COMPONENTS WITH LOOSE LAYER STRUCTURE AND VEHICLE FRONT ASSEMBLY STRATEGY

Abstract

Subassembly (118) for a vehicle front end (12), comprising: a grill (116); and a headlight assembly (62), wherein the headlight assembly (62) comprises a housing (64) carrying at least one lamp (66) and a lens (68) attached to the housing (64), wherein the lens (68) comprises at least one attribute for engaging with the grill (116); wherein the at least one attribute comprises an opening (138) formed in the lens (68).

Description

TECHNICAL AREA

[0001] This document generally concerns vehicle manufacturing and in particular a sub-assembly for a vehicle front end. GENERAL STATE OF THE ART

[0002] Conventional vehicle front-end design and construction typically utilizes independent positioning, support, and attachment features for front-end components during the assembly process. This is particularly true for visible exterior or body components such as headlight assemblies, grilles, and trim panels. This individualized approach aims to ensure the aesthetic appearance of the front-end assembly, which is known to be of high importance to the customer.

[0003] Given the importance of the aesthetic appearance of the front-end assembly, manufacturers invest considerable effort in tooling, fixtures, and labor to achieve consistent gap widths, particularly between visible body components. The installation of the headlight assembly, for example, is discreet and designed to achieve a uniform gap width and flushness between the headlight assembly and the associated fender. In other words, the positioning, carrying, and installation of headlight assemblies are performed more or less sequentially, either before or after another front-end component.

[0004] Typically, the headlight assemblies are mounted to the vehicle body relative to the already attached fenders to achieve uniform gap widths between them and flushness relative to the fenders. This uniformity and flushness are expected by the customer and are considered a sign of high build quality. Once mounted, the headlight assemblies are no longer adjustable. Therefore, the subsequent installation of another body component (e.g., the grille) is also carried out separately. The grille is positioned between the headlight assemblies and mounted to the vehicle body in such a way that the gap widths between each headlight assembly and the grille are the same. However, given the fixed positions of the headlight assemblies, the ability to achieve such uniform gap widths is limited.Ultimately, the grille is positioned to achieve the most uniform gap widths and the highest possible flushness for the given fixed positions of the headlight assemblies.

[0005] The WO 2013 / 189 064 A1 standard is known from the state of the art. This describes a sub-assembly for a vehicle front end with a grille and a pair of headlights.

[0006] Recent efforts to achieve consistency in the aesthetic appearance of the front-end assembly include modular design. Such modular design essentially involves the sub-assembly of front-end components (e.g., bumper covers, headlight assemblies, grilles, and / or other components) that can be fitted to the vehicle body in a single operation. Modular design further integrates conventionally designed front-end components in an off-line operation, often resulting in improved gap consistency, flushness, and build quality, ultimately leading to greater customer satisfaction. Furthermore, the modular design of sub-assemblies frees up space in the final assembly line and facilitates the sequencing of complex combinations of front-end components, thereby reducing overall complexity and the need for more expensive facilities such as final assembly plants.

[0007] Despite these advantages over conventional vehicle front-end design and construction / assembly, modular design typically requires more resources, factory floor space, and specialized handling tools, generating associated costs such as shipping, commercial markups, additional labor, weight, and more compared to conventional vehicle front-end design and assembly. Often, cost and / or other facility requirements alone can preclude the possibility of modular design. This can be the case even when improved build quality and attributes such as an aggressive appearance and unusual or previously unfeasible styling enhancements are desired to enable new designs to be competitive in the market.

[0008] Accordingly, there is a need for alternative approaches to vehicle front-end assembly processes. Any such processes should be applicable to any vehicle, passenger car or truck, and any vehicle body construction (e.g., unitary, body-on-frame, etc.) and should aim to enable superior build quality, a modern and aggressive appearance and unusual or previously unachievable styling improvements, ease of assembly, reduced installation time and number of attachments, positioning relationships of front-end components and subassemblies to adjacent systems, components and subassemblies, and / or improved customer satisfaction, each without the limitations associated with conventional vehicle front-end design and construction or modular design.

[0009] These improvements to vehicle front-end assembly processes necessitate further complementary improvements to the designs of vehicle front-end components and their subassemblies. Custom front-end components and / or subassemblies should incorporate combinations of hand clearance, anti-rotation, sliding or shifting, and other assembly-aiding attributes that would not be required for standard and / or modular vehicle assembly. These attributes should be an integral part of the component designs to reduce or eliminate costly assembly tooling and should allow for improved build quality and elements such as aggressive appearance or unusual or previously unfeasible styling enhancements. SUMMARY

[0010] In accordance with the purposes and advantages described herein, a subassembly for a vehicle front end is provided. The subassembly includes a grille and a headlight assembly. The headlight assembly includes a housing carrying at least one lamp and a lens attached to the housing, the lens including at least one attribute for engaging with the grille.

[0011] In one possible embodiment, at least one attribute includes an opening formed in the lens. In another, the opening extends through the housing.

[0012] In another possible embodiment, the opening is a hole with a recessed section. In yet another, the recessed section is formed in the lens and extends a distance from a surface of the lens to guide the grill.

[0013] In yet another possible embodiment, the grill restricts movement of the headlight assembly relative to the grill in a Y-axis direction.

[0014] In yet another possible embodiment, the at least one attribute includes a channel formed in the lens. In another, the at least one attribute includes at least one clamp that restricts movement of the grille relative to the headlight assembly.

[0015] In yet another possible embodiment, at least one attribute is a cavity formed in the lens to accommodate an overlapping section of the grill. In another embodiment, the cavity corresponds in shape to the overlapping section of the grill.

[0016] In yet another possible embodiment, a subassembly for a vehicle front end comprises a grille with at least one extension, a housing that carries at least one lamp, and a lens attached to the housing, the lens having at least one attribute for receiving the at least one extension.

[0017] In another possible embodiment, the at least one attribute includes a cavity having a shape corresponding to the at least one extension.

[0018] In yet another instance, the attribute "at least one" includes a cavity formed in the lens to accommodate the "at least one extension".

[0019] In yet another possible embodiment, the cavity is a channel whose shape corresponds to at least one extension.

[0020] In another possible embodiment, the at least one extension is a loop and the loop overlaps at least one section of the lens.

[0021] In another possible embodiment, a subassembly for a vehicle front end comprises a grille, a housing that carries at least one lamp, and a lens attached to the housing. The lens has at least one attribute for engaging with the grille and restricting movement of the lens relative to the grille in a Y-axis direction.

[0022] In another possible embodiment, the at least one attribute for engaging with the grill includes an opening formed in the lens. In another, the opening extends a distance from a surface of the lens to receive a pin extending from the grill.

[0023] In yet another possible embodiment, at least one attribute includes a cavity formed in the lens to accommodate an overlapping section of the grill.

[0024] In yet another possible embodiment, the housing includes at least one attribute for restricting movement of the housing in a Z-axis direction.

[0025] The following description shows and describes several preferred embodiments of the subassembly for a vehicle front end. It is understood that other different embodiments of the subassembly are possible and that its various details can be modified in several obvious aspects without deviating from the methods set forth and described in the following claims. Accordingly, the drawings and descriptions are to be considered illustrative and not limiting. BRIEF DESCRIPTION OF THE FIGURES IN THE DRAWINGS

[0026] The accompanying figures of the drawings are included herein and form part of the description. They illustrate several aspects of the process for mounting a vehicle front end to a body, as well as supplementary improvements to vehicle front end components and subassemblies. Together with the description, they serve to explain certain fundamental concepts. The figures in the drawings show: Fig. 1. A perspective view of a vehicle and a Cartesian coordinate system; Fig. 2 A perspective view of the front end of a vehicle with a hood, fenders and fender bracket, shown in a spread-out view; Fig. 3 A perspective view of the front end of a vehicle with a chassis, active grille locking flaps and a hood latch, shown in a spread-out view; Fig. 4 a perspective view of a passenger-side headlight assembly; Fig. 5 a top view of the front of a passenger-side fender; Fig. 6 a perspective partial view of a fender attribute that accommodates a headlight assembly attribute during assembly; Fig. 7 a perspective partial view of a housing attribute of the active grille locking flaps, which accommodates a passenger-side headlight assembly attribute during assembly; Fig. 8 a top view of a passenger-side headlight assembly from the rear; Fig. 9 a partial top view of a headlight assembly pin engaging with a fender support bracket, from the side; Fig. 10 a perspective view of the front end of a vehicle with a headlight assembly shown in a stretched view; Fig. 11 a perspective view of the front end of a vehicle with the grille shown in a splayed view; Fig. 12 A top view of a subassembly of the vehicle front end, comprising the headlight assemblies and the grille, from the front; Fig. 13 a top view of a passenger-side headlight assembly from the front; Fig. 14 a cross-sectional view of the passenger-side headlight assembly, which includes openings for receiving grille guide pins; Fig. 15 a top view of the housing of the active grill closure flaps from above, showing the grill and headlight assemblies in a separated view; Fig. 16 a cross-sectional view of the housing of the active grill locking flaps, which includes an opening for receiving a grill guide pin; Fig. 17 a perspective view of the front end of a vehicle with the fairing shown in an expanded view; Fig. 18 a perspective view of an assembled front end of a vehicle; and Fig. 19 a cross-sectional view of the lens of the headlight assembly.

[0027] Detailed reference will now be made to the present embodiments of the vehicle front-end components and subassemblies and associated methods for mounting a vehicle front end to a body, with examples of the same shown in the accompanying figures, in which the same reference numerals are used to represent the same elements. DETAILED DESCRIPTION

[0028] It will now be on Fig. Reference is made to Figure 1, which shows a broad perspective view of a vehicle 10. The vehicle 10 shown is an off-road vehicle used to describe an embodiment of the vehicle front-end assembly process and associated vehicle front-end components and subassemblies of these components. However, it is understood that the described process, components, and subassemblies can be used with any type of vehicle (e.g., passenger cars, pickup trucks, minivans, off-road vehicles, vans, and various types of trucks, etc.).

[0029] As in Fig. Figure 1 shows a three-dimensional Cartesian coordinate system that generally orients the vehicle 10 relative to the X, Y, and Z directions. The coordinate system includes an origin O and X, Y, and Z axis lines oriented as indicated by the arrows. The X axis generally represents an X-axis direction along a longitudinal extent of the vehicle, the Y axis generally represents a Y-axis direction across a width of the vehicle, and the Z axis generally represents a Z-axis direction along a vertical extent of the vehicle.

[0030] Throughout this description, reference is made to the X-axis direction, the Y-axis direction, and the Z-axis direction, which generally correspond to the X, Y, and Z directions of the coordinate system. For example, the phrase "restricted in the X-axis direction" indicates a restriction of movement along a vehicle's length. The same applies to restrictions in the Y-axis and Z-axis directions. These restrictions can be absolute, in which case no movement is permitted in the identified direction, or they can be limited, in which movement is permitted within certain limits or tolerances (defined, specified, or otherwise) in the identified direction. Similarly, the phrase "an X-axis positioner" refers to any attribute of a component, whether an exterior body component or otherwise, that restricts movement in the X-axis direction.Examples of such attributes include surfaces of components, openings including slots, holes, countersunk and chamfered slots and holes, and surfaces in openings, and pins, tabs, lugs, notches, burrs, etc.

[0031] Reference is now made to Fig. Figure 2 shows an expanded view of part of a vehicle front end 12 of the vehicle 10. As shown, the vehicle front end 12 includes a section of an A-pillar 14, a firewall 16, a body shell 18, opposing hydroformed brackets 20, a support bracket 22 connected between the hydroformed brackets, and a hood 24 supported by the body shell. Although not shown, the vehicle body shell 18 typically also supports a windshield, dashboard, and instrument panel while separating the passenger compartment from the engine compartment.

[0032] During the assembly of the vehicle front end 12, a right and left fender 26 are attached at different points. The left fender 26 is not shown in this figure for clarity. Brackets, including bracket 28 and a fender nose bracket 30, are attached to the hydroformed fixtures 20 and serve as Z-axis positioners to limit movement of the fender 26 in the Z-axis direction. The fenders 26 are also attached along a surface of the hydroformed fixtures 20. The tab 32, for example, is attached adjacent to the A-pillar 14, and the tab 34 is attached directly to the A-pillar.As shown, at least the tab 32 adjacent to the A-pillar 14 is used as an X-axis positioner to limit movement in the X-axis direction and to enable positioning of the fender 26 relative to a door (not shown) of the vehicle 10 in order to achieve a uniform spacing or gap width and flushness between them. A bracket 36 serves to connect a lower front section of the fender 26 to a lower front section of the hydroforming bracket 20. In the described embodiment, the bracket 36 is mounted between the hydroforming bracket 20 and a fender reinforcement bracket 38.

[0033] What's next in Fig. As shown in Figure 2, a radiator hood 24 is also attached at various points on the front end 12 of the vehicle. More precisely, the radiator hood 24 is attached to the bodywork 18 by means of a pair of hinges 38, as is known. Although shown in an extended and open position (raised at approximately a 45° angle), the radiator hood 40 is positioned during assembly to achieve a uniform distance and flushness between the radiator hood and the fenders 26. To achieve correct positioning prior to installation, an installation fixture (not shown) uses reference positioners 42 in the hydroformed holders 20.The positioners 42 include 2-way and 4-way positioners that restrict movement in the X-axis and / or Y-axis direction and allow the radiator hood 24 to be positioned so that there is a uniform distance and flushness between the radiator hood and the fenders 26 when the radiator hood is in the fitted and closed position.

[0034] As in Fig. As shown in Figure 3, further components, including a cooling module assembly 44, are attached at various mounting points on the vehicle front end 12. In the described embodiment, the cooling module assembly 44 comprises a chassis 46, an assembly 48 with active grille shutters (AGS), a cooling pack (not shown), and a hood latch 50. The AGS assembly 48 comprises an AGS housing 52, a plurality of shutters 54, and control and activation mechanisms, which are not shown for clarity. Although an AGS assembly 48 is used to describe the vehicle front-end assembly method, the invention is not limited to vehicles with an AGS assembly. For such vehicles, attributes of the AGS housing 52 used in the assembly methods and described in detail below can be provided by other components.For example, a chassis or a fairing support member may incorporate some or all of the attributes of the AGS housing in alternative embodiments.

[0035] Furthermore, the cooling pack can take various forms depending on the type of vehicle it is installed in. A typical cooling pack includes a radiator, a condenser, and related components, while electric and hybrid vehicles, for example, may incorporate different variations of heat exchangers and components. These cooling pack components can be selected and combined in any way known in the field, depending on the vehicle's heating, ventilation, and air conditioning requirements.

[0036] To understand the vehicle front-end assembly process described here, the primary component of the cooling module assembly 44 used to describe the assembly process is the AGS housing 52. Like several other front-end components, the AGS housing 52 includes certain attributes that are used as positioners during the assembly process. The remaining components of the cooling module assembly 42 are less important in the described assembly process, but may themselves contain attributes in alternative assembly processes.

[0037] Although the chassis is 46 in Fig. As shown in Figure 3, the chassis 46 is positioned away from the front end 12 of the vehicle and is attached to the hydroforming fixtures 20 by means of positioners. The positioners include 2-way and 4-way positioners 56, which restrict movement in the X-axis and Y-axis directions. A surface 58 on the underside of the chassis 46 serves as a Z-axis positioner, further restricting its movement in the Z-axis direction. Before the chassis 46 is attached to the hydroforming fixtures 20, the AGS assembly 48 is mounted to the chassis using a Y-axis positioner 60. The Y-axis positioner 60 centers the AGS assembly 48 on the chassis 46.

[0038] In the described method for mounting the vehicle front end 12, the outer skin components or visible components are supported by at least one non-skin component or non-visible component, such that a first skin component is movable relative to the non-skin component(s). For example, the headlight assemblies 62, i.e., skin components, are supported relative to the cooling module assembly 44, i.e., a non-skin component, and the fenders 26, i.e., skin components, such that movement of the headlight assemblies in the X-axis and Z-axis directions is restricted. In this way, the headlight assemblies 62 can move freely in the Y-axis direction while being supported and before they are attached to the vehicle front end 12.Since the right and left headlight assemblies 62 are identical, the further description of the assembly procedure focuses on the right or passenger-side headlight assembly of the vehicle, it being understood that the same description also applies to the left or driver-side headlight assembly.

[0039] As in Fig. As shown in Figure 4, the headlight assembly 62 includes typical features such as a housing 64, lamps 66, and a lens 68. However, the headlight assembly 62 in the described embodiment also includes certain attributes that restrict movement of the headlight assembly 62 in one or more directions during assembly. As noted above, these attributes can include external surfaces of components, openings (including slots, holes, countersunk and chamfered slots and holes), surfaces in openings, and pins, brackets, tabs, notches, burrs, etc. Certain of these attributes serve to support the headlight assembly 62 and restrict its movement during the assembly process.This allows the headlight assembly 62 to be initially supported in its position relative to the fender 26 and the cooling module assembly 44, while allowing movement to align the headlight assembly with a grille 70 and corresponding fender 26. These attributes can vary for different vehicles, including, for example, vehicles that do not use an AGS assembly. Furthermore, other headlight assembly attributes are used to support, position, engage, and / or constrain the movement of other components during the assembly process, as described in more detail below.

[0040] Similar to the headlight assembly 62, the fenders 26 and the AGS housing 50 each include attributes that support the headlight assembly 62 and / or restrict its movement. In the described embodiment, these attributes support the headlight assembly 62 and prevent it from rotating and / or detaching from the vehicle 10 during assembly. As suggested above, the headlight assembly 62 is supported relative to the fenders 26 and the cooling module assembly 44. In the described embodiment, four attributes of the headlight assembly 62, in combination, support the headlight assembly, restrict its movement, and align it with at least one of the fenders 26, the radiator hood 24, and / or the cooling module assembly 44. Of course, in alternative embodiments according to the invention, additional or fewer attributes can be used.

[0041] To align the headlight assembly 62 with the fender 26, a pin 72, hereinafter referred to as a detent pin, extends from a rear side of the headlight assembly housing 64. The detent pin 72 includes a hexagonal base for driving a threaded extension into the housing 64 to secure the detent pin thereto. As best as in Fig. As shown in Figure 7, the locking bolt 72 extends further from the housing 64 than the other individual attributes. Accordingly, the locking bolt 72 is the first attribute to engage with the vehicle front end 12 during assembly. More precisely, the locking bolt 72 engages with a first attribute of the fender 26 and performs an initial alignment of the headlight assembly 62.

[0042] As stated above and best in Fig. As shown in Figure 5, the fender 26 includes a first attribute that serves as a Z-axis positioner. In the described embodiment, the first fender attribute includes a projection 74 that extends from an inner surface of the fender 26 generally in the Y-axis direction to the center of the vehicle 10. The projection 74 can be formed in one piece or otherwise and includes a slot that has a feedthrough seal 76 with a similarly shaped slot 78 for receiving the detent pin 72 during assembly. The feedthrough seal slot 78 can include a chamfer to provide further assistance in positioning the slot with the detent pin 72 or otherwise.

[0043] As in Fig. As shown in Figure 6, the feedthrough seal 76 is designed to include a ridge 80 in the slot 78. In the described embodiment, the ridge 80 extends inwards on all four sides of the slot 78 and is designed to temporarily engage the locking pin 72 after it is inserted into the feedthrough seal 76. As shown, the locking pin 72 includes a head 82, a neck 84, and a base 86. After insertion, as shown by action arrow A, the head 82 is engaged behind the feedthrough seal ridge 80 and secured in position by the ridge adjacent to the neck 84. It should be noted that this arrangement is sufficient to support the headlight assembly but also allows the locking pin to be removed from the feedthrough seal by pulling the headlight assembly 62 in the opposite direction during assembly, if necessary.The headlight assembly 62 will be permanently attached to the front end 12 of the vehicle in a later step of the process.

[0044] In addition to temporarily engaging the locking pin 72 and supporting the headlight assembly 62, the feedthrough seal slot 78 acts as a Z-axis positioner for the headlight assembly, preventing movement in the Z-axis direction. Furthermore, the slot 78 allows the locking pin 72, and thus the headlight assembly 62, to move in the Y-axis direction within the slot for subsequent alignment with other components, including the fender 26 and / or other body components. After the locking pin 72 is inserted into its position in the feedthrough seal 76, another feature of the headlight assembly 62 engages with the vehicle front end 12, essentially suspending and securing the headlight assembly in its position while still allowing movement in the Y-axis direction.

[0045] As in Fig. As shown in Figure 7, the second attribute of the headlight assembly 62 is a bracket 88, which in the described embodiment is generally referred to as a self-locking bracket. In the described embodiment, the self-locking bracket 88 is formed integrally with the headlight assembly housing 64 and generally extends in the X-axis direction from a rear surface of the housing 64. The housing 64 is a molded plastic or similar material, and the bracket 88 is thinly formed so that it bends from a normal or rest position into a curved position during assembly. This allows the bracket 88 to move over a first attribute of the AGS housing 52 during assembly and then engage with it.

[0046] In the described embodiment, the first AGS housing attribute is a receptacle 92 formed integrally with the AGS housing 52. The receptacle 92 includes an upwardly extending tab 94. When the headlight assembly 62 is installed, a distal end of the bracket 88 moves upward and over the tab 94 until the tab is aligned with a first opening 96 formed in the bracket. At this point, the tab 94 is engaged in the first opening 96, which is generally rectangular in shape. This allows the bracket 88 to return to its normal, unmoved position. In this position, the tab 94 extends through the first opening 96 and loosely secures or suspends the headlight assembly 62 in its position.In addition to supporting the headlight assembly 62, the first opening 96 is dimensioned to allow movement of the tab 94 within it, which permits the headlight assembly to move in the Y-axis direction for later alignment with other components.

[0047] In the described embodiment, a guide pin 98 provides further alignment of the headlight assembly 62 during assembly. As shown in Fig. As shown in Figure 8, the guide pin 98 extends from a first projection 100 of the headlight assembly housing 64. In the described embodiment, the pin 98 is a one-piece formed star pin which, together with the first projection 100, forms the third attribute of the headlight assembly 62. In the described embodiment, the first projection 100 is also one-piece formed with the headlight assembly housing 64.

[0048] The guide pin 98 engages during assembly with a slot 102 formed in a first surface 104 of the AGS housing 50 (best shown in Fig. 7 and Fig. 10) The slot 102 is a second AGS housing attribute and serves as a Z-axis positioner, further preventing movement of the headlight assembly 62 in the Z-axis direction. Although no chamfer is provided in the described embodiment, the slot 102 can include a chamfer to provide further assistance in guiding the pin 98 into the slot. As with other attributes, the slot 102 allows the headlight assembly 62 to move within the slot in the Y-axis direction for subsequent alignment with other components.

[0049] A pin 106, which engages with a second attribute of the fender 26 and serves as a Z-axis positioner, further prevents the movement of the headlight assembly 62 in the Z-axis direction. As in Fig. 9 shown (perhaps best shown in Fig. 4) The pin 106 extends from a lower outboard section of the headlight assembly 62. In the described embodiment, the fender 26 includes a fish-mouth opening 108 for receiving the pin 106. Furthermore, the fender reinforcement bracket 38 can include a corresponding or even narrower fish-mouth opening 110 than shown, which, together with the fender fish-mouth opening 108, receives the pin 106. Both openings are rounded at their open edges to guide the pin 106 during assembly.

[0050] After the intervention, the pin 106 and / or the fish-mouth opening 108 prevents movement of the headlight assembly 62 in the Z-axis direction. As shown, the pin 106 is designed to extend beyond an outer surface of at least the fender reinforcement bracket 38 and / or the fender 26 to allow movement of the headlight assembly 20 in the Y-axis direction for subsequent alignment with other components, including the fender and / or other body components. The designed extension is sufficient to allow a desired range of movement in the Y-axis direction without loosening the fender reinforcement bracket 38 and / or the fender 26.

[0051] When the locking bolt 72, the self-locking bracket 88, the guide pin 98, and the pin 106 of the headlight assembly 62 are engaged, the movement of the headlight assembly in the X-axis direction is also restricted. In the described embodiment, which is shown in Fig. As shown in Figure 10, the first surface 104 and a second surface 114 of the AGS housing 50 are formed in one piece and both serve as X-axis positioners. Together, the surfaces position the headlight assembly 62 in the X-axis direction and help to prevent its rotation during assembly. Of course, independent surfaces for positioning the headlight assembly 62 in the X-axis direction can be added to the AGS housing 50, or in alternative embodiments, additional one-piece AGS surfaces or spacers can be used.

[0052] At this stage of the described assembly process, the chassis 46 is attached to the hydroformed brackets 20, the cooling module assembly 44 is attached to the chassis, and the radiator hood 24 is positioned and attached to the fairing 18. The fenders 26 are attached to the A-pillar 14 and the hydroformed brackets 20 and loosely support the headlight assembly 62. The headlight assembly 62 is similarly loosely supported by the cooling module assembly 44, and more precisely by the AGS housing 50, as described above.

[0053] As in Fig. As shown in Figure 11, the loosely mounted headlight assembly 62 is engaged by a grill 116 in the described embodiment. The grill 116 engages with the headlight assembly 62 in such a way that movement of the grill relative to the headlight assembly is restricted. In other words, a second skin component, i.e., the grill 116, is connected to the first skin component, i.e., the headlight assembly 62, such that the first skin component and the second skin component are fixed relative to each other and movable relative to at least one non-skin component, e.g., the cooling module assembly 44. In other words, the grill 116 serves as a mounting device for correctly aligning the headlight assemblies 62 relative to the grill.In this way, the grille 116 and the headlight assemblies 62 are connected or coupled to each other in a manner that achieves a uniform distance or a uniform gap width and flushness between them.

[0054] By connecting these skin components in this way, the front-end developer can incorporate certain features, including unusual or previously unimplementable style enhancements, which will be described in more detail later. Using a skin component as a mounting point for one or more other skin components ensures consistently superior build quality, even with an aggressive appearance or the use of unusual style enhancements. The assembly method delivers these enhancements with easy installation, reduced installation time and number of attachments, and does so simply and cost-effectively without the need for additional tools.

[0055] Once the grille 116 and the headlight assemblies 62 are connected to form a sub-assembly 118, the sub-assembly continues to be loosely supported by the fenders 26. This allows the sub-assembly 118, shown in Fig. 12, to move in the Y-axis direction to allow centering of the grille 116 / subassembly 118, while maintaining uniform distances or gap widths between the grille, the headlight assemblies 62, and the fenders 26 before attachment to the vehicle front end 12. In alternative embodiments, the headlight assemblies 62 can be designed to serve as a mounting device for engaging the grille 116 and restricting its movement in a similar manner to that described above.

[0056] As stated above, joining the body panels in a way that achieves uniform positioning relative to one another offers front-end designers considerable opportunities to enhance the vehicle's appearance by incorporating certain design features. These front-end features include, for example, various interlocking grille extensions that allow the body panels to interlock. As shown in Fig. As shown in Figure 12, a first and second loop 120, 122 extend from the grill 116 and interlock with an adjacent headlight assembly 124, 126, thus creating an interlocking sub-assembly 118.

[0057] In the described embodiment, the first and second loops 120, 122 are formed integrally as part of the grill 116 and are generally rectangular in shape. In alternative embodiments, the grill extensions can be attachment elements, and each extension can include one or more loops. The loops can take on various shapes, including a first shape for the first loop and a second shape for the second loop. Alternative extensions can include shapes other than loops, such as one or more straight extensions, various uniform curves, and / or circles. In other words, the interlocking extensions can take on any shape.

[0058] As shown, the first and second loops 120, 122 are accommodated in corresponding channels 128, 130, which are formed in the lens of each headlight assembly 124, 126. Thus, channel 128 in the first headlight assembly 124 corresponds to the respective first loop 120, and channel 130 in the second headlight assembly 126 is a mirror image of channel 128 and corresponds to the second loop 122. In the described embodiment, the first and second loops 120, 122 are secured in their position in the corresponding lens channels 128, 130 by spring clips 132, as shown in Fig. Figure 13 shows that the spring clamps 132 are attached to tabs 133 formed in the channels 128, 130, providing further support for the grille 116 during the assembly process. In addition to the various attributes of the grille 116 and the headlight assemblies 124, 126, which ensure uniform spacing or gap widths between the components, the spring clamps provide further support in ensuring uniform spacing or gap widths between the first and second loops 120, 122 and their corresponding channels 128, 130. Of course, the grille extensions can be secured adjacent to the headlight assemblies, or, in alternative embodiments, not secured at all.

[0059] As generally described above and best explained in Fig. As shown in Figure 14, the grill 116 serves as an installation device during assembly to correctly align the headlight assemblies 62 relative to the grill. In the described embodiment, grill guide pins 134 and 136 are generally arranged to engage with corresponding openings 138 and 140 of the passenger-side headlight assembly 124. The position of the openings 138 and 140 on the passenger-side headlight sub-assembly 124 is best determined in Fig. 13 shown. These grille and headlight assembly attributes work together as described below to achieve uniform distances or gap widths between the components and to restrict movement of the resulting subassembly 118 in one or more directions.

[0060] Returning to Fig. 14. The openings 138, 140 of the headlight assembly receive the grille guide pins 134, 136. The guide pins 134, 136 are star pins with chamfered heads, which allow the positioning of the openings 138, 140 during assembly. In the described embodiment, the first opening 138 includes a recessed section 142, which is designed to receive the pin 136 during installation and guide or channel it into a non-recessed section or hole 144.

[0061] As further shown, the recessed section 142 is formed in the lens 68 of the headlight assembly 62 and extends over a distance equal to a surface of the lens. A width or major diameter 146 of the extended recessed section 142 meets specific design tolerances (e.g., +0.5 mm) such that the grille guide pin 134 is aligned within the major diameter 146 during assembly. When the pin 134 enters and engages in the extended recessed section 142, as shown by action arrow B, the recessed section guides or channels the pin (shown with a dashed line and labelled 134') into the hole 144, which is dimensioned to receive the pin (shown with a dashed line and labelled 134") and prevents movement of the grill on the Y-axes and the Z-axes relative to the headlight assembly 124.

[0062] In the described embodiment, the hole 144 is formed in both the lens 68 and the housing 64 of the headlight assembly 124 and aligns the headlight assembly with the grille 116. In other embodiments, the hole may be formed only in the housing, or the opening may be formed solely in the lens. In each embodiment, the hole 144 acts as a 4-way positioner, preventing movement in four different directions along the Y-axes and the Z-axes. In other words, the hole 144 serves as both a Y-axis and a Z-axis positioner to restrict movement and enable positioning of the headlight assembly 124 relative to the grille 116 to achieve a uniform distance or gap width between them.

[0063] The second opening 140 similarly includes a chamfered section 148 designed to receive the pin 136 and guide it into an unchamfered section or slot 150. As in Fig. As shown in Figure 14, the chamfered section 148 is formed in the lens 68 of the headlight assembly 124 and extends over a distance equal to one area of ​​the lens. An outer cross-section 152 of the extended chamfered section 148 meets specific design tolerances (e.g., +0.5 mm) such that the grille guide pin 136 is aligned in the outer cross-section 152 during assembly. When the pin 136 enters and engages with the extended chamfered section 148, as shown by action arrow C, the chamfered section guides or channels the pin (shown with a dashed line and labelled 136') into the slot 150, which is dimensioned to receive the pin (shown with a dashed line and labelled 136") and prevent movement of the grill 116 on the Y-axis relative to the headlight assembly 124 (e.g., into and out of the figure), while restricting movement on the Z-axes (e.g.,is made possible in the figure up and down).

[0064] Again, in the described embodiment, the slot 150 is formed in both the lens 68 and the housing 64 of the headlight assembly 124 and aligns the headlight assembly with the grille 116. In other embodiments, the slot may be formed only in the housing, or the opening may be formed solely in the lens. In any embodiment, the slot 150 acts as a two-way positioner, preventing movement in two different directions along the Y-axes. In other words, the slot 150 serves as a Y-axis positioner to restrict movement and enable positioning of the headlight assembly 62 relative to the grille 116 to achieve a uniform distance or gap width between them.

[0065] In the described embodiment, the grill 116 includes additional attributes in the form of grill guide pins for engaging the driver's side headlight assembly 124. As stated above, the passenger-side and driver's side headlight assemblies 124 and 126 are mirror images of each other. Accordingly, the additional grill pins engage with attributes of the driver's side headlight assembly 126 in the same manner as described above to achieve uniform distances or gap widths between the components. While the four grill pins in the described embodiment are generally arranged in each corner of the grill 116, alternative embodiments can arrange the grill pins at a different location on the grill and the corresponding openings at a different location on the headlight assemblies 124, 126. Additional grill pins or even fewer grill pins and corresponding openings can also be used.

[0066] While the openings 138, 140 in the headlight assembly 124 serve as guides for the grill pins 134, 136 and relative positioners for the grill 116 and the headlight assembly, attributes formed on the AGS housing 50 provide further guidance for aligning the grill during assembly. As in Fig. As shown in Figure 15, the AGS housing includes 50 guides 154 which engage with corresponding guide wedges or switches 156 on the grill 116 during assembly. Contact between the guide surfaces 154 and switches 156 guides or directs the grill / headlight sub-assembly 118 to a central position where an additional grill attribute engages with the cooling module assembly 44.

[0067] In this central position, a plurality of alignment tabs 158 on the grill 116 are generally aligned with a corresponding plurality of receptacles 160 on the AGS housing 50. As shown, the openings 162 in the grill alignment tabs 158 are larger than corresponding openings 164 on the AGS housing 50 to accommodate certain tolerances. In the described embodiment, the switches 156 and the alignment tabs 158 are formed integrally with the grill 116 and the guide surfaces 154, and the receptacles 160 are formed integrally with the AGS housing 50. Again, in alternative embodiments, additional guide surfaces, switches, alignment tabs, and / or receptacles, or even fewer or none at all, can be used.

[0068] In the described embodiment, the grill 116 is designed to engage with the headlight assemblies 124 and 126 before the cooling module assembly 44 engages, and then to be guided to the central position. This engagement sequence is achieved by the grill design, the headlight assembly design, including the extended recessed and / or chamfered openings 142 and 148, and by an appropriate selection of grill pin lengths, such that the extended recessed and / or chamfered openings of the headlight assemblies 62 engage before the subassembly 118 is guided to the central position and engages with the AGS housing 50. Of course, alternative embodiments may use more or fewer steps and may differ with respect to the engagement sequence of the components.

[0069] How best to Fig. As shown in Figure 11, the AGS housing 50 includes an opening 166 designed to receive a grill guide pin 168. The guide pin 168, as shown in Fig. Figure 16 shows a star pin with a chamfered head that allows for positioning of the opening 166 during assembly. In the described embodiment, the opening 166 is a slot that receives and guides the pin 168 into the slot. An outer cross-section 172, formed in the AGS housing 50, meets specific design tolerances (e.g., 0.5 mm) such that the pin 168 should align itself within the outer cross-section. As the pin 168 engages in the slot 170, chamfered walls 174 guide the pin as required into the slot, which is dimensioned to receive the pin (shown with a dashed line and labeled 168') and prevents movement along the Y-axis, while allowing movement along the Z-axis as shown. More precisely, the opening 166 is used as a Y-axis positioner to limit movement and to enable positioning of the subassembly 118 relative to the AGS housing 50.

[0070] As explained, the engagement of the cooling module assembly 44 restricts the movement of the second skin component, i.e., the grille 116, relative to the at least one non-skin component, i.e., the cooling module assembly 44. In the described embodiment, the cooling module assembly 44 is engaged by the grille 116 such that movement of the grille and the headlight assemblies, i.e., the skin component subassembly 118, is restricted in the Y-axis direction. This effectively centers the grille 116 on the cooling module assembly 44 and secures the skin component subassembly 118, including the grille and the headlight assemblies 124, 126, in its position relative to the cooling module assembly 44. Once the loosely supported subassembly 118 is centered, the subassembly with the grille 116 and the headlight assemblies 124, 126 is fixed to the front end of the vehicle 12.

[0071] In the described embodiment, fixing the subassembly 118 to the vehicle front end 12 involves several fasteners. These fasteners serve to attach the subassembly 118 to varying front-end components on the X-plane positioner. As shown in Fig. As shown in Figure 7, for example, the first surface 104 of the AGS housing 50 serves as an X-axis positioner and includes an opening 103 through which a fastener extends. A ninety-degree compressed air gun is used to secure the fastener in its position and to secure the grill 116 and the headlight housing 64 to the AGS housing 50. Similarly, the headlight assembly 124 is secured to the AGS housing 50 using a second opening 176 in the bracket 88 (shown in Figure 7). Fig. 7) A fastener 178, shown in Fig. 9 is used to secure a lower section of the headlight assembly 124 to the fender 26 adjacent to the fish-mouth Z-positioner 108. Further fasteners are used to attach the grille 116 to the AGS housing 50 using openings 162.

[0072] As described above, during the assembly process, openings 162 in alignment tabs 158 running along an upper section of the grille 116 are aligned with matching openings 164 in corresponding receptacles 160, and fasteners are used to secure the grille 116 and the AGS housing 50 at this point in the assembly process. Of course, additional or fewer fasteners can be used to secure the subassembly 118 to the vehicle front end 12.

[0073] Once the sub-assembly has been secured, a panel 180 is attached to the front of the vehicle 12, as shown in Fig. Figure 17 shows that, like other skin components, the panel incorporates attributes that restrict movement in one or more directions and help to align the panel during assembly. In the described embodiment, a first attribute, which is a first pin 182, engages with an attribute in the fender 26 (best shown in Figure 17). Fig. 5) The fender attribute is an opening 184 that acts as a 4-way positioner, limiting movement in four different directions along the Y-axes and the Z-axes. In other words, the opening 184 acts as both a Y-axis positioner and a Z-axis positioner. A second attribute, or trim pin, engages in an opening in the driver's side fender in the same manner as described above for the passenger side fender.

[0074] In the described embodiment, the trim pin 182 is arranged on a side wall 186 of a notch formed in the trim. During assembly, the side wall 186 generally faces the fender 26 and assists in aligning a first upper edge 188 of the trim with a lower edge 190 of the fender 26, as shown in Fig. Figure 18 shows that the fender 26 and the trim panel 180 are coupled together in such a way as to achieve a uniform distance or gap width between them. Of course, alternative embodiments can arrange the trim panel pins elsewhere on the trim panel and the corresponding openings elsewhere on the fenders 26 and achieve the same result, and additional fasteners can be used to secure the trim panel 180 to the vehicle front end 12.

[0075] As in Fig.As shown in Figure 19, the lens 68 of the headlight assembly 124 is used as a fairing positioning feature to align the fairing 180 with the headlight assembly. More precisely, in the described embodiment, the lens 68 is shaped along a lower edge 194 with a channel 192 to receive an upper edge 196 of the fairing 180 and limit its movement in the Z-axis direction. In other words, the channel 192 is another headlight assembly feature that acts as a Z-axis positioner. Within the channel 192, a retaining bracket 198 is designed to guide the upper fairing edge 196 into the channel during assembly to achieve a correct position of the fairing 180 relative to the headlight assembly 124 and, necessarily, to the grille 118.In this way, the fairing 180 and the headlight assembly 124 are coupled to each other in a manner that achieves a uniform distance or gap width between them. Given the relationship between the headlight assemblies 124, 126 and the grille 118, a uniform distance or gap width is also achieved between the fairing 180 and the grille.

[0076] In short, numerous advantages arise from the methods for mounting vehicle front-end components to a vehicle body. The described mounting methods can be applied to any type of vehicle and body construction and enable superior build quality, a modern and aggressive appearance, unusual or previously unattainable styling improvements, ease of assembly, reduced installation time and number of attachments, positioning of front-end components and subassemblies to adjacent systems, components and subassemblies, and / or improved customer satisfaction, each without the limitations associated with conventional vehicle front-end design and construction or modular design.

[0077] Furthermore, these improvements to vehicle front-end assembly processes necessitate complementary improvements to the designs of vehicle front-end components and their subassemblies. Individual front-end components, including headlight assemblies, and / or subassemblies, including the grille and headlight assemblies, should incorporate combinations of hands-free access, anti-rotation, sliding or sliding, and other assembly-aiding features that would not be required for conventional and / or modular vehicle assembly. These features should be an integral part of the component designs to reduce or eliminate costly assembly tooling and should allow for improved build quality and attributes such as an aggressive appearance or unusual or previously unfeasible styling enhancements, including overlapping component designs.

[0078] The foregoing served the purposes of illustration and description. It is not to be understood as exhaustive or as limiting the embodiments to the exact form disclosed. In light of the foregoing teachings, obvious modifications and variations are possible. All such modifications and variations are within the scope of protection of the attached claims when interpreted within the extent to which they are legally and reasonably entitled.

Claims

[1] Subassembly (118) for a vehicle front end (12), comprising: a grill (116); and a headlight assembly (62), wherein the headlight assembly (62) comprises a housing (64) carrying at least one lamp (66) and a lens (68) attached to the housing (64), wherein the lens (68) comprises at least one attribute for engaging with the grill (116); wherein the at least one attribute comprises an opening (138) formed in the lens (68). [2] Subassembly (118) according to claim 1, wherein the opening (138) extends through the housing (64). [3] Subassembly (118) according to claim 1, wherein the opening (138) is a hole (144) with a recessed section (142). [4] Subassembly (118) according to claim 3, wherein the recessed section (142) is formed in the lens (68) and extends over a distance from a surface of the lens (68) to guide the grill (116). [5] Subassembly (118) according to claim 1, wherein the at least one attribute restricts a movement of the headlight assembly (62) relative to the grill (116) in a Y-axis direction. [6] Subassembly (118) for a vehicle front end (12), comprising: a grill (116); and a housing (64) carrying at least one lamp (66) and a lens (68) attached to the housing (64), wherein the lens (68) has at least one attribute for engaging with the grill (116) and restricting a movement of the lens (68) relative to the grill (116) in a Y-axis direction, wherein the at least one attribute for engaging with the grill (116) includes an opening (140) formed in the lens (68). [7] Subassembly (118) according to claim 6, wherein the opening (140) extends a distance from a surface of the lens (68) to receive a pin (136) extending from the grill (116). [8] Subassembly (118) according to claim 6, wherein the at least one attribute includes a cavity (128) formed in the lens (68) to accommodate an overlapping section (120) of the grill (116). [9] Subassembly (118) according to claim 6, wherein the housing (64) includes at least one attribute (106) for limiting a movement of the housing (64) in a Z-axis direction.

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