WO2009007935A2

WO2009007935A2 - Console box for motor vehicles

Info

Publication number: WO2009007935A2
Application number: PCT/IB2008/052790
Authority: WO
Inventors: Ravi Chitteti; Takaaki Nemoto
Original assignee: Sabic Innovative Plastics Ip B.V.
Priority date: 2007-07-12
Filing date: 2008-07-10
Publication date: 2009-01-15
Also published as: WO2009007935A3

Abstract

A console box (110) for motor vehicles designed to increase the safety to occupants during a collision. The console box includes a rigid, upper space box (115) and a more flexible lower stand (120). The space box (115) includes at least two side walls (130) and a plurality of inner support walls (160). The inner support walls (150) may be oriented horizontally, vertically (155), at an incline, or a combination thereof. The space box (115) portion is constructed from a more rigid plastic material, such as a fiber-reinforced plastic material, capable of absorbing impact energy from a collision event while helping prevent the seats (105) between which the console box is located from contacting one another. The stand portion (120) of the console box (110) is constructed from a more flexible plastic material capable of helping the space box portion (115) to be more properly oriented between the seats (105) during a collision event.

Description

CONSOLE BOX FOR MOTOR VEHICLES

FIELD OF INVENTION

[0001] The present invention relates to safety measures, and in particular, to safety measures for automobiles that help protect seat occupants during a side-on collision or a collision including side impact forces.

BACKGROUND OF INVENTION

[0002] Protection of motor vehicle occupants during a collision has grown increasingly important. Various safety measures, such as air bags, have been implemented over the years to protect occupants, especially from front and rear collisions. However, due to the nature of the collisions, protection of occupants from side impact collisions or collisions involving side impact forces have been more difficult to achieve. This can be especially important when a passenger car is impacted by a motor vehicle having a higher bumper on the side, thereby overriding the outer crash measures. As a result, the front seats of the car can contact one another causing injuries to the occupants. Advances in side airbags have helped prevent injury caused by contact with the chassis of the motor vehicle. However, minimal protection is afforded a motor vehicle occupant from the seat and/or person next to the occupant.

[0003] In one prior art solution, to protect seat occupants upon a motor vehicle collision including side impact forces, various seats have been proposed to help protect the occupants, hi these seats, reinforcing members are employed that are installed in seat cushions and/or seatbacks to reinforce them. With these reinforcing members, the mechanical strength of the seats is increased, so that even when the associated motor vehicle is subjected to a side-on vehicle collision, the seats are prevented from severe damage thereby protecting the seat occupants. However, these reinforcing members may be uncomfortable and also provide less protection from the seat and/or person next to the occupant if the collision is sufficiently severe to dislodge the seat. [0004] In an alternative solution, a space box is provided between seats in a motor vehicle wherein the space box is constructed from a material, such as a foamed aluminum or a rigid urethane foam, and is formed into a honeycomb structure member, or the like. However, in these solutions, the edges of the honeycomb structure are exposed to the side impact force. If the side-impact does not generate a force perpendicular to the structure, then this results in a high load on some of the edges causing those edges to fail first and more quickly than desired.

[0005] In another proposed solution, a shock absorbing structure is placed between the two seats. The shock absorbing structure is designed to absorb the forces of a seat during a collision involving side impact forces. However, as the devices absorb forces, these devices do not prevent the seats from contacting one another in the event the side impact forces are sufficiently strong.

[0006] Other prior art solutions are available, but these are generally constructed from steel parts that are connected using bolts/screws. The steel assembly satisfies safety requirements, but uses heavier, more expensive materials that, due to the weight of the metal, helps reduce the fuel efficiency of the motor vehicle.

[0007] Accordingly, it would be beneficial to provide a console box that is lighter than prior art solutions. It would also be beneficial to provide a console box capable of absorbing impact forces while also helping to prevent contact between motor vehicle seats in a collision involving side impact forces. It would also be beneficial to provide a console box that provides increased safety from all collisions involving side-impact forces and not just those having only a side-impact force.

SUMMARY OF THE INVENTION

[0008] The present invention addresses the issues associated with the prior art by providing a console box for motor vehicles designed to increase the safety to occupants during a collision that includes side impact forces. The console box of the present invention includes a rigid upper space box constructed from a material designed to withstand higher loads before crushing or breaking. The space box is connected to a lower stand portion constructed from a more flexible material designed to permit the space box to move based on the direction of the impact force to help ensure that, regardless of the direction of the side impact force, the more rigid space box remains located between the two seats in the event of a collision having side impact forces. The space box and stand portions are each constructed from an organic polymer material, thereby enabling lighter weight materials to be used, thereby decreasing the weight of the structure and/or increasing the fuel efficiency of the motor vehicle.

[0009] Accordingly, in one aspect, the present invention provides a console box including a space box portion comprising two side walls and a plurality of support walls disposed between the two side walls and a stand portion connected to the space box portion; wherein the space box portion is constructed from a rigid plastic material and wherein the stand portion is constructed from a flexible plastic material.

[0010] In another aspect, the present invention provides a method of forming a console box including the steps of molding a rigid plastic material to form a space box portion having two side walls and a plurality of support walls disposed between the two side walls, molding a flexible plastic material to form a stand portion, and connecting the space box portion to the stand portion.

BRIEF DECRIPTION OF THE DRAWINGS

[0011] The various embodiments of the present invention can be understood with reference to the following drawings. The components are not necessarily to scale. Also, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0012] Figure 1 is a front view of a motor vehicle interior showing the console box according to one embodiment of the present invention.

[0013] Figure 2 is a perspective view of a motor vehicle space box according to one embodiment of the present invention. [0014] Figure 3 is a side view of the inner walls of a motor vehicle space box according to one embodiment of the present invention.

[0015] Figure 4 is a side view of the inner wall structures of a motor vehicle space box according to another embodiment of the present invention.

[0016] Figure 5 is a side view of the inner wall structures of a motor vehicle space box according to yet another embodiment of the present invention.

[0017] Figure 6 is a side view of the inner wall structures of a motor vehicle space box according to still another embodiment of the present invention.

[0018] Figure 7 is a side view of a stand of a motor vehicle console box according to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The present invention is more particularly described in the following description and examples that are intended to be illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, the singular form "a," "an," and "the" may include plural referents unless the context clearly dictates otherwise. Also, as used in the specification and in the claims, the term "comprising" may include the embodiments "consisting of and "consisting essentially of." Furthermore, all ranges disclosed herein are inclusive of the endpoints and are independently combinable.

[0020] As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about" and "substantially," may not to be limited to the precise value specified, in some cases. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value.

[0021] The present invention provides by providing a console box for motor vehicles designed to increase the safety to occupants during a collision that includes side impact forces. The console box separates the seats that are mounted on the floor. The console box includes a space box to maintain the gap between seats in case of side impact. The space box is mounted on a stand that is connected to the floor of the vehicle. The entire unit is included in the console box. To maintain the gap between the seats during a collision event, the space box is beneficially constructed from a rigid material and/or construction. As such, the rigidity is achieved, in part, by using a plurality of walls. These walls, which may be horizontal, vertical, and/or inclined, offer resistance to seat movement during a collision event. The space box is constructed from a plastic material that provides a high Young's modulus.

[0022] In the console box of the present invention, the space box is mounted on a stand. Beneficially, the stand is sufficiently flexible to permit movement of the space box when a collision event occurs. The stand is also constructed from a plastic material, although a different plastic material is generally utilized to give the stand the flexibility to bend sideways when an impact occurs.

[0023] Accordingly, in one aspect, the present invention provides a console box having an upper space box portion constructed from a more rigid plastic material and a lower stand portion constructed from a more flexible plastic material. As used herein, a "rigid" material includes plastic materials having, in one embodiment, a Young's modulus of 4000 MPa or greater. In another embodiment, a "rigid" material includes plastic materials having a Young's modulus of 4500 MPa or greater. In still another embodiment, a "rigid" material includes plastic materials having a Young's modulus of 5000 MPa or greater. Conversely, as used herein, a "flexible" material includes plastic materials having, in one embodiment, a Young's modulus of 3000 MPa or less. In another embodiment, a "flexible" material includes plastic materials having a Young's modulus of 2500 MPa or less. In still another embodiment, a "flexible" material includes plastic materials having a Young's modulus of 2000 MPa or less.

[0024] The space box portion of the console box includes at least two side walls to help diffuse impact energy from a collision event and spread the energy to different portions of the space box. In addition, the space box includes a plurality of inner support walls disposed between the side walls to provide additional support to the space box. The space box is beneficially constructed from a lightweight material, such as from an organic polymer or plastic. The space box can be constructed in a single piece or can include a plurality of pieces that form the side walls and the inner support walls. As the space box portion of the console box is designed to receive the majority of the impact forces during the collision event, the space box is beneficially constructed from a more rigid polymer.

[0025] The space box portion of the console box may be formed from any organic polymer capable of forming a space box capable of providing increased safety to motor vehicle occupants during a collision involving side-impact forces. The organic polymer may be a crystalline polymer or an amorphous polymer. The organic polymer used in the present invention may be selected from a wide variety of thermoplastic resins or blends of thermoplastic resins. The organic polymer may also be a blend of polymers, copolymers, terpolymers, or combinations including at least one of the foregoing organic polymers. Examples of organic polymers that may be used in the present invention include, but are not limited to, polyacetals, polyacrylics, polycarbonates, polystyrenes, polyesters, polyamides, polyamideimides, polyarylates, polyarylsulfones, polyethersulfones, polyphenylene sulfides, polyvinyl chlorides, polysulfones, polyimides, polyetherimides, polytetrafluoroethylenes, polyetherketones, polyether etherketones, polyether ketone ketones, polybenzoxazoles, polyoxadiazoles, polybenzothiazinophenothiazines, polybenzothiazoles, polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines, polybenzimidazoles, polyoxindoles, polyoxoisoindolines, polydioxoisoindolines, polytriazines, polypyridazines, polypiperazines, polypyridines, polypiperidines, polytriazoles, polypyrazoles, polypyrrolidines, polycarboranes, polyoxabicyclononanes, polydibenzofurans, polyphthalides, polyacetals, polyanhydrides, polyvinyl ethers, polyvinyl thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl halides, polyvinyl nitriles, polyvinyl esters, polysulfonates, polysulfides, polythioesters, polysulfones, polysulfonamides, polyureas, polyphosphazenes, polysilazanes, or the like, or a combination including at least one of the foregoing organic polymers. [0026] As discussed, the space box is beneficially constructed from an organic polymer having a higher rigidity. Nevertheless, in select embodiments of the present invention, the space box is constructed from a fiber-reinforced plastic material. The fiber reinforcements enhance the impact strength and/or Young's modulus of the material, thereby increasing the rigidity of the plastic material and, therefore, the space box. rn one embodiment, the space box is constructed from a glass fiber reinforced plastic material, such as one of the VERTON^® resin grades available from General Electric. These resins include long glass fiber versions (i.e. fibers having a length greater than 5 mm) that are embedded within a plastic resin, such as polyamide-based resins, polypropylene-based resins, polyester resins, polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) resins, acrylic-styrene- acrylonitrile (ASA) resins or a combination thereof.

[0027] The space box includes two side walls and a plurality of inner support walls. In alternative embodiments, the space box may also be enclosed such that a front wall and/or a back wall are provided as well as top and/or bottom walls. The inner support walls provide additional support to the space box during a collision event. The inner walls may be oriented horizontally, vertically, at an incline, or a combination thereof. The inner walls may be in the form of a pattern, such as a honeycomb or other geometric pattern, or may be randomly oriented. The inner walls may have, in alternative embodiments, support ribs between the inner walls to help prevent the inner walls from bending during a collision event, hi general, the shape, number and orientation of the inner walls may vary based on one or more factors including, but not limited to, the presence of a front wall, back wall, top wall and/or bottom wall, the type of material used to form the space box, the selected impact resistance of the space box and/or the type of vehicle in which the space box will be located.

[0028] The space box portion of the present invention can be formed from any known process capable of forming a plastic material into a space box. In beneficial embodiments, the space box is formed from a molding process wherein the plastic material is melted and then formed into a selected shape, hi one embodiment, the space box is beneficially formed using an injection molding process. Nevertheless, the concepts of the present invention may be carried out using any known molding process, such as compression molding, capable of forming a space box that provides increased safety to motor vehicle occupants during a collision involving side-impact forces.

[0029] Li addition to the space box portion of the console box, the console box also includes a stand portion to which the space box is attached. The stand portion is designed to provide flexibility to the space box to enable the space box portion of the console box to move in relation to the direction of the impact forces, thereby helping to keep the space box portion of the console box between the two seats. As a result, the space box is better able to provide impact support by being more properly located in the event of a collision event.

[0030] The stand portion of the console box may be formed from any organic polymer capable of being used in a molding process to form a stand capable of providing flexibility to a space box. The organic polymer may be a crystalline polymer or an amorphous polymer. The organic polymer used in the present invention may be selected from a wide variety of thermoplastic resins or blends of thermoplastic resins. The organic polymer may also be a blend of polymers, copolymers, terpolymers, or combinations including at least one of the foregoing organic polymers. Examples of organic polymers that may be used in the present invention include, but are not limited to, polyacetals, polyacrylics, polycarbonates, polystyrenes, polyesters, polyamides, polypropylenes, polyamideimides, polyarylates, polyarylsulfones, polyethersulfones, polyphenylene sulfides, polyvinyl chlorides, polysulfones, polyimides, polyetherimides, polytetrafluoroethylenes, polyetherketones, polyether etherketones, polyether ketone ketones, polybenzoxazoles, polyoxadiazoles, polybenzothiazinophenothiazines, polybenzothiazoles, polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines, polybenzimidazoles, polyoxindoles, polyoxoisoindolines, polydioxoisoindolines, polytriazines, polypyridazines, polypiperazines, polypyridines, polypiperidines, polytriazoles, polypyrazoles, polypyrrolidines, polycarboranes, polyoxabicyclononanes, polydibenzofurans, polyphthalides, polyacetals, polyanhydrides, polyvinyl ethers, polyvinyl thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl halides, polyvinyl nitriles, polyvinyl esters, polysulfonates, polysulfides, polythioesters, polysulfones, polysulfonamides, polyureas, polyphosphazenes, polysilazanes, or the like, or a combination including at least one of the foregoing organic polymers

[0031] Unlike the space box, the material used for the stand portion is beneficially selected to provide flexibility as opposed to rigidity. As such, the space box is typically formed from a different plastic material, although some plastic materials have a sufficient range of characteristics that it may be possible for the same base resin to be used, hi beneficial embodiments of the present invention, the resin is a polyester-based resin, such as a XENO Y^® resin available from GE Plastics. The polyester-based resin may also include blends of polyester and another plastic resin, such as polycarbonate and/or acrylonitrile/butadiene/styrene (ABS).

[0032] As with the space box portion, the stand portion can be formed from any known process capable of forming a plastic material into a stand. In beneficial embodiments, the stand is formed from a molding process wherein the plastic material is melted and then formed into a selected shape. In one embodiment, the stand is beneficially formed using an injection molding process. Nevertheless, the concepts of the present invention may be carried out using any known molding process, such as compression molding, capable of forming a stand that provides flexibility to a console box during a collision involving side-impact forces.

[0033] The space box portion is attached to the stand portion to form the console box. The stand portion is connected to the space box portion using any known means for connecting two plastic components to one another, hi one embodiment, the space box is connected to the stand using one or more mechanical fasteners including, but not limited to, snap fits, nuts and bolts, screws, nails, and the like or a combination thereof, hi another embodiment, the space box is connected to the stand using one or more chemical fasteners including, but not limited to, an adhesive material. In still another embodiment, the space box is connected to the stand using a welding process, such as vibration welding or heat welding. [0034] The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of the illustrative embodiments of the invention wherein like reference numbers refer to similar elements.

[0035] Figures 1-3 provide several schematics of the location of a console box according to one embodiment of the present invention, hi this embodiment, two seats 105 are shown in a motor vehicle. The console box 110 is shown to be located between the two seats 105.

[0036] The console box 110 includes an upper more rigid space box 115 connected to a lower more flexible stand 120. The stand 120 connects the console box 115 to the floor 125 of the motor vehicle. As previously discussed, the stand 120 is constructed from a flexible material that enables the space box 115 to move in relation to an impact force. As this direction of movement would be substantially similar to the movement of the seats 105 during a collision event, the result is that the space box 115 is able to remain substantially between the seats 105 during a collision event, thereby providing protection and helping to prevent the seats 105 from contacting one another. In addition, due to the flexibility of the stand 120, the console box 110 is effective in collisions involving almost exclusive side impact forces as well as those wherein side and front impact forces are present.

[0037] One embodiment of a space box 115 constructed using the concepts of the present invention is shown in Figure 1. hi this embodiment, as may be seen, the space box 115 includes side walls 130 as well as a front wall 135 and rear wall 140. As a result of the side walls 130, unlike prior art embodiments utilizing open support structures, the direction of the force 145 will not result in one or more edges of the space box 115 from receiving an inordinate amount of the force 145 thereby helping to prevent a collapse of the space box 115 at the edges. In addition, as may be seen in Figure 3, the space box 115 includes a plurality of inner wall structures 150 that include a plurality of vertical inner walls 155 and a plurality of inner support wall structures 160, each of which is designed to provide impact resistance during a collision event and helping to prevent the two seats from contacting one another during a collision event.

[0038] Figures 4-6 show alternative embodiments of the inner wall structures shown in Figure 3. In Figure 5, the inner walls 150 are in the form of a honeycomb structure 165. In Figure 6, the inner walls 150 include a plurality of vertical walls 170 and horizontal walls 175 resulting in a series of square or rectangular cell structures. In Figure 7, the inner walls 150 include a plurality of vertical walls 180 and a plurality of support ribs 185. As with these embodiments, any inner wall structure capable of providing sufficient support to prevent the two seats 105 from contacting one another in a collision event involving side impact forces may be used in the present invention.

[0039] Figure 7 provides a side view of a stand 120 according to one embodiment of the present invention. As may be seen, the space box 115 can be attached to the stand 120 using a plurality of fastening devices, such as snap fits, screws, nuts/bolts, etc. using connection holes 190. The stand 120 can be connected to a floor of a motor vehicle using any known fastening mechanism capable of connecting a plastic piece to another structure using one or more connection tabs 195.

[0040] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. All citations referred herein are expressly incorporated herein by reference.

Claims

1. A console box for a motor vehicle comprising:

a) a space box portion comprising two side walls and a plurality of support walls disposed between the two side walls; and

b) a stand portion connected to the space box portion;

wherein the space box portion is constructed from a rigid plastic material and wherein the stand portion is constructed from a flexible plastic material.

2. The console box of Claim 1, wherein the rigid plastic material is selected from polyamide-based resin, a polypropylene-based resin, a polyester resin, a polycarbonate/acrylonitrile-butadiene-styrene resin, an acrylic-styrene-acrylonitrile resin, or a combination including at least one of the foregoing resins.

3. The console box of any of Claims 1 - 2, wherein the rigid plastic material comprises a fiber-reinforced plastic material.

4. The console box of any of Claims 1 - 3, wherein the flexible plastic material is selected from a polyester resin, a polycarbonate resin, an acrylonitrile/butadiene/styrene resin, or a combination including at least one of the foregoing resins.

5. The console box of any of Claims 1 - 4, wherein the rigid plastic material has a Young's modulus of 4000 MPa or greater.

6. The console box of any of Claims 1 - 5, wherein the flexible plastic material has a Young's modulus of 3000 MPa or less.

7. A method of forming a console box comprising:

molding a rigid plastic material to form a space box portion having two side walls and a plurality of support walls disposed between the two side walls;

molding a flexible plastic material to form a stand portion; and

connecting the space box portion to the stand portion.

8. The method of Claim 7, wherein the rigid plastic material is selected from polyamide-based resin, a polypropylene-based resin, a polyester resin, a polycarbonate/acrylonitrile-butadiene-styrene resin, an acrylic-styrene-acrylonitrile resin, or a combination including at least one of the foregoing resins.

9. The method of any of Claims 7 — 8, wherein the rigid plastic material comprises a fiber-reinforced plastic material.

10. The method of any of Claims 7 - 9, wherein the flexible plastic material is selected from a polyester, a polypropylene, a polycarbonate, an acrylonitrile/butadiene/styrene, or a combination including at least one of the foregoing resins.

11. The method of any of Claims 7 - 10, wherein the space box portion is formed using an injection molding process.

12. The method of any of Claims 7 - 11, wherein the stand portion is formed using an injection molding process.