Patent Publication Number: US-8118348-B2

Title: Glove box knee bolster assembly for vehicle and method of manufacturing

Description:
This application is a Divisional application and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 12/246,692 entitled “GLOVE BOX KNEE BOLSTER ASSEMBLY FOR VEHICLE AND METHOD OF MANUFACTURING,” filed Oct. 7, 2008 now U.S. Pat. No. 7,810,869. The above-referenced patent application is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     1. Field 
     The presently disclosed subject matter relates to devices, systems, and processes useful as an impact load distribution arrangement for a glove box and/or knee bolster assembly mounted to a vehicle instrument panel. 
     2. Description of the Related Art 
     Existing glove box and knee bolster assemblies often include an energy absorbing component that can minimize injury to a vehicle occupant&#39;s knee (or other body part) when the body part strikes the glove box or knee bolster lid. This energy absorbing component is typically positioned between the lid and a storage bin wall of the glove box, or between a trim panel and a structural wall. In one particular application, the energy absorbing component includes a plurality of parallel and intersecting ribs that engage a surface of the lid of the glove box. The plurality of parallel and intersecting ribs are located between the storage bin wall and the lid and are designed to carry the impact load generated when the occupant&#39;s knee (or other body part or structure) contacts the lid to absorb the energy of this impact. The lid is typically secured to the ribs by vibration welding. 
     SUMMARY 
     According to one aspect of the disclosure, a glove box/knee bolster assembly for a vehicle panel can include a lid that includes a top edge, a bottom edge, a front surface configured and dimensioned to be complementary with a contour of the vehicle panel, and a rear surface opposite the front surface. An energy absorbing panel can be located adjacent the rear surface of the lid and can have an elasticity characteristic in a direction normal to the rear surface of the lid, the energy absorbing panel having a facing surface facing the rear surface of the lid and an opposing surface facing away from the rear surface of the lid. A plurality of hooks can extend from at least one of the rear surface of the lid and the energy absorbing panel, the plurality of hooks being configured to apply at least one of a force on the opposing surface of the energy absorbing panel towards the rear surface of the lid and a force on the lid in a direction towards the energy absorbing panel. A secondary connecting structure can include at least one of a weld, an adhesive, and a screw, connecting the lid to the energy absorbing panel. 
     According to another aspect of the disclosed subject matter, a glove box/knee bolster assembly for a vehicle panel can include a storage bin that has a plurality of walls connected to one another. An energy absorbing panel can be located adjacent the plurality of walls, and the energy absorbing panel can cooperate with the plurality of walls to define a storage compartment having a plurality of sides and an open top. The energy absorbing panel can include a rib wall that extends across one side of the storage compartment, including a first plurality of ribs that extend from and along the rib wall, each rib of the first plurality of ribs being spaced from other ribs of the first plurality of ribs, and a second plurality of ribs that extend from and along the rib wall, each rib of the second plurality of ribs being spaced from other ribs of the second plurality of ribs, and each rib of the second plurality of ribs intersecting a respective rib of the first plurality of ribs. The energy absorbing panel can also include a plurality of openings formed in at least one of the first plurality of ribs and second plurality of ribs. A lid can be provided that includes a top edge, a bottom edge, a first side edge that extends from the top edge to the bottom edge, and a second side edge that extends from the top edge to the bottom edge. The lid can further include a front surface configured and dimensioned to be complementary with a contour of the vehicle panel, the front surface bounded by the front, top, first side, and second side edges of the lid. The lid can also include a rear surface bounded by the front, top, first side, and second side edges of the lid, the rear surface extending substantially parallel with the rib wall and secured to the first and second plurality of ribs by a weld, the weld cooperating with the first and second plurality of ribs. The rear surface of the lid can be configured to define a first load path that extends from the lid to the energy absorbing panel, and can include a plurality of hooks extending from the rear surface of the lid and passing through respective ones of the plurality of openings. The plurality of hooks can engage the first and second plurality of ribs at respective openings and cooperate with the first and second plurality of ribs to define a second load path from the lid to the energy absorbing panel that is distinct from the first load path. 
     According to another aspect of the disclosed subject matter, a method for manufacturing a glove box/knee bolster assembly can include providing a glove box that includes a storage bin, an energy absorbing panel connected to the storage bin, the energy absorbing panel including a rib wall and a plurality of ribs extending from and along the rib wall, and a lid that includes a rear surface and a plurality of hooks extending from the rear surface. The method can include spacing the rear surface of the lid from the rib wall with the plurality of ribs, securing the plurality of hooks to respective ones of the plurality of ribs such that the hooks apply a force to the energy absorbing panel in a direction towards the rear surface of the lid, forming a vibration weld between the rear surface of the lid and the plurality of ribs, and mounting the glove box to pivot on a vehicle panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosed subject matter of the present application will now be described in more detail with reference to exemplary embodiments of the apparatus and method, given by way of example, and with reference to the accompanying drawings, in which: 
         FIG. 1  is an exploded perspective view of a vehicle instrument panel and glove box assembly made in accordance with principles of the disclosed subject matter. 
         FIG. 2  is an exploded perspective view of the glove box assembly of  FIG. 1 . 
         FIG. 3  is a rear view of a lid of the glove box assembly of  FIG. 1 . 
         FIG. 4  is a cross-sectional view taken along line A-A of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     A description will now be made below with respect to examples of apparatuses and methods of the presently disclosed subject matter with reference to the accompanying drawings and in accordance with exemplary embodiments of the disclosed subject matter. 
       FIG. 1  illustrates an embodiment of a glove box assembly  10  made in accordance with principles of the disclosed subject matter. The glove box assembly  10  can be pivotally mounted to the instrument panel  12  in a manner known in the art. The glove box assembly  10  can be configured and dimensioned to receive a variety of items for storage within the instrument panel  12 . The glove box assembly  10  is combined with a knee bolster structure in this particular example. 
     With reference to  FIG. 2 , the glove box assembly  10  can include a storage bin  14 , an energy absorbing panel  16  secured to the storage bin  14 , and a lid  18  secured to the energy absorbing panel  16 . The storage bin  14  can receive a variety of items for storage within the glove box assembly  10 . The lid  18  can have a front surface  20  that is configured and dimensioned to be complimentary with the contour of the instrument panel  12 . 
     The lid  18  and the energy absorbing panel  16  can be configured and dimensioned to carry an impact load generated by a vehicle occupant&#39;s knee (or other body part or object) that strikes the front surface  20  of the lid  18 . The impact load applied by the knee to the lid  18  can be transmitted from lid  18  to the energy absorbing panel  16  via two distinct load paths between the lid  18  and the energy absorbing panel  16 , as will be described in more detail below. 
     The energy absorbing panel  16  can include a rib wall  22  and a plurality of ribs  24 ,  26  that extend from one side of the wall (e.g., the side facing the lid  18  when assembled). The ribs  24 ,  26  can act to space the lid  18  from the rib wall  22 , and include a first set of ribs  24  and a second set of ribs  26  that extend perpendicular to the first set of ribs  24 . The ribs of the first set  24  can be spaced from and extend parallel to one another. The ribs of the second set  26  can also be spaced from one another and can extend parallel to one another. As illustrated in  FIG. 2 , the first set of ribs  24  can extend horizontally and the second set of ribs  26  can extend vertically with respect to an orientation when mounted in a vehicle. Each of the ribs  24 ,  26  can have an edge  28  that forms a facing surface spaced from one side  30  of the wall  22  (see also  FIG. 4 ) and that contacts or possibly contacts a rear surface  34  of the lid  18 . The first and second set of ribs  24 ,  26  can intersect one another to define a plurality of spaces  32 . The ribs  24 ,  26  can be integrally molded with the rib wall  22  from a plastic material, such as polypropylene, polystyrene, polyethylene, polyvinylchloride, acrylic resins, etc., to form a single homogenous energy absorbing panel component. 
     Referring to  FIGS. 3 and 4 , the lid  18  can include a rear surface  34  and a plurality of hooks  36  that extend from the rear surface  34  toward the one side  30  of the energy absorbing panel wall  22 . Each of the hooks  36  can be L-shaped with a first leg  38  extending away from the rear surface  34  and a second leg  40  extending from the first leg  38  at a position spaced from the rear surface  34 . The first leg  38  can extend perpendicular to the rear surface  34  and the second leg  40  can extend perpendicular to the first leg  38  and parallel to the rear surface  34 . In the depicted embodiment, the first leg  38  has a length that is greater than the length of the second leg  40  and equal to the depth of the ribs  24 ,  26 . Each of the second legs  40  can extend in the same direction from their respective first leg  38 . 
     The plurality of hooks  36  can include a first set of hooks located adjacent the first lateral edge  42  of the lid  18  and a second set of hooks located adjacent the second lateral edge  44  of the lid  18 . Each of the hooks  36  of the first set can be aligned along a column that extends parallel to the first edge  42 . And, each of the hooks  36  of the second set can be aligned along a column that extends parallel to the second edge  44 . The first and second set of hooks  36  can be located adjacent the respective lateral edges  42 ,  44  at a position spaced from the upper and lower edges  46 ,  48  of the lid  18 . The hooks  36  can be integrally molded with the rear surface  34  from a plastic material, such as polypropylene, to form a single homogenous lid component. 
     As shown in  FIG. 4 , the edges  28  of the ribs  24 ,  26  can abut the rear surface  34  of the lid  18  to space the rear surface  34  from the one side  30  of the rib wall  22 . These edges  28  can be secured to the rear surface  34  by vibration welds in a manner that is known in the art. The vibration welds can cooperate with the rear surface  34  and the ribs  24 ,  26  to define a first load path that extends from the lid  18  to the rib wall  22 . Additionally, the lid  18  can be secured to the ribs  24  by the plurality of hooks  36 . 
     With continued reference to  FIG. 4 , certain ones of the first set of ribs  24  can include at least one opening  50 . The second leg  40  of each of the plurality of hooks  36  can extend into and through a respective one of the openings  50  and engage the associated rib  24 . The engagement can be in the form of a friction fit, a snap fit, loss fit, or other similar engagement. The openings  50  can be formed in the respective ribs  24  at a location along the ribs  24  that abuts the one side  30  of the rib wall  22 . The second leg  40  can also abut the one side  30  of the rib wall  22 . The hooks  36  can engage the certain ones of the ribs  24  along the openings  50  to define a second load path from the front surface  20  of the lid  18  through the ribs  24 ,  26  and to the rib wall  22  when a vehicle occupant&#39;s knee strikes the front surface  20 . The second load path can be distinct from the first load path. In addition, the hooks  36  can be configured and made from a material that provides a different elasticity for the second load path as compared to the first load path. Moreover, the overall elasticity characteristic of the ribs  24 ,  26  in a direction normal to the surface  30  of the rib wall  22  can be different than the overall elasticity characteristic of the hooks  36  when engaged with the surface  30  of the rib wall  22 . In addition, the hooks  36  ensure contact between lid  18  and the ribs  24 ,  26  to provide a consistent amount of damping when an object strikes the front surface  20  of the lid  18 . 
     Referring to  FIGS. 2 and 4 , the storage bin  14  can include a plurality of walls  52 ,  54 ,  56 ,  58  connected to and extending from one another. The plurality of walls  52 ,  54 ,  56 ,  58  can be integrally molded as a single piece from a plastic material, such as polypropylene, to form a single homogenous storage bin component, or can be separate components that are adhered or otherwise attached via known attachment structures. As illustrated in  FIGS. 1 ,  2  and  4 , the lid  18 , energy absorbing panel  16 , and storage bin  14  define a receptacle having an opening extending across the top to provide a vehicle occupant with access to the storage bin  14 . 
     In this exemplary embodiment, the energy absorbing panel  16  is shown and described as a separate component from the storage bin  14 . However, it is possible to integrally form the storage bin  14  and the energy absorbing panel  16  as a single homogenous component. Alternatively, the storage bin  14  can include an additional wall that spans from the left side wall  56  to the right side wall  58  and the ribs  24 ,  26  (with or without a separate wall such as rib wall  22  of  FIGS. 2-4 ) can be affixed to this additional wall. 
     While certain embodiments of the disclosed subject matter are described above, it should be understood that the disclosed subject matter can be embodied and configured in many different ways without departing from the spirit and scope of the disclosed subject matter. For example, if a glove box is not desired in a particular vehicle, a dedicated knee bolster assembly can be provided in place of the glove box. The knee bolster assembly could simply be mounted in a non-pivoting manner with respect to the instrument panel, and no box or storage structure provided within the knee bolster lid. The absorbing panel and hook structures can be connected to the lid of the knee bolster in a manner similar to that of the glove box structure described in detail above. It should also be understood that while the ribs  24 ,  26  are shown as crossing each other at right angles, the angle of crossing can vary. In addition, the ribs  24 ,  26  could also be non-linear or wavy structures that cross each other at various random or dedicated angles in accordance with either a design purpose or in accordance with a desire to provide different elasticity characteristics at certain locations of the front surface  20  of the lid  18 . The ribs  24 ,  26  are disclosed as being formed homogonously and continuously with the wall  22 . However, it is contemplated that the ribs  24 ,  26  could be a separate structure that can be separately adhered or attached to the wall  22  or even to the lid  18 . Moreover, if the ribs  24 ,  26  are attached or are integrated with the rear surface  34  of the lid  18 , the hooks  36  could be provided extending from the surface  30  of the rib wall, and could be attachable to the ribs  24 ,  26  in an opposite direction as compared to that shown in the drawings. 
     Although openings  50  are disclosed in the ribs  24 ,  26  to provide an attachment structure to which the hooks  36  can be attached, it is also contemplated that separate connective structures could be provided on the ribs  24 ,  26  for attachment to the hooks  36 . For example, a metal clasp or spring lock could be molded into the ribs  24 ,  26  or rib wall  22  to provide an anchor for the hooks  36  to attach. Additionally, the hooks  36  can take on a variety of shapes sizes, materials, and configurations, depending on a particular application, including being formed as a ratchet type hook that would allow a variable amount of connective force to be applied between the hooks  36  and the ribs  24 ,  26  or rib wall  22 . Additionally, it should be noted that the configuration of the hooks  36  can be in any of various directions, including up, down, left, and right with respect to the lid  18 . In addition, the relative direction between different hooks  36  can be aligned in the same direction or can be in different directions. For example, the hooks  36  could be in opposition to each other or in alternating directions to provide a secure connection when connected to the energy absorbing panel  16 . 
     The vibration weld for attaching the rear surface  34  of the lid  18  to the edge  28  of the ribs  24 ,  26  could also be replaced with an adhesive or a separate attachment structure without departing from the spirit and scope of the presently disclosed subject matter. 
     Ribs  24 ,  26  are shown as a main component of the energy absorbent panel  16 . However, other structures could be provided in place of the ribs, such as a rigid or soft foam damper or even spring type structures. In such a case, the hooks  36  could be configured to attach to the side surface  30  of the rib wall  22  directly or a separate attachment structure could be provided within the damper or spring for attachment to the hooks  36 . 
     While the subject matter has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention. All related art references discussed in the above Description of the Related Art section are hereby incorporated by reference in their entirety.