Magnesium Vehicle Console Brackets for Crash and NVH Loads

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Solution Overview

Problem

Existing vehicle consoles are heavy and do not contribute significantly to performance, such as crash performance, load bearing, and noise, vibration, and harshness (NVH) performance, due to their composition of plastic components with minimal steel reinforcements.

Innovation Solution

A vehicle console design utilizing magnesium alloy brackets in a mirroring configuration with integrated upper and lower arms to couple to the vehicle frame, which distribute loads vertically and horizontally, reducing weight and complexity while enhancing structural integrity and performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic components with minimal steel reinforcements are used in the console, then the console can be manufactured with ease and lower cost, but the console becomes heavy and does not contribute to performance

Engineering Contradiction:

Improvemanufacturing easeVSAvoidconsole mass

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The console utilizes a composite structure combining magnesium alloy brackets with plastic components. The magnesium alloy provides high strength-to-weight ratio, reducing overall mass while maintaining structural integrity and performance contribution.

Inventive Principle:

Principle #40Composite materials

2Strength

If steel stampings are used to manufacture the console, then the console can achieve adequate strength, but the console becomes heavy and complex

Engineering Contradiction:

Improvestructural strengthVSAvoidconsole mass

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The console replaces traditional steel stampings with magnesium alloy brackets that provide equivalent or superior strength characteristics while reducing density and mass.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The console is divided into functional segments: magnesium alloy brackets for structural support and load-bearing, and plastic components for housing and non-structural functions. This segmentation allows optimization of each part's material properties.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If traditional console designs are used, then the console can provide basic storage functionality, but the console does not contribute to crash performance, load bearing performance, or NVH performance

Engineering Contradiction:

Improvefunctional versatilityVSAvoidperformance contribution

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The magnesium alloy brackets serve multiple functions simultaneously: structural support, crash load bearing, vibration damping for NVH performance, and anchoring for storage compartments. This multi-functionality transforms the console from a passive storage element to an active performance contributor.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12559038B2Vehicle console

Publication Date: 2026.02.24 MAGNESIUM PRODUCTS OF AMERICA INC

AI summary

A console for a vehicle includes a first bracket and a second bracket disposed opposite the first bracket in a mirroring configuration relative to the first bracket. Each of the first bracket and the second bracket includes a body, an upper arm extending from an upper front portion of the body and configured to couple to a vehicle frame, a lower arm extending from a lower front portion of the body and configured to couple to a vehicle frame, and a first end and a second end, wherein the first end includes a first leg configured to couple to a floor of the vehicle and the second end includes a second leg configured to couple to the floor of the vehicle. The first bracket and the second bracket are mutually coupled in at least one region.