WO2005009794A1

WO2005009794A1 - Attachment system for rails within a vehicle

Info

Publication number: WO2005009794A1
Application number: PCT/US2004/023005
Authority: WO
Inventors: Thomas S. Hodgson; Mathias R. Fox; Steven M. Spoerre; Kermit A. Anderson; William R. Beland
Original assignee: Johnson Controls Technology Company
Priority date: 2003-07-22
Filing date: 2004-07-16
Publication date: 2005-02-03
Also published as: KR20060059967A; CN1826246A; EP1646532A1

Abstract

An attachment system (20) for a rail system within a vehicle includes a bracket member having a first portion (24) configured for attachment to the rail system and a second portion (30) configured for attachment to a structural member of the vehicle. The first portion (24) and the second portion (30) are interconnected by a third portion that is configured to permit movement of the first portion (24) relative to the second portion (30) when a condition occurs. An attachment system is also disclosed that includes an opening in a base of a rail (12) of the rail system, and a retainer having one end coupled to the structural portion and another end engaging the opening and configured to support the rail (12) and to permit movement of the rail (12) relative to the structural portion when a condition occurs.

Description

ATTACHMENT SYSTEM FOR RAILS WITHIN A VEHICLE CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present Application claims the benefit of priority, as available under 35 U.S.C. § 119(e)(1 ) to U.S. Provisional Patent Application No. 60/489,134 titled "Attachment System For Rails Within A Vehicle" filed on July 22, 2003 (which is incorporated by reference in its entirety).

[0002] The following U.S. Patent is hereby incorporated by reference: U.S. Patent No. 6,669,260 titled "Modular System for a Vehicle" filed May 1 , 2001 and issued on December 30, 2003.

FIELD

[0003] The present invention relates to an attachment system for rails within a vehicle. The present invention relates more particularly to a system for attaching rails to an overhead portion of a vehicle. The present invention relates more particularly to a system for attaching rails to an overhead portion of a vehicle and intended to accommodate forces on the rails that may be created during a collision or other impact on the vehicle.

BACKGROUND

[0004] Rail systems or tracks are increasingly being used within vehicles for mounting various modules or articles for use by the occupants of a vehicle. Such rail systems may be attached to an overhead portion of the vehicle, such as the interior roof structure, and are configured for attachment of the modules or articles for access by the occupants of the vehicle. Mounting of the modules or articles to the rail system increases the weight of the system and results in increased force levels that are transmitted to the attachment structures used to secure the rails to the vehicle structure during rapid deceleration events such as collisions or other vehicle impact scenarios. [0005] In such rail systems, the rails are typically attached to the structure of the vehicle by generally rigid attachment systems such as by threaded fasteners, spring clips, etc.

[0006] It would be desirable to provide an attachment system for rail systems in a vehicle that is designed to accommodate the increased forces resulting from the weight of the modules or articles attached to the rail systems during vehicle collisions. It would also be desirable to provide an attachment system for a rail system intended to maintain the physical integrity of the rail system in the event that deformation of vehicle structure occurs.

[0007] Accordingly, it would be advantageous to provide an attachment system for rail systems that absorbs energy from the rail system and the modules in the event of a collision. It would also be advantageous to provide an attachment system for rail systems that permits limited movement of the rail system relative to the vehicle structure during accident scenarios. It would also be advantageous to provide an attachment system for rail systems that secures the rail systemJo the vehicle structure in a rigid manner during normal vehicle operating conditions and secures the rail system to the vehicle structure in a flexible manner during vehicle collision scenarios.

[0008] Accordingly, it would be advantageous to provide an attachment system for a rail system in a vehicle having any one or more of these or other advantageous features.

SUMMARY

[0009] The present invention relates to an attachment system for coupling a rail system to an interior of a vehicle and includes a bracket member having a first portion configured for attachment to the rail system and a second portion configured for attachment to a structural member of the vehicle, where the first portion and the second portion are interconnected by a third portion that is configured to permit movement of the first portion relative to the second portion when a condition occurs.

[0010] The present invention also relates to a retainer device for permitting movement of an object between a fixed position and a tethered position within a vehicle when a condition occurs. The device includes a bracket having a first portion adapted to couple to the object and a second portion adapted to couple to the vehicle. A third portion interconnects the first portion and the second portion to position the object in the fixed position before the condition occurs and to permit movement of the object to the tethered position after the condition occurs.

[0011] The present invention also relates to an attachment system for coupling a rail system to a structural portion of a vehicle and includes an opening in a base of a rail of the rail system, and a retainer having a first end coupled to the structural portion and a second end engaging the opening and configured to support the rail and to permit movement of the rail relative to the structural portion when an event occurs.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIGURE 1 is a schematic representation of a rail system in a vehicle according to an exemplary embodiment.

[0013] FIGURE 2 is a schematic representation of a top view of an attachment system for a rail system in a vehicle according to an exemplary embodiment.

[0014] FIGURE 3 is a schematic representation of a perspective view of a portion of an attachment system for a rail system in a vehicle according to an exemplary embodiment.

[0015] FIGURE 4 is a schematic representation of a perspective view of a cutaway portion of an attachment system for a rail system in a vehicle according to an exemplary embodiment.

[0016] FIGURE 5 is a schematic representation of a cross-sectional elevation view of an attachment system in a pre-deployment configuration for a rail system in a vehicle according to an exemplary embodiment.

[0017] FIGURE 6 is a schematic representation of the cross-sectional elevation view of the attachment system of FIGURE 5 in a post-deployment configuration for a rail system in a vehicle according to an exemplary embodiment.

[0018] FIGURE 7 is a graphic image of a perspective view of an article attachment system for a rail system in a vehicle according to another exemplary embodiment.

DETAILED DESCRIPTION

[0019] The various embodiments for an attachment system for a rail system are shown and described for rail systems configured to attach to an overhead portion of a vehicle (shown schematically as a vehicle roof structure). However, the description of the various embodiments of the attachment system for a rail system are equally applicable to attachment systems for other locations within a vehicle, such a floor areas, cargo storage areas, seat backs, side panels, etc.

[0020] Referring to FIGURE 1 , a rail system 10 for a vehicle is shown according to an exemplary embodiment. Rail system 10 may include one or more, (shown as two) elongated members (e.g. tracks, etc.) shown as rails 12 disposed on a panel 14 in a vehicle (shown as an overhead panel such as a headliner, etc.) and configured to receive various modules or articles (shown generally as articles 18) such as shown and described in U.S. Patent No. 6,669,260 titled "Modular System for a Vehicle" filed May 1 , 2001 and issued on December 30, 2003 (the disclosure of which is incorporated by reference).

[0021] Referring to FIGURES 2 through 6, an attachment system 20 for a rail system in a vehicle (such as, but not limited to, the rail system of FIGURE 1 ) is shown according to an exemplary embodiment. Attachment system 20 includes a base member 22 (e.g. bracket, plate, interface, etc.) that includes a first portion 24 for attachment of rails 12 to the base member 22, and a second portion 30 for attachment of base member 22 to a structural portion 16 (shown in FIGURES 5 and 6) of the vehicle (e.g. cross header, roof bow, pillar, panel, etc.).

[0022] According to one embodiment, base member 22 is made of a light-weight material such as a thermoplastic material (e.g. ABS plastic, polycarbonate, glass- filled polypropylene, etc.) in a molding process (such as injection molding, insert molding, etc.) and is shown as a generally rectangular member, but may be any suitable shape and contour as desired for attaching the rail system to the structural portion of the vehicle. According to one exemplary embodiment where the rail system is provided on an overhead portion of the vehicle interior, the base member 22 is shown in FIGURES 5 and 6 as located above panel 14, shown schematically as a headliner, (e.g. on the back surface or "C" surface of the headliner) and between the headliner and a structural portion 16 of the vehicle roof.

[0023] First portion 24 includes one or more apertures 26 (shown schematically in FIGURES 2 and 4 as provided within bosses having stiffening gussets or webs) for receiving fasteners of a conventional type for securing the rails 12 to the first portion 24 of base member 22. According to an exemplary embodiment, the rails 12 are disposed against a surface of the panel 14 (shown as a headliner) that faces the interior of the vehicle (e.g. an "A" surface of the headliner) and configured for attachment to the first portion 24 by conventional fasteners, so that the headliner is "sandwiched" between the rails 12 and the first portion 24 of the base member 22 (see FIGURES 5 and 6).

[0024] Second portion 30 of base member 22 includes retaining structure 32 configured for holding a resilient connector 34 (shown schematically in FIGURE 3 as a spring clip, such as a Z-axis clip, etc.) secured with a conventional fastener (shown as a threaded fastener in FIGURES 5 and 6). The fastener is intended to enhance serviceability by permitting the base member to be removed from the vehicle structure by removing the fastener and thereby allowing the resilient connector to remain coupled to the structural portion 16. According to an alternative embodiment, the base member may be molded around the resilient connector to encapsulate at least a portion of the resilient connector for securing the resilient connector to the base.

[0025] The resilient connector 34 is shown to engage structural portion 16 of the vehicle (e.g. through an aperture, slot, etc.) in a manner that is intended to secure the base member to the structural portion of the vehicle. The attachment of the second portion of the base member to the vehicle structure is intended to provide structural support to the first portion of the base member and to the rail system (and various articles or modules attached thereto). [0026] Second portion 30 of base member 22 further includes a deployable section 40 that is configured to permit movement of the rail system relative to the structural portion 16 during a collision or other impact to the vehicle, such as may result in deformation of the structural portion. Deployable section 40 comprises a panel having one or more "weakened" areas of material 42 (shown as a series of "slots" separated by relatively small "links" or "bridges" of material) that are sized and shaped to be "broken" or "severed" by certain predetermined force levels that may be associated with deformation of the structural portion of the vehicle, but that provide sufficient strength to support the rail system during "normal" vehicle operating conditions. According to an alternative embodiment, the weakened areas of material may be provided by grooves, scores, perforations, etc. that are sized to permit separation during appropriate predetermined force levels associated with deformation of the structural portion.

[0027] Deployable section 40 further includes a third section configured to function as connecting sections (e.g. links, tethers, strips, carriers, straps, hangers, etc. - shown schematically as two tethers 44) associated with the weakened areas of material that interconnect the first portion 24 and the second portion 30 of base member 22. As shown schematically in FIGURE 6, separation (e.g. breaking, shearing, severing, etc.) of the weakened areas of material results in "deployment" of tethers 44 so that resilient connectors 34 remain attached to the structural portion 16 of the vehicle, but the rail system 10 is permitted to "release" or otherwise move independent of the structural portion 16 and remain "tethered" by tethers 44 within a restricted range of movement, generally determined by the length and flexibility of the tethers. In the embodiment of an overhead system as shown in the FIGURES, the rail system 10 and the first portion 24 of the base member may "break-away" (e.g. shift downward) from the second portion 30 of the base member 22 by a certain distance determined by the length and resiliency of the tethers 44, where the rail system 10 and first portion 24 of the base member 22 remain "tethered" by the resilient connectors 34 and the tethers 44 to the structural portion 16.

[0028] According to a preferred embodiment, the deployment section 40 is a separate member that is coupled to the base member (e.g. by insert molding, etc.). To secure first portion 24 to deployment section 40, deployment section 40 is formed with engaging structure (shown as apertures or openings 46) within which the material of the base member may extend or otherwise engage in a restricting or retaining manner during formation of the base member (e.g. molding). According to an alternative embodiment, the engaging structure may have other forms (e.g. lips, ridges, channels, etc.) that are configured to be retained within the base member upon molding. According to one embodiment, the panel of the deployment section is made of a relatively strong, but ductile material such as a relatively thin metallic material (e.g. steel, steel alloys, aluminum, etc.) that is integrally molded into the base member. According to alternative embodiments, the panel of the deployment section may be made of any suitable material that provides sufficient strength to support the rail system during normal conditions, but also provides sufficient ductility and flexibility to function as tethers during accident scenarios involving deformation of the structural portion of the vehicle. Further, the panel of the deployment section may be coupled to the base member by any suitable method, such as adhesives, chemical bonding, or fasteners (e.g. screws, rivets, etc.).

[0029] Referring to FIGURE 7, an attachment system for a rail system in a vehicle is shown according to another exemplary embodiment. Attachment system 50 is intended to permit the rail to "slide" longitudinally against a generally fixed retainer when a certain predetermined force on the rail is exceeded by allowing a slot in the rail to slide along the retainer (e.g. "slotted rail" retainer, etc.). Attachment system 50 includes a channel 52 (e.g. groove, etc.) in a base 54 of the rail 12 that is oriented against a mounting panel of the vehicle (e.g. headliner, etc.). A slot 62 is provided longitudinally along a predetermined length of rail 12 within channel 52. A retainer member 56 has a first end 58 configured to extend into channel 52 and a fastener 64 is provided to attach channel 52 of rail 12 to first end 58 of retainer member 56 in a generally abutting relationship to provide a slidable interface. Retainer member 56 ^■ includes a second end 60 that is configured for attachment to a resilient connector 34. Resilient connector 34 is attachable to the structural portion of the vehicle (not shown) by insertion through a suitable aperture or the like in the structural portion in a conventional manner (not shown for clarity). [0030] The slidable interface between first end 58 of retainer member 56 and channel 52 is configured to permit relative movement (e.g. sliding, etc.) of the channel 52 of rail 12 relative to the generally fixed retainer member 56 and resilient connector 34 and the structural portion 16. The degree of movement of rail 12 that is permitted by retainer 56 is predetermined and may be varied according to the coefficients of friction of the interfacing surfaces between channel 52 and first end 58 of retainer member 56, and the clamping force between rail 12 and the retainer 56 provided by fastener 64. According to an alternative embodiment, the slidable interface may be provided between the second end of the retainer member and the retainer clip. According to another alternative embodiment, the slidable interface may be provided between the retainer clip and a slot within a structural portion of the vehicle.

[0031] According to any preferred embodiment, the attachment system for a rail system within a vehicle is intended to provide an attachment system that permits movement of the rail system relative to certain support or "anchor" locations that are intended to secure the rail system to the vehicle structure, during certain predetermined vehicle operation or structural deformation conditions to minimize potential degradation of the physical integrity of the rail system (and articles or modules attached thereto) during such vehicle operation of structural deformation conditions.

[0032] It is important to note that the construction and arrangement of the elements of the various embodiments of the attachment system provided herein is illustrative only. Although only a few exemplary embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments (such as variations in configurations, shape and size, mounting arrangements, construction of weakened areas of material, methods of coupling the panel of the deployment section to the base member, location and configuration of tethers, operation or deployment of the tethers, selection of materials for desired characteristics such as friction, strength, flexibility, ductility, etc., use of materials/colors, combinations of shapes, etc.) without materially departing from the novel teachings and advantages of the inventions. Further, the attachment system may be used in any type of vehicle such as trucks, recreational vehicles, minivans, sport utility vehicles, passenger automobiles, etc. and at any suitable location within the vehicle (such as floors, floor console systems, cargo storage areas, etc.). Accordingly, all such modifications are intended to be within the scope of the invention as defined in the appended claims.

[0033] The order or sequence of any process or method steps may be varied or re- sequenced according to alternative embodiments. In the claims, any means-plus- function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the inventions as expressed in the appended claims.

Claims

What is Claimed is:

1. An attachment system for a rail system fixed to a structural portion of a vehicle, comprising: a bracket having a first portion coupled to the rail system and a second portion coupled to the structural portion and a third portion interconnecting the first portion and the second portion wherein the third portion is movable from a secured position to a released position so that the rail system is at least partially releasable from the structural portion.

2. The attachment system of Claim 1 wherein the third portion is movable from the secured position to a released position during an accident condition.

3. The attachment system of Claim 1 wherein the deployment section includes a weakened section that is configured to separate to create at least one tether member that permits movement of the rail system independent of the structure of the vehicle within a predetermined range of movement.

4. The attachment system of Claim 1 wherein the deployment portion is formed of a first material and the bracket is formed of a second material.

5. The attachment system of Claim 1 wherein the deployment portion is integrally formed with the bracket.

6. The attachment system of Claim 1 wherein the bracket is disposed on a first side of a panel within the vehicle and the rail system is disposed on a second side of the panel.

7. The attachment system of Claim 6 wherein the panel is a headliner.

8. The attachment system of Claim 1 wherein the second portion is coupled to the structure by a resilient connector.

9. The attachment system of Claim 1 wherein the first portion is coupled to the rail system for a fastener.

10. The attachment system of Claim 3 wherein the weakened section comprises a plurality of openings.

11. The attachment system of Claim 1 wherein the first portion is tethered to the second portion by the third portion when a condition results in a predetermined force being exceeded.

12. A retainer device for permitting movement of an object between a fixed position and a tethered position within a vehicle when a condition occurs, comprising a bracket having a first portion adapted to couple to the object and a second portion adapted to couple to the vehicle, and a third portion interconnecting the first portion and the second portion to position the object in the fixed position before the condition occurs and to permit movement of the object to the tethered position after the condition occurs.

13. The retainer device of Claim 12 wherein the third portion has at least one weakened section configured to separate when the condition occurs.

14. The retainer device of Claim 12 wherein the third portion comprises a substantially flexible material.

15. The retainer device of Claim 12 wherein the object is restrained within a limited range of motion in the tethered position by the third portion.

16. The retainer device of Claim 12 wherein the first portion is connected directly to the second portion before the condition occurs and the first portion is connected indirectly to the second portion after the condition occurs.

17. The retainer device of Claim 12 wherein the condition is representative of an accident condition.

18. An attachment device for a rail system within a vehicle including at least one rail member coupled to a structure of the vehicle, comprising: an elongated opening within the rail member, and a retainer member having a first end coupled to the rail member and movably engaging the elongated opening and a second end fixed to the vehicle so that the rail member is movable relative to the vehicle when an event occurs.

19. The attachment device of Claim 18 further comprising a slidable interface between the retainer member and the rail member.

20. The attachment device of Claim 19 wherein the first end of the retainer member is coupled to the rail member by a fastener.

21. The attachment device of Claim 20 wherein the slidable interface is adjustable by varying at least one of a coefficient of friction of the rail member, a coefficient of friction of the retainer member, and a force imparted by the fastener.

22. The attachment device of Claim 20 wherein the fastener is configured to move within the elongated opening.

23. The attachment device of Claim 18 wherein the event is a collision.