Grooved-Core Vehicle Cargo Floor for Insulation and Load Support
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Solution Overview
Problem
Existing vehicle floor structures in cargo areas face challenges in achieving both sufficient strength and thermal insulation while being lightweight, with thermal bridges and inefficient material use leading to increased weight and energy consumption.
Innovation Solution
A stratified floor structure comprising a first abrasion-resistant layer, a core plastic layer with grooves for longitudinal structural elements, and a third structural layer, where the core layer provides thermal insulation and distributes load through grooves, eliminating thermal bridges and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wooden slats and multiple boards are used to ensure load-bearing capacity, then structural strength is improved, but thermal insulation deteriorates due to thermal bridges created by the slats
Solution Approach 1:
The patent removes the wooden slats that created thermal bridges from the floor structure. Instead, it uses a continuous insulation layer made of rigid foam boards that span the entire floor cavity, eliminating the thermal bridging effect while maintaining structural integrity through differently configured support elements.
Solution Approach 2:
The patent employs a composite structure combining rigid foam insulation boards with strategically positioned support elements. The foam boards provide continuous thermal insulation, while the support elements (which do not penetrate the insulation layer) provide structural strength, creating a synergistic composite system that addresses both thermal and mechanical requirements.
2Strength
If traditional floor structures with multiple layers and components are used, then load-bearing capacity is achieved, but weight increases
Solution Approach 1:
The patent eliminates redundant structural components such as wooden slats and multiple overlapping boards that added weight without proportionally increasing strength. The simplified design uses fewer, more efficiently configured elements that provide the same or better load-bearing capacity at reduced weight.
Solution Approach 2:
The use of rigid foam boards combined with optimized support elements creates a high-strength-to-weight ratio structure. The foam material provides both insulation and structural rigidity, reducing the need for additional heavy reinforcement while maintaining load-bearing capacity.
3Strength
If irregular distribution of wooden slats is used, then structural support is provided, but manufacturing precision and assembly quality deteriorate
Solution Approach 1:
The patent divides the floor structure into distinct, standardized segments: full-size rigid foam boards and clearly defined support elements positioned at specific intervals. This segmentation with standardized dimensions and positions enables precise manufacturing and straightforward assembly, eliminating the irregularity problems of the previous design.
Solution Approach 2:
The patent changes the configuration parameters of the support elements, positioning them to contact only the lower board rather than penetrating through multiple layers. This parameter change simplifies the assembly process and improves manufacturing precision by reducing the complexity of component interactions.
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 structure achieves improved thermal insulation, reduced weight, and enhanced load-bearing capacity with simplified assembly, minimizing construction errors and fuel consumption.
Implementation Method 1
the core layer comprises a plurality of grooves on one of its faces... the core layer provides thermal insulation and distributes load through grooves, eliminating thermal bridges
Data Source
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AI summary
The invention relates to a multilayer floor structure for the cargo space of a land vehicle, comprising a first layer (1) for protection against abrasion, a second sealing layer (2) adapted to be exposed to the outside of the vehicle, a core plastic layer (4), and a third structural layer (3) adapted to support longitudinal structural elements (6), the third layer (3) being interposed between the core layer (4) and the second layer (2) such that the core layer (4) is arranged between the first layer (1) and the third layer (3). The core layer (4) comprises a plurality of grooves (5) on one of its faces, the grooves (5) being arranged spaced from one another and located between the core layer (4) and the third structural layer (3). Each of the longitudinal structural elements (6) are housed in one of the grooves (5) such that there is a distancing (d) between the longitudinal structural elements (6) and the first layer (1) through the interposition of the core layer (4).