Integrated Vehicle Storage Box Partition Without Volume Loss
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Solution Overview
Problem
Existing vehicle storage boxes require additional partition parts for division and strength, leading to increased costs, noise, and reduced design quality, and existing materials like fiber or bead foam either lack strength or reduce accommodation volume.
Innovation Solution
A vehicle storage box molded in one piece from a resin sheet member, integrating a partition that protrudes convexly from the bottom, using a resin sheet, skin material, and non-woven fabric to provide strength, design quality, and sound/heat insulation without additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a sheet-like fiber material or bead foam is used to mold the vehicle storage box including the partition in one piece, then the partition is integrated into the storage box, but the partition made of fiber material is not strong enough and bead foam needs to be formed thicker which reduces the volume for accommodation
Solution Approach 1:
The patent uses a composite structure combining a resin sheet base material with a skin material layer. The resin sheet provides structural strength and rigidity for the partition, while the skin material forms the design-quality surface. This composite approach allows the partition to be both integrated and sufficiently strong without requiring excessive thickness that would reduce accommodation volume.
2Strength
If a separate partition part made of hard resin is used, then the partition strength is sufficient, but an additional processing cost is required to assemble the partition part into the vehicle storage box
Solution Approach 1:
The patent merges the partition with the storage box body into a single integrated component molded from the stacked resin sheet and skin material. This eliminates the need for separate partition parts and assembly operations, reducing manufacturing complexity and cost while maintaining the necessary partition strength through the composite material structure.
3Adaptability or versatility
If a separate partition part made of hard resin is used, then the storage area can be divided, but abnormal noise could occur when stored items come into contact with the partition part due to vehicle vibrations
Solution Approach 1:
The composite structure of resin sheet base material with skin material layer provides both the structural integrity needed for storage area division and vibration-damping properties that reduce abnormal noise. The layered composite construction inherently dampens vibrations better than solid hard resin, preventing noise generation when stored items contact the partition.
4Shape
If a skin material is used to form the vehicle storage box, then the design quality is improved, but the skin material alone does not provide the partition with the necessary strength
Solution Approach 1:
The patent employs a composite material system where the skin material forms the aesthetic surface layer for design quality, while the resin sheet base material provides the structural strength. This layered composite allows the partition to have both the necessary mechanical strength and the desired surface appearance without compromising either property.
5Weight of moving object
If the vehicle storage box is made with bead foam, then the storage box is lightweight and has cushioning properties, but the vehicle storage box needs to be formed thicker to achieve the required strength, which reduces the volume for accommodation
Solution Approach 1:
The resin sheet base material with skin material layer composite provides high strength-to-weight ratio, achieving the required partition strength without the excessive thickness needed by bead foam. This maintains lightweight construction and full accommodation volume while providing sufficient structural strength.
Data Source
AI summary
A vehicle storage box of the present invention, that is laid on a luggage compartment floor, includes an accommodating portion bounded by a bottom and a wall rising from the bottom in an upward direction of a vehicle, wherein the accommodating portion is provided with a partition protruding convexly from the bottom in the upward direction of the vehicle, wherein the bottom, the wall, and the partition are molded in one piece by stacking a base material made of a resin sheet and a skin material, and wherein the skin material faces a vehicle interior.