U.S. patent application number 10/439714 was filed with the patent office on 2004-11-18 for vehicle storage box.
Invention is credited to DePue, Todd, Hein, David A., Lyons, Doug, Schoemann, Michael P., Slaven, John P..
Application Number | 20040226953 10/439714 |
Document ID | / |
Family ID | 33417872 |
Filed Date | 2004-11-18 |
United States Patent
Application |
20040226953 |
Kind Code |
A1 |
Hein, David A. ; et
al. |
November 18, 2004 |
Vehicle storage box
Abstract
A foldable sheet for making a storage box for a vehicle. The
foldable sheet has multiple portions foldably connected together
along at least one fold line. The portions are foldable to at least
a partially define a storage box. One of the portions includes a
hinge configured to allow the storage box to pivot with respect to
the vehicle.
Inventors: |
Hein, David A.; (Sterling
Heights, MI) ; DePue, Todd; (Brighton, MI) ;
Slaven, John P.; (Shore, MI) ; Schoemann, Michael
P.; (Waterford, MI) ; Lyons, Doug;
(Southfield, MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C. / LEAR CORPORATION
1000 TOWN CENTER
TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075-1238
US
|
Family ID: |
33417872 |
Appl. No.: |
10/439714 |
Filed: |
May 16, 2003 |
Current U.S.
Class: |
220/558 |
Current CPC
Class: |
B60R 7/06 20130101 |
Class at
Publication: |
220/558 |
International
Class: |
B65D 006/12 |
Claims
What is claimed is:
1. A foldable sheet for making a storage box for a vehicle, the
foldable sheet comprising: multiple portions foldably connected
together along at least one fold line, wherein the portions are
foldable along the at least one fold line to at least partially
define a storage box body, and wherein one of the portions includes
a hinge that is configured to allow the storage box body to pivot
with respect to the vehicle.
2. The foldable sheet of claim 1 wherein the portion that includes
the hinge includes first and second sections that are foldably
connected together along an additional fold line, and wherein the
first and second sections are foldable along the additional fold
line such that the first section defines a bottom panel of the
storage box body and the second section defines a hinge member
attached to the bottom panel, the hinge member including the
hinge.
3. The foldable sheet of claim 2 wherein the second section
includes a first subsection and a second subsection foldably
connected together along a hinge member fold line, each subsection
including a hinge portion, and wherein the subsections are foldable
along the hinge member fold line such that the hinge portions
cooperate to define the hinge.
4. The foldable sheet of claim 1 wherein the at least one fold line
includes first, second, and third fold lines, and the multiple
portions include a first portion, a second portion foldably
connected to the first portion along the first fold line, a third
portion foldably connected to the second portion along the second
fold line, and a fourth portion foldably connected to the third
portion along the third fold line, and wherein the first, second,
and fourth portions are configured to define a back panel, a bottom
panel, and a front panel, respectively, of the storage box body,
and the third panel is configured to define a hinge member
connected to the storage box body and including the hinge.
5. The foldable sheet of claim 4 wherein the fourth portion
includes a substrate and a cover layer disposed on at least a
portion of the substrate.
6. The foldable sheet of claim 4 wherein the fourth portion has at
least one hollow chamber.
7. The foldable sheet of claim 4 further comprising a fifth portion
connected to the first portion, the second portion, or the fourth
portion along a fourth fold line, wherein the fifth portion is
foldable along the fourth fold line to define a first side panel of
the storage box.
8. The foldable sheet of claim 7 further comprising a sixth portion
connected to the first portion, the second portion, or the fourth
portion along a fifth fold line, wherein the sixth portion is
foldable along the fifth fold line to define a second side panel of
the storage box.
9. A storage box for mounting in a vehicle, the storage box
comprising: multiple portions that are connected together along at
least one fold line, the portions being folded along the at least
one fold line such that the portions at least partially define a
storage box body, the storage box body being configured to be
mounted in the vehicle.
10. The storage box of claim 9 wherein one of the portions defines
a hinge member that includes a hinge for allowing the storage box
body to pivot.
11. The storage box of claim 10 wherein the hinge member includes
first and second sections that are connected together along a hinge
member fold line, each section including a hinge portion, and
wherein the sections are folded along the hinge member fold line
such that the hinge portions cooperate to define the hinge.
12. The storage box of claim 9 wherein the at least one fold line
includes first and second fold lines, and the multiple portions
include a back panel, a bottom panel arrangement connected to the
back panel along the first fold line, and a front panel connected
to the bottom panel arrangement along the second fold line.
13. The storage box of claim 12 wherein the bottom panel
arrangement includes a bottom panel and a hinge member connected to
the bottom panel along a third fold line, and wherein the hinge
member is folded along the third fold line such that the hinge
member extends below the bottom panel, the hinge member including a
hinge for allowing a portion of the storage box to pivot.
14. The storage box of claim 12 wherein the front panel includes a
substrate and a cover layer is disposed on at least a portion of
the substrate.
15. The storage box of claim 12 wherein the front panel has at
least one hollow chamber.
16. A method for making a storage box for mounting in a vehicle,
the method comprising: forming a foldable member having multiple
portions connected together along at least one fold line; and
folding the portions along the at least one fold line such that the
portions at least partially define a storage box body, that is
configured to be mounted in the vehicle.
17. The method of claim 16 wherein one of the portions of the
foldable member defines a hinge member, the hinge member including
a hinge that is configured to allow the storage box body to
pivot.
18. The method of claim 17 wherein the hinge member includes first
and second sections that are foldably connected together along a
hinge member fold line, each section including a hinge portion, and
wherein the method further includes folding the first and second
sections along the hinge member fold line such that the hinge
portions cooperate to define the hinge.
19. The method of claim 16 wherein the foldable member includes a
first portion, a second portion foldably connected to the first
portion along a first fold line, and a third portion foldably
connected to the second portion along a second fold line, and
wherein the step of folding the portions is performed such that the
first, second, and third portions define a back panel, a bottom
panel arrangement, and a front panel, respectively, of the storage
box body.
20. The method of claim 16 wherein the step of forming a foldable
member includes blow molding a parison into a preconfigured shape.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a foldable sheet for making
a vehicle storage box and a method for making a storage box for
mounting in a vehicle.
[0003] 2. Background Art
[0004] Hinged storage boxes such as glove boxes, console bins, and
overhead storage containers are used in motor vehicles. These
hinged storage boxes are often made from many individual
components. For example, a glove box may consist of back, side, and
bottom box panels, a multi-component door, a hinge, a latch, a
handle, bumpers, pivot stops, brackets, and various fasteners used
to connect these components together. Having a large number of
components increases manufacturing complexity and cost. In
addition, quality problems are more likely since each component can
have defects and be misassembled, resulting in squeak and rattle
issues as well as poor fit and finish.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present invention, a foldable
sheet for making a vehicle storage box is provided. The foldable
sheet includes multiple portions foldably connected together along
at least one fold line. The portions are foldable along the at
least one fold line to at least partially define a storage box
body. One of the portions includes a hinge configured to allow the
storage box body to pivot with respect to a vehicle.
[0006] The portion that includes the hinge may include first and
second sections that are foldably connected together along an
additional fold line. The first and second sections may be foldable
along the additional fold line such that the first section defines
a bottom panel of the storage box body and the second section
defines a hinge member attached to the bottom panel and including
the hinge. The second section may include a first subsection and a
second subsection foldably connected along a hinge member fold line
and cooperable to define the hinge.
[0007] According to another aspect of the invention, a storage box
for mounting in a vehicle is provided. The storage box includes
multiple portions connected together along at least one fold line.
The portions are folded along the at least one fold line to at
least partially define a storage box body that is configured to be
mounted in the vehicle.
[0008] At least one of the portions may define a hinge member that
includes a hinge for allowing the storage box body to pivot. The
hinge member may include first and second sections connected
together along a hinge member fold line and that cooperate to
define the hinge.
[0009] According to another aspect of the invention, a method for
making a storage box for mounting in a vehicle is provided. The
method includes forming a foldable member having multiple portions
connected together along at least one fold line. The method further
includes folding the portions along the at least one fold line such
that the portions at least partially define a storage box body that
is configured to be mounted in the vehicle.
[0010] One of the portions of the foldable member may define a
hinge member including a hinge that allows the storage box body to
pivot. The hinge member may include first and second sections
foldably connected along a hinge member fold line and that each
include a hinge portion. The method may further include folding the
first and second sections along the hinge member fold line such
that the hinge portions cooperate to define the hinge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a foldable sheet for making
a storage box;
[0012] FIG. 2 is a perspective view of the storage box made from
the foldable sheet;
[0013] FIG. 3 is a cross-section of the storage box;
[0014] FIG. 4 is a section view of a mold for making the foldable
sheet, the mold including a forming tool and a blade tool which are
shown in retracted positions;
[0015] FIG. 5 is a section view of the mold showing the forming
tool and the blade tool in advanced positions; and
[0016] FIG. 6 is a section view of the mold showing the forming
tool in the retracted position and the blade tool in the advanced
position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0017] FIG. 1 shows a foldable member, such as foldable sheet 10
according to the invention. The foldable sheet 10 is configured to
at least partially define a vehicle storage box, such as a glove
box 11 shown in FIG. 2, that is mountable in a vehicle. More
specifically, foldable sheet 10 includes multiple portions that are
foldably connected together along at least one fold line, such that
the portions are foldable to at least partially define the glove
box 11.
[0018] In the embodiment shown in FIG. 1, for example, the foldable
sheet 10 includes a first portion 12 that defines a back panel of
the glove box 11. The first portion 12 is foldably connected to a
second portion 14 along a first fold line 16, and the second
portion 14 is configured to define a bottom panel of the glove box
11. A third portion 18, or hinge member, is foldably connected to
the second portion 14 along a second fold line 20. The second
portion 14 and the third portion 18 define a bottom panel
arrangement 22. The bottom panel arrangement 22 is foldably
connected to a fourth portion 24, or front panel, along a third
fold line 26.
[0019] The third portion 18 includes a first section 28 and a
second section 30. The first section 28 and the second section 30
are foldably connected along a hinge member fold line 32. The first
section 28 includes a first hinge portion 34, and the second
section 30 includes a second hinge portion 36. The first hinge
portion 34 and the second hinge portion 36 cooperate to define a
hinge when the first section 28 and the second section 30 are
folded together. The first section 28 and the second section 30
also include holes 38 that may be drilled, punched, or molded into
the foldable sheet 10.
[0020] The foldable sheet 10 may also include a fifth portion 40
foldably connected to the first portion 12 along a fourth fold line
42, and a sixth portion 44 foldably connected to the first portion
12 along a fifth fold line 46. The fifth and sixth portions 40 and
44, respectively, may be configured to define first and second side
panels, respectively, of the glove box 11.
[0021] Alternatively, the foldable sheet 10 may have any suitable
configuration for at least partially forming the glove box 11. For
example, the fifth portion 40 and the sixth portion 44 may each be
foldably connected to the first portion 12, the second portion 14,
or the fourth portion 24. Also, the first portion 12, the bottom
panel arrangement 22, and the fourth portion 24 do not need to be
foldably connected to each other. Instead, the first portion 12,
the bottom panel arrangement 22, and the fourth portion 24 may be
foldably connected via the fifth portion 40 or the sixth portion
44. For example, the fifth portion 40 may be foldably connected to
the first portion 12 and the bottom panel arrangement 22 without
the first portion 12 and the bottom panel arrangement 22 being
foldably connected to each other along the first fold line 16.
Similar arrangements are possible using the sixth portion 44
instead of the fifth portion 40. Likewise, the bottom panel
arrangement 22 may be foldably connected to the fourth portion 24
via the fifth portion 40 or sixth portion 44 rather than by the
third fold line 26. Furthermore, one or more of the portions 12,
14, 18, 24, 40 and 44 may be deleted if not required for a
particular application. Still further, the foldable sheet 10 may be
used to at least partially form any suitable vehicle storage box or
compartment, such as a floor or overhead console, that is mountable
to a vehicle.
[0022] Referring to FIG. 2, a glove box 11 made from the foldable
sheet 10 of FIG. 1 is shown. The glove box 11 is assembled by
folding and joining together various portions of the foldable sheet
10. The foldable sheet may be folded by hand or it may be fixtured
and folded by automated equipment. The first portion 12 is folded
perpendicular to the second portion 14 along the first fold line
16. The second portion 14 is folded perpendicular to the first
section 28 along the second fold line 20. The first section 28 and
the second section 30 of the third portion 18 are folded along the
hinge member fold line 32 to be parallel and adjacent to each
other. The fourth portion 24 is folded along the third fold line 26
such that the fourth portion 24 is parallel to the second section
30. The fifth portion 40 and sixth portion 44 are folded
perpendicular to the first portion 12 such that they are adjacent
to the second portion 14 and the fourth portion 24. The fifth
portion 40 and/or the sixth portion 44 may be attached to the
fourth portion 24 using adhesives, fasteners, snap tabs, insert
molded tabs, or a tongue and groove assembly. For example, the
fourth portion 24 may be formed with at least one groove to receive
a tongue of the fifth portion 40 or the sixth portion 44. Adhesives
may be used to glue the tongue and groove together. Alternatively,
or supplementary, the fifth portion 40 and/or sixth portion 44 may
be attached to the second portion 14.
[0023] When folded, the glove box 11 includes a storage box body 52
positioned above the hinge member 18. The storage box body 52 is
defined by the first, second, fourth, fifth, and sixth portions 12,
14, 24, 40 and 44, respectively, of the foldable sheet 10.
[0024] Referring to FIG. 3, a cross-section of the glove box 11
taken along section line A-A of FIG. 2 is shown. A hinge 56 is
formed by the first hinge portion 34 and the second hinge portion
36. The hinge 56 may be located along any area of the hinge member
18 above the holes 38. The holes 38 in the first section 28 and the
second section 30 align with each other to provide through holes
that can be used to attach the hinge member 18 to a mating surface
of a vehicle component. For example, bolts or screws may be
inserted through the holes 38 to fixedly attach the hinge member 18
to an instrument panel or other interior vehicle component. When
attached, the portion of the hinge member 18 below the hinge 56
remains stationary with respect to the mating surface. The hinge 56
allows the storage box body 52 to pivot with respect to the vehicle
as shown by the curved arrow.
[0025] Referring to FIG. 2, the fifth portion 40 and/or the sixth
portion 44 may include a pivot stop 58. The pivot stop or stops may
engage another component, such as an instrument panel or housing to
prevent the storage box body 52 from pivoting beyond a
predetermined point.
[0026] Returning to FIG. 3, the fourth portion 24 may include
multiple hollow chambers 60 that are configured to manage energy
when impacted. For example, in the case of a glove box, the hollow
chambers 60 may absorb energy when impacted by the knees of an
occupant during a frontal crash.
[0027] Referring to FIGS. 4-6, a method for making the foldable
sheet 10 will now be described. In one embodiment, the foldable
sheet 10 may be made using a blow molding process. However, the
foldable sheet 10 may be made by any suitable manufacturing process
including injection molding and compression molding.
[0028] Referring to FIG. 4, for example, a mold 70 is shown having
first and second mold portions 71 and 72, respectively, that define
first and second cavities 73 and 74, respectively. The first mold
portion 71 includes a forming tool 76 that is moveable between a
retracted position, shown in FIG. 4, and an advanced position,
shown in FIG. 5. The second mold portion 72 includes a blade tool
78 is movable between a retracted position, shown in FIG. 4, and an
advanced position, shown in FIGS. 5 and 6.
[0029] A parison 80 made of a polymeric material, such as
polypropylene, is first inserted into the mold 70. The mold 70 is
then closed by bringing the first mold portion 71 and the second
mold portion 72 into contact with each other. Next, the parison 80
is expanded to contact the mold 70 and create the foldable sheet 10
using blow molding techniques.
[0030] Optionally, a cover layer 82 may be provided over a portion
of the foldable sheet 10. The cover layer 82 may be a polymeric
material, such as a thermoplastic elastomer or thermoplastic
olefin, or any other suitable material that may provide color or
texturing if such features are not provided on the underlying
foldable sheet. The cover layer 82 may be microperforated to
prevent air bubbles from forming between the cover layer 82 and the
parison 80 when the parison 80 is expanded against the cover layer
82. In one embodiment, the cover layer 82 may be a sheet that is
positioned in the mold 70 before the parison 80 is inserted and
expanded. The cover layer 82 may be retained to the mold 70 by
fasteners (not shown) or vacuumed to the surface of the mold 70. In
another embodiment, the cover layer 82 may be co-extruded into the
mold 70 with the parison 80. The cover layer 82 can also be molded
to cover surfaces that contact mating components and provide a
cushioning effect.
[0031] Referring to FIG. 5, hollow chambers 60 are formed by
advancing the forming tool 76 into the parison 80. Specifically,
the forming tool 76 pushes a first surface 84 into contact with a
second surface 86 to form hollow chambers 60 separated by ribs 88.
In addition, the blade tool 78 is advanced to form and/or cut a
portion of the cover layer 82 and provide a smooth edge. The blade
tool 78 remains advanced throughout the remainder of the blow
molding process.
[0032] Referring to FIG. 6, the forming tool 76 is shown in the
retracted position. In the embodiment shown in FIG. 6, the forming
tool 76 is retracted to be flush with the surface of the first mold
portion 71 that defines the first cavity 73 to provide a smooth
surface. The voids formed when the forming tool 76 is retracted are
filled by the blow molding process. Specifically, positive pressure
provided in the hollow chambers 60 forces adjacent rib walls
together such that each rib 88 is formed with a fused double-wall
structure.
[0033] Secondary operations may be performed after the foldable
sheet 10 is molded. Such operations may include trimming flash
material, or offal, from the foldable sheet 10, drilling holes,
flame treating, and/or painting.
[0034] While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *