Honeycomb Vehicle Load Ramp for High Strength-to-Weight Capacity
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Solution Overview
Problem
Current load ramps for vehicles lack innovative features and functionality that cater to consumer desires, necessitating a solution that enhances performance and usability.
Innovation Solution
A load ramp manufacturing method involving a corrugated layer positioned between two layers, with resin application and curing under controlled temperature and pressure to form a honeycomb structure with a polyurethane resin, providing a load capacity of at least 100 kg and a thickness of 10 mm to 30 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid layer structure is used for the load ramp, then the load capacity is improved, but the weight of the ramp increases
Solution Approach 1:
The patent employs a honeycomb corrugated layer structure that creates a porous configuration providing void spaces throughout the ramp body. This structure reduces the overall weight of the ramp while maintaining structural integrity and load-bearing capacity through the geometric arrangement of the honeycomb cells, which distribute mechanical loads efficiently across the structure.
Solution Approach 2:
The patent utilizes a composite construction combining a corrugated layer (potentially paper or cardboard material) with a polyurethane resin matrix. This composite material system achieves high strength-to-weight ratio by integrating the structural framework of the corrugated layer with the binding and load-distributing properties of the polyurethane resin, resulting in a lightweight yet strong load ramp.
2Strength
If the thickness of the load ramp is increased to improve load capacity, then the strength is improved, but the volume of the ramp increases
Solution Approach 1:
The honeycomb corrugated layer creates a porous structure that provides high strength-to-volume ratio. The geometric configuration of the honeycomb cells allows the ramp to maintain adequate thickness for load-bearing while minimizing overall volume through the efficient use of space and material distribution within the cellular structure.
Solution Approach 2:
The patent transitions from a solid two-dimensional layer to a three-dimensional honeycomb structure, utilizing the vertical dimension of the cell walls and spaces to provide structural strength. This dimensional transformation allows the ramp to achieve high load capacity with reduced overall thickness and volume compared to a solid structure.
3Strength
If a honeycomb corrugated layer is used, then the strength-to-weight ratio is improved, but the manufacturing complexity increases
Solution Approach 1:
The honeycomb structure is created by segmenting the corrugated layer into repeating cellular units with ridges and valleys forming standardized patterns. This segmentation approach simplifies manufacturing by using modular, repeatable geometric elements that can be produced through consistent forming processes, reducing overall manufacturing complexity despite the sophisticated final structure.
Solution Approach 2:
The patent specifies standardized parameter ranges for the honeycomb structure (cell dimensions, wall thickness, corrugation geometry) that optimize the strength-to-weight ratio while maintaining manufacturability. By establishing fixed parameter ranges rather than custom designs, the manufacturing process is simplified while still achieving the desired structural performance.
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 creates a robust and efficient load ramp with a honeycomb structure, enhancing load capacity and usability, addressing the need for improved vehicle features and functionality.
Implementation Method 1
applying a resin to a first exterior surface of the first layer. An amount of the resin applied to the first exterior surface can be sufficient to permeate the first layer and contact the corrugated layer
Implementation Method 2
curing the resin to form the load ramp for the vehicle
Data Source
AI summary
A load ramp for a vehicle includes a corrugated layer that has a first surface and a second surface. A first layer is positioned adjacent to the first surface of the corrugated layer. A second layer is positioned adjacent to the second surface of the corrugated layer such that the corrugated layer is positioned between the first and second layers. A thickness of the load ramp can be in the range of about 10 mm to about 30 mm. A load capacity of the load ramp can be at least about 100 kg. A method of manufacturing the load ramp is also disclosed.