Vehicle Console Bin with Orthogonal Walls and Living Hinges
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Solution Overview
Problem
Existing vehicle console storage compartments with angled walls have limited interior space due to their design, and their complex molds require extensive maintenance and repair, limiting efficiency and space utilization.
Innovation Solution
A vehicle console bin with orthogonally positioned walls attached at living hinges, allowing for rotational operation from a planar to a vertical position, which increases interior space and simplifies the molding process by using a mold with lifters that form connecting edges and a clip member for secure closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If angled walls are used in existing vehicle console storage compartments, then the design is simpler to manufacture, but the interior space is limited
Solution Approach 1:
The bin is divided into a base and multiple walls that are separately formed and then assembled together through living hinges. This segmentation allows each component to be optimized independently while achieving the desired orthogonal configuration that maximizes interior space.
Solution Approach 2:
The bin walls are designed to fold from a planar configuration into a three-dimensional orthogonal structure. This dimensional transformation enables the bin to achieve maximum interior volume while using a simplified two-dimensional mold for manufacturing.
2Volume of moving object
If complex molds are used to achieve orthogonal walls, then the interior space is maximized, but maintenance and repair become extensive
Solution Approach 1:
By segmenting the bin into a base and separate walls connected by living hinges, the design uses a simpler mold that forms flat components. This reduces mold complexity and maintenance requirements while still achieving the orthogonal configuration for maximum interior volume.
Solution Approach 2:
The bin walls transition from a planar parameter state during molding to a three-dimensional orthogonal state during assembly. This parameter change allows the use of simple flat molds that are easy to maintain while producing walls that form the desired orthogonal structure for maximizing interior volume.
3Productivity
If orthogonal walls are implemented, then storage capacity increases, but the molding process becomes more complex
Solution Approach 1:
The bin is segmented into a base and multiple walls that are formed as separate planar components using simple molds. These segments are then assembled through living hinges to create the orthogonal structure, achieving high storage capacity without requiring complex molding processes.
Solution Approach 2:
The molding process produces two-dimensional planar components that are then transformed into a three-dimensional orthogonal structure through folding at living hinges. This approach achieves maximum storage capacity while keeping the molding process simple and easy to manufacture.
4Ease of manufacture
If angled wall design is used, then manufacturing is simpler, but space utilization is limited
Solution Approach 1:
The bin is segmented into separate wall components that are manufactured as flat pieces using simple molding processes. These segments are then assembled at orthogonal angles using living hinges, achieving both manufacturing simplicity and maximum space utilization.
Solution Approach 2:
The walls are manufactured in a two-dimensional planar state using simple processes, then transformed into a three-dimensional orthogonal configuration during assembly. This dimensional change enables maximum space utilization while maintaining manufacturing simplicity.
Data Source
AI summary
A vehicle console includes a housing having an interior volume. A console bin is disposed within the interior volume. The console bin is an injection molded member having a base and a plurality of bin walls coupled to the base at living hinges, wherein the plurality of bin walls form an interior surface that extends orthogonally from the base.