U.S. patent application number 14/086018 was filed with the patent office on 2014-03-20 for vehicle component and component assembly comprising elastic averaging features.
This patent application is currently assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC. The applicant listed for this patent is GM GLOBAL TECHNOLOGY OPERATIONS LLC. Invention is credited to Jeffrey A. Abell, Ronald Charles Daul, Lane G. Lindstrom, David A. Okonski, Elmer B. Santos, Mark A. Smith, Xiang Zhao.
Application Number | 20140080036 14/086018 |
Document ID | / |
Family ID | 46019926 |
Filed Date | 2014-03-20 |
United States Patent
Application |
20140080036 |
Kind Code |
A1 |
Smith; Mark A. ; et
al. |
March 20, 2014 |
Vehicle Component and Component Assembly Comprising Elastic
Averaging Features
Abstract
An assembly for a vehicle includes a first member including a
plurality of elastically deformable locating protrusions extending
outward, and a second member defining a cavity extending inward and
including a plurality of elastically deformable compression
features disposed within the cavity. The locating protrusions of
the first member are disposed within the cavity of the second
member in press fit engagement with the compression features of the
second member to secure the first member relative to the second
member. The average of the elastic deformation between all of the
locating protrusions of the first member and all of the compression
features of the second member precisely aligns the first member
relative to the second member. The assembly may include but is not
limited to a multiple unit battery pack, a multiple unit fuel cell
pack, a dashboard assembly or adjoining body panels.
Inventors: |
Smith; Mark A.; (Huntington
Woods, MI) ; Zhao; Xiang; (Novi, MI) ; Daul;
Ronald Charles; (Northville, MI) ; Okonski; David
A.; (Lake Orion, MI) ; Lindstrom; Lane G.;
(Oxford, MI) ; Santos; Elmer B.; (Rochester Hills,
MI) ; Abell; Jeffrey A.; (Rochester Hills,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GM GLOBAL TECHNOLOGY OPERATIONS LLC |
Detroit |
MI |
US |
|
|
Assignee: |
GM GLOBAL TECHNOLOGY OPERATIONS
LLC
Detroit
MI
|
Family ID: |
46019926 |
Appl. No.: |
14/086018 |
Filed: |
November 21, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13229926 |
Sep 12, 2011 |
|
|
|
14086018 |
|
|
|
|
Current U.S.
Class: |
429/508 ;
429/163 |
Current CPC
Class: |
H01M 2/1083 20130101;
H01M 2/1094 20130101; Y02E 60/50 20130101; H01M 2/1077 20130101;
Y02E 60/10 20130101; H01M 8/2475 20130101; Y10T 29/49622 20150115;
B60K 1/04 20130101 |
Class at
Publication: |
429/508 ;
429/163 |
International
Class: |
H01M 2/10 20060101
H01M002/10 |
Claims
1. A vehicle member, comprising: a first face and a second opposing
face, the vehicle member defining a cavity that extends inward into
the second face; a first set and a second set of a plurality of
elastically deformable protrusions that extend outward from an
outer surface of the first face; a first set and a second set of a
plurality of compression features disposed within the cavity;
wherein the respective first sets and the respective second sets of
the plurality of elastically deformable protrusions and the
plurality of compression features are spaced apart from each other;
and wherein the respective first sets and the respective second
sets of the plurality of elastically deformable protrusions and the
plurality of compression features are geometrically distributed
relative to each other such that when the first surface of a first
of the vehicle member is matingly engaged face-to-face adjacent
with the second surface of a second of the vehicle member, each of
the plurality of elastically deformable protrusions press fit
engage with respective ones of the plurality of compression
features with an averaged elastic deformation between all of the
plurality of elastically deformable protrusions of the first
vehicle member and all of the plurality of compression features of
the second vehicle member that precisely aligns the first and
second vehicle members along a longitudinal central axis of at
least one of the plurality of elastically deformable
protrusions.
2. The vehicle member of claim 1, wherein: each of the plurality of
compression features comprises a compression protrusion that
extends along an axis that is parallel with a central axis of at
least one of the plurality of the elastically deformable
protrusions, a compression rib that forms an interior wall in the
cavity that extends between opposing side walls of the cavity and
that extends along a plane that is parallel with the central axis
of at least one of the plurality of the elastically deformable
protrusions, a compression ridge that forms a ridge of material
that is peripherally disposed at a side wall of the cavity that
extends along a line that is parallel with the central axis of at
least one of the plurality of the elastically deformable
protrusions and that extends inward toward a center of the cavity,
or any combination of the foregoing compression protrusion,
compression rib and compression ridge; and the compression
protrusion, the compression rib, and the compression ridge are all
spaced apart from each other to define a region therebetween that
is smaller than one of the plurality of elastically deformable
protrusions to cause an interference fit engagement between
associated ones of the plurality of compression features and the
respective elastically deformable protrusion.
3. The vehicle member of claim 1, wherein: at least one of the
plurality of elastically deformable protrusions has a cylindrical
shaft.
4. The vehicle member of claim 1, wherein: each of the plurality of
elastically deformable protrusions has a cross sectional shape
perpendicular to its respective central axis, the cross sectional
shape defining a circular shape, a heptagon shape, an octagon
shape, a decagon shape, or a dodecagon shape.
5. The vehicle member of claim 1, wherein: at least one of the
plurality of elastically deformable protrusions is formed of an
active material that is changeable from a first shape to a second
different shape.
6. The vehicle member of claim 5, wherein: the first shape results
when the active material is in an energized state, and the second
shape results when the active material is in a de-energized
state.
7. The vehicle member of claim 5, wherein: the second shape is an
inverted taper shape having a central axis that extends along a
central axis of at least one of the plurality of the elastically
deformable protrusions.
8. The vehicle member of claim 1, further comprising: a through
hole that extends from the first face to the second face, wherein
at least some of the plurality of elastically deformable
protrusions are disposed proximate the hole to provide precise
alignment of a first of the vehicle member with a second of the
vehicle member relative to the hole when the first and second
vehicle members are matingly engaged with each other.
9. The vehicle member of claim 1, wherein the vehicle member is a
battery pack or fuel cell pack member.
10. An assembly, comprising: a plurality of members, each of the
plurality of members comprising: a first face and a second opposing
face, each member of the plurality of members defining a cavity
that extends inward into the second face; a first set and a second
set of a plurality of elastically deformable protrusions that
extend outward from an outer surface of the first face; and a first
set and a second set of a plurality of compression features
disposed within the cavity; wherein the respective first sets and
the respective second sets of the plurality of elastically
deformable protrusions and the plurality of compression features
are spaced apart from each other; and wherein the first surface of
a first of the plurality of members is matingly engaged
face-to-face adjacent with the second surface of a second of the
plurality of members, the respective first sets and the respective
second sets of the plurality of elastically deformable protrusions
and the plurality of compression features being geometrically
distributed relative to each other such that each of the plurality
of elastically deformable protrusions press fit engage with
respective ones of the plurality of compression features with an
averaged elastic deformation between all of the plurality of
elastically deformable protrusions of the first member and all of
the plurality of compression features of the second member that
precisely aligns the first and second members along a longitudinal
axis of the assembly.
11. The assembly of claim 10, wherein: the plurality of members are
arranged face-to-face adjacent with each other along a longitudinal
axis to define a continuous stack of the plurality of members that
number more than two members.
12. The assembly of claim 10, wherein: each of the plurality of
members is identical to another of the plurality of members.
13. The assembly of claim 10, wherein: each of the plurality of
compression features comprises a compression protrusion that
extends along an axis that is parallel with a central axis of at
least one of the plurality of the elastically deformable
protrusions, a compression rib that forms an interior wall in the
cavity that extends between opposing side walls of the cavity and
that extends along a plane that is parallel with the central axis
of at least one of the plurality of the elastically deformable
protrusions, a compression ridge that forms a ridge of material
that is peripherally disposed at a side wall of the cavity that
extends along a line that is parallel with the central axis of at
least one of the plurality of the elastically deformable
protrusions and that extends inward toward a center of the cavity,
or any combination of the foregoing compression protrusion,
compression rib and compression ridge; and the compression
protrusion, the compression rib, and the compression ridge are all
spaced apart from each other to define a region therebetween that
is smaller than one of the plurality of elastically deformable
protrusions to cause an interference fit engagement between
associated ones of the plurality of compression features and the
respective elastically deformable protrusion.
14. The assembly of claim 10, wherein: at least one of the
plurality of elastically deformable protrusions has a cylindrical
shaft.
15. The assembly of claim 10, wherein: each of the plurality of
elastically deformable protrusions has a cross sectional shape
perpendicular to its respective central axis, the cross sectional
shape defining a circular shape, a heptagon shape, an octagon
shape, a decagon shape, or a dodecagon shape.
16. The assembly of claim 10, wherein: at least one of the
plurality of elastically deformable protrusions is formed of an
active material that is changeable from a first shape to a second
different shape.
17. The assembly of claim 16, wherein: the first shape results when
the active material is in an energized state, and the second shape
results when the active material is in a de-energized state.
18. The assembly of claim 16, wherein: the second shape is an
inverted taper shape having a central axis that extends along a
central axis of at least one of the plurality of the elastically
deformable protrusions.
19. The assembly of claim 10, wherein: each of the plurality of
members comprises a through hole that extends from the first face
to the second face, wherein at least some of the plurality of
elastically deformable protrusions are disposed proximate the hole
to provide precise alignment of the first member with the second
member relative to the hole.
20. The assembly of claim 10, wherein the assembly is an energy
storage device assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims the benefit of
U.S. patent application Ser. No. 13/229,926, filed on Sep. 12,
2011, which claims the benefit of U.S. Provisional Patent
Application Ser. No. 61/411,614, filed on Nov. 9, 2010, the
disclosures of which are hereby incorporated by reference herein in
their entirety.
FIELD OF THE INVENTION
[0002] The invention generally relates to an article of manufacture
for a vehicle and an assembly that incorporates the article, and
more specifically to an article of manufacture that incorporates
elastically deformable features to secure and align the article to
other articles, including other identical articles.
BACKGROUND
[0003] When manufacturing various different assemblies for a
vehicle, it is often very important to precisely align a first
member relative to a second member to align stacked assemblies or
to achieve small, uniform gaps for function or appearance. The
various different vehicular assemblies in which a first member must
be precisely aligned with a second member may include, but are not
limited to, multiple plates of a battery pack for an electric
vehicle, multiple plates of a fuel cell pack for a hydrogen fuel
cell, one or more components of a dashboard assembly relative to
each other or a support structure, a body panel relative to the
support structure, or a trim panel relative to the body panel.
[0004] The different members may be aligned with a datum reference
structure, in which one or more surfaces of the different members
are pressed against the datum reference structure to remove the
various degrees of movement between the different members.
Alternatively, locating features may be machined into or otherwise
attached to the different members. However, in order to account for
the part variations between the locating features, a certain amount
of clearance must be designed into the locating features, which
decreases the precision of the alignment.
SUMMARY OF THE INVENTION
[0005] In an embodiment, a vehicle member includes a first face and
a second opposing face, the vehicle member defining a cavity that
extends inward into the second face. A first set and a second set
of a plurality of elastically deformable protrusions extend outward
from an outer surface of the first face. A first set and a second
set of a plurality of compression features are disposed within the
cavity. The respective first sets and the respective second sets of
the plurality of elastically deformable protrusions and the
plurality of compression features are spaced apart from each other.
The respective first sets and the respective second sets of the
plurality of elastically deformable protrusions and the plurality
of compression features are geometrically distributed relative to
each other such that when the first surface of a first of the
vehicle member is matingly engaged face-to-face adjacent with the
second surface of a second of the vehicle member, each of the
plurality of elastically deformable protrusions press fit engage
with respective ones of the plurality of compression features with
an averaged elastic deformation between all of the plurality of
elastically deformable protrusions of the first vehicle member and
all of the plurality of compression features of the second vehicle
member that precisely aligns the first and second vehicle members
along a longitudinal central axis of at least one of the plurality
of elastically deformable protrusions.
[0006] In an embodiment, an assembly includes a plurality of
members, each of the plurality of members having a first face and a
second opposing face, each member of the plurality of members
defining a cavity that extends inward into the second face. A first
set and a second set of a plurality of elastically deformable
protrusions extend outward from an outer surface of the first face.
A first set and a second set of a plurality of compression features
are disposed within the cavity. The respective first sets and the
respective second sets of the plurality of elastically deformable
protrusions and the plurality of compression features are spaced
apart from each other. The first surface of a first of the
plurality of members is matingly engaged face-to-face adjacent with
the second surface of a second of the plurality of members, the
respective first sets and the respective second sets of the
plurality of elastically deformable protrusions and the plurality
of compression features being geometrically distributed relative to
each other such that each of the plurality of elastically
deformable protrusions press fit engage with respective ones of the
plurality of compression features with an averaged elastic
deformation between all of the plurality of elastically deformable
protrusions of the first member and all of the plurality of
compression features of the second member that precisely aligns the
first and second members along a longitudinal axis of the
assembly.
[0007] In an embodiment, an interference fit engagement between
locating protrusions of a first member and compression features of
a second member secure the first member and the second member
together during manufacture of the assembly. A plurality of
elastically deformable locating protrusions and a plurality of
elastically deformable compression features define multiple points
of contact between the first member and the second member. The
average of the elastic deformation between the locating protrusions
and the compression features provides a precise and highly
repeatable alignment of the first member relative to the second
member, thereby precisely positioning the first member relative to
the second member without the need of expensive datum alignment
tools. The multiple contacts also increase the structural stiffness
of the connection.
[0008] The above features and advantages and other features and
advantages of the present invention are readily apparent from the
following detailed description of the best modes for carrying out
the invention when taken in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic perspective view of an assembly for a
vehicle, wherein the assembly includes an energy storage device
manufactured from a plurality of members.
[0010] FIG. 2 is a schematic plan view of a first face of one of
the members of the energy storage device shown in FIG. 1.
[0011] FIG. 3 is a schematic plan view of a second face of one of
the members of the energy storage device shown in FIG. 1.
[0012] FIG. 4 is a schematic side view of a portion of one of the
members of the energy storage device taken along cut line 4-4 shown
in FIG. 2, with some hidden line detail removed for clarity.
[0013] FIG. 5 is an enlarged schematic plan view of a portion of
one of the members of the energy storage device shown in FIG. 2
showing a plurality of locating protrusions.
[0014] FIG. 6 is an enlarged schematic plan view of a portion of
one of the members of the energy storage device shown in FIG. 3
showing a plurality of compression features.
[0015] FIG. 7 is a schematic plan view of a first alternative shape
of one of the locating protrusions.
[0016] FIG. 8 is a schematic plan view of a second alternative
shape of one of the locating protrusions.
[0017] FIG. 9 is a schematic plan view of a third alternative shape
of one of the locating protrusions.
[0018] FIG. 10 is a schematic plan view of a fourth alternative
shape of one of the locating protrusions.
[0019] FIG. 11 is an enlarged schematic side view of one of the
plurality of the locating protrusions manufactured from an active
material, and shown in an initial and/or final shape.
DESCRIPTION OF THE EMBODIMENTS
[0020] Referring to the Figures, wherein like numerals indicate
like parts throughout the several views, an assembly for a vehicle
is shown generally at 20. As shown herein, the assembly 20 includes
an energy storage device 22, such as but not limited to a battery
pack or a fuel cell pack. However, the assembly 20 may include some
other vehicular assembly 20 not shown or described herein,
including but not limited to a dashboard assembly 20 or a body
panel assembly 20. Although the invention disclosed herein is
described incorporated into the energy storage device 22, it should
be appreciated that the invention may be incorporated into other
vehicular assemblies 20, and that the energy storage device 22 is
simply described as an exemplary embodiment of a vehicular assembly
20 including the invention.
[0021] Referring to FIGS. 1 through 3, the energy storage device 22
includes a plurality of generally planar members 24. Each of the
members includes a first face 26, shown in FIG. 2, and a second
face 28, shown in FIG. 3. The first face 26 and the second face 28
of the plurality of planar members 24 are defined by opposing,
i.e., opposite, surfaces of each of the planar members 24. The
plurality of planar members 24 are arranged face-to-face adjacent
each other along a longitudinal axis 30 to define a continuous
stack 32 of planar members 24. Accordingly, each first face 26 of
one of the planar members 24 is disposed adjacent a second face 28
of another of the planar members 24. The stack 32 of planar members
24 may include any number of planar members 24. For example, the
energy storage device 22 may include several hundred of the planar
members 24. It should be appreciated that the exposed face of the
end members of the stack 32 are not disposed adjacent other planar
members 24.
[0022] For the purpose of describing the invention, the plurality
of planar members 24 is described herein in terms of a first member
34, shown in FIG. 2, and a second member 36, shown in FIG. 3.
However, it should be appreciated that the stack 32 of planar
members 24 may include, but is not required to include, more than
the first member 34 and the second member 36, and that the
description of the first member 34 and the second member 36 is
applicable to all of the plurality of planar members 24.
[0023] Referring also to FIGS. 4 through 6, each of the first
member 34 and the second member 36 may include a plurality of
elastically deformable locating protrusions 38 (depicted in groups
38.1, 38.2 and 38.3, for example, in FIG. 2) extending outward from
an outer surface of the first face 26. The locating protrusions 38
on the first member 34 and the second member 36 extend outward from
the first face 26 of each member along a central axis 40 of each of
the locating protrusions 38 respectively. Each of the locating
protrusions 38 includes a cross sectional shape perpendicular to
their respective central axis 40. The cross sectional shape of the
locating protrusions 38 may define, but is not limited to, one of a
circular shape shown in FIG. 4, a heptagon shape shown in FIG. 7,
an octagon shape shown in FIG. 8, a decagon shape shown in FIG. 9,
or a dodecagon shape shown in FIG. 10. The various locating
protrusions 38 may also be of different sizes or varying scales
within the same assembly 20 and or members 24, incorporating both a
coarse and fine locating sequence.
[0024] Each of the first member 34 and the second member 36 may
define a cavity 42 extending inward into the second face 28 of the
first member 34 and the second member 36 respectively. Preferably,
the cavity 42 extends inward a depth 44 that is equal to or greater
than a length 46 of the locating protrusions 38. Each of the first
member 34 and the second member 36 may further include a plurality
of compression features 48, 50, 52 (depicted in groups: 48.1, 50.1,
52.1; 48.2, 50.2, 52.3; and 48.3, 50.3, 52.3, for example, in FIG.
3) disposed within the cavity 42 of the first member 34 and the
second member 36 respectively. The plurality of compression
features 48, 50, 52 may include but are not limited to a
combination of at least one compression protrusion 48, at least one
compression rib 50, and at least one compression ridge 52. Each
compression protrusion 48 is a generally cylindrical shaft that
extends along an axis that is parallel with the central axis 40 of
each of the locating protrusions 38 respectively. Each compression
rib 50 is an intermediate or interior wall that extends between
opposing side walls of the first member 34 and the second member 36
respectively, and that extends along plane that is parallel with
the central axis 40 of each of the locating protrusions 38
respectively. Each compression ridge 52 is a ridge of material
disposed peripherally about the side walls of the first member 34
and the second member 36 respectively, and that extend along a line
parallel with the central axis 40 of each of the locating
protrusions 38 respectively inward toward a center of the cavity
42. The compression protrusions 48, the compression ribs 50 and the
compression ridges 52 are all spaced from each other to define at
least one region therebetween that is substantially equal to yet
slightly smaller than one of the locating protrusions 38.
Accordingly, insertion of the locating protrusions 38 into the
region between the various compression features 48, 50, 52 forces
the locating protrusion 38 and/or at least one of the compression
features 48, 50, 52 to compress.
[0025] Accordingly, each of the first member 34 and the second
member 36 are preferably identical, with each of the first member
34 and the second member 36 including a plurality of elastically
deformable locating protrusions 38, and each of the first member 34
and the second member 36 defining a cavity 42 and including a
plurality of elastically deformable compression features 48, 50, 52
disposed within their respective cavities.
[0026] The locating protrusions 38 and the compression features 48,
50, 52 include and are manufactured from an elastically deformable
material. For example, the locating protrusions 38 and the
compression features 48, 50, 52 may include and be manufactured
from a polymer material, including but not limited to a plastic.
Additionally, the locating protrusions 38 may include, but are not
required to include, an active material capable of changing between
a first shape and a second shape in response to a signal, such as
but not limited to an electrical signal or a thermal signal. As
described in greater detail below, upon applying the signal, the
active material forming the locating protrusions 38 changes from a
non-energized shape into a temporary, energized shape, i.e., the
first shape. Upon removal of the signal, the active material
changes back to the non-energized shape, e.g., the second
shape.
[0027] Each adjacent pair of members, i.e., the first member 34 and
the second member 36, includes the locating protrusions 38 of the
first member 34 disposed within the cavity 42 of the second member
36. The locating protrusions 38 of the first member 34 are disposed
within the cavity 42 of the second member 36 in press fit
engagement with the compression features 48, 50, 52 of the second
member 36. Insertion of the locating protrusions 38 into the cavity
42 elastically deforms one of the locating protrusions 38 and/or at
least one of the compression features 48, 50, 52. The elastic
deformation between each of the locating protrusions 38 and at
least one of the compression features 48, 50, 52 secures the first
member 34 and the second member 36 together, relative to each
other. The average of the elastic deformation between all of the
locating protrusions 38 of the first member 34 and all of the
compression features 48, 50, 52 of the second member 36 precisely
and consistently aligns the first member 34 relative to the second
member 36 along the longitudinal axis 30 of the stack 32.
[0028] While the invention has so far been described to include
multiple identical members 24, each defining both the locating
protrusions 38 and the compression features 48, 50, 52, it should
be appreciated that the members need not be identical. For example,
as shown in FIG. 1, the assembly 20 may include each of the
generally planar members 24 defining one of the locating features
38 and the compression features 48, 50, 52, with an elongated
member 56 defining the other of the locating features 38 and the
compression features 48, 50, 52. As shown, the generally planar
members 24 define the compression features 48, 50, 52, with the
elongated member 56 defining the locating protrusions 38. The
elongated member 56 spans a length 54 of the stack 32 of planar
members 24, thereby securing the generally planar members 24
together and positioning the generally planar members 24 relative
to each other.
[0029] A method of manufacturing the assembly 20 is provided. While
the method is described relative to the exemplary energy storage
device 22 shown in the drawings, it should be appreciated that the
scope of the method is not limited to the manufacture of the energy
storage device 22, but is also applicable to the manufacture of
other assemblies 20.
[0030] The method includes forming the first member 34 to include
the plurality of elastically deformable locating protrusions 38.
The first member 34 is formed such that the locating protrusions 38
extend outward from the exterior surface, i.e., the first face 26,
of the first member 34. The locating protrusions 38 may be formed
in any desirable area of the first face 26. Preferably, the
locating protrusions 38 are formed in areas having a critical
alignment requirement, including but not limited to cooling
channels, side profiles, tie rod holes, battery cells, seal areas,
etc.
[0031] Forming the first member 34 may include forming the
plurality of locating protrusions 38 integrally with the first
member 34 from a common material. For example, the first member 34
and the locating protrusions 38 may be formed through a plastic
injection molding process or the like from a polymer, i.e., plastic
material. Alternatively, the first member 34 and the locating
protrusions 38 may be machined into the first member 34 through
conventional machining processes.
[0032] Alternatively, forming the first member 34 to include the
plurality of locating protrusions 38 may include forming the
locating protrusions 38 separately from the first member 34. The
separate and distinct locating protrusions 38 may be formed from
the same material used for the first member 34, or alternatively,
may be formed from a different material than used to form the first
member 34, such as but not limited to an active material. If the
locating protrusions 38 are formed separately from the first member
34, then forming the first member 34 to include the plurality of
locating protrusions 38 includes mounting the locating protrusions
38 to the pre-formed first member 34. The locating protrusions 38
may be mounted in any suitable manner, such as but not limited to
fasteners, chemical bonding, welding, or over molding. For example,
if the locating protrusions 38 are formed separately from the first
member 34, then, forming the locating protrusions 38 separately
from the first member 34 may include over molding the plurality of
locating protrusions 38 onto the pre-formed first member 34.
[0033] The method further includes forming the second member 36 to
define a cavity 42, and to include the plurality of elastically
deformable compression features 48, 50, 52 disposed within the
cavity 42. As described above, each member may include both the
locating protrusions 38 on the first face 26 and the cavity 42 with
the compression features 48, 50, 52 therein on the second face 28,
or may alternatively include separate members, such as the
elongated member 56 described above. The cavity 42 with the
compression features 48, 50, 52 are formed in positions along the
second member that generally correspond to and align with the
locating projections 38 of the first member 34.
[0034] Forming the second member 36 may include forming the
plurality of compression features 48, 50, 52 integrally with the
second member 36 from a common material. For example, the second
member 36 and the compression features 48, 50, 52 may be formed
through a plastic injection molding process or the like from a
polymer, i.e., plastic material. Alternatively, the second member
36 and the compression features 48, 50, 52 may be machined into the
second member 36 through conventional machining processes.
[0035] The method further includes inserting the locating
protrusions 38 of the first member 34 into the cavity 42 of the
second member 36 in press fit engagement with the plurality of
compression features 48, 50, 52. Inserting the plurality of
locating protrusions 38 into the cavity 42 in press fit engagement
includes elastically deforming the locating protrusions 38 and/or
at least one of the compression features 48, 50, 52. In so doing,
the elastic deformation of the locating protrusion 38 and/or at
least one of the compression features 48, 50, 52 secures the first
member 34 and the second member 36 relative to each other.
Additionally, the average of the elastic deformation between all of
the plurality of locating protrusions 38 and all of the plurality
of compression features 48, 50, 52 precisely and repeatably aligns
the first member 34 relative to the second member 36.
[0036] If the material used to form the plurality of locating
protrusions 38 includes an active material, in which the active
material locating protrusions 38 include a first shape when in the
energized state, and a second shape when in the de-energized shape,
then the method further includes energizing the locating
protrusions 38 to cause each of the plurality of locating
protrusions 38 to change into the first shape prior to inserting
the plurality of locating protrusions 38 into the cavity 42. The
method further includes de-energizing the locating protrusions 38
to cause each of the locating protrusions 38 to change into the
second shape after the plurality of locating protrusions 38 are
inserted into the cavity 42. If the second shape is an initial
and/or final shape, and the first shape is a temporary installation
shape, then energizing the locating protrusions 38 causes the shape
of the locating protrusions 38 to change from the initial shape,
i.e., the second shape, into the temporary installation shape,
i.e., the first shape. Upon the locating protrusions 38 being
inserted into the cavity 42 and into engagement with the
compression features 48, 50, 52, the locating protrusions 38 may be
de-energized to cause the locating protrusions 38 to thereby change
back into the initial and/or final shape.
[0037] For example, the first shape, e.g. the temporary
installation shape, may include but is not limited to a cylindrical
shape, and the second shape, e.g., the initial and/or final shape,
may include but is not limited to an inverted taper, shown
generally at 58 in FIG. 11, extending along the central axis 40 of
each respective locating protrusion 38. Accordingly, the inverted
taper of the locating protrusions 38 may wedge into or otherwise
more firmly grasp the compression features 48, 50, 52 to better
secure the locating protrusions 38 within the cavity 42.
[0038] Once the locating protrusions 38 are inserted into the
cavities into press fit engagement with the compression features
48, 50, 52, then the method may further include fixing the first
member 34 and the second member 36 together. Fixing the first
member 34 and the second member 36 may include permanently
attaching the first member 34 and the second member 36 together.
The first member 34 and the second member 36 may be permanently
attached in any suitable manner specific to the type of assembly 20
being manufactured. For example, fixing the first member 34 and the
second member 36 together may include but is not limited to
fastening the first member 34 and the second member 36 together
with a fastener, welding the first member 34 and the second member
36 together, or bonding the first member 34 and the second member
36 together with a chemical adhesive. In so doing, the press-fit
engagement between the locating protrusions 38 of the first member
34 and the compression features 48, 50, 52 of the second member 36
are only intended to be a temporary alignment and attachment, with
the final and permanent attachment being achieved through other
fixing processes.
[0039] While exemplary modes for carrying out the invention have
been described in detail, those familiar with the art to which this
invention relates will recognize various alternative designs and
embodiments for practicing the invention within the scope of the
appended claims.
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