threads 94 cut into the bore surface 84 and the second set of threads 96 threadedly engage the threaded portion 60 of the receiving fastener 24 supported by the vehicle body structure 12. In one example, the receiving fastener 24 includes a U-shaped nut as described above.

[0073] In one example, the fastener 82 includes a shoulder 102 between the first body portion 90 and the second body portion 92. In one example, the fastener 82 has a hollow area 110 in the first body portion 90 to reduce weight.

[0074] Figures 11A to 11D The installation process of the tolerance compensation device 80 is shown. As Figure 11A shown, the joint between the housing 14 and the vehicle body structure 12 is intentionally configured with a clearance 104 to account for tolerance stack-up. As the fastener 82 is installed into the housing 14, the fastener 82 is first aligned via an internal step feature 106 formed within a protruding portion 108 of the housing, as Figure 11B shown. The fastener 82 rotates from an initial position where the shoulder 102 is spaced from the vehicle body structure 12 by a certain clearance ( Figure 11C ) to a final position where the shoulder 102 abuts the vehicle body structure 12 to eliminate the clearance ( Figure 11D ). As Figure 11CAs shown, the self - tapping thread 94 is driven into the hole surface 84 of the housing 14, and the machined thread 96 begins to engage in the threaded portion 60 of the receiving fastener 24. As Figure 11D shown, once the shoulder 102 abuts completely against the body structure 12 via the receiving fastener 24, the joint can be fully torqued. In this position, the self - tapping thread 94 is now bound in place with the housing 14 to keep the housing stable.

[0075] When tolerance stack - up results in no clearance between components, Figures 11A to 11D the joint of the example shown in works. When tolerance stack - up results in a clearance between components during installation, Figures 11A to 11D the joint of the example shown in also works. The depth of the self - tapping thread 94 allows for various tolerance stack - ups and joint thicknesses and is configured to self - adjust for any clearance between the minimum and maximum designs of the joint.

[0076] Figure 12 Another example of the tolerance compensation device 120 is shown, where the fastener 122 includes a thread 124 that cuts into the hole surface 84 of the housing 14 as the fastener 122 rotates relative to the housing 14 to fix the housing 14 to the body structure 12. In this example, the fastener 122 includes a first fastener 122, and the thread includes an external thread 124. The thread 124 is formed as the same self - tapping thread as the first body portion 90 of the fastener 82 described above. In one example, the first fastener 122 includes a hole 126 ( Figures 13A to 13C ) extending from the head 128 of the first fastener 122 to the distal end 130 of the first fastener 122. In one example, the hole 126 includes an internal thread 132 that mates with a second fastener 134. In one example, the second fastener 134 extends from the head 136 to the distal end 138 and includes a standard threaded bolt.

[0077] Figures 13A to 13C The installation process of the tolerance compensation device 120 is shown. As Figure 13A shown, the joint between the housing 14 and the body structure 12 is intentionally configured with a clearance 140 to account for tolerance stack - up. The second fastener 134 is screwed into the hole 126 of the first fastener 122, as Figure 13A shown. The second fastener 134 is screwed into the hole 126 until the head 136 of the second fastener 134 abuts against the head 128 of the first fastener 22, as Figure 13BAs shown. Once the head 136 engages another head 128, the first fastener 122 and the second fastener 134 are then rotated together such that the external threads 124 cut into the hole surface 126 of the housing 14. The first fastener 122 and the second fastener 134 are rotated together until the distal end 138 of the second fastener 134 is received within the threaded portion 60 of the receiving fastener 24 and the distal end 130 of the first fastener 122 engages the vehicle body structure 12, as Figure 13C shown. In one example, the receiving fastener 24 includes a U-shaped nut as described above.

[0078] In one example, one or more split tabs 160 cooperate with the distal end 138 of the second fastener 134, as Figure 14A shown. The tabs 160 prevent the fastener 134 from passing all the way through until it rotates within the self-tapping insert. Once the tolerance gap is completed, the tabs 160 separate to allow the fastener 134 to pass through, as Figure 14B shown.

[0079] The present disclosure provides a tolerance compensator that is a simple and lightweight design and that can be easily integrated into a main component assembly (e.g., a headlamp). Compared with existing designs, the tolerance compensator of the present disclosure has a reduced number of parts and can be integrated into the injection molds of many plastic components on a vehicle.

[0080] The foregoing description is exemplary in nature and not restrictive. Changes and modifications to the disclosed examples may become apparent to those skilled in the art, and such changes and modifications do not necessarily depart from the nature of the present disclosure. Accordingly, the scope of protection conferred on the present disclosure can be determined only by studying the appended claims.

[0081] According to the present invention, there is provided an assembly having: a housing having an inner bore defined by a hole surface; a fastener insertable within the inner bore; a receiving portion within a vehicle body structure having an opening aligned with the inner bore; and wherein the fastener includes threads that cut into the hole surface as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving portion, or wherein the fastener cooperates with an insert positioned within the inner bore to secure the housing to the vehicle body structure via the receiving portion.

[0082] According to an embodiment, the inner bore includes a threaded hole, and wherein the insert includes a threaded outer surface that threadedly engages the threaded hole via a threaded interface such that rotation of the fastener causes the insert to rotate until the head of the insert abuts the vehicle body structure.

[0083] According to an embodiment, the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein the insert includes a plurality of thread grippers that extend radially inwardly from the inner surface to engage external threads on the fastener.

[0084] According to an embodiment, the head of the insert is in an initial position spaced apart from the body structure by a clearance, and wherein the fastener engages the plurality of thread grippers, causing the insert to rotate via the threaded interface between the insert and the housing to move the insert to a final position where the clearance is eliminated and the head of the insert abuts the body structure.

[0085] According to an embodiment, the receiving portion includes a receiving fastener, and wherein when the insert is in the final position, the fastener rotates through the insert such that the distal end of the fastener is received within the opening of the receiving fastener to secure the housing to the body structure.

[0086] According to an embodiment, the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein the fastener includes a self-tapping fastener that cuts into the inner surface to rotate the insert relative to the housing.

[0087] According to an embodiment, the receiving portion includes a receiving fastener, and wherein the head of the insert is in an initial position spaced apart from the body structure by a clearance, and wherein the self-tapping fastener rotates the insert to a final position where the clearance is eliminated and the head of the insert abuts the body structure, and wherein the fastener rotates through the insert such that the distal end of the fastener extends beyond the insert.

[0088] According to an embodiment, the insert includes a first anti-rotation feature that mates with a second anti-rotation feature on the housing to prevent the insert from rotating out of the housing in a first condition, and wherein in a second condition, the rotational force of the fastener within the insert overrides the first and second anti-rotation features to attach the housing to the body structure.

[0089] According to an embodiment, the fastener may be selected between a first fastener having at least a first size and a second fastener having a second size different from the first size, and wherein the insert includes an inner surface defining an insert bore that extends from the head to the distal end of the insert, and wherein the insert bore includes a first internal feature for receiving the first fastener and a second internal feature for receiving the second fastener.

[0090] According to an embodiment, the fastener includes threads cut into the bore surface.

[0091] According to an embodiment, the fastener extends from a head to a distal end, and wherein the fastener includes a first body portion extending from the head and a second body portion extending from the first body portion to the distal end, wherein the first body portion is defined by a first diameter and the second body portion is defined by a second diameter less than the first diameter, and wherein the threads include a first set of threads formed on the first body portion and a second set of threads formed on the second body portion.

[0092] According to an embodiment, the receiving portion includes receiving the fastener, and wherein as the fastener rotates within the inner bore, the first set of threads cuts into the bore surface and the second set of threads threadedly engages the opening in the receiving fastener.

[0093] According to an embodiment, the fastener includes a shoulder between the first body portion and the second body portion, and wherein the fastener rotates from an initial position in which the shoulder is spaced apart from the body structure by a gap to a final position in which the shoulder abuts the body structure to eliminate the gap.

[0094] According to an embodiment, the fastener includes a first fastener, and the threads include external threads, and wherein the first fastener includes a bore extending from the head of the first fastener to the distal end of the first fastener, and wherein the bore includes internal threads for mating with a second fastener.

[0095] According to an embodiment, the second fastener extends from a head to a distal end, and wherein the second fastener is screwed into the bore of the first fastener until the head of the second fastener abuts the head of the first fastener, and wherein the first fastener and the second fastener are then rotated together such that the external threads cut into the bore surface of the housing.

[0096] According to an embodiment, the receiving portion includes a receiving fastener, and wherein the first fastener and the second fastener rotate together until the distal end of the second fastener is received within the opening of the receiving fastener and the distal end of the first fastener engages the vehicle body structure.

[0097] According to the present invention, a method includes: inserting a fastener into a bore in a housing, wherein the bore is defined by a bore surface; providing a receiving portion for a vehicle body structure such that an opening in the receiving portion is aligned with the bore; and cutting the bore surface with external threads on the fastener as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving portion, or positioning an insert within the bore to cooperate with the fastener to secure the housing to the vehicle body structure via the receiving portion.

[0098] In one aspect of the present invention, the method includes positioning the insert within the bore, and wherein the bore includes a threaded bore and wherein the insert includes a threaded outer surface that threadably engages the threaded bore via a threaded interface, and the method includes rotating the fastener to cause the insert to rotate until the head of the insert abuts the vehicle body structure.

[0099] In one aspect of the present invention, the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein: the insert includes a plurality of thread grippers that extend radially inwardly from the inner surface to engage external threads on the fastener, or the fastener includes a self-tapping fastener.

[0100] In one aspect of the present invention, the receiving portion includes a receiving fastener, and the method includes cutting the bore surface with external threads on the fastener as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving fastener.

Claims

1. An assembly, comprising: a housing having an inner bore defined by a bore surface; a fastener capable of being inserted into the inner bore; a receiving portion within a body structure, the receiving portion having an opening aligned with the inner bore; and wherein the fastener includes threads that cut into the bore surface as the fastener rotates relative to the housing to secure the housing to the body structure via the receiving portion, or wherein the fastener cooperates with an insert positioned within the inner bore to secure the housing to the body structure via the receiving portion.

2. The assembly according to claim 1, wherein the inner bore includes a threaded bore, and wherein the insert includes a threaded outer surface that threadedly engages the threaded bore via a threaded interface such that rotation of the fastener causes rotation of the insert until a head of the insert abuts the body structure.

3. The assembly according to claim 2, wherein the insert includes an inner surface that defines an insert bore extending from the head to a distal end of the insert, and wherein the insert includes a plurality of thread grippers that extend radially inwardly from the inner surface to engage external threads on the fastener.

4. The assembly according to claim 3, wherein the head of the insert is in an initial position spaced apart from the body structure by a gap, and wherein the fastener engages the plurality of thread grippers, thereby causing the insert to rotate via the threaded interface between the insert and the housing to move the insert to a final position where the gap is eliminated and the head of the insert abuts the body structure, and optionally, wherein the receiving portion includes a receiving fastener, and wherein when the insert is in the final position, the fastener rotates through the insert such that a distal end of the fastener is received within the opening of the receiving fastener to secure the housing to the body structure.

5. The assembly according to claim 2, wherein the insert includes an inner surface that defines an insert bore extending from the head to a distal end of the insert, and wherein the fastener includes a self-tapping fastener that cuts into the inner surface to rotate the insert relative to the housing, and optionally, wherein the receiving portion includes a receiving fastener, and wherein the head of the insert is in an initial position spaced apart from the body structure by a gap, and wherein the self-tapping fastener rotates the insert to a final position where the gap is eliminated and the head of the insert abuts the body structure, and wherein the fastener rotates through the insert such that a distal end of the fastener extends beyond the insert.

6. The assembly according to claim 2, wherein the insert includes a first anti-rotation feature that mates with a second anti-rotation feature on the housing to prevent the insert from rotating out of the housing in a first condition, and wherein in a second condition, the rotational force of the fastener within the insert overrides the first and second anti-rotation features to attach the housing to the body structure.

7. The assembly according to claim 2, wherein the fastener is selectable between a first fastener having at least a first size and a second fastener having a second size different from the first size, and wherein the insert includes an inner surface defining an insert bore that extends from the head to the distal end of the insert, and wherein the insert bore includes a first internal feature for receiving the first fastener and a second internal feature for receiving the second fastener.

8. The assembly according to claim 1, wherein the fastener includes threads cut into the bore surface, and wherein the fastener extends from a head to a distal end, and wherein the fastener includes a first body portion extending from the head and a second body portion extending from the first body portion to the distal end, wherein the first body portion is defined by a first diameter and the second body portion is defined by a second diameter less than the first diameter, and wherein the threads include a first set of threads formed on the first body portion and a second set of threads formed on the second body portion.

9. The assembly according to claim 8, wherein the receiving portion includes a receiving fastener, and wherein as the fastener rotates within the inner bore, the first set of threads cuts into the bore surface and the second set of threads threadably engages the opening in the receiving fastener, and optionally, the fastener includes a shoulder between the first body portion and the second body portion, and wherein the fastener rotates from an initial position where the shoulder is spaced apart from the body structure by a gap to a final position where the shoulder abuts the body structure to eliminate the gap.

10. The assembly according to claim 8, wherein the fastener includes a first fastener and the threads include external threads, and wherein the first fastener includes a bore extending from the head of the first fastener to the distal end of the first fastener, and wherein the bore includes internal threads for mating with a second fastener.

11. The assembly according to claim 10, wherein the second fastener extends from a head to a distal end, and wherein the second fastener is screwed into the bore of the first fastener until the head of the second fastener abuts the head of the first fastener, and wherein the first fastener and the second fastener are then rotated together such that the external threads cut into the bore surface of the housing.

12. The assembly according to claim 11, wherein the receiving portion includes a receiving fastener, and wherein the first fastener and the second fastener rotate together until the distal end of the second fastener is received within the opening of the receiving fastener and the distal end of the first fastener engages the vehicle body structure.

13. A method comprising: inserting a fastener into a bore in a housing, wherein the bore is defined by a bore surface; providing a receiving portion for a vehicle body structure such that an opening in the receiving portion is aligned with the bore; and either cutting the bore surface with external threads on the fastener as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving portion, or positioning an insert within the bore to cooperate with the fastener to secure the housing to the vehicle body structure via the receiving portion.

14. The method according to claim 13, comprising positioning the insert within the bore, and wherein the bore includes a threaded bore and wherein the insert includes a threaded outer surface that threadably engages the threaded bore via a threaded interface, and the method includes rotating the fastener to cause the insert to rotate until the head of the insert abuts the vehicle body structure, and optionally, wherein the insert includes an inner surface that defines an insert bore extending from the head to the distal end of the insert, and wherein: the insert includes a plurality of thread grippers that extend radially inwardly from the inner surface to engage external threads on the fastener, or the fastener includes a self-tapping fastener.

15. The method according to claim 13, wherein the receiving portion includes a receiving fastener, and the method includes cutting the bore surface with external threads on the fastener as the fastener rotates relative to the housing to secure the housing to the vehicle body structure via the receiving fastener.

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