Elastic assembly arrangement

Abstract

Elastic joining arrangement (10) comprising: a first component (12) comprising an essentially rigid material and an opening (16) defined by an opening wall (18); an elastically deformable second component (14) comprising: a cutout section (26) comprising a neck section (32) and at least one outer bead section (34), wherein the neck section (32) is narrower than the at least one outer bead section (34) and has a neck section width (36); and an outer wall (20) of the second component (14) which is detachably engaged with the opening wall (18), wherein the elastically deformable second component (14) is arranged inside the opening (16); and a third component (24) which is detachably engaged with the cutout section (26) of the elastically deformable second component (14), wherein the elastically deformable second component (14) is configured to deform elastically in the vicinity of the cutout section (26) upon contact with an outer surface (30) of the third component (24), wherein the third component (24) is at least partially formed from an elastically deformable material and is configured to deform elastically upon contact with the cutout section (26) of the elastically deformable second component (14), and wherein the outer surface (30) of the third component (24) has a width (38) which is greater than the neck section width (36).

Description

FIELD OF THE INVENTION

[0001] The present invention relates to matable components and, more particularly, to a resilient mating assembly. BACKGROUND

[0002] Currently, components to be assembled in a manufacturing process are subject to positional variability due to the mating arrangements between the components. A common assembly involves components that are mutually positioned relative to each other by 2-way and / or 4-way male alignment features; typically, undersized structures are received in corresponding oversized male alignment features such as openings in the form of holes and / or slots. Alternatively, double-sided adhesive tape, adhesives, or welding processes can be used to join parts together.Regardless of the precise mating configuration, there is a gap between at least a portion of the alignment features designed to accommodate the expected size and positional variation tolerances of the mating features as a result of manufacturing (or production) variations. As a result, significant positional variation between the mated components is possible, which can contribute to the presence of undesirably large and varying gaps and otherwise poor fit. The gap between the alignment and attachment features can lead to relative movement between mated components, contributing to poor quality perception. Additional undesirable effects include, for example, squeaking and rattling of the mated components.

[0003] US 4,158,511 A describes an elastic joining assembly comprising a first component comprising a rigid material and an opening defined by an opening wall, an elastically deformable second component, and a third component. An outer wall of the second component releasably engages the opening wall of the first component such that the second component is disposed within the opening. The third component releasably engages a cutout portion of the second component. Further, the second component is configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component.

[0004] US 2 946 612 A describes a similar elastic joining arrangement.

[0005] A similar elastic joining arrangement is also described in US 5 513 603 A.

[0006] US 3 248 995 A also describes a similar elastic joining arrangement.

[0007] US 5 580 204 A also describes a similar elastic joining arrangement.

[0008] US 5 538 079 A describes a heat exchanger in which several tubes are arranged in a cutout of a respective elastic component, which in turn is arranged in a respective opening of a head plate.

[0009] An object of the invention is to provide an elastic joining assembly in which undesirable effects such as squeaking and rattling due to relative movement of components of the joining assembly are suppressed. SUMMARY OF THE INVENTION

[0010] This object is achieved by an elastic joining arrangement having the features of claim 1.

[0011] In an exemplary embodiment, an elastic joining assembly includes a first component comprising a substantially rigid material and an opening defined by an opening wall. The assembly also includes an elastically deformable second component having a cutout portion. The elastically deformable second component also includes an outer wall of the second component releasably engaged with the opening wall, the second component being disposed substantially within the opening. The elastic joining assembly further includes a third component releasably engaged with the cutout portion of the elastically deformable second component, the elastically deformable second component being configured to elastically deform proximate the cutout portion upon contact with an outer surface of the third component.

[0012] In another exemplary embodiment, a method for elastically assembling matable components is provided. The method includes engaging a first component comprising a substantially rigid material with an elastically deformable second component comprising an elastically deformable material proximate an opening wall of the first component. The method also includes inserting a third component into a cutout portion of the elastically deformable second component, wherein the elastically deformable second component and the third component form a contact engagement proximate an outer surface of the third component and a cutout portion edge of the cutout portion.The method further includes elastically deforming the elastically deformable second component near the cutout portion edge of the cutout portion upon contact with the outer surface of the third component. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Further features, advantages and details appear only by way of example in the following detailed description of embodiments, which detailed description refers to the drawings in which: Fig. Figure 1 is a plan view of an elastic joining arrangement; Fig. 2 is a cross-sectional view taken along line 2-2 illustrating engagement between a first component and a second component of the elastic joining assembly; Fig. Figure 3 is a perspective view of the engagement between the second component and a third component of the elastic joining assembly; Fig. 4 is a plan view of the engagement between the second component and the third component in accordance with another aspect of the invention; and Fig. 5 is a flow diagram illustrating a method for elastically assembling matable components of the elastic assembly. DESCRIPTION OF THE EMBODIMENTS

[0014] In Fig. 1 and Fig. 2, an elastic joining assembly 10 is illustrated. The elastic joining assembly 10 includes matable components, such as a first component 12 and an elastically deformable second component 14, configured to engage one another. In one embodiment, the elastic joining assembly 10 is utilized in a vehicle application. However, it should be appreciated that the components may be associated with numerous other applications and industries, such as, for example, appliance and aerospace applications.

[0015] The first component 12 is formed from a substantially rigid material, such as, for example, a sheet metal, while the elastically deformable second component 14 is formed at least partially from an elastically deformable material, which is described in detail below. The elastically deformable nature of the elastically deformable second component 14 provides an insert that provides a compliant interface for indirectly joining or coupling components to the first component 12.

[0016] In an engaged position, the elastically deformable second component 14 is disposed substantially within an opening 16 of the first component 12, which is defined by an opening wall 18. The elastically deformable second component 14 includes an outer second component wall 20 that engages the first component 12 proximate the opening wall 18. The engagement between the first component 12 and the elastically deformable second component 14 may be facilitated by numerous contemplated coupling structures that provide releasable engagement between the components. One such structure includes a tongue and groove arrangement. As shown in Fig. 2, the outer wall 20 of the second component includes a circumferential recess 22 extending around the outer wall 20 of the second component, the circumferential recess 22 being configured to snugly receive the aperture wall 18 therein. Alternatively, the aperture wall 18 of the first component 12 may include a recess configured to snugly receive at least a portion of the outer wall 20 of the second component therein. Either configuration, or a combination thereof, provides a "snap" engagement between the first component 12 and the elastically deformable second component 14.As noted above, it is contemplated that the elastically deformable second component 14 is releasably engaged within the opening 16 of the first component 12, thereby providing interchangeable flexibility between inserted elastically deformable second components as well as the ability to incorporate the elastically deformable second component 14 into existing first components as an add-on feature.

[0017] Based on Fig. 3, the elastically deformable second component 14 is used as an intermediate piece between the first component 12 ( Fig. 1) and a third component 24 to be mated and aligned with the first component 12. More specifically, the third component 24 is a plug-in portion that can extend from numerous structures or components (not shown) to be mated and aligned with the first component 12.

[0018] The elastically deformable second component 14 includes a cutout portion 26 defined by a cutout portion edge 28. The cutout portion 26 is configured to engage and receive the third component 24. In particular, upon insertion of the third component 24 into the cutout portion 26 of the elastically deformable second component 14, the cutout portion edge 28 engages an outer surface 30 of the third component 24. The cutout portion 26 can be formed in numerous shapes and at various positions on the elastically deformable second component 14. In the illustrated embodiment, the cutout portion 26 includes a neck portion 32 and at least one outer bead portion 34. The neck portion 32 is narrower than the at least one outer bead portion 34 and includes a neck portion width 36 ( Fig. 4).

[0019] The third component 24 can be formed in numerous geometries and, in the illustrated embodiment, comprises a substantially tubular member that can be solid or that can include a hollow portion therein. Regardless of the precise geometry of the third component 24, the third component 24 includes an outer surface width 38 that is greater than a neck portion width 36. Although reference is made to a single elastically deformable second component and a single third component, embodiments of the elastic joining assembly 10 include a plurality of elastically deformable second components and a plurality of third components, as described in detail below.

[0020] As will be appreciated from the description provided herein, the elastically deformable nature of the elastically deformable second component, along with the particular orientations described above, enables the precise alignment of the third component 24 (and any structures or components attached thereto) relative to the first component 12 by accounting for the positional variation of the retention and / or locating features of the first component 12 and / or the third component 24 inherent in manufacturing processes. The self-alignment advantages associated with the elastic joining assembly 10 are described further below.

[0021] Upon translation of the third component 24 toward the elastically deformable second component 14 and the first component 12, the third component 24 is positioned and engaged with the cutout portion 26 of the elastically deformable second component 14. More specifically, the outer surface 30 of the third component 24 engages the cutout portion edge 28 proximate the neck portion 32. Subsequent translation results in elastic deformation of the elastically deformable second component 14. As noted above, the neck portion width 36 is more specifically smaller than the outer surface width 38, thereby ensuring contact between the third component 24 and the neck portion 32 of the elastically deformable second component 14.

[0022] In another embodiment ( Fig. 4), the third component 24 is also formed at least partially from an elastically deformable material. In such an embodiment, the third component 24 is configured to elastically deform upon contact with the cutout portion 26 of the elastically deformable second component 14.

[0023] Any suitable elastically deformable material may be used for the elastically deformable second component 14, as well as for the third component 24 in an elastically deformable embodiment. The term "elastically deformable" refers to components or portions of components, including component features, comprising materials with generally elastic deformation properties, wherein the material is configured to undergo an elastically reversible change in its shape, size, or both in response to the application of a force. The force causing the elastically reversible or elastic deformation of the material may include a tensile force, a compressive force, a shear force, a bending force, or a torsional force, or various combinations of these forces. The elastically deformable materials may undergo linear elastic deformation, e.g.,one described in accordance with Hooke's law or exhibit a nonlinear elastic deformation.

[0024] Numerous examples of materials that may at least partially form the components include various metals, polymers, ceramics, inorganic materials, or glasses, or composites of any of the aforementioned materials, or any other combinations thereof. Many composite materials are contemplated, including various filled polymers, including polymers filled with glass, ceramics, metal, and an inorganic material, particularly polymers filled with glass, metal, ceramics, inorganic fibers, or carbon fibers. Any suitable filler morphology may be utilized, including all shapes and sizes of particles and fibers. In particular, any suitable fiber type may be used, including continuous and discontinuous fibers, woven and nonwoven fabrics, felts, or tows, or a combination thereof.Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium, or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers and thermosetting polymers, or composites thereof, or any other combinations thereof, including a wide variety of copolymers and polymer blends. In one embodiment, a preferred plastic material is one with elastic properties such that it deforms elastically without fracture, such as a material comprising an acrylonitrile-butadiene-styrene (ABS) polymer, particularly a polycarbonate-ABS (PC / ABS) polymer blend such as ABS-acrylic.The material may have any shape and be formed or manufactured by any suitable process, including stamped or formed sheet metal, composite sheets or other plates, forgings, extruded parts, pressings, castings, or molded parts, and the like, to incorporate the deformable features described herein. The material or materials may be selected to provide a predetermined elastic response of the elastically deformable second component 14 and the third component 24, if elastically deformable. The predetermined elastic response may include, for example, a predetermined elastic modulus.

[0025] The exact position at which engagement occurs between the outer surface 30 and the cutout portion 26 varies depending on the positional variation imposed by manufacturing factors. Due to the elastic deformability properties of the elastic material from which the elastically deformable second component 14 is made, the initial location of engagement is made less critical. Further insertion of the third component 24 into the cutout portion 26 eventually results in a fully engaged position of the third component 24. In the fully engaged position, a close, fitting engagement between the third component 24 and the first component 12 is achieved through contact engagement between the outer surface 30 and the cutout portion edge 28. Such a condition is ensured by dimensioning the outer surface width 38 greater than the neck portion width 36.The engagement between the third component 24 and the cutout portion 26 causes elastic deformation in the vicinity of the cutout portion 26 and the third component 24, regardless of whether the third component 24 is made of an elastically deformable material. The formability of the materials reduces problems associated with positional fluctuation.

[0026] In one embodiment, the first component 12 may include a plurality of openings configured to receive a plurality of elastically deformable second components. A plurality of third components may also be included. The plurality of third components may be releasably engaged with a single cutout portion of a single elastically deformable second component and / or may be releasably engaged within different cutout portions of the plurality of elastically deformable second components. The elastic deformation of the plurality of elastically deformable second components elastically averages out any positional errors of the first component 12 and the third component 24, in other words, gaps and / or misalignment that would otherwise be present due to positional errors associated with portions or segments of the first component 12 and the third component 24, particularly with locating and retaining features.More specifically, the positional variation of each third component 24 is compensated by the remaining third components to average the positional variation of each component as a whole. Elastic averaging provides elastic deformation of the interface(s) between mated components, with the average deformation providing accurate alignment, with the manufacturing positional variation being limited to X. min , defined by Xmin=X / N, where X is the manufacturing position variation of the location features of the mated components and N is the number of inserted features. To achieve elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that are overconstrained and provide an interference fit with a mating feature of another component and its contact surface(s). The overconstrained condition and the interference fit resiliently reversibly (elastically) deform at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components enables repeatable insertion and removal of the components, facilitating assembly and disassembly.The positional fluctuation of the components can result in varying forces being exerted across regions of the contact surfaces that are over-determined and engaged during insertion of the component in an engagement condition. It will be appreciated that a single inserted component can be elastically averaged with respect to a length of the component's circumference. The principles of elastic averaging are described in detail in US 2013 / 0019455 A1. The embodiments disclosed above provide the capability of converting an existing component that is incompatible with the elastic averaging principles described above into an arrangement that enables elastic averaging and the associated benefits.

[0027] As in Fig. 5 and based on Fig.1-4, a method for elastically assembling matable components 100 is also provided. The elastically matable assembly 10, and more particularly, the elastically deformable nature of the elastically deformable second component 14, have been described above, and specific structural components need not be described in detail. The method 100 includes establishing an engagement 102 of the first component 12 with the elastically deformable second component 14 proximate the opening wall 18 of the first component 12. The method 100 also includes inserting 104 the third component 24 into the cutout portion 26 of the elastically deformable second component 14, wherein the elastically deformable second component 14 and the third component 24 form a contact engagement proximate the outer surface 30 of the third component 24 and the cutout portion edge 28.The method 100 further includes elastically deforming 106 the elastically deformable second component 14 proximate the cutout portion edge 28 of the cutout portion 26 in contact with the outer surface 30 of the third component 24.

Claims

[1] Elastic joining arrangement (10) comprising: a first component (12) comprising a substantially rigid material and an opening (16) defined by an opening wall (18); an elastically deformable second component (14) comprising: a cutout portion (26) having a neck portion (32) and at least one outer bead portion (34), wherein the neck portion (32) is narrower than the at least one outer bead portion (34) and has a neck portion width (36); and an outer wall (20) of the second component (14) releasably engaging the opening wall (18), the elastically deformable second component (14) being disposed within the opening (16); and a third component (24) releasably engaged with the cutout portion (26) of the elastically deformable second component (14), wherein the elastically deformable second component (14) is configured to elastically deform proximate the cutout portion (26) upon contact with an outer surface (30) of the third component (24), wherein the third component (24) is formed at least partially from an elastically deformable material and is configured to elastically deform upon contact with the cutout portion (26) of the elastically deformable second component (14), and wherein the outer surface (30) of the third component (24) has a width (38) greater than the neck portion width (36). [2] The resilient joining assembly (10) of claim 1, wherein the outer wall (20) of the second component (14) includes a peripheral recess (22) configured to snugly receive the aperture wall (18) therein. [3] The resilient joining assembly (10) of claim 1, wherein the opening wall (18) of the first component (12) includes a recess configured to snugly receive the outer wall (20) of the second component (14) therein. [4] The elastic joining assembly (10) of claim 1, further comprising a contact engagement between the outer surface (30) of the third component (24) and a cutout portion edge (28) of the cutout portion (26) of the elastically deformable second component (14). [5] The elastic joining assembly (10) of claim 1, further comprising a plurality of elastically deformable second components (14) releasably engaged with the first component (12). [6] The elastic joining assembly (10) of claim 5, wherein each elastically deformable second component (14) is releasably engaged with a respective opening (16) of the first component (12).

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