GB2560929A

GB2560929A - A bracket for mounting a lamp housing to a motor vehicle

Info

Publication number: GB2560929A
Application number: GB1704930.5A
Authority: GB
Inventors: Jones David; Boys Martin; Bonham Chris
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-03-28
Filing date: 2017-03-28
Publication date: 2018-10-03
Also published as: GB201704930D0

Abstract

A bracket 100 for mounting a vehicle lamp has a first locating feature (apertures 114, 116, fig 2) for securing to a structural element (e.g. outrigger 150, fig 6), a second locating feature (boss 32 and set screw 34 in tapered bore 118, fig 3) for securing to the lamp housing 30 with compliance in the location of the lamp housing 30 relative to the structural element. The compliance allows for tolerances during assembly. A cruciform protrusion 122 gives a third locating feature to position the bracket relative to a fender, and a tab (126, fig 3) prevents rotation. Apertures (114, 116, fig 2) are oversized to provide compliance. The bracket can be injection moulded with a reinforcing lattice (106, fig 2). The assembly can withstand loads driving off road.

Description

(71) Applicant(s):

(56) Documents Cited:

EP 1491401 A2 US 20080157563 A1

EP 1481878 A1 US 20050073854 A1

Jaguar Land Rover Limited (Incorporated in the United Kingdom)

Abbey Road, Whitley, Coventry, Warwickshire, CV3 4LF, United Kingdom (58) Field of Search:

INT CL B60Q, B62D, F21V Other: EPODOC,WPI (72) Inventor(s):

David Jones Martin Boys Chris Bonham (74) Agent and/or Address for Service:

JAGUAR LAND ROVER

Patents Department W/1/073, Abbey Road, Whitley, Coventry, Warwickshire, CV3 4LF, United Kingdom (54) Title of the Invention: A bracket for mounting a lamp housing to a motor vehicle Abstract Title: Bracket for mounting a lamp housing to a motor vehicle (57) A bracket 100 for mounting a vehicle lamp has a first locating feature (apertures 114, 116, fig 2) for securing to a structural element (e.g. outrigger 150, fig 6), a second locating feature (boss 32 and set screw 34 in tapered bore 118, fig 3) for securing to the lamp housing 30 with compliance in the location of the lamp housing 30 relative to the structural element. The compliance allows for tolerances during assembly. A cruciform protrusion 122 gives a third locating feature to position the bracket relative to a fender, and a tab (126, fig 3) prevents rotation. Apertures (114, 116, fig 2) are oversized to provide compliance. The bracket can be injection moulded with a reinforcing lattice (106, fig 2). The assembly can withstand loads driving off road.

FIG. 9

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

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FIG. 10

A BRACKET FOR MOUNTING A LAMP HOUSING TO A MOTOR VEHICLE

TECHNICAL FIELD

The present disclosure relates to a bracket for mounting a lamp housing to a motor vehicle. Particularly, but not exclusively, the disclosure relates to a bracket comprising first and second locating features. Aspects of the invention relate to a bracket, to a motor vehicle, to a motor vehicle lamp mounting assembly and to a method of mounting a lamp housing to a motor vehicle.

BACKGROUND

Exterior trim panels such as lamp housings, bumpers and fenders on modern motor vehicles comprises substantial sub-assemblies that must be securely fixed to a structural element of the vehicle. Commonly the exterior trim panels have a complex outer-surface curvature that contributes to the aerodynamic profile of the vehicle and the aesthetic appeal of the vehicle.

Central to maintaining the aerodynamic profile of the vehicle and the aesthetic appeal of the vehicle is providing a flush outer surface between the multiple exterior trim panels. The flush outer surface may be achieved by managing the steps and gaps between those panels.

Previous arrangements and methods provide insufficient control of those steps and gaps. Furthermore, the use of alternate materials and build sequences has meant that current solutions are unable to satisfy step and gap requirements.

Lamp housings on modern vehicles may weigh up to 7.5 kg each. The use of novel materials for exterior trim panels such as bumpers and fenders means that those panels may not have sufficient strength to support the lamp housings.

It is the aim of the present invention solve one or more of the aforementioned problems.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a bracket, a motor vehicle, a motor vehicle lamp mounting assembly and a method of mounting a lamp housing to a motor vehicle as claimed in the appended claims.

According to an aspect of the invention, there is provided a bracket for mounting a lamp housing to a motor vehicle, the bracket comprising: a first locating feature configured to secure the bracket to a structural element of the motor vehicle; and a second locating feature configured to secure a lamp housing to the bracket, wherein the second locating feature provides compliance in the location of the lamp housing relative to the structural element of the motor vehicle along at least one axis.

Variations in the build dimensions from vehicle to vehicle may thus be managed to ensure the desired location of the lamp housing.

The second locating feature may be configured to bear at least a partial load of the lamp housing. Non-weight bearing materials may thereby be used for parts of the vehicle which otherwise may have been used to support the load of the lamp housing.

The second locating feature may form a sliding joint with the lamp housing. The at least one axis may be the motor vehicle X-axis.

The bracket may comprise a forward face and a rearward face and wherein the second locating feature may comprise a through-bore extending between the forward face and the rearward face for receiving a feature of the lamp housing.

The through-bore may comprise a boss. The through-bore may be tapered to a central plane between the forward and rearward faces of the bracket. The taper may provide a touch condition for the boss.

The bracket may include a third locating feature configured to locate the bracket relative to a fender of the motor vehicle.

The third locating feature may comprise a protrusion extending from the rearward face of the bracket.

The protrusion may comprise a cruciform.

The bracket may comprise an anti-rotation feature to prevent relative rotation between a fender and the bracket. The anti-rotation feature may be located on a rearward side of the bracket.

The bracket may be injection moulded.

According to another aspect of the invention, there is provided a structural element in combination with the bracket as hereinbefore described.

According to yet another aspect of the invention, there is provided a motor vehicle comprising the bracket as hereinbefore described.

According to a further aspect of the invention, there is provided a motor vehicle lamp mounting assembly comprising: a lamp housing for housing at least one lamp; a structural element of the motor vehicle; and a bracket for mounting the lamp housing, wherein the bracket includes a first locating feature and a second locating feature, the first locating feature being configured to secure the bracket to the structural element of the motor vehicle; and the second locating feature being configured to secure the lamp housing to the bracket, wherein the second locating feature provides compliance in the location of the lamp housing relative to the structural element of the motor vehicle along at least one axis.

The assembly may include a fender having an external surface, wherein the bracket comprises a third locating feature, the third locating feature being configured to locate the bracket relative to the fender.

The structural element of the vehicle may comprise a body in white. The structural element of the vehicle may comprise an outrigger.

The first locating feature may comprise at least one aperture for connecting to the outrigger.

The at least one aperture may be oversized to provide compliance along the Y and Z axes.

According to a still further aspect of the invention, there is provided a method of mounting a lamp housing to a motor vehicle comprising: providing a lamp housing for housing at least one lamp, providing a structural element of the motor vehicle; and providing bracket having a first locating feature configured to secure the bracket to a structural element of the motor vehicle; and a second locating feature configured to secure the lamp housing to the bracket, securing the bracket to the structural element of the motor vehicle using the first locating feature, locating the lamp housing in the bracket, setting the position of the lamp housing relative to the structural element of the motor vehicle along at least one axis, and securing the lamp housing to the structural element of the motor vehicle using the second locating feature.

The method may comprise providing a fender, providing the bracket with a third locating feature and setting the position of the bracket relative to the fender using the third locating feature before securing the bracket to the structural element of the motor vehicle.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a side elevation of a motor vehicle;

Figure 2 is an isometric view of the forward face of a bracket;

Figure 3 is an isometric view of the rearward face of the bracket of Figure 2;

Figure 4 is an isometric view of the bracket installed to a structural element of the motor vehicle;

Figure 5 is an isometric view of the bracket installed to a structural element of the motor vehicle;

Figure 6 is an alternate isometric view of Figure 5 with the bracket engaging a fender of the motor vehicle;

Figure 7 is side elevation of Figure 6;

Figure 8 is an alternate isometric view of Figure 5 with the bracket engaging a lamp housing of the motor vehicle;

Figure 9 is an alternate isometric view of Figure 8; and

Figure 10 is a flow chart of the method steps for aligning a lamp and fender on the motor vehicle of Figure 1.

DETAILED DESCRIPTION

A motor vehicle 10 is provided with a bonnet 20, lamp housings 30, a bumper 40 and a fender 50, all arranged at a front end of the motor vehicle 10. The motor vehicle 10 is further provided with a driver/passenger door 60. A Cartesian axis system associated with the vehicle 10 comprises an X-axis extending fore-to-aft, a Y-axis extending left-to-right (from the driver's perspective i.e. through the page), and a Z-axis extending top-to-bottom.

The bumper 40 wraps around the entire front end of the motor vehicle 10. Substantially identical lamp housings 30 and substantially identical fenders 50 are provided on the left hand and right sides of the motor vehicle 10. For the purpose of describing the present invention, only the left hand side (from the driver's perspective) shall be described in detail.

The bonnet 20, lamp housing 30, bumper 40 and fender 50 each provide an external surface for the motor vehicle 10 and therefore contribute to the aerodynamic profile of the motor vehicle 10. The bumper 40 abuts a lens of the lamp housing 30 at a bumper-lamp interface 44. The lens of the lamp housing 30 abuts the fender 50 at a fender-lamp interface 46.

The lamp housing 30, bumper 40 and fender 50 are each provided with various inwardly extending surfaces and attachment features in order that they may be securely fixed to one another and/ or to a structural element of the vehicle 10. The structural element may comprise the body in white (BiW), or brackets or outrigger connected to or integral with the body in white. By attaching the bonnet 20, lamp housing 30, bumper 40 and fender 50 providing the external surfaces of the motor vehicle 10 to each other, the steps and gaps between those external surfaces may be closely managed. The attachment of these components to each other need not necessarily be load bearing, but for locating adjacent surfaces relative to one another instead. This enables the aforementioned components to be manufactured out of novel, lightweight materials such as polymers or composite materials.

By attaching at least one of the bonnet 20, lamp housing 30, bumper 40 and fender 50, which are attached to each other, to a structural element of the vehicle 10 in a load bearing manner, the aforementioned at least one component is securely supported and can withstand the aerodynamic loading and vibration effects experienced by the motor vehicle 10 in use, including vibrations experienced when the motor vehicle 10 is used off road. The attachments of these vehicle components to a structural element of the vehicle must be load bearing. Components such as the lamp housing 30 can weigh in excess of 7kg, and attaching to a structural element of the vehicle in a load bearing manner avoids loading weaker, non-structural components such as the fender 50 which may be manufactured from a lightweight polymer.

The lamp housing 30 is mounted to the structural element of the vehicle by a bracket 100 as will be described in more detail below.

Referring to Figures 2 and 3, the bracket 100 has a forward face 102 and a rearward face 104. The forward face 102 is predominantly covered in a reinforcing structure. The reinforcing structure comprises a series of lattices 106 bounded by a rim 108. The forward face 102 includes a planar section 110, where no reinforcing structure is provided. The rearward face 104 is predominantly planar, save of a reinforcing structure covering one end thereof. The reinforcing structure similarly comprises a series of lattices 106 bounded by a rim 108. A tab 126 extends from the reinforcing structure provided on the rearward face 104.

A first locating feature comprises a pair of apertures 114, 116 which extend between the respective planar sections 110, 112 of the forward face 102 and the rearward face 104.

A second locating feature comprises a through-bore 118 extending between the respective reinforcing structures of the forward face 102 and the rearward face 104. The through-bore 118 is defined by a portion of the rim 108 of each of the forward face 102 and the rearward face 104 and is tapered to a central plane 120 between the forward and rearward faces 102, 104 of the bracket 100.

A third locating feature comprises a protrusion extending from the rearward face 104 of the bracket 100. The protrusion comprises a cruciform 122 and terminates in a point 124 distal from the bracket 100.

A tab 126 extends from the reinforcing structure provided on the rearward face 104. The tab comprises an anti-rotation feature to prevent relative rotation between the fender 50 and the bracket 100.

The bracket 100 is injection moulded.

The first locating feature is configured to secure the bracket 100 to a structural element of the motor vehicle 10. The second locating feature is configured to secure a lamp housing 30 to the bracket 100, and forms a sliding joint with the lamp housing 30 as will be explained in more detail below. The second locating feature provides compliance in the location of the lamp housing 30 relative to the structural element of the motor vehicle along at least one axis. The at least one axis is the X axis as shown in Figure 1. The third locating feature is configured to locate a fender 50 of the motor vehicle 10 relative to the bracket 100.

Referring to Figures 4 to 9 the motor vehicle lamp mounting assembly comprises the lamp housing 30, a structural element of the motor vehicle 10, and the bracket 100 described above.

The structural element comprises an outrigger 150. The outrigger has an L-shaped form, with a first end 152 including a connection region 154 for connecting to the BiW (not shown in the Figures) and a second end 156, also including a connection region 158 for connection to the BiW. The L-shaped form defines a space 160 into which the lamp housing 30 is located. During assembly, the bracket 100 is attached to the outrigger 150 adjacent the second end 156 by a pair of fasteners 162, which pass through the pair of apertures 114, 116 of the bracket 100 and a coincidental pair of apertures in the outrigger 150 (not shown).

The pair of apertures 114, 116 in the bracket 100 are oversized relative to those in the outrigger 150 so as to provide compliance in Y and Z (as shown in Figure 1) when fitting the bracket 100.

The fender 50 includes an internal fender arm 52, best shown in Figure 6. The internal fender arm 52 includes a bracket locating aperture 54 and a bracket securing aperture 56. The internal fender arm 52 terminates in flange 58. During assembly, the bracket locating aperture 54 is used to locate the bracket 100 by passing the cruciform 122 through the bracket locating aperture 54. This aligns the bracket securing aperture 56 of the fender 50 with the through-bore 118 of the bracket 100. Furthermore, the flange 58 abuts tab 126 of the bracket 100, so as to prevent relative rotation between the fender 50 and the bracket 100.

The lamp housing 30 is assembled to the bracket 100 and fender 50 using fastening arrangement 34, which passes through a boss 32 arranged within the through-bore 118 of bracket 100. The taper to the central plane 120 of the through-bore 118 of the bracket 100 provides a touch condition for the boss 32.

The method of mounting the lamp housing 30 to the motor vehicle 10 comprises the following steps (see Figure 10).

Firstly, the fender 50 is secured to the vehicle 10, by either direct connection to the BiW or by brackets connected to the body in white (Step 1). The fender 50 is positioned flush with the driver/passenger door 60, however because of tolerance in the BiW the exact location of the fender 50 varies from vehicle 10 to vehicle.

Once the fender 50 is secured to the vehicle 10, the outrigger 150 is secured to the BiW (Step 2).

The bracket 100 is then loosely attached to the outrigger 150 (Step 3). The bracket 100 is fitted to the outrigger 150 via the first locating feature. Specifically, the pair of fasteners 162 are passed through the coinciding pairs apertures of the bracket 114, 116 and the outrigger 150 so as to loosely hold in place the bracket 100 to outrigger 150. The third locating feature is used to locate the bracket 100 relative to the fender 50 of the motor vehicle 10 (Step 4). Specifically, cruciform 122 engages in bracket locating aperture 54 to set the Z-position and Y-position of the bracket 100 relative to the fender 50. Movement of the bracket 100 in Z and

Y is accommodated by the oversize nature of the coinciding pairs apertures of the bracket 114, 116 of the first locating feature, relative to the outrigger 150 apertures. The pair of fasteners 162 are then finally fastened to secure the bracket 100 to the outrigger 150 (Step 5).

With the bracket 100 and outrigger 150 securely fixed to the BiW, the lamp housing 30 is positioned in the bracket 100 (Step 6) with the required X-position to ensure a flush condition between the bumper-lamp interface 44 and a fender-lamp interface 46. The lamp housing 30 is connected to the fender 50 by the set screw fastening arrangement 34, which passes through the boss 32 arranged within the through-bore 118 of bracket 100 to secure the lamp housing 30 (Step 7).

The X-position gap between the lamp housing 30 and fender 50 is set by the set screw fastening arrangement 34 based on an average tolerance of the BiW, however the position of the lamp housing 30 within the bracket 100 will vary in dependence on the position of the fender 50 which is ultimately dictated by tolerances within the BiW. These will vary from vehicle 10 to vehicle.

Claims

1. A bracket for mounting a lamp housing to a motor vehicle, the bracket comprising:

a first locating feature configured to secure the bracket to a structural element of the motor vehicle; and a second locating feature configured to secure a lamp housing to the bracket, wherein the second locating feature provides compliance in the location of the lamp housing relative to the structural element of the motor vehicle along at least one axis.

2. The bracket according to claim 1, wherein the second locating feature is configured to bear at least a partial load of the lamp housing.

3. The bracket according to claim 1 or claim 2, wherein the second locating feature forms a sliding joint with the lamp housing.

4. The bracket according to any preceding claim, wherein the at least one axis is the motor vehicle X-axis.

5. The bracket according to any preceding claim, wherein the bracket comprises a forward face and a rearward face and wherein the second locating feature comprises a through-bore extending between the forward face and the rearward face for receiving a feature of the lamp housing.

6. The bracket according to claim 5, wherein the through-bore comprises a boss.

7. The bracket according to claim 6, wherein the through-bore is tapered to a central plane between the forward and rearward faces of the bracket.

8. The bracket according to claim 7, wherein the taper provides a touch condition for the boss.

9. The bracket according to any preceding claim, comprising a third locating feature configured to locate the bracket relative to a fender of the motor vehicle.

10. The bracket according to claim 9, wherein the third locating feature comprises a protrusion extending from the rearward face of the bracket.

The bracket according to claim 10, wherein the protrusion comprises a cruciform.

12. The bracket according to any preceding claim, wherein the bracket comprises an anti-rotation feature to prevent relative rotation between a fender and the bracket.

13. The bracket according to claim 12, wherein the anti-rotation feature is located on a rearward side of the bracket.

14. The bracket according to any preceding claim, wherein the bracket is injection moulded.

15. A structural element in combination with the bracket according to any of claims 1 to 14.

16. A motor vehicle comprising the bracket according to any of claims 1 to 14.

17. A motor vehicle lamp mounting assembly comprising:

a lamp housing for housing at least one lamp;

a structural element of the motor vehicle; and a bracket for mounting the lamp housing, wherein the bracket includes a first locating feature and a second locating feature, the first locating feature being configured to secure the bracket to the structural element of the motor vehicle; and the second locating feature being configured to secure the lamp housing to the bracket, wherein the second locating feature provides compliance in the location of the lamp housing relative to the structural element of the motor vehicle along at least one axis.

18. The motor vehicle assembly according to claim 17, comprising a fender, wherein the bracket comprises a third locating feature, the third locating feature being configured to locate the bracket relative to the fender.

19. The motor vehicle assembly according to claim 17 or claim 18, wherein the structural element of the vehicle comprises a body in white.

20. The motor vehicle assembly according to claim 17 or claim 18, wherein the structural element of the vehicle comprises an outrigger.

21. The motor vehicle assembly according to claim 20, wherein the first locating feature comprises at least one aperture for connecting to the outrigger.

22. The motor vehicle assembly according to claim 21, wherein the at least one aperture is oversized to provide compliance along the Y and Z axes.

23. A method of mounting a lamp housing to a motor vehicle comprising:

providing a lamp housing for housing at least one lamp, providing a structural element of the motor vehicle; and providing bracket having a first locating feature configured to secure the bracket to a structural element of the motor vehicle; and a second locating feature configured to secure the lamp housing to the bracket, securing the bracket to the structural element of the motor vehicle using the first locating feature, locating the lamp housing in the bracket, setting the position of the lamp housing relative to the structural element of the motor vehicle along at least one axis, and securing the lamp housing to the structural element of the motor vehicle using the second locating feature.

24. The method of claim 23 comprising:

providing a fender, providing the bracket with a third locating feature, setting the position of the bracket relative to the fender using the third locating feature before securing the bracket to the structural element of the motor vehicle.

Intellectual

Property

Office

Application No: GB1704930.5 Examiner: Terence Newhouse