Composite Core Reinforced Areas Tractor Trailer
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Solution Overview
Problem
Composite panels used in storage trailers often lack the necessary strength for mechanical fastening due to partially hollow cores, which are lighter and cost-effective but insufficient for commercial applications.
Innovation Solution
A method of producing a composite core member for tractor trailers that involves creating a partially hollow honeycomb structure by vacuum forming thermoplastic sheets and inserting reinforced material into gaps, followed by thermal welding and lamination to enhance strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a partially hollow honeycomb core structure is used, then weight is reduced and material cost is decreased, but strength for mechanical fastening is insufficient
Solution Approach 1:
The patent applies local quality by creating a non-uniform core structure with solid reinforced regions positioned at ends and along edges where mechanical fastening is required, while maintaining hollow honeycomb sections in intermediate areas. This localized reinforcement strategy provides necessary strength at critical locations while preserving weight reduction benefits in non-critical areas.
Solution Approach 2:
The patent employs composite materials by combining hollow honeycomb thermoplastic sections with solid reinforced material sections within the same core structure. This composite approach allows the core to exhibit both the weight-saving properties of hollow structures and the strength properties of solid materials where needed for mechanical fastening applications.
2Strength
If reinforced material is added to the core, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the hollow honeycomb structure through vacuum forming before inserting the solid reinforced material sections. This sequence simplifies manufacturing by establishing the base structure first, then adding reinforcement elements in a subsequent straightforward insertion and bonding step, rather than attempting to create the complex composite structure in a single difficult operation.
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 method results in a composite panel with increased strength and reduced weight, suitable for mechanical fastening, while maintaining cost-effectiveness and efficiency in production.
Implementation Method 1
followed by thermal welding and lamination to enhance strength and durability
Implementation Method 2
followed by thermal welding and lamination to enhance strength and durability
Data Source
AI summary
A method of producing a composite core member along a production line is disclosed. The core member is designed to be used within a composite panel of a tractor trailer. The method comprises the steps of providing an intermediate core member comprising a reinforced material positioned on at least one end of the intermediate core member and producing at least two strips of reinforced material. The intermediate core member is inserted between the strips of reinforced material and the strips of reinforced material are coupled to a first side and a second side of the intermediate core member to form the core member.