Claims:WE CLAIM:
1. A component receptacle (200) for motor vehicles (10), the component receptacle (200) comprising:
a body (210) having an opening (220) configured to receive a component (110), the opening (220) having an inner peripheral edge (230); and
a material interface (240) adapted on the inner peripheral edge (230) of the opening (220); wherein the component (110) received in the opening (220) sealingly engages with the material interface (240) and tightly fits in the opening (220).

2. The component receptacle (200) as claimed in claim 1, wherein the material interface (240) is molded on the inner peripheral edge (230) of the opening (220).

3. The component receptacle (200) as claimed in claim 1 and 2, wherein the inner peripheral edge (230) of the opening comprises at least one hole (212), the hole (212) receives a portion of the material interface (240).

4. The component receptacle (200) as claimed in claim 1, wherein the material interface (240) is made of a thermoplastic elastomer (240) comprising rubber or foam.
5. The component receptacle (200) as claimed in claim 1, wherein the component receptacle (200) is made of polymer material selected from a group comprising of poly propylene, Acrylonitrile Butadiene Styrene (ABS), Nylon based materials, Poly-Vinyl Chloride (PVC), and Poly Carbonate (PC).

6. A method (300) of manufacturing a component receptacle (300) for motor vehicles (10), the method (300) comprising the steps of:
forming (310) a body (210) of the component receptacle (200);
forming (320) an opening (220) in the body (210), the opening (220) having an inner peripheral edge (230) and configured to receive a component (110);
positioning (330) the body (210) in a mold; and
overmolding (340) a material interface (240) on the inner peripheral edge (230) of the opening (220).

7. The method (300) as claimed in claim 6, wherein the inner peripheral edge (230) of the opening (220) comprises at least one hole (212), the hole (212) receives a portion of the overmolded material interface (240).
, Description:FIELD OF THE INVENTION
[001] The present invention relates to a component receptacle for motor vehicles and a method of manufacturing the same.

BACKGROUND OF THE INVENTION
[002] A typical motor vehicle has multiple receivable components mounted on and received by other receiving components. For instance, a visor is mounted on a headlamp assembly for increased aerodynamics or improved aesthetics. A lens is mounted on a headlamp to protect the headlamp from external damaging factors such as gravel, water etc. A fuel cap is received by a slot in a fuel tank wherein the slot is an opening for receiving fuel and the fuel cap provides an enclosure to the slot of the fuel tank. A speedometer is received in a housing located rear to the headlamp assembly. A lens is mounted on a turn signal indicator to protect a light source inside the turn signal indicator from external damaging factors, etc.
[003] These receivable components are configured such that they snuggly fit or have a snap fit mechanism or are tightly fit by screws, nuts and bolts, in the receiving components. The receivable components are tightly coupled with the receiving components for a reason that the receivable components such as headlamp visors, lens, fuel tank caps, speedometers, etc. should not move or vibrate when the motor vehicle is in motion, especially on a rough terrain. However, in spite of the tight coupling of the receivable components with the receiving components there still are many problems.
[004] One major problem arises due to inherent manufacturing variations. In the sense, although a receivable component like a housing for a speedometer is made with respect to shape and outer physical characteristics of the speedometer, which is the receiving component, however both the components involve separate manufacturing techniques, processes and machines. Therefore, there are generally defects in the housing due to which the speedometer does not tightly fit inside the housing. On the other hand, a manufacturing defect may also cause an extreme tight fit of the receivable component inside the receiving component.
[005] In view of the above, if the speedometer is not snuggly fit inside the housing, the speedometer cannot withstand vibrations arising from the motor vehicle. Such vibrations in the motor vehicle are essentially those that emanate due to the engine and those that emanate when the vehicle is in motion. These vibrations cause the speedometer to vibrate, which causes damage to both, the speedometer and the speedometer housing. Further, the vibration of the speedometer causes dials of the speedometer to rattle/ flicker profusely when the vehicle is in motion, which affects the perceived indication of the rider. Thus, over a period of time, the speedometer becomes loose and either the speedometer or the housing has to be replaced.
[006] If however, the speedometer casing has an extreme tight fit with the housing; it is also as undesirable as a loose fit. For example, an extremely tight fit causes undesirable friction between walls of the speedometer casing and the housing. This undesirable friction between the walls of the speedometer casing and the housing leads to white powder formation and causes damage to both, the speedometer and the housing as well.
[007] Thus, there is a need in the art for a component receptacle which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] In one aspect, the present invention is directed to a component receptacle for motor vehicles. The component receptacle comprises a body having an opening configured to receive a component, the opening having an inner peripheral edge; and a material interface adapted on the inner peripheral edge of the opening; wherein the component received in the opening sealingly engages with the material interface and tightly fits in the opening.
[009] In an embodiment of the present invention, the material interface is molded on the inner peripheral edge of the opening.
[010] In another embodiment of the present invention, the inner peripheral edge of the opening comprises at least one hole, the hole receives a portion of the material interface.
[011] In a further embodiment of the present invention, the material interface is made of thermoplastic elastomer comprising rubber or foam. Further, the component receptacle is made of polymer material Acrylonitrile Butadiene Styrene (ABS), Nylon based materials, Poly-Vinyl Chloride (PVC), and Poly Carbonate (PC).
[012] In another aspect, the present invention is directed towards a method of manufacturing a component receptacle for motor vehicles, the method comprising the steps of: forming a body of the component receptacle; forming an opening in the body, the opening having an inner peripheral edge and configured to receive a component; positioning the body in a mold; and overmolding a material interface on the inner peripheral edge of the opening.
[013] In an embodiment of the present invention, the inner peripheral edge of the opening comprises at least one hole, the hole receives a portion of the overmolded material interface.

BRIEF DESCRIPTION OF THE DRAWINGS
[014] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 shows a side view of a motor vehicle in accordance with an embodiment of the invention.
Figure 2 shows a rear view of the motor vehicle in accordance with an embodiment of the invention.
Figure 3 shows an instrument cluster in accordance with an embodiment of the invention.
Figure 4 shows an instrument cluster in accordance with an embodiment of the invention.
Figure 5 shows a cross sectional view of the instrument cluster in accordance with an embodiment of the invention.
Figure 6 shows a component receptacle in accordance with an embodiment of the invention.
Figure 7 shows a component receptacle in accordance with an embodiment of the invention.
Figure 8 shows a method of manufacturing the component receptacle in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[015] The present invention relates to a component receptacle for motor vehicles and a method of manufacturing the same.
[016] Figure 1 illustrates an exemplary motor vehicle, in accordance with an embodiment of the invention. The motor vehicle 10 comprises an IC engine 12 that is vertically disposed. Preferably, the IC engine 12 is a single-cylinder type IC engine. The motor vehicle 10 comprises a front wheel 14, a rear wheel 16, a frame member (not shown), a seat assembly 18 and a fuel tank 20. The motor vehicle 10 has a head pipe (not shown) in the frame member, the head pipe supports a steering shaft (not shown) and two telescopic front suspensions 22 (only one shown) attached to the steering shaft through a lower bracket (not shown). The two telescopic front suspensions 22 support the front wheel 14. The upper portion of the front wheel 14 is covered by a front fender 24 mounted to the lower portion of the telescopic front suspension 22 at the end of the steering shaft. A handlebar 26 is fixed to upper bracket (not shown) and can rotate to both sides. A head light (not shown) affixed inside a headlamp assembly 28, a visor 30 positioned above the headlamp assembly 28, a pair of rear view mirrors 40 and instrument cluster 100 is arranged on an upper portion of the head pipe. The frame member comprises a down tube that may be located in front of the IC engine 12 and extends slantingly downward from head pipe. In an embodiment, the IC engine 12 is mounted vertically, with a cylinder block extending vertically above a crankcase.
[017] The fuel tank 20 is mounted on a horizontal portion of a main tube (not shown) the frame member. Seat rails are joined to main tube and extend rearward to support the seat assembly 18. A rear swing arm 32 is connected to the frame member to swing vertically, and the rear wheel 16 is connected to rear end of the rear swing arm 32. Generally, the rear swing arm 32 is supported by two suspensions 36 on either side of the motor vehicle 10. The rear wheel 16 arranged below the seat assembly 18 rotates by the driving force of the IC engine 12 transmitted through a chain drive (not shown) from the IC engine 12. A rear fender 38 is disposed above the rear wheel 16.
[018] Further, as shown in figure 2, the motor vehicle 10 comprises a tail light 42, a pair of turn indicators 44 disposed in the front of the motor vehicle 10 and a pair of turn indicators 46 disposed in the rear of the motor vehicle 10. Further, an exhaust pipe 48 of the motor vehicle 10 extends vertically downward from the IC engine 12 up to a point and then extends below the IC engine 12, longitudinally along the vehicle length before terminating in a muffler 50. The muffler 50 is typically disposed adjacent to the rear wheel 16.
[019] Referring to Figures 2 and 3, the motor vehicle 10 has an instrument cluster 100 disposed above the headlamp assembly 28 and behind the visor 30. In an embodiment, the instrument cluster 100 is capable of receiving one or more components (110), for example, gauges 110. In an embodiment, the gauges 110 is analog gauges, while in an alternative embodiment, the gauges 110 is digital gauges. In a further embodiment, the gauges 110 are a hybrid gauge comprising both analog and digital units.
[020] In one aspect, the present invention relates to a component receptacle 200. As seen in Figure 4, the instrument cluster 100 has the component receptacle 200 in accordance with an embodiment of the present invention and at least one gauge 110. The component receptacle 200 has a body 210 wherein the body 210 has an opening 220 (shown in Figure 6). Thus, as shown in Figures 5 and 6, the body 210 of the component receptacle 200 is configured such that the gauge 110 snuggly fits inside the opening 220 of the body 210. In an embodiment, the gauge 110 may be a digital/ analog speedometer or RPM meter or odometer or any combinations thereof.
[021] In various embodiments of the invention, the body 210 may be a housing, or a frame, or fuel tank, etc. having an opening to receive the components. For instance: a housing of an instrument panel wherein the housing has an opening to receive the various gauges; or a fuel tank, wherein the fuel tank has an opening to receive a fuel cap; or a headlamp assembly, wherein the headlamp has an opening to receive a lens; or a turn indicator, wherein the turn indicator has an opening to receive a lens of the turn indicator. Thus, although the present disclosure describes the invention vis-à-vis the instrument cluster 100, the description must not be construed to be limited only to the instrument cluster 100 as shown in the Figures.
[022] Figure 6 shows the component receptacle 200 in accordance with an embodiment of the present invention. The component receptacle 200 essentially has a body 210. In the present embodiment, the body 210 is configured/ shaped such that it can be received over the headlamp assembly. As seen in the figure, the body 210 has an opening 220. Thus, opening has an inner peripheral edge 230 defining the opening 220.
[023] According to the present invention, and referring to Figure 6, the inner peripheral edge 230 of the opening 220 has a layer of material interface 240, for instance a layer of material interface 240 adapted thereon. In an embodiment of the invention, the material interface 240 is molded on the inner peripheral edge 230 of the opening 220. According to the present embodiment, the gauge/s 110 is then received inside the opening 220. Thus, outer wall of the gauge/s 110 sealingly engages with the layer of the material interface 240 and thus tightly fits inside the opening 220 of the body 210. The layer of the material interface 240 is essentially made to obviate frictional engagement of the outer wall of the gauge/s 110.
[024] In an embodiment as shown in Figure 7, the inner peripheral edge 230 of the body 210 has at least one hole 212 therein. Thus, when the material interface 240 is molded over the inner peripheral edge 230, the material interface 240 is also received inside the hole 212. This ensures anchoring of the layer of material interface 240 on the inner peripheral edge 230 of the opening 220 formed in the body 210 of the component receptacle 200.
[025] In an embodiment of the invention, the material interface 240 is made of a soft material, for example, a thermoplastic elastomer like rubber. The thermoplastic elastomer generally exhibits enhanced flexibility and rebound characteristics. In an alternative embodiment, the material interface 240 is made of a foam material. In another embodiment of the invention, the body 210 of the component receptacle 200 is made of polymer material, for example, poly propylene material. In alternative embodiments, the component receptacle is made of other polymer materials such as Acrylonitrile Butadiene Styrene (ABS), Nylon based materials, Poly-Vinyl Chloride (PVC), Poly Carbonate (PC) etc.
[026] Another aspect of the present invention provides a method of manufacturing the component receptacle 200. Shown in Figure 8 is a process flow of the method of manufacturing the component receptacle 200 of the present invention. At step 310 of the method 300, a body 210 of the component receptacle 200 is formed. In an embodiment of the invention, the body 210 component receptacle 200 is made of a polymer material, for example, polypropylene material. In alternative embodiments, the component receptacle is made of other polymer materials such as Acrylonitrile Butadiene Styrene (ABS), Nylon based materials, Poly-Vinyl Chloride (PVC), Poly Carbonate (PC) etc. At step 320, an opening 220 is formed in the body 210 wherein the opening 220 has an inner peripheral edge 230. The opening is formed such that a component can be received therein. At step 330, the body 210 of the component receptacle 200 is positioned inside a mold. Further, at step 340 a material interface 240 is overmolded on the inner peripheral edge 230 of the opening 220 of the body 210. In an embodiment of the invention, the method 300 also includes a step of molding the holes 212 with the material interface 240. This ensures anchoring of the material interface 240 on the inner peripheral edge 230 of opening 220 formed in the body 210 of the component receptacle 200. In an embodiment of the invention, the material interface 240 is made of a soft material, for example, any thermoplastic elastomer like rubber, which generally exhibits enhanced flexibility and rebound characteristics. In an alternative embodiment, this can be made of a foam material.
[027] Advantageously, the present invention solves the problem of vibration of the gauges inside the body caused due to manufacturing defects. Further, the invention also solves the problem of damage caused to the body or to the gauges due to their frictional engagement. Consequently, the present invention entirely obviates white powder formation happening due to frictional engagement of the components. Furthermore, the present invention also solves the problem of rattling/ vibration of the dials of the gauges due to the presence of the thermoplastic polymer.
[028] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.