Patent Publication Number: US-2010117394-A1

Title: Floor module including seating

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The instant application claims priority to U.S. Provisional Application Ser. No. 60/875,844 filed 19 Dec. 2006, the entire specification of which is expressly incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a floor module including seating for motor vehicles. 
     DESCRIPTION OF THE RELATED ART 
     Presently, vehicle floor pans are typically made of metal and are stamped of several pieces. Often, four or more sections are separately stamped and these sections are placed in the vehicle. The floor pan sections span between the vehicle&#39;s fire wall and the vehicle&#39;s spare wheel well. The vehicle floor pan sections are typically secured to the load bearing structure of a vehicle by welding. The floor pan sections can be placed in vehicles having a load bearing structure of the rail type, or the load bearing structure can be of the unitized body type. In each case, the load bearing structure includes die rails extending the longitudinal length of the vehicle. Cross members extend perpendicular to and between the longitudinal rails to provide further support. The current vehicle floor pan assemblies are susceptible to corrosion, are noisy, and are relatively difficult to assemble and install in a vehicle. 
     Once the floor pans are installed, seats are typically secured to the upper cross members. Often, seats are able to be stowed above the floor pan. That is, some of the seats in a vehicle are moveable between a stowed position adjacent the floor pan and an upright position for seating. 
     In addition to the floor pan being assembled in the vehicle, additional items are typically added. For example, duct work for ducting air from the front of the vehicle to the rear is typically added. Similarly, wiring raceways and wiring may be added to provide a manner of providing electrical contact between the front of the vehicle and elements near the rear of the vehicle. 
     U.S. Pat. No. 6,739,641 is assigned to the assignee of the present invention and comprises and comprises a composite spare wheel well. The patent discloses a vehicle wheel well assembly that is adapted for connection with a vehicle floor pan. The wheel well assembly is formed as a unitary member. 
     U.S. Patent Application Publication No. 2005/0127716 is assigned to the assignee of the present invention and shows modular vehicle floor compartments. The modular compartments comprise a series of compartments arranged within a vehicle. The compartments are connected to a support structure of a vehicle. 
     U.S. Pat. No. 6,375,247 to Volz, et al discloses a body of a motor vehicle with a seat module. The seat module is separately formed and inserted as a prefabricated unit into a load bearing structure of the body in such a way that a floor part in the region of the seat module forms a double floor with the vehicle floor of the body. 
     U.S. Pat. No. 6,843,336 to Chernoff et al discloses a vehicle belly pan. The vehicle chassis has substantially all of the mechanical, electrical and structural compartments necessary for a fully functioning vehicle. 
     U.S. Patent Application Publication No. 2005/0040675 shows a floor module for a vehicle. The floor module comprises a floor plate that is cut to size and ready for installation to a mounting rail. 
     German Patent No. DE 196 08 127 A1 discloses a method for manufacturing a fiber composite component. The component may comprise a motor vehicle floor. 
     SUMMARY OF THE INVENTION 
     According to the present invention, there is provided a floor module for disposition in a vehicle having a load bearing structure having side rails and at least one lower cross member disposed between the side rails. The floor module comprises a lower floor section. The floor module further comprises at least one side wall extending transversely from said floor section. The lower floor section and the side wall define a cavity therein. The floor module further comprises an upper floor section and a mounting flange extending from the upper floor section. The mounting flange is adapted to engage at least one of the vehicle side rails. The floor module further comprises a seat moveable between a stowed position in said cavity and an upright useable position. 
     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 
         FIG. 1  is an exploded view of one embodiment of the present invention; 
         FIG. 2  is an exploded cross-section view of a view taken along lines  2 - 2  of  FIG. 1 ; and 
         FIG. 3  is a cross-sectional view of a seat module in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A floor module for disposition in a vehicle is generally shown at  10 . The vehicle has a load bearing structure generally indicated at  12 . The load bearing structure  12  may be of the rail type or may be of the unitized body type as shown in  FIG. 1 . The load bearing structure  12  has at least a pair of longitudinal rails  14  that extend in the direction of the length of the vehicle. At least one lower cross member  16  extends between the longitudinal rails  14  to provide stability to the load bearing structure  12 . Typically, more than one lower cross member  16  is disposed transversely and between longitudinal rails  14  as is well known. 
     A floor module  10  in accordance with one embodiment of the present invention is shown in  FIG. 3 . The floor module  10  includes a lower floor section  18  having outside edges  19 . The lower floor section  18  is configured to provide a floor for the vehicle. The lower floor section  18  can take any contour or shape desired. 
     The floor module  10  further includes at least one side wall  20  extending transversely from the lower floor section  18 . More preferably, four contiguous side walls  20  extend from the outside edges  19  of the lower floor section  18 . The side walls  20  and lower floor section  18  define a cavity  28 . 
     The floor module  10  further includes an upper floor segment  24  extending outwardly from each side walls  20 . The upper floor segments  24  form a load floor that can receive finishing materials, such as carpeting or the like. More specifically, the upper floor segments  24  connect above the lower floor section  18  to form a portion of the load floor of the vehicle. The upper floor segments  24  are connected preferably by being integrally molded to form the load floor. 
     The floor module includes  10  at least one mounting flange  26  extending from a least a portion of the upper floor segment  24 . Preferably, one mounting flange  26  extends from each side of the upper floor segment  24  adjacent the outer peripheral edge, as shown in  FIG. 3 . The mounting flanges  26  extend outwardly from the upper floor segment  24  on the sides of the modules  10 . As shown in  FIG. 3 , the mounting flanges  26  extend upwardly and then outwardly from the upper floor segment  24  so that they can mate with a portion of the longitudinal rail  14  to which they will be connected. It will be appreciated that the mounting flanges  26  can be configured in any shape that allows them to be connected with the associated longitudinal rails  14 . The mounting flanges  26  may be connected with the associated longitudinal rails  14  in any manner. However, it is preferred that an adhesive  27  be applied to the mounting flanges  26  which will be used to adhesively secure the mounting flanges  26  and thereby the module to the longitudinal rail  14 . Any suitable adhesive may be used to secure the mounting flange  26  with the longitudinal rail  14 . 
     As set forth above, the lower floor section  18  and lower portion  22  of the side walls  20  define a cavity  28 . The cavity  28  is for receiving a seat  30  when the seat  30  is in a stowed position. The seat  30  is preferably moveable out of the stowed position to an upright useable position (not shown), in any well-known manner. It will be appreciated that in some applications, a portion of the seat  30  itself may take the place of the pivotal floor section  32  (described below) to provide a portion of the load floor. 
     The floor module  10  further includes a pivotal floor section  32 . More specifically, a pivotal floor section  32  is pivotally connected to the upper floor segment  24 . The pivotal floor section  32  is disposed over the cavity  28 . The pivotal floor section  32  provides a portion of the load floor for the floor module  10 . That is, when the floor module  10  is inserted in the vehicle, and the seats  30  are in the stowed position, the pivotal floor section  32  is contiguous and substantially coplanar with the upper floor segments  24  to comprise a load floor. Accordingly, items may be placed on top of the pivotal floor section  32  and upper floor segment  24 . The pivotal floor section  32  may be connected to the upper floor segments  24  in any suitable manner. 
     The pivotal floor section  32  is pivotal with respect to the upper floor segment  24 . More specifically, the pivotal floor section  32  is arranged such that it is disposed over the cavity  28 . In this manner, the pivotal floor section  32  can be pivoted to allow access to the cavity  28  to allow the seat  30  to be moved between a stowed position and an upright useable position (not shown) in any well-known manner. The pivotal floor section  32  preferably is connected to the upper floor segment  24  in any suitable manner that allows it to pivot to allow access to the cavity  28 , such as, for example, by a living hinge. It will be appreciated, however, that the pivotal floor section  32  may be a separate piece from the upper floor segment  24  and secured thereto by use of suitable hinges or the like. The connection should be in a manner that allows pivoting movement of the pivotal floor section  32  so that access to the cavity  28  can be made. 
     The floor module  10  further includes one or more upper cross members  36 . The upper cross members  36  extend between the mounting flanges  26 . The upper cross members  36  preferably comprise the same material as the floor section  18  and mounting flange  26 . The upper cross members  36  aid in providing support to the floor module  10 . Further, the upper cross members  36  provide an attachment point for attaching items such as seats to the floor module  10 . 
     Each upper cross member  36  is secured to the floor module  10 . Preferably, the cross member  26  is secured to the upper floor segment  24 . While the upper cross member  36  can be connected to the upper floor segment  24  in any suitable manner, it is preferred that the upper cross member  36  be adhesively secured to the upper floor segment  24 . It will be appreciated, however, that mechanical fasteners may also be used to secure the upper cross member  36  to the upper floor segment  24 . 
     The top side of the pivotal floor section  32  is preferably covered with a decorative material. For example, the top side of the pivotal floor section  32  may be covered with carpet  38 . Additionally, as set forth above, the top side of the upper floor segment  24  is preferably covered with carpet  38 . The carpet  38  can be secured to the pivotal floor section  32  and upper floor segment  24  in any manner. Preferably, the carpet  38  is adhesively secured. 
     The top surface of the lower floor segment  18  that is inside of cavity  28 , may also include a noise damping material  39 . The noise damping material  39  can comprise any material that can absorb sound and help dissipate it or block it from passing therethrough. One such example of a damping material is cotton shoddy. However, any suitable damping material or combination of damping materials may be used. The noise damping material  39  can be applied to the lower floor segment  18  in any suitable manner. By way of non-limiting example, the noise damping material can be adhesively secured to the lower floor segment  18 . It will also be appreciated that the noise damping material can be applied to the side walls  20  inside the cavity  28  (not shown). 
     The bottom side of the lower floor section  18  may include a noise or vibration damper  40  thereon. The damper  40  is used to reduce noise and vibration at the lower floor section  18 . The damper  40  can also be applied to the side wall  20  and to the upper floor segment  24 . The damper  40  may comprise any kind of damper, such as, for example, a damper that can be applied as a liquid by spraying it on or by manual application techniques, such as, for example, by brushing or application by spatula, and cured. Alternatively, the damper  40  can comprise a damping pad that is secured such as by adhesive to the bottom side of the lower floor section  18  that can be used to dampen noise and vibration at the lower floor section  18 . By way of non-limiting example, the damper may comprise a water-based damping material, such as BETADAMP® dampers commercially available from The Dow Chemical Company. Also, rubber-based damping materials, such as BETAPHON® dampers which are also commercially available from The Dow Chemical Company may be used. It will be appreciated, however, that any suitable damping material may be used within the context of the present invention. 
     It is preferred that the lower floor section  18 , side walls  20 , upper floor segment  24  and mounting flange  26  be made as a single one-piece unit. By way of non-limiting example, the lower floor section  18 , side walls  20 , upper floor segment  24  and mounting flange  26  can be integrally formed by compression or injection molding. Either a thermoset or thermoplastic may be used. Preferably, the plastic material is reinforced. One suitable thermoset material that may be used is a continuous reinforced epoxy material. An example of one suitable epoxy material that may be used is DER 383 which is commercially available from The Dow Chemical Company. One suitable thermoplastic that may be used is reinforced polypropylene. While it is preferred that continuous fiber reinforcement be used, it will be appreciated that any suitable reinforcement material may be used. Glass fibers, carbon fibers, natural fibers or aramid fibers may be used. Additionally, the fibers may in form of a mat. While some materials are specified that may be used to make the lower floor section  18 , side walls  20 , upper floor segment  24  and mounting flange  26 , it will be understood that the material used to make these components can comprise any material that provides the requisite strength. Further, it is preferred that the pivotal floor section  32  and the upper cross members  36  be made from the same materials as the lower floor section  18 , side walls  20 , upper floor segment  24  and mounting flange  26 . 
     As shown in  FIG. 1 , the floor module  10  may also include a console  42 . The console  42  may be integrally formed with the upper floor segment  24 . Alternatively, the console  42  can be secured in any manner, such as, for example, by suitable adhesive to the upper floor segment  24 . 
     The floor module  10  may further include accessory items, such as air ducts  44  or wiring raceways  46  having wires  47 . The air ducts  44  can be connected to or molded as part of any of the components. As shown, the air ducts  44  and wiring raceways  46  are shown as connected to the outside of the side walls  20 . If not molded as part of any component, the accessory items can be connected in any suitable manner, such as, for example, with the use of adhesives. It will be appreciated that any suitable accessory item can incorporated into the floor module. 
     Additionally, the floor module  10  may include a heat shield  48  secured below the lower floor section  18 . Currently, some vehicles have hot sides to the vehicle. The hot side is that side of the vehicle in proximity to the vehicle&#39;s exhaust system. A heat shield  48  may be secured under the lower floor section  18 . Most preferably, a heat shield  48  is used only on the hot side of the vehicle to prevent heat transfer between the lower floor section  18  and the item on the vehicle causing the heat, such as, for example, the exhaust system. The heat shield  48  can comprise any suitable material that helps prevent the transfer of heat. Preferably, the heat shield  48  is secured to the lower floor section  18 , which, as set forth above, may also include the damper  40  thereon. The heat shield  48  can be secured in any suitable manner, such as, for example, by the use of adhesives or suitable mechanical fasteners. 
     Further, the floor module may include an underbody shield  50 . The underbody shield  50  may be used to protect the floor module  10  from impact, such as, for example, by road debris. The underbody shield  50  can comprise any suitable material and take any configuration as is well known in the art. As with the heat shields  48 , the underbody shields  50  may be applied either directly to the damper  40  of the lower floor section  18  or to any intermediate heat shield  48 . The underbody shields may be secured such as, for example, by the use of suitable adhesives or mechanical fasteners. 
     As set forth above, several elements of the floor module  10  such as upper cross member  36 , carpet  38 , noise damper material  39 , or accessory items  44 , 46  may be adhesively secured. Similarly, the floor module  10 , itself, is preferably adhesively secured to the longitudinal rails  14 . In each case, any suitable adhesive may be used to make the connection. Since the floor module  10  is intended to be secured to the vehicle in the trim shop, it is preferred that the adhesive, at least on the mounting flange  26 , be curable at room temperature. This is because the vehicle typically will not undergo any manufacturing steps at elevated temperature at this point. Suitable adhesives include, by way of non-limiting example, polyurethane based adhesives. 
     It is intended that the floor module  10  be assembled off-line, that is, not at the assembly plant, and inserted into the vehicle in the vehicle&#39;s trim shop. Thus, access to the interior of the vehicle is limited. Because the floor module  10  is to be inserted in the trim shop after significant manufacture of the vehicle has been completed, it is intended that the floor module  10  be inserted into the vehicle through a door opening  52 . Further, because the floor modules  10  have significant content, such as, for example, seats  30 , carpet  38 , dampers  40 , air ducts  44 , wiring raceways  46 , heat shields  48  and underbody shields  50 , it is intended that more than one floor module  10  be separately inserted into the vehicle and secured.  FIG. 3  shows a single floor module  10  that is intended to be located in one opening  54  ( FIG. 1 ) in a vehicle load bearing structure  12 . It will be appreciated, however, that a floor module  10  can be configured to be placed in more than one opening in the vehicle frame assembly  12 . For example,  FIG. 1  shows two floor modules  10 , each intended for insertion into two openings  54  in the vehicle&#39;s load bearing structure. Like numbers represent like components among the various embodiments. As seen in  FIG. 2 , the floor module  10  may include two cavities  28 , each adapted to receive seats  30  in side-by-side arrangement. The interior side walls  20  of the floor module are connected at the upper floor segments  24 . Since only one of the lower floor sections  18  will be on the hot side of the vehicle, only the one lower floor section  18  would include a heat shield  48 . 
     Also, as shown in  FIG. 1 , the front floor modules  10  will not include a seat therein. Rather, a mounting point such as the upper cross member  36  is provided to provide a mounting point for a seat that is intended to remain in an upright position. The lower floor section  18  may be used to provide additional room for the front seat passengers. Alternatively, the floor modules providing the front floor may simply comprise one upper floor section  24 . In such a case, no side walls  20  or lower floor section  18  is necessary. Additionally, no pivotal floor section  32  is necessary. An upper cross member  36  is provided to attach a seat. 
     As shown in  FIGS. 1 and 2 , floor modules  10  having side-by-side cavities  28  can be placed one in front of the other and connected such that any air ducts  44 , wiring raceways  46 , wire  17 , heat shields  48  or underbody shield  50  line up and are contiguous when the floor modules  10  are installed on the longitudinal rails  14 . Although not shown, the air ducts and wiring raceways can include openings that allow air or wires to pass into the vehicle interior at any desired locations. As shown in  FIG. 1 , the floor modules are placed one in front of the other. It will be appreciated, however, that as an alternative to having one floor module  10  for side-by-side seating, a single floor module  10  may be produced for one side of the vehicle (not shown), i.e., one floor module  10  for the driver side and one floor module  10  for the passenger side. In such an instance, fore and aft cavities  28  are provided. In such an arrangement, multiple floor modules  10  can be arranged side-by-side. Such an arrangement might be particularly useful in that different materials can be used on different sides of the vehicle. For example, modules on the hot side of the vehicle may be made of a different material from the floor modules  10  on the cold side of the vehicle. 
     By having multiple modules capable of being interconnected on the vehicle load support structure  12 , flexibility with the floor modules can be provided. Further, by providing fully contented floor modules, each of which is fully assembled off-line and inserted into the vehicle during the trim operations, significant labor savings can be obtained. Also, the seating arrangement for each vehicle can be quickly tailored to any desired specification. Floor modules having different content can be placed at any location in the vehicle to serve any purpose necessary. 
     To construct a floor module  10  in accordance with the present invention, the lower floor section  18 , side walls  20 , upper floor segment  24  and mounting flange  26  are integrally formed as set forth above. The pivotal floor section  32  can be integrally formed at the same time with the lower floor section  18  and side walls  20 . Alternatively, the pivotal floor section  32  is pivotally secured to the upper floor segment  24  of the side walls  20  in any suitable manner. 
     The upper cross member  36  is secured to the upper floor segment  24  in any suitable manner, such as with the use of adhesives. A noise damping material  39  may be applied in the cavity  28 . Seats  30  are then connected to the floor module  10  and stowed in cavity  28 . A damper  40  can be applied to the bottom side of the lower floor section  18 . Heat shields  48  and underbody shields  50  may then be secured to the bottom side of the lower floor section  18 . Carpet can be secured to the upper floor segment  24  and the pivotal floor segment  32 . Once the fully constructed floor module  10  is assembled off-line, that is, not at the assembly plant, it is inserted as a single unit into the vehicle. An adhesive is applied to the mounting flange  26 . The mounting flange  26  is then adhesively secured to longitudinal rails  14  to secure the module  10  with the vehicle. 
     The invention has been described in an illustrative manner. It is to be understood that the terminology used is intended to be in the nature of words of description. Obviously many modifications and variations are possible in light of the above teachings.