Motor vehicle hybrid shelf assembly

A motor vehicle hybrid shelf assembly includes a metallic sheet body. A body shelf defines a plane having multiple apertures. Each of the apertures is at least partially surrounded by a peripheral flange created from a portion of the shelf extending away from the plane defined by the shelf. A first leg of the peripheral flange of each of the apertures is integrally connected to the shelf and is angularly oriented with respect to the shelf, and a second leg of the peripheral flange is angularly oriented with respect to the first leg. A reinforcement member of a polymeric material is integrally connected to at least the second leg of the peripheral flange. Multiple ribs formed of the polymeric material directly contact a surface of the body to stiffen the body. The ribs extend between successive peripheral flanges and integrally connect to the reinforcement member of the peripheral flanges.

FIELD

The invention relates generally to a rear speaker mounting shelf for a motor vehicle.

BACKGROUND

In common motor vehicle rear speaker mounting shelf structures, a single plate or multiple plates of steel material are joined typically by welding or fastening to outer frame structure of the vehicle, which are also commonly made of a steel material. Steel material is used for known speaker mounting shelf structures to provide structural strength to support features such as the loads imparted from rear seat belt retractors, seat back latches, deck lid hinges, speaker and woofer attachments and the like. Steel material similar to the material of the vehicle frame also allows welding of the shelf to vehicle frame connections.

While material coatings such as a polymeric coating applied onto the steel structural members are known which are relied on to reduce noise, polymeric material coatings applied to known speaker mounting shelf structures are not relied on for structural strength or stiffness. This field can therefore benefit from improved rear speaker mounting shelf structure designs.

SUMMARY

According to several aspects, a motor vehicle hybrid shelf assembly includes a body formed of a metallic sheet. A shelf of the body defines a plane having at least one aperture created therein. The at least one aperture is at least partially surrounded by a peripheral flange created from a portion of the shelf extending away from the plane defined by the shelf. A reinforcement member of a polymeric material is integrally connected to the peripheral flange.

In one aspect, the peripheral flange defines an L-shape having a first leg integrally connected to the body and oriented substantially parallel to the body, and a second leg angularly oriented with respect to the first leg.

In another aspect, the reinforcement member entirely covers the second leg.

In another aspect, the reinforcement member further covers a portion of the first leg.

In another aspect, the peripheral flange defines an S-shape having a first leg integrally connected to the body and angularly oriented with respect to the body, a second leg angularly oriented with respect to the first leg, and a third leg angularly oriented with respect to the second leg.

In another aspect, the reinforcement member entirely covers the third leg.

In another aspect, the reinforcement member further covers a portion of the second leg.

In another aspect, the reinforcement member covers an entire perimeter of the peripheral flange.

In another aspect, the reinforcement member is connected to the body by multiple integrally formed interlocks.

In another aspect, the body further includes opposed side portions adapted to be welded, riveted or fastened to a structure of the motor vehicle.

In another aspect, the body defines a metal material including one of aluminum and steel; and the side portions define a metal material including one of aluminum and steel and are fixed to the body.

According to further aspects, the body further includes a beam defining a reinforcing structure for the body.

In another aspect the beam is positioned proximate to a vehicle front facing portion of the body.

In another aspect, the body includes multiple second apertures each having a peripheral flange with a reinforcement member of a polymeric material integrally connected to each peripheral flange, and a rib connected to the body between the at least one aperture and each of the second apertures.

According to further aspects, a motor vehicle hybrid shelf assembly includes a body formed of a metallic sheet. A shelf of the body defines a plane having multiple apertures created therein. Each of the apertures is at least partially surrounded by a peripheral flange created from a portion of the shelf extending away from the plane defined by the shelf. A first leg of the peripheral flange of each of the apertures is integrally connected to the shelf and is angularly oriented with respect to the shelf. A second leg of the peripheral flange of each of the apertures is angularly oriented with respect to the first leg. A reinforcement member of a polymeric material is integrally connected to at least the second leg of the peripheral flange of each of the apertures.

In another aspect, the reinforcement member is also integrally connected to the first leg of the peripheral flange of each of the apertures.

In another aspect, multiple ribs are formed of the polymeric material of the reinforcement member. The ribs directly contact and extend away from a surface of the body and act to stiffen the body. The ribs extend between successive ones of the peripheral flanges and are integrally connected to the reinforcement member of the successive ones of the peripheral flanges and define an integrally extending member joined between multiple ones of the apertures.

In another aspect, opposed end portions of a ferrous material different than a material of the body are fixed to the body and are adapted to be welded to a structure of the motor vehicle, wherein the metallic sheet of the body is an aluminum material.

In another aspect, the polymeric material is adapted to be applied in an over-molding process and defines a fiber reinforced material.

According to further aspects, a motor vehicle hybrid shelf assembly includes a body is formed of a metallic sheet having multiple raised stiffening members. A shelf of the body defines a plane having multiple apertures created therein. Each of the apertures is at least partially surrounded by a peripheral flange created from a portion of the shelf extending away from the plane defined by the shelf. A first leg of the peripheral flange of each of the apertures is integrally connected to the shelf and is angularly oriented with respect to the shelf. A second leg of the peripheral flange of each of the apertures is angularly oriented with respect to the first leg. A reinforcement member of a polymeric material is integrally connected to at least the second leg of each peripheral flange. Multiple ribs are formed of the polymeric material. The ribs directly contact and extend away from a surface of the body and act to stiffen the body. The ribs extend between successive ones of the peripheral flanges and are integrally connected to the reinforcement member of the successive ones of the peripheral flanges and define an integrally extending member joined between multiple ones of the apertures.

Further aspects, examples, and advantages will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.

DETAILED DESCRIPTION

With reference toFIG. 1, a motor vehicle hybrid shelf assembly is generally indicated by reference number10. According to several aspects, the hybrid shelf assembly10is a structural member of an exemplary motor vehicle frame12used in a motor vehicle (not shown). The hybrid shelf assembly10is connected for example by welding, fastening or riveting at a first end or side portion14to a first member16of the frame12and at an opposed second end or side portion18to a second member20of the frame12. The hybrid shelf assembly10includes a main body22made of a metal including aluminum or steel. The body22can be formed for example by stamping and includes multiple integral reinforcing structures such as a front flange24, a rear flange26, multiple raised ribs28, and the like. To facilitate fixing the first side portion14and the second side portion18directly to the frame12which is commonly a ferrous metal material such as steel, the first side portion14and the second side portion18can be fixed by welding, fastening, or riveting. According to several aspects the first side portion14and the second side portion18can also be formed of a metal material such as steel or aluminum.

The body22supports multiple components such as a first speaker30, a second speaker32, a woofer34, and may also support other items (not shown) such as but not limited to seat belt retraction systems, wiring harnesses, tubing, ventilation components or ducting, and the like. One or more reel housings36can be fixed to the front flange24, which are used to retract and store seat belts such as a first rear seat belt38, a second rear seat belt40, and a third rear seat belt42. The front flange24and the body22are therefore designed to incorporate the stress and loading induced by the various seat belts, as well as the components supported by the body22. The rear flange26can also be connected to a rear cowling46at a junction with a rear window of the vehicle (not shown). In addition of the use of a light weight metal such as aluminum to minimize weight of the body22, multiple reinforcement members48of a polymeric material are integrally connected to the body22at various locations, such as where loading and vibration is induced by the weight of the speakers. According to several aspects, a material of the reinforcement members48is adapted to be applied in an over-molding process and defines a glass fiber reinforced material.

Referring toFIG. 2and again toFIG. 1, the hybrid shelf assembly10includes multiple apertures, with each aperture positioned to locate one of the speakers (shown and described in reference toFIG. 1). For example a first aperture50is for locating the first speaker30, a second aperture52for locating the second speaker32, and a third aperture54for locating the woofer34. Each of the first aperture50, the second aperture52and the third aperture54can be reinforced by the addition of a raised peripheral flange created in the body22, such as a first raised peripheral flange56, which reinforces the first aperture50. In addition, portions of the reinforcement members48are located at the perimeter of multiple ones of the body apertures, including a first reinforcement member58integrally connected to the first raised peripheral flange56, and a second reinforcement member60integrally connected to a second raised peripheral flange62adjacent the second aperture52. A third reinforcement member64is integrally connected to a peripheral flange adjacent to the third aperture54.

With continuing reference toFIG. 2and again toFIG. 1, in order to provide additional structural reinforcement for the body22, the reinforcement members48can further include connecting members66, which for example integrally connect the first reinforcement member58to the second reinforcement member60. The connecting members66also provide an added benefit of allowing the first reinforcement member58and the second reinforcement member60to be simultaneously co-molded in a single injection molding “shot” of polymeric material, which reduces molding injection time, and reduces mold cost by reducing the quantity of molding gates required. The connecting members66can themselves be integrally connected using one or more joining members68, which can be oriented at any angle with respect to the connecting members66, but are preferably oriented substantially perpendicular to the connecting members66. The joining members68are also integrally connected to the body22, and are created during the same injection molding shot which forms the connecting members66and the reinforcement members48.

Additional polymeric material reinforcement can be provided during the same molding shot to the front flange24, using second joining members70, which can be integrally connected to one or more of the connecting members66. Additional apertures, such as for example an aperture72, can be reinforced with the same polymeric material of the reinforcement members48, but molded via a separate injection molding gate and a separate molding shot, and therefore providing a separate reinforcement member74about the perimeter of the aperture72. Where structural features such as a beam76or a tube are incorporated into the body22, separate polymeric material reinforcement can also be provided, such as by a reinforcement member77. According to several aspects, the beam76is positioned proximate to a vehicle rear facing portion of the body22.

Referring toFIG. 3and again toFIGS. 1 through 2, according to several aspects, the peripheral flange proximate one or more of the apertures can define an L-shape. For example, the peripheral flange56of the first aperture50defines an L-shape having a first leg78integrally connected to the body22and oriented substantially parallel to the body22, and a second leg80angularly oriented with respect to the first leg78. According to several aspects, the reinforcement member58entirely covers the second leg80. According to further aspects, the reinforcement member58further covers a portion of the first leg78. According to several aspects, any of the peripheral flanges can also define an S-shape, such as the peripheral flange62of the second aperture52, which is described in greater detail in reference toFIG. 4.

A first shelf S1of the body22defines a first plane “A” having the first aperture50created therein. A second shelf S2of the body22defines a second plane “B” having the second aperture52created therein. As previously noted, each of the first aperture50and the second aperture52is at least partially surrounded by either the peripheral flange56, or the peripheral flange62created from a portion of the shelf S1, S2extending away from the plane “A” or “B” defined by the shelf. It is noted the first shelf S1and the second shelf S2are provided as exemplary aspects of the body22, and that any planar portion of the body22can include an aperture, a channel, or another reinforcement feature having a polymeric material reinforcement member created about a perimeter of a peripheral flange of the aperture, or a reinforcement member extending away from the planar portion.

Referring now toFIG. 4and again toFIG. 3, according to several aspects and as noted above, the peripheral flange62defines an S-shape. The peripheral flange62includes a first leg82integrally connected to the body22and angularly oriented with respect to the body22, a second leg84angularly oriented with respect to the first leg82, and a third leg86angularly oriented with respect to the second leg84. According to further aspects, the reinforcement member60includes a first portion88entirely covering the third leg86. According to additional aspects, the reinforcement member60further includes a second portion90that covers a portion of the second leg84. According to further aspects, the reinforcement members58,60can cover an entire perimeter of the peripheral flanges56,62.

Referring toFIG. 5, and again toFIGS. 1 through 2, as previously noted the body22is predominantly made of an aluminum material and the opposed side portions14,18are each formed of a ferrous material and are adapted to be fixed to the body, for example by fastening. Apertures92are provided for application of fasteners (not shown) used to join the first and the second side portions14,18to the body22. The first and the second side portions14,18are provided of a ferrous material to suit welding of the first and the second side portions14,18to the steel material frame12of the vehicle, and to minimize the interaction of dissimilar metals at these junctions. The first and the second side portions14,18can also include polymeric material reinforcement members such as a plurality of reinforcement members94, as well as the reinforcement member74provided about the perimeter of the aperture72previously described in reference toFIG. 2.

Referring toFIG. 6and again toFIGS. 1 through 5, reinforcements members such as a reinforcement member96can be used to span externally facing angled surfaces such as a substantially planar surface98and a surface100which is oriented substantially perpendicular to surface98. To assist in retaining the reinforcement members in integral contact with the body22, each of the reinforcement members of the present disclosure can further include one or more interlocks102, shown and described in greater detail in reference toFIG. 7. Reinforcement members such as a reinforcement member104can also be used to span internally facing angled surfaces such as a substantially planar surface106and a surface108which is oriented substantially perpendicular to surface106. Additional reinforcement members such as a reinforcement member110can be used to integrally connect proximate reinforcement members, such as to connect the first reinforcement member58integrally connected to the first raised peripheral flange56to a reinforcement member112created at a raised perimeter of an aperture114. Each reinforcement member directly contacts and extends away from a surface of the body22and stiffens the body22.

Referring toFIG. 7and again toFIG. 6, multiple interlocks such as the representative interlock102shown are integral portions of the multiple reinforcement members such as the reinforcement member96shown. Each interlock extends through an aperture114created in the body22or through a similar aperture create in one of the first or the second side portions14,18. Each of the interlocks can end flush with an opposite surface116of the panel they extend through, such as the body22, or can have a bulbous-shaped button118, which overlaps the surface116of the panel to thereby create a positive lock to prevent pullout of the interlock. A height “H” of any reinforcement member, such as the reinforcement member96, can vary as necessary to provide additional localized stiffness to the body22, or as necessary to span between adjacent reinforcement members.

Referring toFIG. 8and again toFIG. 1, one or more reinforcement channels such as a U-shaped channel120can be created in the body22, for example between the front flange24and a proximate flange122. Additional polymeric material reinforcement members which define an X-shape, such as X-shaped reinforcement members124,126can be injection molded and are integrally connected to each of the front flange24and the flange122. Additional X-shaped reinforcement members, such as reinforcement members128can be either smaller or larger than the X-shaped reinforcement members124,126to suit the stiffness requirements of body22, particularly at areas such as the loading positions of the seat belt reel housings36(shown inFIG. 1).

According to several aspects, a motor vehicle hybrid shelf assembly10includes a body22formed of a metallic sheet. A shelf S1of the body22defines a plane “A” having at least one aperture50created therein. The at least one aperture50is at least partially surrounded by a peripheral flange56created from a portion of the shelf extending away from the plane “A” defined by the shelf. A reinforcement member58of a polymeric material is integrally connected to the peripheral flange56.

It is noted that items identified herein as being a stamping of a metal material can also be provided as cast, forged, or extruded structures. A motor vehicle hybrid shelf assembly10of the present disclosure offers several advantages, including the ability to tailor a structural performance of different model vehicle shelf assemblies for different structural loading requirements, different NVH (i.e., noise, vibration, harshness) requirements, and for different vehicle options that may impact the shelf assemblies. The use of the polymeric material reinforcement members as well as the use of aluminum material for substantial portions of the body provide for weight savings compared to an entirely steel shelf assembly.