Lightweight Composite Hatch Cover with Spacer Gap
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Solution Overview
Problem
Existing hatch covers for protected vehicles are heavy due to the use of metallic materials and require significant operating forces to open and close, leading to increased production costs and time, while spring-assisted mechanisms add weight and expense.
Innovation Solution
A protected component comprising an outside cover layer, an inside splinter protection layer, spacers between the layers, and a casting compound that connects all components in a one-piece structure, using plastic materials to reduce weight and eliminate the need for welding, riveting, or screwing, allowing for a composite structure with integrated functions like sealing and mechanism attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic protective materials are used for the hatch cover, then protective function is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a metallic protective layer with a plastic material layer. The metallic layer provides the necessary protective function against ballistic missiles and explosions, while the plastic material reduces the overall weight of the hatch cover. This composite structure allows the component to meet protective requirements without using solid metallic construction throughout, thereby reducing weight.
Solution Approach 2:
The hatch cover is segmented into multiple functional layers: an outer metallic protective layer and an inner plastic material layer. This segmentation allows each layer to perform its specific function optimally - the metallic layer for protection and the plastic layer for weight reduction - while together they resolve the contradiction between protective function and weight.
2Reliability
If multiple manufacturing processes (welding, gluing, screwing) are used to assemble the hatch cover, then protective function is improved, but production time and costs increase
Solution Approach 1:
The patent merges the protective layer and the plastic material layer into a single integrated component through co-molding or co-extrusion processes. This combining eliminates the need for separate assembly steps such as welding, gluing, or screwing, thereby significantly reducing production time and costs while maintaining the protective function through the integrated composite structure.
Solution Approach 2:
The manufacturing process is designed to produce multiple functions (protection, weight reduction, and structural integrity) in a single operation. The co-molding or co-extrusion process simultaneously creates the metallic protective layer and the plastic material layer as an integrated component, eliminating the need for multiple separate manufacturing and assembly processes.
3Ease of operation
If spring-assisted or powered opening and closing mechanisms are added, then ease of operation is improved, but weight and costs increase
Solution Approach 1:
The patent changes the weight parameter of the hatch cover by using lightweight plastic material in combination with a thin metallic protective layer. This weight reduction makes the hatch cover light enough to be operated manually without requiring spring-assisted or powered mechanisms, thereby improving ease of operation without adding the weight and cost of such mechanisms.
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 solution results in a lightweight, cost-effective, and ergonomically improved hatch cover that maintains protective functionality with reduced production complexity and weight, enabling easier operation and installation.
Implementation Method 1
a potting compound that fills the gap, wherein the potting compound connects the cover layer, the splinter protection layer, the spacers, and the intermediate layer to one another
Implementation Method 2
a plurality of spacers arranged between the cover layer and the splinter protection layer to keep the cover layer spaced from the splinter protection layer, so that a gap is provided between the cover layer and the splinter protection layer
Implementation Method 3
The spacers are positively connected to the intermediate layer, the spacers have a contact surface on the outside, and the intermediate layer has correspondingly shaped openings which enable a positive connection of the openings with the contact surface of the spacers, thus securing the spacers against rotation relative to the intermediate layer
Data Source
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AI summary
Protected component (5), in particular hatch cover, comprising an outer cover layer (8), an inner splinter protection layer (15), several spacers (22 - 25) arranged between the cover layer (8) and the splinter protection layer (15) to keep the cover layer (8) spaced apart from the splinter protection layer (15), so that a gap (42) is provided between the cover layer (8) and the splinter protection layer (15), and a potting compound (55) that fills the gap (42) to connect the cover layer (8), the splinter protection layer (15) and the spacers (22 - 25) together.