Composite Utility Vehicle Structure With Glossy Watertight Core
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Solution Overview
Problem
Existing composite sandwich structures face challenges in achieving a high gloss surface without additional outer layers, and they are prone to moisture infiltration, which can reduce the operational lifetime and increase the weight of the structure.
Innovation Solution
A modular utility vehicle construct is developed using a composite open area core sandwich structure, where a high gloss surface sheet and structural skin are adhered to the open area core with a viscous adhesive, creating a balanced surface tension to prevent delamination and moisture infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a sandwich-structured composite is used to reduce weight, then weight is reduced, but the surface cannot achieve a high gloss finish without additional outer layers
Solution Approach 1:
The patent changes the surface properties of the core material by applying a release agent that creates a non-stick surface. This allows the thermoplastic polymer to be molded directly onto the core without adhering to it, enabling the core itself to form a high-gloss surface finish without requiring additional outer layers
Solution Approach 2:
The patent creates a composite structure where a thermoplastic polymer is molded onto a porous core material. The resulting composite panel combines the lightweight properties of the porous core with the high-gloss surface finish of the thermoplastic, achieving both weight reduction and surface quality in a single integrated component
2Weight of moving object
If an open area core is used to reduce weight, then weight is reduced, but moisture infiltration occurs at edges reducing operational lifetime
Solution Approach 1:
The patent uses a thermoplastic polymer shell that is molded directly onto the porous core. This continuous thermoplastic shell seals the edges of the open area core, preventing moisture infiltration while maintaining the lightweight porous core structure. The thermoplastic acts as a protective barrier that preserves the core's weight advantages without compromising reliability
3Weight of moving object
If conventional sandwich structures are used, then weight is reduced, but additional outer layers are required for high gloss surfaces increasing complexity
Solution Approach 1:
The patent merges the core material and surface finish into a single integrated component. By molding the thermoplastic polymer directly onto the porous core in one operation, the invention eliminates the need for separate outer layers and post-production coating steps, reducing both weight and production complexity while achieving a high-gloss surface finish
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 achieves a lightweight, robust, and watertight modular utility vehicle construct that maintains a high gloss exterior surface without additional layers, reducing weight and production costs while enhancing durability and resistance to environmental elements.
Implementation Method 1
a high gloss surface sheet and structural skin are adhered to the open area core with a viscous adhesive, creating a balanced surface tension to prevent delamination
Implementation Method 2
a surface sheet adhered to a first face of the open area core by a first adhesive layer, and a structural skin adhered to a second face of the open area core by a second adhesive layer
Data Source
AI summary
A modular utility vehicle construct that is light weight yet robust is provided. The construct is formed with a composite open area core sandwich structure capable of withstanding typical wear and tear and environmental elements experienced by utility vehicle compartments. The use of the composite sandwich structure allows for replacement of traditional materials such as steel or aluminum, without a loss of strength, in a vehicle's containment construct while also reducing the overall weight of the vehicle and increasing the ability to customize the vehicle's utility features to suit the specific needs of the purchaser.