Vehicle Floor Element with Friction Stir Welded Metal Cover
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Solution Overview
Problem
Existing floor elements for refrigerated vehicles face challenges in achieving a balance between low weight, high load-bearing capacity, and cost-effective production while maintaining good thermal insulation properties.
Innovation Solution
A floor element design featuring a cover layer made of light metal materials processed using friction stir welding, combined with a wooden base layer and polyurethane foam filling, which allows for cost-effective manufacturing and optimal load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If prefabricated surface elements are used for cover layers, then load-bearing capacity and thermal insulation are improved, but production cost increases
Solution Approach 1:
The patent replaces expensive prefabricated surface elements with a cost-effective combination of wooden base layer, metal profile framework, and foam filling. The wooden base layer provides a practical alternative to costly prefabricated panels while maintaining structural integrity and load-bearing capacity when combined with the foam-filled profile framework.
Solution Approach 2:
The invention employs a composite structure combining wood (base layer), metal profiles (framework), and foam material (filling). This composite approach leverages the strengths of each material: wood provides base strength and stiffness, metal profiles provide structural framework and shape retention, and foam provides thermal insulation and load distribution, achieving both high load-bearing capacity and cost-effectiveness.
2Strength
If foam filling is used to support load, then load-bearing capacity improves, but weight increases
Solution Approach 1:
The foam filling is strategically positioned within the profile framework chambers to provide load-bearing support only where needed. The metal profiles create a structural skeleton that distributes loads efficiently, allowing foam to be used locally for reinforcement rather than throughout the entire structure, thus minimizing weight while maintaining load-bearing capacity.
Solution Approach 2:
The patent optimizes the density and distribution parameters of the foam filling to achieve the right balance between load-bearing capacity and weight. By controlling foam density and positioning it strategically within the profile framework, the design maximizes load support while minimizing unnecessary weight addition.
3Strength
If metal profile framework is used, then structural strength improves, but manufacturing complexity increases
Solution Approach 1:
The metal profile framework is divided into standardized, modular profile elements that can be manufactured separately and assembled systematically. This segmentation into repeatable units simplifies manufacturing processes, allows for standardized production techniques, and reduces overall manufacturing complexity while maintaining structural strength through the framework geometry.
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 design achieves a lightweight, high-strength floor element with improved thermal insulation and reduced production costs, ensuring efficient load transfer and minimal environmental impact.
Implementation Method 1
The molded parts are welded to one another by friction stir welding
Implementation Method 2
the foam filling ensures the required heat-insulating effect of the floor element
Data Source
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AI summary
The invention relates to a floor element for a vehicle, such as a truck, semi-trailer, or trailer, comprising an upper surface layer (1) comprising an upper surface layer (2), the free surface of which forms a loading area (F) for a load (T) to be placed on it, and a load-bearing layer (3) made of a wood-based material, which supports the surface layer (2). By forming the surface layer (2) of the upper surface layer (1) with at least two prefabricated molded parts (4, 4a) made of a light metal material, extending over the length of the floor element (B), which butt against each other at their longitudinal sides and are joined together by friction stir welding (5), such a floor element can be manufactured at a lower cost while still exhibiting good load-bearing capacity and sufficient insulation properties.