Carpeted Vehicle Load Floor With Integrated Living Hinges
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Solution Overview
Problem
Existing carpeted load floors in automotive vehicles require numerous assembly steps, are costly due to labor-intensive processes, and often feature unsightly, heavy metal hinges that are difficult to open with one hand, while also being non-recyclable and prone to quality defects.
Innovation Solution
A carpeted vehicle load floor with a pivotable, segmented cover made from compression-molded, sandwich-type composite panels featuring living hinges integrated into the carpet layer, allowing the cover to fold compactly and pivot easily between open and closed positions, reducing assembly complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate metal hinges are used to connect the cover to the panel, then the cover can pivot, but the device becomes heavy and unsightly
Solution Approach 1:
The hinge function is merged with the carpet layer itself. The carpet is formed with an unbonded portion that acts as a living hinge, eliminating the need for separate metal hinge components. This integration reduces weight while maintaining the pivoting capability of the cover.
Solution Approach 2:
The carpet layer, being a flexible material, is designed with an unbonded portion that provides the hinge function. This flexible film approach replaces rigid metal hinges, significantly reducing the weight of the moving cover while enabling smooth pivoting motion.
2Ease of operation
If separate metal hinges are used to connect the cover to the panel, then the cover can pivot, but the device becomes complex and costly to manufacture
Solution Approach 1:
The hinge functionality is combined with the carpet layer in a single integrated component. The carpet is formed with an unbonded portion during the same manufacturing process, eliminating multiple assembly steps and reducing device complexity. This reduces both manufacturing cost and assembly complexity.
3Strength
If traditional assembly methods are used for the load floor, then structural integrity is achieved, but numerous assembly steps and labor are required
Solution Approach 1:
Multiple components (carpet, cover, and hinge mechanisms) are merged into a single integrated structure formed in one compression molding operation. This eliminates numerous separate assembly steps, significantly improving productivity while maintaining structural integrity through the integrated design.
Solution Approach 2:
The hinge functionality and carpet attachment are built into the structure during the initial molding process rather than being assembled later. This preliminary action of incorporating all necessary features during manufacturing eliminates subsequent assembly steps and labor requirements.
4Stability of the object's composition
If the cover is made as a single piece, then structural integrity is maintained, but it cannot fold compactly
Solution Approach 1:
The cover is segmented into multiple sections connected by living hinges formed in the carpet layer. This segmentation allows the cover to fold into a compact configuration for storage while each segment maintains structural integrity. The unbonded portions of the carpet create flexible joints that enable folding without compromising the overall strength of the cover.
Data Source
AI summary
A carpeted, vehicle load floor including a pivotable, carpeted cover segmented into articulated sectional members is provided. The load floor includes a compression-molded composite panel and the segmented cover to removably cover a storage area in the interior of the vehicle. The cover is segmented into articulated, planar sectional members to allow desired cover positioning over the storage area. The members are pivotally connected to one another for folding one over the other. The load floor also includes a substantially continuous carpet layer bonded to a top support surface of the panel and top support surfaces of each of the members. A first living hinge allows the carpeted cover to pivot between different use positions and a second living hinge allows the members to easily pivot and fold one over the other in a compact, folded, open position of the cover.