Patent Publication Number: US-2017355316-A1

Title: Motor vehicle hybrid shelf assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of prior U.S. application Ser. No. 15/178,145 filed on Jun. 9, 2016, presently allowed. The entire disclosure of the above application is incorporated hereby by reference. 
    
    
     FIELD 
     The invention relates generally to a rear speaker mounting shelf for a motor vehicle. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art. 
     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. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
         FIG. 1  is a front left perspective view of a motor vehicle hybrid shelf assembly having a of the present disclosure; 
         FIG. 2  is a bottom right perspective view of the hybrid shelf assembly of  FIG. 1 ; 
         FIG. 3  is a cross sectional elevational view taken at section  3  of  FIG. 2 ; 
         FIG. 4  is a cross sectional elevational view taken at area  4  of  FIG. 3 ; and 
         FIG. 5  is a bottom right perspective view of the first and second side portions of the hybrid shelf assembly of  FIG. 1 ; 
         FIG. 6  is a front left perspective view of a motor vehicle hybrid shelf assembly of  FIG. 1 ; 
         FIG. 7  is a cross sectional end elevational view taken at section  7  of  FIG. 6 ; and 
         FIG. 8  is a bottom perspective view of the hybrid shelf assembly of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. 
     With reference to  FIG. 1 , a motor vehicle hybrid shelf assembly is generally indicated by reference number  10 . According to several aspects, the hybrid shelf assembly  10  is a structural member of an exemplary motor vehicle frame  12  used in a motor vehicle (not shown). The hybrid shelf assembly  10  is connected for example by welding, fastening or riveting at a first end or side portion  14  to a first member  16  of the frame  12  and at an opposed second end or side portion  18  to a second member  20  of the frame  12 . The hybrid shelf assembly  10  includes a main body  22  made of a metal including aluminum or steel. The body  22  can be formed for example by stamping and includes multiple integral reinforcing structures such as a front flange  24 , a rear flange  26 , multiple raised ribs  28 , and the like. To facilitate fixing the first side portion  14  and the second side portion  18  directly to the frame  12  which is commonly a ferrous metal material such as steel, the first side portion  14  and the second side portion  18  can be fixed by welding, fastening, or riveting. According to several aspects the first side portion  14  and the second side portion  18  can also be formed of a metal material such as steel or aluminum. 
     The body  22  supports multiple components such as a first speaker  30 , a second speaker  32 , a woofer  34 , 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 housings  36  can be fixed to the front flange  24 , which are used to retract and store seat belts such as a first rear seat belt  38 , a second rear seat belt  40 , and a third rear seat belt  42 . The front flange  24  and the body  22  are therefore designed to incorporate the stress and loading induced by the various seat belts, as well as the components supported by the body  22 . The rear flange  26  can also be connected to a rear cowling  46  at 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 body  22 , multiple reinforcement members  48  of a polymeric material are integrally connected to the body  22  at 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 members  48  is adapted to be applied in an over-molding process and defines a glass fiber reinforced material. 
     Referring to  FIG. 2  and again to  FIG. 1 , the hybrid shelf assembly  10  includes multiple apertures, with each aperture positioned to locate one of the speakers (shown and described in reference to  FIG. 1 ). For example a first aperture  50  is for locating the first speaker  30 , a second aperture  52  for locating the second speaker  32 , and a third aperture  54  for locating the woofer  34 . Each of the first aperture  50 , the second aperture  52  and the third aperture  54  can be reinforced by the addition of a raised peripheral flange created in the body  22 , such as a first raised peripheral flange  56 , which reinforces the first aperture  50 . In addition, portions of the reinforcement members  48  are located at the perimeter of multiple ones of the body apertures, including a first reinforcement member  58  integrally connected to the first raised peripheral flange  56 , and a second reinforcement member  60  integrally connected to a second raised peripheral flange  62  adjacent the second aperture  52 . A third reinforcement member  64  is integrally connected to a peripheral flange adjacent to the third aperture  54 . 
     With continuing reference to  FIG. 2  and again to  FIG. 1 , in order to provide additional structural reinforcement for the body  22 , the reinforcement members  48  can further include connecting members  66 , which for example integrally connect the first reinforcement member  58  to the second reinforcement member  60 . The connecting members  66  also provide an added benefit of allowing the first reinforcement member  58  and the second reinforcement member  60  to 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 members  66  can themselves be integrally connected using one or more joining members  68 , which can be oriented at any angle with respect to the connecting members  66 , but are preferably oriented substantially perpendicular to the connecting members  66 . The joining members  68  are also integrally connected to the body  22 , and are created during the same injection molding shot which forms the connecting members  66  and the reinforcement members  48 . 
     Additional polymeric material reinforcement can be provided during the same molding shot to the front flange  24 , using second joining members  70 , which can be integrally connected to one or more of the connecting members  66 . Additional apertures, such as for example an aperture  72 , can be reinforced with the same polymeric material of the reinforcement members  48 , but molded via a separate injection molding gate and a separate molding shot, and therefore providing a separate reinforcement member  74  about the perimeter of the aperture  72 . Where structural features such as a beam  76  or a tube are incorporated into the body  22 , separate polymeric material reinforcement can also be provided, such as by a reinforcement member  77 . According to several aspects, the beam  76  is positioned proximate to a vehicle rear facing portion of the body  22 . 
     Referring to  FIG. 3  and again to  FIGS. 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 flange  56  of the first aperture  50  defines an L-shape having a first leg  78  integrally connected to the body  22  and oriented substantially parallel to the body  22 , and a second leg  80  angularly oriented with respect to the first leg  78 . According to several aspects, the reinforcement member  58  entirely covers the second leg  80 . According to further aspects, the reinforcement member  58  further covers a portion of the first leg  78 . According to several aspects, any of the peripheral flanges can also define an S-shape, such as the peripheral flange  62  of the second aperture  52 , which is described in greater detail in reference to  FIG. 4 . 
     A first shelf S 1  of the body  22  defines a first plane “A” having the first aperture  50  created therein. A second shelf S 2  of the body  22  defines a second plane “B” having the second aperture  52  created therein. As previously noted, each of the first aperture  50  and the second aperture  52  is at least partially surrounded by either the peripheral flange  56 , or the peripheral flange  62  created from a portion of the shelf S 1 , S 2  extending away from the plane “A” or “B” defined by the shelf. It is noted the first shelf S 1  and the second shelf S 2  are provided as exemplary aspects of the body  22 , and that any planar portion of the body  22  can 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 to  FIG. 4  and again to  FIG. 3 , according to several aspects and as noted above, the peripheral flange  62  defines an S-shape. The peripheral flange  62  includes a first leg  82  integrally connected to the body  22  and angularly oriented with respect to the body  22 , a second leg  84  angularly oriented with respect to the first leg  82 , and a third leg  86  angularly oriented with respect to the second leg  84 . According to further aspects, the reinforcement member  60  includes a first portion  88  entirely covering the third leg  86 . According to additional aspects, the reinforcement member  60  further includes a second portion  90  that covers a portion of the second leg  84 . According to further aspects, the reinforcement members  58 ,  60  can cover an entire perimeter of the peripheral flanges  56 ,  62 . 
     Referring to  FIG. 5 , and again to  FIGS. 1 through 2 , as previously noted the body  22  is predominantly made of an aluminum material and the opposed side portions  14 ,  18  are each formed of a ferrous material and are adapted to be fixed to the body, for example by fastening. Apertures  92  are provided for application of fasteners (not shown) used to join the first and the second side portions  14 ,  18  to the body  22 . The first and the second side portions  14 ,  18  are provided of a ferrous material to suit welding of the first and the second side portions  14 ,  18  to the steel material frame  12  of the vehicle, and to minimize the interaction of dissimilar metals at these junctions. The first and the second side portions  14 ,  18  can also include polymeric material reinforcement members such as a plurality of reinforcement members  94 , as well as the reinforcement member  74  provided about the perimeter of the aperture  72  previously described in reference to  FIG. 2 . 
     Referring to  FIG. 6  and again to  FIGS. 1 through 5 , reinforcements members such as a reinforcement member  96  can be used to span externally facing angled surfaces such as a substantially planar surface  98  and a surface  100  which is oriented substantially perpendicular to surface  98 . To assist in retaining the reinforcement members in integral contact with the body  22 , each of the reinforcement members of the present disclosure can further include one or more interlocks  102 , shown and described in greater detail in reference to  FIG. 7 . Reinforcement members such as a reinforcement member  104  can also be used to span internally facing angled surfaces such as a substantially planar surface  106  and a surface  108  which is oriented substantially perpendicular to surface  106 . Additional reinforcement members such as a reinforcement member  110  can be used to integrally connect proximate reinforcement members, such as to connect the first reinforcement member  58  integrally connected to the first raised peripheral flange  56  to a reinforcement member  112  created at a raised perimeter of an aperture  114 . Each reinforcement member directly contacts and extends away from a surface of the body  22  and stiffens the body  22 . 
     Referring to  FIG. 7  and again to  FIG. 6 , multiple interlocks such as the representative interlock  102  shown are integral portions of the multiple reinforcement members such as the reinforcement member  96  shown. Each interlock extends through an aperture  114  created in the body  22  or through a similar aperture create in one of the first or the second side portions  14 ,  18 . Each of the interlocks can end flush with an opposite surface  116  of the panel they extend through, such as the body  22 , or can have a bulbous-shaped button  118 , which overlaps the surface  116  of 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 member  96 , can vary as necessary to provide additional localized stiffness to the body  22 , or as necessary to span between adjacent reinforcement members. 
     Referring to  FIG. 8  and again to  FIG. 1 , one or more reinforcement channels such as a U-shaped channel  120  can be created in the body  22 , for example between the front flange  24  and a proximate flange  122 . Additional polymeric material reinforcement members which define an X-shape, such as X-shaped reinforcement members  124 ,  126  can be injection molded and are integrally connected to each of the front flange  24  and the flange  122 . Additional X-shaped reinforcement members, such as reinforcement members  128  can be either smaller or larger than the X-shaped reinforcement members  124 ,  126  to suit the stiffness requirements of body  22 , particularly at areas such as the loading positions of the seat belt reel housings  36  (shown in  FIG. 1 ). 
     According to several aspects, a motor vehicle hybrid shelf assembly  10  includes a body  22  formed of a metallic sheet. A shelf S 1  of the body  22  defines a plane “A” having at least one aperture  50  created therein. The at least one aperture  50  is at least partially surrounded by a peripheral flange  56  created from a portion of the shelf extending away from the plane “A” defined by the shelf. A reinforcement member  58  of a polymeric material is integrally connected to the peripheral flange  56 . 
     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 assembly  10  of 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. 
     The description of the invention is merely exemplary in nature and 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.