Honeycomb Load Structure with Over Mold Coating
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Solution Overview
Problem
Existing load structures in vehicles face challenges in providing protection from weather elements like mud and water while minimizing weight and cost, as they often require additional heavy and expensive materials such as thermoplastic olefin or vinyl coatings.
Innovation Solution
A honeycomb reinforced load structure with a polyurethane coating and a moisture impervious layer on one or both sides, combined with a carpeted surface, which uses an over mold process to apply a resin coating and includes a barrier layer to prevent resin penetration into the core, reducing weight and cost while maintaining protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a floor mat is added over the load structure to protect from mud and water, then protection from weather elements is improved, but weight increases
Solution Approach 1:
The patent combines the protective function with the load structure itself by integrating a moisture impervious layer and polyurethane coating directly onto the panel surface. This merging eliminates the need for separate floor mats while providing the required protection from mud and water, thereby avoiding additional weight.
Solution Approach 2:
The patent employs thin film coatings (polyurethane coating and moisture impervious layer) applied directly to the panel surface to provide protection. These thin films offer weather element protection without the weight penalty of traditional floor mats, as they are integrated into the panel structure itself.
2Object-affected harmful factors
If thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but cost and weight increase
Solution Approach 1:
The patent changes the material parameter from expensive thermoplastic olefin or vinyl to a more cost-effective polyurethane coating combined with a moisture impervious layer. This material substitution maintains protective functionality while reducing cost, as the coating system is applied directly to the panel rather than requiring expensive adhesive bonding of separate layers.
Solution Approach 2:
The protective functions are merged into a single integrated coating system (polyurethane coating with moisture impervious layer) applied directly to the panel. This eliminates the need for separate expensive materials like thermoplastic olefin or vinyl and their associated adhesive bonding processes, thereby reducing overall cost.
3Object-affected harmful factors
If thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but weight increases
Solution Approach 1:
The patent merges the protective function into the panel structure itself through direct application of polyurethane coating and moisture impervious layer. This integration eliminates the need for separate heavy materials like thermoplastic olefin or vinyl, providing protection while minimizing weight addition.
Solution Approach 2:
The patent uses thin film coatings (polyurethane and moisture impervious layer) that provide effective protection from weather elements without the weight penalty of thicker materials like thermoplastic olefin or vinyl. These thin films are applied directly to the panel, offering protection with minimal weight increase.
4Ease of manufacture
If an over mold process is used to apply resin coating, then ease of manufacture is improved, but resin penetration into core may occur
Solution Approach 1:
The patent applies a barrier layer to the honeycomb core before applying the polyurethane coating through the over mold process. This preliminary action prevents resin penetration into the core during manufacturing, protecting the structural integrity of the honeycomb while still allowing the over mold process to be used for its manufacturing efficiency.
Solution Approach 2:
The barrier layer acts as an intermediary between the honeycomb core and the polyurethane coating. It prevents direct contact between the resin and the core structure, blocking resin penetration while allowing the coating process to proceed. This intermediary layer preserves the core's structural integrity while enabling the manufacturing benefits of the over mold process.
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 provides a lightweight, cost-effective, and moisture-resistant load structure that is easy to clean and maintain, suitable for various applications including vehicle floors and components, while maintaining structural integrity and aesthetics.
Implementation Method 1
a polyurethane coating and a moisture impervious layer on one or both sides
Implementation Method 2
uses an over mold process to apply a resin coating
Implementation Method 3
includes a barrier layer to prevent resin penetration into the core
Data Source
AI summary
A load structure may include a panel having a core, and a coating of polyurethane around the core. The load structure may also have a layer of carpet or felt on at least a portion of a first side of the panel. The load structure may further include an over mold coating on a second side of the panel.