Motor vehicle system with lattice-shaped component

Abstract

The present disclosure provides an automotive system having a lattice member. An automotive system is presented. In one example, a cabin interior storage compartment includes a continuous lattice panel. The lattice panel has a portion defining a door for the cabin interior storage compartment and a living hinge portion defining a seam configured to allow the door to rotate about the seam to access the cabin storage compartment. Other examples are also provided.

Description

Technical Field

[0001] The present disclosure relates to automotive systems, particularly interior components used in automotive cabins. Background Art

[0002] Additive manufacturing (commonly known as 3D printing) offers design and manufacturing flexibility. The technology stands out for its ability to create complex geometries and structures that are difficult to achieve with traditional manufacturing methods. In the automotive sector, additive manufacturing is opening up new avenues for innovation, particularly in the design and production of cabin comfort features.

[0003] Automotive original equipment manufacturers (OEMs) face the challenge of effectively integrating additive manufacturing technologies into vehicle cabin comfort features. One issue is how to leverage these technologies to create innovative, customer-desired features that benefit the driving and passenger experience. This can include developing customizable comfort features where additive manufacturing is utilized to produce components such as knee bolsters, console pads, and various forms of comfort and protective padding. Class A surfaces are intended to be aesthetically pleasing surfaces that match the vehicle’s interior design while maintaining functionality. Producing steering wheel covers, armrest pads, console tops, and other user-contact surfaces requires striking a balance between aesthetic appeal and functional performance. Summary of the Invention

[0004] An automotive system is proposed. The automotive system includes an interior storage compartment comprising a continuous lattice panel. The lattice panel has a portion defining a door for the interior storage compartment and a movable hinge portion defining a seam, the seam being configured to allow the door to rotate about the seam to access the interior storage compartment. The interior storage compartment may also include a thermoplastic layer assembled on the lattice panel and configured to mate to a Class B surface of the vehicle. The portion defining the door may have a material having a greater durometer hardness than the portion defining the seam. The continuous lattice panel may be a mesh, and the mesh may include interwoven strands.

[0005] Another embodiment of an automotive system is presented. The automotive trim system includes: a body defining a channel therethrough and an exterior Class A surface; and a lattice member mated with the body such that the lattice member defines another exterior Class A surface, the other exterior Class A surface being adjacent to the exterior Class A surface and defining a terminal register for the channel, the terminal register being configured to allow air exchange with the channel. The lattice member may be assembled with a thermoplastic layer configured to fit to a Class B surface of a vehicle. The body may have a material having a durometer durometer greater than that of the lattice member mated with the body. The lattice member may be a mesh, and the mesh may have interwoven strands. The plurality of interwoven strands may be formed from a printed material. In some embodiments, the automotive system further includes an environmental control system fluidly coupled to the channel.

[0006] In another embodiment, the automotive system includes: an automotive trim component having a body defining an acoustic channel therein and an exterior Class A surface; and a lattice member that cooperates with the body so that the lattice member defines another exterior Class A surface adjacent to the exterior Class A surface and a structural acoustic matrix configured to direct sound from the acoustic channel into a vehicle cabin.

[0007] The automotive trim component may also include a thermoplastic layer assembled on the grid, the thermoplastic layer being configured to conform to a Class B surface of a vehicle. A portion of the grid defining the structural acoustic matrix comprises a material having a durometer hardness greater than that of the grid defining the Class A surface. The grid may be a mesh. In some embodiments, the mesh comprises interwoven strands. Printed material may form the interwoven strands. In some embodiments, the acoustic channel may be coupled to a vehicle air intake or other similar type of component. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1A and Figure 1B is a perspective view of an automotive system according to one embodiment;

[0009] Figure 2 yes Figure 1A and Figure 1B A perspective view of an embodiment of an automotive system;

[0010] Figure 3 is a perspective view of an automotive system according to one embodiment;

[0011] Figure 4 is a perspective view of an automotive system according to one embodiment;

[0012] Figure 5is a perspective view of an automotive system according to one embodiment; and

[0013] Figure 6 is an exploded view of an automotive system according to one embodiment. DETAILED DESCRIPTION

[0014] Embodiments are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale. Some features may be exaggerated or minimized to illustrate details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art.

[0015] The various features shown and described with reference to any one of the accompanying drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features may be desired consistent with the teachings of this disclosure.

[0016] This disclosure relates to additive manufacturing technology in automotive design to improve cabin comfort, functionality, and aesthetics. Additive manufacturing can create parts customized to specific user needs and also integrate features to enhance the overall driving experience.

[0017] In various aspects of the present disclosure, it is proposed to integrate functional elements such as handles, switches, lighting devices and projector floor lights into additively manufactured parts. Incorporating these features into the overall design of the vehicle contributes to the aesthetic appeal of the interior of the vehicle.

[0018] In one aspect of the present disclosure, applications of lattice structures and multi-material components are disclosed. These structural components possess mechanical properties such as shock absorption, thermal and acoustic insulation, and weight reduction. These properties allow for a high degree of customization and performance in various parts, including knee bolsters, console pads, and various forms of comfort and protective padding. Leveraging the unique capabilities of additive manufacturing to produce these complex geometries and material integrations provides unprecedented levels of customization and innovation in automotive interior design.

[0019] In another aspect of the present disclosure, a grid-like matrix for integrating handles into an automotive interior or cabin is disclosed. Applying a grid design as a basis for embedding handles into various portions of a vehicle cabin can simplify the manufacturing process while meeting design and functionality requirements.

[0020] In yet another aspect, the present disclosure further explores the application of these structures in environmental or acoustic management systems for vehicles connected to the vehicle interior. By integrating the lattice design within automotive trim components, airflow management and sound guidance within the vehicle cabin can also be integrated. This can increase the adjustability of environmental control, making the cabin space more comfortable and adaptable to changing conditions, and can allow for precise tuning of the acoustic experience, directing sound in a way that enhances the passenger's auditory environment. The adaptability of the disclosed component additive manufacturing can allow for precise control of the density and composition of the lattice structure, enabling the production of components tailored to specific functional requirements while maintaining aesthetic harmony with the vehicle's interior design.

[0021] exist Figure 1A and Figure 1B In the vehicle 10, the cabin interior 12 has an instrument panel 14. The instrument panel 14 has an integrated cabin interior storage compartment 16, which is characterized by a continuous grid panel 18. The panel 18 includes a portion of a door 20 that serves as the storage compartment 16. The door 20 is integrated using a movable hinge portion 22 that defines a seam 24. The seam 24 allows the door 20 to rotate thereabout, thereby providing access to the cabin storage compartment 16. The cabin storage compartment 16 is depicted as a glove box, however the continuous grid panel 18 can be incorporated into any cabin storage compartment, such as a console storage device, a door storage pocket, a lower compartment, or an overhead box. The adaptability of the continuous grid panel 18 to various storage needs within the vehicle's cabin 12 can reduce assembly complexity.

[0022] The lattice panel 18 is coupled to a thermoplastic layer 26. The thermoplastic layer 26 is assembled on the lattice structure 18 so that the interior storage compartment 16 can conform to a Class B surface 28 of the vehicle 10. The portion of the panel designated as the door 20 is constructed of a material having a greater durometer durometer than the seam 24 defined by the living hinge 22. This variation in material durometer facilitates operation of the door 20 and contributes to the durability of the storage compartment 16.

[0023] In the illustrated configuration, the lattice panel 18 is a mesh 30. The mesh 30 is composed of interwoven strands 32, a structure that maintains the overall integrity of the panel while allowing a degree of flexibility in application. These strands 32 are formed from a variety of printed materials 34, which can be deposited by any of a variety of additive manufacturing techniques. The printed material 34 can be made of any suitable material, including plastic and thermoplastic polyurethane (TPU). In addition to TPU, materials can also include acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polypropylene (PP), polyamide (PA or nylon), and acrylic resin (PMMA). These materials can be deposited by various additive manufacturing techniques, such as fused deposition modeling (FDM) or selective laser sintering (SLS).

[0024] Figure 2 is a perspective view of a lattice panel 18 having a door portion 20 and a living hinge portion 22 establishing a seam 24. A mesh structure 30 composed of interwoven strands 32 maintains the panel 18's durability and flexibility.

[0025] exist Figure 3 and Figure 4 In FIG. 3 , exterior door assembly 36 has an automotive trim component 38. Automotive trim component 38 has a body 40 defining a passage 42 therethrough and an exterior Class A surface 44. Exterior Class A surface 44, while being part of vehicle cabin interior 12, is exterior to trim component 38. A grille 46 cooperates with body 40 to define another exterior Class A surface 48 aligned with exterior Class A surface 44. Exterior Class A surface 48, adjacent to exterior Class A surface 44, defines a terminal register 50 for passage 42. This allows air exchange with passage 42.

[0026] The grid 46 can be a mesh 30 made of interwoven strands 32. The mesh structure can be combined with the thermoplastic layer 26 to fit securely with the vehicle's Class B surface 28. For the body 40, a material with a higher durometer hardness than the material used for the grid 46 is selected to enhance durability and structural integrity. Examples of materials that typically have a higher durometer hardness for the body 40 than for the grid 46 include glass-filled nylon or polystyrene (HIPS) for the body, thereby providing increased rigidity and resistance to physical deformation, while the grid can utilize more flexible materials such as TPU or ABS. The mesh 30 of the grid 46 can be formed by applying interlocking strands 32 using additive manufacturing. These strands 32 can be made from a range of printed materials 34, such as plastics and TPU, ABS, PC, PP, PA or nylon, as well as PMMA. The use of these materials can be processed by methods such as FDM and SLS.

[0027] The duct 42 can be fluidly coupled to the climate control system within the vehicle 10. This connection allows for adjustment of the airflow, thereby directly affecting the cabin climate and air quality. The adjustability of the grille 46 is advantageous for other embodiments in which the registers 50 may be located in hard-to-reach areas. This adjustability can improve the efficiency of the climate control system and allow for a more customizable approach to managing cabin conditions.

[0028] The customer contact surface on the exterior Class-A surface 44 of the automotive trim component 38 can be customized for stiffness by adjusting the contact geometry, such as through a softer surface texture or a layered lattice structure with variable stiffness across different regions. This adjustment can provide functional surface textures, such as those designed to stabilize a passenger's arm during dynamic events (such as off-road driving).

[0029] exist Figure 5 In FIG, exterior door assembly 36 includes an automotive trim component 52. Trim component 52 has a body 54 defining an acoustic channel 56 that contributes to sound dynamics within vehicle cabin 12, and an interior Class-A surface 58 that defines the interior surface of cabin 12. Grille 46 is integrated with body 54 to form an additional exterior Class-A surface 60 that abuts exterior Class-A surface 56 to form part of a structural acoustic matrix 62 configured to direct sound from acoustic channel 56 into cabin 12.

[0030] The mesh 30 within the mesh 46 helps guide sound through the acoustic channel 42 into the vehicle cabin to enhance the auditory environment for the vehicle occupants. The mesh structure 30, composed of interwoven strands 32, is combined with the thermoplastic layer 26 to maintain a secure attachment to the vehicle's Class B surface 28. A material with a higher durometer hardness is selected for the body 54 of the automotive trim component 52 compared to the grid 46. The strands 32 of the grid 46 can be formed from a variety of materials 34, including plastic, TPU, ABS, PC, PP, PA, or nylon and PMMA, via additive manufacturing to provide flexibility in the design and function of the acoustic channel 42. This flexibility allows for modulation of sound within the vehicle's interior space. The acoustic channel 42 can be acoustically coupled to the vehicle's environmental control system, vehicle air intake, or other similar components, or to conventional acoustic systems. The adjustability of the grid 46 facilitates alternative embodiments in which the structural acoustic matrix 62 can be positioned in hard-to-reach areas. This adjustability can increase the efficiency of the environmental control system and allow a more customizable approach to managing cabin conditions. The matrix 62 can be positioned to optimize sound quality in areas that typically pose acoustic design challenges, thereby enhancing the listening experience within the vehicle cabin 12. Precise placement can result in improved performance of the sound system, thereby contributing to the overall acoustic environment.

[0031] Figure 6 6 is an exploded view of an automotive trim component 64 that can be used with any of the aforementioned embodiments. It has a lattice top surface 66, a lattice middle layer 68, and a backside layer 70 for attachment. The top surface 64 and the middle layer 66 are made of a differently tuned mesh 30 having interwoven strands 32. The top surface 64 visible to the vehicle occupants can feature a texture designed to secure the passenger's arms during dynamic driving conditions (such as off-roading). This variability in the lattice of the layers allows for selective reinforcement across the component, with denser areas of the lattice helping to increase stiffness where needed.

[0032] The backside layer 68 can be made of TPU for robust attachment to the vehicle's mating surface. The mesh 30 forming both the top surface 64 and the middle layer 66 enables the integration of graphical or tactile features for a user interface on the top surface 64 while the backside layer 66 maintains structural integrity. This multi-layer approach promotes a cohesive system that provides tactile engagement, aesthetic appeal, and environmental or acoustic management within the vehicle cabin.

[0033] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it should be understood that various changes can be made without departing from the spirit and scope of the disclosed material.

[0034] As previously described, features of the various embodiments may be combined to form additional embodiments that may not be explicitly described or shown in this disclosure. Although various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, it will be recognized by those of ordinary skill in the art that one or more features or characteristics may be compromised to achieve desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, strength, durability, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. For this reason, embodiments that are described as being less desirable than other embodiments or prior art implementations with respect to one or more characteristics are within the scope of this disclosure and may be desirable for a particular application.

[0035] According to the present invention, an automotive system is provided, comprising: an interior storage compartment, the interior storage compartment comprising a continuous lattice panel having a portion defining a door for the interior storage compartment and a movable hinge portion defining a seam, the seam being configured to allow the door to rotate about the seam to access the interior storage compartment.

[0036] According to one embodiment, the interior storage compartment further comprises a thermoplastic layer assembled on the lattice panel and configured to fit to a Class B surface of the vehicle.

[0037] According to one embodiment, the portion defining the door has a material having a greater durometer hardness than the portion defining the seam.

[0038] According to one embodiment, the continuous lattice panel is a mesh.

[0039] According to one embodiment, the mesh comprises interwoven strands.

[0040] According to one embodiment, printed material forms said interwoven strands.

[0041] According to the present invention, an automotive system is provided, comprising: an automotive trim component, the automotive trim component having: a body, the body defining a channel therethrough and an exterior Class A surface; and a lattice member, the lattice member cooperating with the body so that the lattice member defines another exterior Class A surface, the another exterior Class A surface being adjacent to the exterior Class A surface and defining a terminal register for the channel, the terminal register being configured to allow air exchange with the channel.

[0042] According to one embodiment, the grid is assembled with a thermoplastic layer configured to fit to a Class B surface of a vehicle.

[0043] According to one embodiment, the body comprises a material having a greater durometer hardness than the grid with which it cooperates.

[0044] According to one embodiment, the grid is a mesh.

[0045] According to one embodiment, the mesh comprises interwoven strands.

[0046] According to one embodiment, printed material forms said interwoven strands.

[0047] According to one embodiment, the invention also features an environmental control system fluidly coupled to the passageway.

[0048] According to the present invention, an automotive system is provided, comprising: an automotive trim component having a body defining an acoustic channel therein and an exterior Class A surface; and a lattice member cooperating with the body so that the lattice member defines another exterior Class A surface adjacent to the exterior Class A surface and a structural acoustic matrix configured to direct sound from the acoustic channel into a vehicle cabin.

[0049] According to one embodiment, the automotive trim component further comprises a thermoplastic layer assembled on the grid, the thermoplastic layer being configured to adapt to a Class B surface of a vehicle.

[0050] According to one embodiment, a portion of the lattice defining the structural acoustic matrix comprises a material having a greater durometer hardness than the lattice defining the Class A surface.

[0051] According to one embodiment, the grid is a mesh.

[0052] According to one embodiment, the mesh comprises interwoven strands.

[0053] According to one embodiment, a plurality of printed materials forms said interwoven strands.

[0054] According to one embodiment, the acoustic channel is coupled to the air inlet.

Claims

1. An automotive system comprising: An interior storage compartment includes a continuous lattice panel having a portion defining a door for the interior storage compartment and a living hinge portion defining a seam configured to allow the door to rotate about the seam to access the interior storage compartment. 2 . The automotive system of claim 1 , wherein the interior storage compartment further comprises a thermoplastic layer assembled on the grid panel and configured to conform to a Class B surface of a vehicle. 3 . The automotive system of claim 1 , wherein the portion defining the door comprises a material having a greater durometer hardness than the portion defining the seam.

4. The automotive system of claim 1, wherein the continuous lattice panel is a mesh.

5. The automotive system of claim 4, wherein the mesh comprises interwoven strands.

6. The automotive system of claim 5, wherein printed material forms the interwoven strands.

7. An automotive system comprising: An automotive trim component having: a body defining a passage therethrough and an exterior Class A surface; and a lattice member that cooperates with the body so that the lattice member defines another exterior Class A surface that is adjacent to the exterior Class A surface and defines a terminal register for the channel, the terminal register being configured to allow air exchange with the channel.

8. The automotive system of claim 7, wherein the lattice is assembled with a thermoplastic layer configured to conform to a Class B surface of a vehicle.

9. The automotive system of claim 7, wherein the body comprises a material having a greater durometer hardness than the grid member mated with the body.

10. The automotive system of claim 7, wherein the grid is a mesh.

11. The automotive system of claim 10, wherein the mesh comprises interwoven strands.

12. The automotive system of claim 11, wherein printed material forms the interwoven strands.

13. The automotive system of claim 7, further comprising an environmental control system fluidly coupled to the passageway.

14. An automotive system comprising: An automotive trim component having a body defining an acoustic channel therein and an exterior Class A surface; and a grille mated with the body such that the grille defines another exterior Class A surface adjacent the exterior Class A surface and a structural acoustic matrix configured to direct sound from the acoustic channel into a vehicle cabin.

15. The automotive system of claim 14, wherein the automotive trim component further comprises a thermoplastic layer assembled on the grid, the thermoplastic layer configured to conform to a Class B surface of a vehicle.

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