Patent Publication Number: US-2005127716-A1

Title: Vehicle floor compartments

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims the benefit of U.S. Provisional Application No. 60/529,681, filed Dec. 15, 2003, the disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to storage compartments and more particularly to motor vehicle floor compartments.  
     BACKGROUND OF THE INVENTION  
      In the field of motor vehicle interior design there is a desire to maximize the efficiency of vehicle interior designs. For example, it is desirable to increase space for carrying cargo or to provide additional leg room for the vehicle&#39;s occupants.  
      One way of accomplishing this is to provide seats that fold or collapse to allow clearance for larger, bulkier items to be loaded into the vehicle. However, the seats are often folded in such a manner that they are on top of the interior floor. In this case, the interior dimensions are not maximized because space is lost as a result of the folded seats resting on the vehicle floor.  
      Another way of maximizing the efficiency of vehicle interior designs relates to the storage of articles. Many vehicles come with devices such as cargo nets or storage compartments that can secure items to prevent them from shifting or rolling about the vehicle during travel. Conventional storage devices are not always practical for articles of various sizes. For example, a cargo net is not practical for securing small loose articles. Likewise a storage compartment is often limited as to the dimensions of the articles it can contain.  
      Still another way of maximizing the efficiency of vehicle interior designs relates to the position of the driver and passenger seats. The positioning of the seats primarily determines the amount of leg room that the driver and the passengers have in the vehicle. Leg room is generally defined as the amount of volume between adjacent rows of seats (e.g., between the front and rear seat rows) or between the seats and the instrument panel (e.g., when measuring front seat leg room) that a passenger has to place their feet and legs when seated. Generally, the amount of space between seats is a function of several factors that include door placement and the overall dimensions of the passenger cabin.  
      Typically, many vehicles have relatively flat floor pans with no depressions that allow for the placement of feet and legs. Thus, the efficiency of the vehicle interior design is not optimized. For example, the driver and front seat passengers have more leg room, while the passengers in the second or further rows of seats are more cramped because they have less leg room. The lack of leg room also lessens the amount of space that is permitted for storing items on the floor of the vehicle behind the first and subsequent rows of seats.  
      Accordingly, there exists a need for a system for increasing the available space within a vehicle interior design, especially for providing increased leg room and cargo storage capacity.  
     SUMMARY OF THE INVENTION  
      In accordance with the general teachings of the present invention, a system for increasing the available space within a vehicle interior design is provided.  
      In accordance with one embodiment of the present invention, the system preferably includes a modular compartment located within the interior surface of a vehicle. The compartment preferably includes a base with at least two sidewalls extending upwardly from the base. The sidewalls preferably connect to a support structure of the vehicle. The base of the modular compartment preferably extends below the support structure of the vehicle.  
      In accordance with an alternative embodiment of the present invention, a modular compartment for the interior floor of a vehicle is provided, wherein the vehicle includes a support structure, the compartment comprising: (1) a base; and (2) at least two sidewalls extending upwardly from said base operable to be connected to the vehicle support structure such that the top of said at least two sidewalls are substantially flush with the interior floor of the vehicle.  
      Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
       FIG. 1  illustrates a schematic view of a vehicle incorporating various preferred embodiments of the present invention;  
       FIG. 2  illustrates a side view of the schematic illustrated in  FIG. 1 ;  
       FIG. 3  illustrates a cross-sectional view taken along lines  3 - 3  of  FIG. 1 ; and  
       FIG. 4  illustrates the same view as  FIG. 3  with the additional features of a sound abatement layer and a foot plate. 
    
    
      The same reference numerals refer to the same parts throughout the various Figures.  
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
      The present invention primarily comprises a compartment preferably having a base that preferably has at least two sidewalls extending upward from the base. The sidewalls preferably have a flange, or other member, which can be adhesively bonded, or otherwise fastened or connected, to a support structure of a vehicle. Without being bound to a particular theory of the invention, the compartment is intended to increase the storage capacity and/or leg room of the vehicle.  
      Referring to  FIGS. 1 and 2 , a vehicle is shown incorporating four presently preferred embodiments of modular compartments  10  of the present invention. Although the vehicle is shown as being configured as a mini-van, it should be appreciated that one or more embodiments of the present invention can be used in any type of vehicle depending on the particular design requirements for the vehicle.  
      The front seats  12 ,  12   a  of the vehicle preferably include a modular compartment  14  located in front of each respective seat. Each modular compartment  14  preferably includes a base  15  with foot plate  17  positioned in the support structure in the interior of the vehicle. The foot plate  17  shall be understood to be that region or area of the compartment  14  upon which the user places their feet or any portion of their feet (i.e., heel point, toe region, etc).  
      The support structure of the vehicle preferably includes two or more longitudinal beams that that run the length of the interior of the vehicle and two or more lateral cross-bars that attach at a generally perpendicular angle to the longitudinal beams. In a conventional setting, e.g., where the floor of the interior of a vehicle is flat, the support structure is located below the floor covering.  
      The compartment  14  preferably further includes at least a pair of sidewalls  19  connected to the base  15 . The base  15  of the compartment preferably defines the floor of the vehicle. As shown, the base  15  is preferably not planar, but rather it includes a portion of the foot plate  17 . The compartment  14  preferably extends below the top surface of the support structure of the vehicle, and enhances or increases the amount of leg room provided by increasing the volume of space that the user has to place their legs and feet.  
      Between the front seats  12 ,  12   a , respectively, a second modular compartment  16  is preferably provided. The second modular compartment  16  preferably includes a base  21  and at least a pair of sidewalls  23 . A footplate  25  may also be located on the base  21 . Typically, the foot plate  25  is positioned on the base  21  near the forward sidewall  23 . While the base  21  is depicted as having a forwardly sloping structure, it should be appreciated that a structure of any slope (or no slope) is also within the scope of the present invention. The base  21  of the second modular compartment  16 , and more specifically the foot plate  25 , preferably provides a place for passengers in the second seat  18  to place their feet.  
      As with the first modular compartment  14 , the second modular compartment  16  preferably extends below the upper surface of the support structure of the vehicle. By extending the base  21  below this point of the support structure, interior space in the vehicle is enhanced in the form of increased leg room. It should be appreciated that some applications may require the second modular compartment  16  to have more or less volume in order to provide more storage space or leg room, as the case may be. The second modular compartment  16  can also serve as a storage compartment by placing items therein.  
      A third modular compartment  20  is preferably located between the second seat  18  and a third seat  22 . As with the previously described embodiments (i.e., compartments  14 ,  16  respectively), the third modular compartment  20  has a base  27  and at least a pair of sidewalls  29  extending upwardly from the base  27 . Additionally, the base  27  preferably extends below the upper surface of support structure of the vehicle. The base  27  of the third modular compartment  20  may also have a footplate  31  formed on its surface. The footplate  31  provides a place for passengers in the third seat  22  to place their feet.  
      The base  27  of the third modular compartment  20  preferably also includes a larger volume than the first and second modular compartments  14 ,  16 , respectively. This greater volume allows for storage of relatively larger items (e.g., luggage) in the third modular compartment  20 . Further, it serves as a seat storage compartment wherein the second seat  18  folds backward into the third modular compartment  20 . Preferably, the size and depth of the third modular compartment  20  allows the folded vehicle seat  18   a  (shown in dashed lines) to be flush with the top or upper surface of the support structure of the interior of the vehicle upon which the seats are mounted.  
      A fourth modular compartment  24  can also be located behind the third seat  22 . As with the previously described embodiments (e.g., compartments  14 ,  16 , and  20 , respectively), the fourth modular compartment  24  preferably extends below the support structure of the vehicle and includes a base  33  and at least a pair of sidewalls  35  extending upwardly from the base  37 .  
      The fourth modular compartment  24  preferably provides a bin for receiving items (e.g., luggage). By virtue of the configuration of the fourth modular compartment  24 , the compartment can receive relatively large items. The fourth modular compartment  24  also preferably has a depth that is sufficient to allow the third seat  22  to fold backwards into the fourth modular compartment  24 , so that the folded third seat  22   a  (shown in dashed lines) will be flush with the top of the support structure of the interior of the vehicle.  
      Each of the modular compartments of the present invention is preferably formed of a composite material. In a preferred embodiment, the composite materials used include, but are not limited to glass-filled, mineral filled, metal mesh reinforced, or mineral-glass filled combinations of semi-crystalline or amorphous polymers and include, but are not limited to polyamides such as various grades of nylon, various polyolefins, such as but not limited to polyethylene, polypropylene, and the like, syndiotactic vinyl aromatic polymers, such as but not limited to syndiotactic polystyrene (SPS) and any blends thereof. Other potential polymers useful in the practice of the present invention include, but are not limited to polyesters, polyesteramides, polyarylates, polyurethane polyureas, polyphenylene sulfides, polytherimides, and the like. It will be appreciated that other thermoplastic or thermoset composite materials may be used within the scope of the present invention. The compartments of the present invention may also be formed of steel, stainless steel, aluminum or laminates thereof in conjunction with polymeric materials. The metal—polymer composite may be of a sandwich construction of metal-polymer-metal or a polymer laminated on one or both sides of the metal.  
      Each of the base, sidewalls and foot plates of the compartments of the present invention are preferably integrally formed, such as by injection molding, blow-molding, and the like. It will be appreciated, however, that any number of conventional techniques may be used to integrally form the components.  
      Referring specifically to  FIG. 2 , the attachment of each modular compartment to the vehicle&#39;s support structure can be seen. The modular compartments  14 ,  16 ,  20 ,  24 , respectively, are preferably affixed between a number of cross-bars  26 ,  28 ,  30 , respectively, on the interior the vehicle.  
      By way of a non-limiting example, the first modular compartment  14  is affixed between an inclined portion  44  of the front portion of the vehicle interior and a first cross-bar  26 , the second modular compartment  16  is located between a first cross-bar  26  and a second cross-bar  28 , the third modular compartment  20  is located between the second cross-bar  28  and a third cross-bar  30 , and the fourth modular compartment  24  is located between the third cross-bar  30  and a fourth cross bar  45  at the rear of the vehicle.  
      Referring now to  FIG. 3 , there is shown a cross-sectional view of the third modular compartment  20  affixed between the second cross-bar  28  and the third cross-bar  30 . The third modular compartment  20  can also be affixed to the longitudinal rails of the vehicle (not shown). While  FIG. 3  depicts the placement of the third modular compartment between two cross-bars, it should be understood that this is generally how the other compartments of the present invention are preferably affixed to the vehicle. Additionally, the other compartments of the present invention can also be fastened to the longitudinal rails (not shown) of the vehicle in a manner similar to the fastening of the compartments of the present invention to the cross-bars described above.  
      Preferably, a mounting flange  36 , or similar member, extends around the entire periphery of the third modular compartment  20 . The mounting flange  36  is preferably configured so as to substantially mate with flanges  38 ,  40  formed on the second cross-bar  28  or the third cross-bar  30 , respectively. Additionally, the remaining sides of the mounting flange  36  may also be mated with flanges (not shown) formed on the sides of longitudinal beams (not shown).  
      The mounting flange  36  is preferably secured to the flanges  38 ,  40  using suitable adhesives or other conventional methods (e.g., fasteners or a combination of adhesives and fasteners). By way of a non-limiting example, preferred adhesives include, but are not limited to polyurethane adhesives and LES (Low Energy Surface) adhesives, such as alkyl borane amine complex initiated acrylic adhesives. Representative of preferred LES adhesives are described in various patents including U.S. Pat. Nos. 5,106,928, 5,143,884, 5,286,821, 5,310,835, 5,376,746, 5,539,070, 5,690,780 and 5,691,065, the entire specifications of which are incorporated herein by reference.  
      Referring now to  FIG. 4 , there is shown a cross-sectional view of the third modular compartment  20  equipped with a foot plate  31 . This particular embodiment of the present invention includes a foot plate  31  that is located along the surface of one of the sidewalls  29  of the third modular compartment  20 . It should be appreciated that it is generally within the scope of this invention to have the foot plate positioned on any surface, or any combination of surfaces, of the modular compartments.  
      In this embodiment of the present invention, the foot plate  31  preferably includes several lateral convolutions  39  or ribs that are intended to trap moisture. The foot  41  of the passenger preferably rests on the convolutions  39 . At the bottom of the convoluted surface  39 , a drain hole  42  is preferably provided. The drain hole  42  preferably allows any accumulated moisture to be drained directly out of the vehicle. It is also contemplated that certain embodiments may not use a drain hole, and may instead depend on other methods, such as evaporation, for removing accumulated moisture. Containing and removing moisture reduces damage to objects, such as clothing or packages that may be touching the floor of the interior cabin of the vehicle.  
      This particular embodiment also preferably includes a base  20  and one sidewall  29  that is lined with a sound abatement layer  43 . Each of the modular compartments  14 ,  16 ,  20 ,  24 , respectively, may also include a sound abatement layer. Similarly, the sound abatement layer  43  may be secured to one or more of the sidewalls  29 .  
      The sound abatement materials may be molded in placed or foamed in place. Preferably, the noise abatement materials include any adequate foam, filled foam, filled elastomeric sheet, or injection moldable filled material. Additionally, the sound abatement layer may also comprise a layer of carpet that is bonded to the respective compartment.  
      The foot plate of the first, second and third modular compartments described above serves to provide the driver and passengers with a place to comfortably place or rest their feet, e.g., during travel. Additionally, the increased volume of the compartment with the foot plate provides additional leg room for the vehicle passengers. This allows the driver and passengers to have better leg and foot positioning without having to design a vehicle compartment that is longer and/or wider.  
      The modular compartments described above offer many advantages over conventional metal automotive floor pans. For instance, they are lighter in weight and less expensive than conventional designs. Additionally, they offer inherent improvements in noise/vibration/harshness (NVH) performance, thermal insulation, molded colors and surface features, dent and ding resistance and corrosion resistance. The modular compartments described above can also be supplied with added functionality: such as carpet, floor mats, and/or NVH materials or attributes. Additionally the modular compartments provide a potential manufacturing advantage as they can used to stow seat assemblies and other parts prior to attachment to the vehicle.  
      The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.