Integrally Molded Composite Floor Structure for Cargo Vehicles
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Solution Overview
Problem
Existing floor structures in cargo vehicles often lack thermal efficiency, are prone to water intrusion and corrosion, and do not efficiently manage weight, leading to reduced fuel efficiency.
Innovation Solution
A composite floor structure made of fiber-reinforced polymer materials, including a platform, transverse beams, longitudinal beams, insert beams, and an underlayment, which are integrally molded to provide a lightweight, thermally efficient, and corrosion-resistant surface for cargo vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metallic and wood materials are used for floor structures, then structural strength and durability are maintained, but weight increases and thermal efficiency decreases
Solution Approach 1:
The patent applies composite materials by integrating multiple functional layers (structural beams, insulation layer, waterproof membrane, wear-resistant surface) into a unified floor structure. This composite approach enables simultaneous achievement of weight reduction, improved thermal efficiency, and maintained structural strength, directly resolving the contradiction between using traditional heavy materials and achieving lightweight thermal-efficient design.
2Reliability
If traditional metallic and wood materials are used for floor structures, then structural strength is maintained, but corrosion resistance and water intrusion protection deteriorate
Solution Approach 1:
The composite floor structure replaces traditional metallic and wood materials with a multi-layer composite system that inherently provides corrosion resistance through materials like foam insulation and polymer-based wear surfaces. The structural integrity is maintained through properly engineered composite beams and reinforcement layers, thus achieving both corrosion resistance and structural strength simultaneously.
Solution Approach 2:
The patent incorporates a waterproof membrane as a thin film layer within the composite structure. This flexible membrane layer provides continuous water intrusion protection while allowing the overall structure to maintain its structural strength through the integrated composite beam and reinforcement system.
3Reliability
If complex multi-component floor structures are used, then functional requirements (insulation, waterproofing, strength) are met, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges multiple functional components (structural beams, insulation, waterproofing, wear surface) into an integrally molded composite floor structure. This consolidation reduces manufacturing complexity by enabling production as a unified component rather than requiring separate fabrication and assembly of multiple parts, thus achieving both functional requirements and manufacturing simplicity.
Solution Approach 2:
The composite material system allows for integrally molding diverse functional layers into a single structure. The compatibility of composite materials enables simultaneous formation of structural, insulating, and protective layers in one manufacturing process, reducing assembly time while meeting all functional requirements.
Data Source
AI summary
A composite floor structure and method of making the same are disclosed. The composite floor structure may include a platform and a plurality of transverse beams. The composite floor structure may also include at least one longitudinal beam and a plurality of insert beams to accommodate the longitudinal beam. The composite floor structure may also include an underlayment between the plurality of transverse beams and the at least one longitudinal beam. Some or all of these components may be integrally molded together to form a fiber-reinforced polymer structure. The composite floor structure may be used for cargo vehicles and other applications.