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My wife's Yaris started rattling within the first couple of months of being brand new - as soon as the temperature started changing (I know, it's a Yaris but when I was researching the problem it was a common complaint in other Toyotas). It rattled where the dash meets the a-pillars. I had it back to Toyota a few times until I finally convinced them to put some felt at that joint and it fixed the problem.
I wouldn't be surprised if the rattle/scrape around the a/c vents (or most anywhere else) where the two different plastics meet is something similar. Something that may have been snug and quiet before while temps were warm will contract a bit when things cool off and allow for more movement.
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