Cellulose Core Composite Load Floor with Wood Grain Finish
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Solution Overview
Problem
Current cargo management systems for automotive vehicles lack an aesthetically pleasing and cost-effective way to achieve a wood grain finish for load floors and trim panels, with simulated wood grain finishes being less attractive and genuine wood being expensive.
Innovation Solution
A cargo management system utilizing a compression-molded composite panel with a cellulose-based core and fiber-reinforced thermoplastic outer layers, bonded with thermoplastic adhesive, and featuring a multi-layer sheet with a pattern layer providing a wood grain finish, which can be either simulated or natural, to create a durable and attractive wood grain appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If simulated wood grain finish is used, then cost is reduced, but aesthetic appeal deteriorates
Solution Approach 1:
The patent applies composite materials by combining a cellulose-based core with fiber-reinforced thermoplastic outer layers and a multi-layer sheet containing a pattern layer. This composite structure enables the load floor to achieve a genuine wood grain finish appearance while maintaining cost-effectiveness and durability, resolving the contradiction between aesthetic appeal and manufacturing cost.
2Reliability
If genuine wood is used, then aesthetic appeal is improved, but cost increases
Solution Approach 1:
The patent uses a pattern layer that copies or simulates the appearance of genuine wood grain through compression molding. This allows the load floor to replicate the aesthetic qualities of genuine wood without using actual wood materials, thereby achieving high aesthetic appeal while maintaining cost-effectiveness.
Solution Approach 2:
The composite structure with cellulose core, thermoplastic layers, and pattern layer creates an artificial material that mimics genuine wood appearance and properties, eliminating the need for expensive natural wood while achieving similar aesthetic results.
3Productivity
If compression-molded composite panel with multi-layer sheet is used, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions and layers into a single integrated compression molding process. The cellulose-based core, fiber-reinforced thermoplastic outer layers, thermoplastic adhesive, and multi-layer sheet with pattern layer are all bonded together in one compression molding operation, improving manufacturing efficiency while the layers work together as a unified structure.
Solution Approach 2:
The composite panel integrates multiple materials and functions into a single component through compression molding, where the cellulose core provides structure, thermoplastic layers provide strength and bonding, and the pattern layer provides aesthetic finish. This integration achieves manufacturing efficiency despite the complexity of the multi-material system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively compartmentalizes the cargo area with a wood grain finish, offering a cost-effective and durable solution that is both aesthetically pleasing and resistant to periodic maintenance, while accommodating design variations and reducing material waste.
Implementation Method 1
compression-molded composite panel including first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material
Implementation Method 2
bonded with thermoplastic adhesive
Implementation Method 3
A multi-layer sheet is bonded to the top surface of the first outer layer by the press molding and has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish
Data Source
AI summary
A cargo management system including a vehicle load floor having a cellulose-based core to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material and positioned between the outer layers. The core has a cellular structure. The outer layers are bonded to the core by the first and second sheets and by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The multi-layer sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.