U.S. patent application number 15/791724 was filed with the patent office on 2019-04-25 for armrest core, armrest incorporating that armrest core and method of manufacturing that armrest assembly.
The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to S. M. Iskander Farooq, Mohammad Omar Faruque, Dean M. Jaradi.
Application Number | 20190118682 15/791724 |
Document ID | / |
Family ID | 65996240 |
Filed Date | 2019-04-25 |
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United States Patent
Application |
20190118682 |
Kind Code |
A1 |
Faruque; Mohammad Omar ; et
al. |
April 25, 2019 |
ARMREST CORE, ARMREST INCORPORATING THAT ARMREST CORE AND METHOD OF
MANUFACTURING THAT ARMREST ASSEMBLY
Abstract
An armrest core includes a lattice having a plurality of void
channel clusters. The void channel clusters have a section geometry
characterized by a lateral dimension D.sub.1 and a vertical
dimension D.sub.2 where D.sub.1<D.sub.2. An armrest assembly
includes the armrest core and an outer cover overlying the armrest
core. A method of manufacturing the armrest assembly is also
disclosed.
Inventors: |
Faruque; Mohammad Omar; (Ann
Arbor, MI) ; Farooq; S. M. Iskander; (Novi, MI)
; Jaradi; Dean M.; (Macomb, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
65996240 |
Appl. No.: |
15/791724 |
Filed: |
October 24, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 64/118 20170801;
B33Y 10/00 20141201; B60N 2/78 20180201; B60N 2/4235 20130101; B60N
2/75 20180201; B33Y 80/00 20141201; B29L 2031/3026 20130101 |
International
Class: |
B60N 2/46 20060101
B60N002/46; B33Y 80/00 20060101 B33Y080/00 |
Claims
1. An armrest core, comprising: a lattice including a plurality of
void channel clusters having a section geometry characterized by a
lateral dimension D.sub.1 and a vertical dimension D.sub.2 where
D.sub.1<D.sub.2.
2. The armrest core of claim 1, wherein said plurality of void
channel clusters are aligned along a longitudinal axis L of said
armrest core wherein said longitudinal axis L is perpendicular to
said lateral dimension D.sub.1 and said vertical dimension
D.sub.2.
3. The armrest core of claim 2, wherein said plurality of void
channel clusters are defined by a plurality of 3D shaped structures
selected from a group consisting of skeletal ovoids, skeletal
ellipsoids, skeletal polyhedra, skeletal octahedra and combinations
thereof.
4. The armrest core of claim 3, further including a cover skin over
at least a portion of said lattice.
5. An armrest assembly, comprising: an armrest core having a
lattice including a plurality of void channel clusters having a
section geometry characterized by a lateral dimension D.sub.1 and a
vertical dimension D.sub.2 where D.sub.1<D.sub.2; and an outer
cover overlying said armrest core.
6. The armrest assembly of claim 5, wherein said plurality of void
channel clusters are aligned along a longitudinal axis of said
armrest core wherein said longitudinal axis is perpendicular to
said lateral dimension D.sub.1 and said vertical dimension
D.sub.2.
7. The armrest assembly of claim 6, wherein said plurality of void
channel clusters are defined by a plurality of 3D shaped structures
selected from a group consisting of skeletal ovoids, skeletal
ellipsoids, skeletal polyhedra, skeletal octahedra and combinations
thereof.
8. The armrest assembly of claim 7, further including a cover skin
over at least a portion of said lattice.
9. The armrest assembly of claim 7, wherein said outer cover
includes a cushion layer and a finish layer concealing said cushion
layer.
10. A method of manufacturing an armrest assembly, comprising:
creating an armrest core lattice including a plurality of void
channel clusters having a section geometry characterized by a
lateral dimension D.sub.1 and a vertical dimension D.sub.2 where
D.sub.1<D.sub.2; and covering said armrest core lattice with an
outer cover.
11. The method of claim 10, further including aligning said
plurality of void channel clusters along a longitudinal axis L of
said armrest core lattice wherein said longitudinal axis L is
perpendicular to said lateral dimension D.sub.1 and said vertical
dimension D.sub.2.
12. The method of claim 11, wherein said creating of said armrest
core lattice includes extruding, with an additive manufacturing
device, a plurality of interconnected 3D shaped structures.
13. The method of claim 11, wherein said creating of said armrest
core lattice includes extruding, with an additive manufacturing
device, a plurality of 3D shaped structures selected from a group
consisting of skeletal ovoids, skeletal ellipsoids, skeletal
polyhedra, skeletal octahedra and combinations thereof.
14. The method of claim 13, further including extending, by said
additive manufacturing device, a cover skin over at least a portion
of said armrest core lattice.
Description
TECHNICAL FIELD
[0001] This document relates generally to the motor vehicle
equipment field and, more particularly, to a new and improved
armrest core, an armrest assembly incorporating that armrest core
and a method of manufacturing that armrest assembly.
BACKGROUND
[0002] An armrest for a motor vehicle side door must have
substantial strength in the vertical direction to support loads
such as a vehicle occupant's arm resting on the armrest. In
contrast, an armrest should be yielding to some degree in the
lateral direction. More specifically, if the motor vehicle is
involved in a side impact collision, there is a possibility that
the armrest will strike the vehicle occupant in the rib area. This
could be due to the vehicle occupant being thrown against the
armrest and/or due to the door bearing the armrest being deflected
into the vehicle occupant. In such a situation, if the armrest is
too stiff laterally and too unyielding, the potential for injury
from vehicle occupant impact with the armrest increases.
[0003] This document relates to a new and improved armrest core
that fully meets the seemingly conflicting requirements for
vertical strength while providing yielding characteristics in the
lateral direction. An armrest assembly incorporating the new and
improved armrest core and a method of manufacturing that armrest
assembly are also provided.
SUMMARY
[0004] In accordance with the purposes and benefits described
herein, a new and improved armrest core is provided. That armrest
core comprises a lattice including a plurality of void channel
clusters having a section geometry characterized by a lateral
dimension D.sub.1 and a vertical dimension D.sub.2 where
D.sub.1<D.sub.2.
[0005] The plurality of void channel clusters may be aligned along
a longitudinal axis L of the armrest core wherein the longitudinal
axis L is perpendicular to the lateral dimension D.sub.1 and the
vertical dimension D.sub.2. Further, the plurality of void channel
clusters may be defined by a plurality of 3D shaped structures
selected from a group consisting of skeletal ovoids, skeletal
ellipsoids, skeletal polyhedra, skeletal octahedra and combinations
thereof. Still further, the armrest core may include a cover skin
over at least a portion of the lattice.
[0006] In accordance with an additional aspect, a new and improved
armrest assembly is provided. That armrest assembly comprises an
armrest core having a lattice including a plurality of void channel
clusters having a section geometry characterized by a lateral
dimension D.sub.1 and a vertical dimension D.sub.2 where
D.sub.1<D.sub.2 and an outer cover overlying the armrest
core.
[0007] The plurality of void channel clusters forming the lattice
of the armrest core may be aligned along a longitudinal axis L of
the armrest core wherein the longitudinal axis L is perpendicular
to the lateral dimension D.sub.1 and the vertical dimension
D.sub.2. Further, the plurality of void channel clusters may be
defined by a plurality of 3D shaped structures selected from a
group consisting of skeletal ovoids, skeletal ellipsoids, skeletal
polyhedra, skeletal octahedra and combinations thereof. Still
further, the armrest core may include a cover skin over at least a
portion of the lattice.
[0008] In addition, the outer cover covering the armrest core may
include a cushion layer and a finish layer concealing the cushion
layer.
[0009] In accordance with yet another aspect, a method is provided
of manufacturing an armrest assembly. That method may be defined as
comprising the steps of: (a) creating an armrest core lattice
including a plurality of void channel clusters having a section
geometry characterized by a lateral dimension D.sub.1 and a
vertical dimension D.sub.2 where D.sub.1<D.sub.2 and (b)
covering the armrest core lattice with an outer cover.
[0010] Still further, the method may include the step of aligning
the plurality of void channel clusters along a longitudinal axis L
of the armrest core lattice. That longitudinal axis L may be
provided perpendicular to the lateral dimension D.sub.1 and the
vertical dimension D.sub.2.
[0011] The step of creating the armrest core lattice may include
extruding, with an additive manufacturing device, a plurality of
interconnected 3D shaped structures. More specifically, the step of
creating the armrest core lattice may include the step of
extruding, with an additive manufacturing device, a plurality of 3D
shaped structures selected from a group consisting of skeletal
ovoids, skeletal ellipsoids, skeletal polyhedra, skeletal octahedra
and combinations thereof.
[0012] In the following description, there are shown and described
several preferred embodiments of the armrest core, the armrest
assembly incorporating that armrest core and the method of
manufacturing that armrest assembly. As it should be realized, the
armrest core, the armrest assembly and the manufacturing method are
capable of other, different embodiments and their several details
are capable of modification in various, obvious aspects all without
departing from the armrest core, armrest assembly and manufacturing
method as set forth and described in the following claims.
Accordingly, the drawings and descriptions should be regarded as
illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] The accompanying drawing figures incorporated herein and
forming a part of the specification, illustrate several aspects of
the armrest core, the armrest assembly incorporating that armrest
core and the method of manufacturing the armrest assembly and
together with the description serve to explain certain principles
thereof.
[0014] FIG. 1 is a perspective view illustrating the new and
improved armrest assembly carried on a side door of a motor vehicle
and the spatial relationship of that armrest assembly to an
operator of the motor vehicle sitting in the driver's seat.
[0015] FIG. 2 is a detailed perspective view of a completed armrest
assembly incorporating an armrest core, having a lattice, and an
outer cover overlying that armrest core.
[0016] FIG. 3a is a detailed perspective view of a portion of an
armrest core lattice including a plurality of void channel clusters
with a particular section geometry as defined by a plurality of
interconnected 3D shaped structures.
[0017] FIG. 3b is a detailed perspective view of one possible
embodiment of such a 3D shaped structure in the form of a skeletal
octahedra.
[0018] FIG. 3c is a view similar to FIG. 2b but illustrating a
second possible embodiment wherein the 3D shaped structure is a
skeletal ovoid.
[0019] FIG. 4 is a detailed perspective view of a portion of an
armrest core lattice incorporating a cover skin over the upper
surface and the lower surface of that lattice.
[0020] Reference will now be made in detail to the present
preferred embodiments of the armrest core, arm reset assembly
incorporating that armrest core and the method of manufacturing
that armrest assembly, examples of which are illustrated in the
accompanying drawing figures.
DETAILED DESCRIPTION
[0021] Reference is now made to FIG. 1 illustrating a new and
improved armrest assembly 10. As illustrated in FIG. 1, the armrest
assembly 10 is mounted to or carried on a side door 12 of a motor
vehicle. That door 12 may be opened to allow access to the motor
vehicle seat such as the driver's seat 14.
[0022] The crash test dummy 16 illustrated in the driver's seat 14
is representative of the position of a driver when operating the
motor vehicle. As should be appreciated, the armrest assembly 10 on
the side door 12 is located a short lateral distance from the rib
area 18. In the event of a side impact collision, the armrest
assembly 10 may contact the rib area 18 and should yield to cushion
the blow and protect the driver.
[0023] As best illustrated in FIG. 2, the armrest assembly 10
comprises an armrest core, generally designated by reference
numeral 20, and an outer cover 22 overlying the armrest core. In
the illustrated embodiment, the outer cover 22 includes a cushion
layer 24 and a finish layer 26 concealing the cushion layer. The
cushion layer 24 may be made from any appropriate material
including, for example, cellular foam, leather, fabric or the
like.
[0024] As best illustrated in FIGS. 3a and 3b, the armrest core 20
includes a lattice 28 having a plurality of void channel clusters
30. Those void channel clusters 30 have a section geometry
characterized by a lateral dimension D.sub.1 and a vertical
dimension D.sub.2 where where D.sub.1<D.sub.2 (see FIG. 3b).
[0025] As further illustrated in FIGS. 3a and 3b, the plurality of
void channel clusters 30 are aligned along a longitudinal axis L of
the armrest core 20. That longitudinal axis L is perpendicular to
the lateral dimension D.sub.1 and a vertical dimension D.sub.2.
More specifically, when installed on the side door 12 of a motor
vehicle and that side door 12 is in the closed position as
illustrated in FIG. 1, the longitudinal axis L, the lateral
dimension D.sub.1 and a vertical dimension D.sub.2 correspond
respectively to the longitudinal axis X, the lateral axis Y and the
vertical axis Z of the SAE vehicle axis system (see FIG. 3a).
[0026] As best illustrated in FIGS. 3a and 3b, the plurality of
void channel clusters 30 are defined by a plurality of 3D shaped
structures 32. Those 3D shaped structures 32 may be selected from a
group of structures consisting of skeletal ovoids, skeletal
ellipsoids, skeletal polyhedra, skeletal octahedra and combinations
thereof.
[0027] FIG. 3b illustrates a single 3D shaped structure 32 having a
skeletal octahedra configuration. More specifically, each 3D shaped
structure in the form of a skeletal octahedra includes a single
vertex 34 at a first end, a single vertex 36 at a second end and
four vertices 38 lying in a single mid plane between the two ends.
A first set of ribs 40 connect the vertex 34 to the mid plane
vertices 38, and a second set of ribs 42 connect the vertex 36 to
the mid plane vertices 38. Together, the ribs 40, 42 define the
skeletal 3D shaped structure of the octahedra outlining the
interior void 44.
[0028] As should be appreciated, the vertical dimension D.sub.2 of
the section geometry of the void channel clusters 30 is defined by
the distance from the vertex 34 at the first end to the vertex 36
at the second end of the 3D shaped structure 32. The lateral
dimension D.sub.1 of the section geometry of the void channel
clusters 30 is defined by the distance between the two opposed
vertices 38 lying in the mid plane along the lateral axis Y. The
longer vertical dimension D.sub.2 provides the lattice 28 with
greater strength in the vertical direction while the shorter
lateral dimension D.sub.1 provides lower strength and more yielding
characteristics in the lateral direction to help protect a driver
from rib injury in the event of a side impact collision.
[0029] FIG. 3c illustrates an alternative embodiment wherein the 3D
shaped structure 32 providing the void channel clusters 30
comprises a skeletal ovoid including a first end vertex 46 and a
second end vertex 48 defining the greater and stronger vertical
dimension D.sub.2 and mid line vertices 50, 52 where one skeletal
ovoid is connected to others to define the more yielding lateral
dimension D.sub.1.
[0030] As illustrated in FIG. 4, the armrest core 20 may also
include a cover skin 54 over at least a portion of the lattice 28.
That cover skin 54 may be integrally formed as a single piece with
the lattice 28. In the illustrated embodiment the cover skin 54
extends across and covers the first or top end 56 and the second or
lower end 58 of the lattice 28. In this configuration, the cover
skin 54 functions to support and stabilize the various 3D shaped
structures 32 of the lattice 28 along the first and second ends of
the lattice in an orderly, equally spaced orientation. As will be
apparent from the following description, the cover skin 54 also
aids in the manufacture of the armrest assembly 10.
[0031] The armrest assembly 10 may be manufactured in a very
efficient and effective manner. More specifically, the method of
manufacturing the armrest assembly 10 includes the steps of
creating the armrest core lattice 28, including the plurality of
void channel clusters 30 having a section geometry characterized by
a lateral dimension D.sub.1 and a vertical dimension D.sub.2 where
D.sub.1<D.sub.2. Further, the method includes the step of
covering that armrest core lattice 28 with an outer cover 22
including a cushion layer 24 and a finish layer 26.
[0032] More specifically, in the illustrated embodiment, the method
includes the step of aligning the plurality of void channel
clusters 30 along a longitudinal axis L of the armrest core lattice
28 wherein the longitudinal axis L is perpendicular to the lateral
dimension D.sub.1 and the vertical dimension D.sub.2 (see FIG. 3a).
In one particularly useful embodiment of the method, the method
includes the step of creating the armrest core lattice 28 by
extruding, with an additive manufacturing device, the plurality of
3D shaped structures 32 that form the lattice. Those 3D shaped
structures may be selected from a group of structures consisting of
skeletal ovoids, skeletal ellipsoids, skeletal polyhedra, skeletal
octahedra and combinations thereof. In other possible embodiments,
the method may also include the step of extruding, with the
additive manufacturing device, the cover skin 54 along any side or
end of the lattice 28 thereby creating a lattice 28 with an
integrally molded cover skin 54.
[0033] The foregoing has been presented for purposes of
illustration and description. It is not intended to be exhaustive
or to limit the embodiments to the precise form disclosed. Obvious
modifications and variations are possible in light of the above
teachings. All such modifications and variations are within the
scope of the appended claims when interpreted in accordance with
the breadth to which they are fairly, legally and equitably
entitled.
* * * * *