Embedded Hardpoint Connectors for Composite Cargo Floor Assemblies
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Solution Overview
Problem
Cargo vehicles constructed with composite materials face challenges in strengthening connections between composite floor assemblies and other vehicle components, such as landing gear and slide rail assemblies, while also needing to maximize interior storage space without increasing overall height.
Innovation Solution
The implementation of composite floor structures with embedded or laminated hardpoint connectors that securely couple other vehicle components to the floor assembly, utilizing a molding process involving expandable core materials and resin injection to integrate connectors within the composite beams, allowing for mechanical fastening and potential adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If composite floor assemblies are used to reduce weight and improve fuel efficiency, then fuel efficiency is improved, but connection strength between floor assembly and vehicle components deteriorates
Solution Approach 1:
The patent uses composite materials (fiberglass-reinforced plastic or similar) for the floor assembly to reduce weight and improve fuel efficiency, while incorporating metal connectors embedded within the composite structure to provide strong attachment points for vehicle components, thus resolving the contradiction between weight reduction and connection strength
Solution Approach 2:
The connectors serve multiple functions: they provide structural reinforcement within the composite floor assembly, create attachment points for vehicle components (landing gear, fuel tanks, slide rails), and distribute loads across multiple beams, making them a multi-functional element that addresses both weight and strength requirements
2Volume of moving object
If connection height between floor assembly and slide rail assembly is reduced to maximize interior storage space, then interior storage space is improved, but connection stability deteriorates
Solution Approach 1:
The patent transitions from vertical connection stability to horizontal/distributive stability by spreading connectors across multiple beams and using wide-flange connector geometry, allowing the connection to remain stable even at reduced height through distributed load paths rather than relying on vertical distance
3Strength
If metal connectors are embedded in composite beams to strengthen connections, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The connectors are positioned and embedded within the composite beams during the molding process itself, rather than being added afterward. This preliminary integration simplifies manufacturing by combining two operations (molding and connector installation) into one, reducing overall complexity despite the sophisticated embedding requirement
4Weight of moving object
If composite materials are used instead of metallic and wood materials, then weight is reduced and fuel efficiency is improved, but connection capability with other vehicle components deteriorates
Solution Approach 1:
The patent applies local quality by using metal connectors at specific locations where connections are needed, while the rest of the floor assembly remains as lightweight composite material. This localized reinforcement provides connection capability exactly where required without compromising the overall weight benefits of composite construction
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
This solution enhances the structural integrity of connections between composite floor assemblies and other vehicle components, reduces the height of these connections, and increases interior storage space by allowing the floor assembly to be lowered closer to the ground, thereby improving fuel efficiency and thermal efficiency while maintaining a suitable overall vehicle height.
Implementation Method 1
introducing an expandable core material into the at least one outer beam skin, expanding the core material in the at least one outer beam skin to form a composite beam
Implementation Method 2
injecting a resin into the plurality of composite beams and the outer floor skin and around the first connector
Data Source
AI summary
A cargo vehicle is disclosed having a composite floor assembly with at least one embedded or laminated hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams, wherein a subset of the plurality of transverse beams includes at least one embedded hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams, wherein at least one hardpoint connector is laminated across a subset of the plurality of transverse beams. The embedded or laminated connector may be used to securely and removably couple other vehicle components to the composite floor assembly, such as a landing gear assembly and/or a slide rail assembly.