Hinged Polymer Bulkhead Assembly for Vehicle Cargo and Cabin Space
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Solution Overview
Problem
Existing bulkhead assemblies in vehicles compromise cargo space and driver comfort due to their typically metal construction, which increases noise and limits seat recline capabilities, while also not maximizing both cabin and cargo area space effectively.
Innovation Solution
A bulkhead assembly comprising polymer material panels that are hingedly attached, allowing for increased cabin space by accommodating seat recline and reducing noise through the use of polymer materials instead of metal, with a design that includes a first panel adjacent to the street-side, a second panel adjacent to the curb-side, and a door panel between them, forming a cavity to accommodate the driver's seat in a reclined position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the bulkhead is placed closer to the cabin seats to maximize cargo area, then cargo space is increased, but operator comfort deteriorates due to limited seat recline capability
Solution Approach 1:
The bulkhead is segmented into multiple panels (street-side panel, curb-side panel, and door panel) that can move independently. The door panel specifically can swing open to create additional space, allowing the bulkhead to adapt its configuration based on whether cargo maximization or operator comfort is the priority at any given time.
Solution Approach 2:
The bulkhead transitions from a static structure to a dynamic one through the hinged door panel that can swing between closed and open positions. This dynamic capability allows the bulkhead to provide maximum cargo space when closed and additional cabin space for seat recline when opened, resolving the spatial conflict between cargo and operator areas.
2Strength
If metal panels are used for the bulkhead, then structural strength is improved, but noise increases due to metal cargo striking and vibration
Solution Approach 1:
The material parameter of the bulkhead panels is changed from metal to polymer. This material substitution maintains sufficient structural strength for the application while fundamentally changing the acoustic properties, resulting in reduced noise from cargo impact and vibration since polymer materials are inherently quieter than metal.
3Volume of moving object
If the bulkhead is placed closer to the cabin seats, then cargo area is maximized, but cabin area is reduced compromising operator comfort
Solution Approach 1:
The bulkhead incorporates a dynamic door panel that can swing open to temporarily expand the cabin area when needed for operator comfort, while maintaining its space-maximizing position for cargo when closed. This dynamic adjustment allows both cargo area maximization and cabin area preservation to be achieved at different times.
Solution Approach 2:
The bulkhead serves multiple functions: it acts as a space-maximizing partition when the door is closed, and it provides additional cabin space and access when the door is opened. This multi-functionality allows the same structure to support both cargo maximization and operator comfort requirements.
Data Source
AI summary
A bulkhead assembly for a vehicle such as, for example, a van or truck comprises a first panel adjacent and substantially perpendicular to a street-side wall of the vehicle, a second panel adjacent and substantially perpendicular to a curb-side wall of the vehicle, and a door panel disposed between the first and second panels, the door being hingedly attached to one of the first and second panels, wherein the panels are formed from a polymer material. In one embodiment, the panel adjacent the street-side wall of the vehicle (i.e., the driver-side panel) defines a cavity extending rearwardly into the cargo area, the cavity being sized (in terms of the cavity's width) to accommodate the seat-back of the driver's seat.