EPP Load Carrier Anchoring via Thermal Contraction

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Solution Overview

Problem

Existing load carriers with particle foam main bodies require laborious fastening methods, such as adhesives or bolts, to secure functional elements like holding rails, which complicates the production process.

Innovation Solution

The load carrier features a positively locking mechanism where functional elements are anchored into depressions with undercut receiving grooves, allowing for easy insertion when the particle foam main body is still soft from heat treatment, and firm fixation as it cools, eliminating the need for additional fastening means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If functional elements are fixed using adhesive or bolts, then the connection strength is sufficient, but the manufacturing process becomes laborious and complex

Engineering Contradiction:

Improveconnection strengthVSAvoidfastening process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent utilizes temperature as a parameter to change the physical state of the particle foam material. During hot state, the material is soft and deformable, allowing easy insertion of functional elements. During cooling, the material hardens and contracts, creating a firm mechanical lock without requiring adhesives or bolts.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The fastening system transitions from a static connection (adhesive or bolt) to a dynamic process where the material properties change with temperature. The particle foam dynamically adjusts its hardness and volume, enabling easy insertion followed by secure fixation.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If functional elements are inserted into depressions in the particle foam, then the fastening process is simplified, but the connection stability may be insufficient without additional fastening means

Engineering Contradiction:

Improvefastening process simplicityVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent exploits the phase transition of the particle foam material from a soft, deformable state during heating to a hard, stable state during cooling. This phase transition ensures that functional elements are easily inserted during the soft state and firmly secured during the hard state, achieving both simplicity and reliability.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The particle foam undergoes thermal contraction during cooling, which creates a mechanical locking effect on the inserted functional elements. The volume reduction of the material as it cools ensures that the functional elements are firmly held in place, providing reliable connection stability.

Inventive Principle:

Principle #37Thermal expansion

3Force

If the particle foam main body is used in a soft state for insertion, then the insertion force required is reduced, but the structural integrity may be compromised

Engineering Contradiction:

Improveinsertion forceVSAvoidstructural integrity

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The patent applies heat treatment to the particle foam before insertion to temporarily soften the material, reducing the insertion force required. After the functional elements are inserted, the material is allowed to cool and harden, restoring its structural integrity and strength.

Inventive Principle:

Principle #10Preliminary action

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 method simplifies the fastening process by using the thermal expansion and contraction of the particle foam to create a stable, non-positive connection between the main body and functional elements, ensuring secure holding without additional fastening tools.

Implementation Method 1

Here, the functional element is inserted by way of its anchoring section into the depression which is assigned to it, the holding ribs being inserted into the receiving grooves which form an undercut of the depression. When, in particular, the insertion of the at least one functional element into the associated depression of the main body takes place, when the main body which is produced by means of a sintering method by way of heat treatment is removed from the sintering mold and has not yet cooled, the insertion can be carried out with a low expenditure of force, while the functional element is fixed firmly in the main body after the latter has cooled.

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 2

the main body which is produced by means of a sintering method by way of heat treatment

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS12168547B2Load carrier and method

Publication Date: 2024.12.17 FEURER FEBRA

AI summary

The invention relates to a charge carrier (10) with a main body (12) made of a particle foam, in particular of expanded polypropylene (EPP) or of expanded polyurethane (EPU), and with at least one functional element (20), which consists of a material that is harder than the particle foam. According to the invention, it is provided that the main body (12) has a depression (26) for each functional element (20), the depression being assigned to the respective element and having extending from it, in two mutually facing boundary surfaces (36), a respective receiving channel (38) which is bounded on three sides by the main body (12) and is open towards the depression (26), and that each functional element (20) has an anchoring portion (28), which protrudes into the depression (26) assigned to it and has retaining ribs (32) which project away from one another and each engage in one of the receiving channels.