Non-Visible Floor-to-Sidewall Mating Configurations

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Solution Overview

Problem

Existing vehicle cargo box designs require visible corrosion protection sealants at floor-to-sidewall seams, which can be unsightly and necessitate expensive bed liners to cover them, failing to meet customer aesthetics and increasing manufacturing costs.

Innovation Solution

The truck bed assembly features non-visible floor-to-sidewall mating configurations using integrated unibody construction with fasteners such as welds, adhesives, and bolts strategically located outboard of the interior surface, eliminating the need for visible sealants within the cargo box.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If corrosion protection sealant is applied in the seam between floor and side wall, then corrosion protection is achieved, but the sealant is visible and unsightly requiring expensive bed liners

Engineering Contradiction:

Improvecorrosion protectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the visible sealant from the interior view by relocating the sealing function to the exterior outboard surface of the side wall. The fastener head is positioned on the outboard surface where it can perform the sealing function without being visible from the cargo box interior, thereby eliminating the need for expensive bed liners while maintaining corrosion protection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary element - the outboard surface of the side wall - as the location for the fastener head. This intermediary position allows the fastener to simultaneously perform both fastening and sealing functions while remaining hidden from the cargo box interior, resolving the contradiction between visible aesthetics and corrosion protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If corrosion protection sealant is applied in the seam between floor and side wall, then corrosion protection is achieved, but visible sealants necessitate expensive bed liners

Engineering Contradiction:

Improvecorrosion protectionVSAvoidaesthetic appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent extracts the sealing function from the visible interior seam and relocates it to the hidden outboard surface. The fastener head is positioned on the exterior surface where it can provide corrosion protection without affecting the aesthetic appearance of the cargo box interior, thereby eliminating the need for bed liners.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of placing the sealing element on the interior surface where it would be visible, the patent inverts the approach by placing the fastener head on the outboard exterior surface. This inversion allows the sealing function to be performed in a location that does not compromise aesthetic appearance.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If traditional visible sealant method is used, then corrosion protection is provided, but customer craftsmanship expectations are not met

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcustomer satisfaction

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent extracts the visible sealant from the customer's view by positioning the fastener head on the outboard exterior surface. This allows corrosion protection to be maintained while the cargo box interior presents a clean, professional appearance that meets customer craftsmanship expectations without requiring additional bed liner components.

Inventive Principle:

Principle #2Taking out (Extraction)

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 reduces manufacturing costs and enhances customer satisfaction by eliminating unsightly sealing interfaces, providing a more aesthetically pleasing and cost-effective cargo box design.

Implementation Method 1

The fastener is a weld or an adhesive

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The fastener is a weld or an adhesive

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11292534B2Vehicle cargo box floor-to-sidewall mating configurations

Publication Date: 2022.04.05 FORD GLOBAL TECH LLC

AI summary

Exemplary vehicle truck bed assemblies may include a unibody construction. A cargo box of an exemplary truck bed assembly may include at least two different floor-to-side wall mating configurations, and each of the at least two different mating configurations is non-visible from within a cargo space established by the cargo box. In addition, each of the at least two different mating configurations may include a fastener, such as a weld, an adhesive, and/or a bolt, for adjoining adjacent mating surfaces of the cargo box floor and side wall.