Embedded Hardpoint Connectors in Composite 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, fuel tanks, and slide rail assemblies, due to the absence or reduction of metallic and wood materials.

Innovation Solution

The implementation of a composite floor assembly with embedded hardpoint connectors, which securely and removably couple other vehicle components to the composite floor, using a manufacturing method that involves positioning connectors in an outer skin, introducing an expandable core material, and expanding it to embed the connectors within the composite beams.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite materials are used to construct cargo vehicles, then weight is reduced and fuel efficiency is improved, but connection strength between floor assembly and other components deteriorates

Engineering Contradiction:

Improvevehicle weightVSAvoidconnection strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses composite materials (fiberglassreinforced plastic) for the floor assembly while integrating metal connectors embedded within the composite structure. This hybrid approach maintains the weight benefits of composites while incorporating metal elements specifically where connection strength is required, resolving the contradiction between lightweight construction and connection strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent merges composite materials and metal connectors into a unified floor assembly structure. The metal connectors are embedded within the composite floor assembly during manufacturing, creating a combined structure that leverages the advantages of both materials: the weight reduction and corrosion resistance of composites, plus the connection strength of metal.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If composite materials replace metallic and wood materials, then thermal efficiency is improved and corrosion is reduced, but connection reliability deteriorates

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidconnection strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs a hybrid composite structure where fiberglassreinforced plastic provides corrosion resistance and thermal efficiency, while embedded metal connectors provide reliable mechanical connections. This resolves the contradiction by assigning different functions to different materials within the same assembly.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different locations within the floor assembly. Composite materials are used for the main structural panels where corrosion resistance and thermal efficiency are priorities, while metal connectors are strategically placed at connection points where strength and reliability are critical.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If embedded connectors are integrated into composite beams, then connection capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveconnection capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent incorporates connectors into the composite floor assembly during the initial manufacturing process rather than installing them separately later. The connectors are positioned and embedded within the composite material while it is being formed, which simplifies the overall assembly process and reduces the complexity of subsequent installation steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent combines the floor assembly manufacturing process with the connector installation process into a single integrated operation. By embedding connectors during composite material formation, the patent eliminates separate installation steps and reduces overall manufacturing complexity despite the added connection capability.

Inventive Principle:

Principle #5Merging (Combining)

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 and connectivity between composite floor assemblies and other vehicle components, improving the overall strength and durability of cargo vehicles while maintaining the advantages of composite materials, such as thermal efficiency and reduced weight.

Implementation Method 1

introducing an expandable core material into the outer skin, expanding the core material around the at least first and second connectors in the outer skin to form a composite beam with the at least first and second connectors embedded therein

Methodology Applied

Scientific EffectExpansion:

Data Source

PatentUS12319357B2Slide rail assembly and landing gear assembly with embedded hardpoint connectors

Publication Date: 2025.06.03 WABASH NATIONAL CORP

AI summary

A cargo vehicle is disclosed having a composite floor assembly with at least one embedded hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams and at least a portion of the composite floor includes at least one embedded hardpoint connector. The embedded 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.