Load Carrier Multi-Position Locking for Lightweight Drop-Test Reliability

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Solution Overview

Problem

Existing load carriers fail to meet the requirements of type-testing standards, particularly in drop tests, while maintaining a lightweight construction, and often require complex or heavy reinforcement measures that are not automatable or lead to significant waste.

Innovation Solution

A load carrier with a lid that can be releasably locked via multiple locking configurations, allowing it to maintain a locked state under high loads by transitioning to alternative locking positions rather than immediately unlocking, and is partially made of lightweight plastic to reduce tare weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If reinforcement measures (strapping, metal bars) are added to pass drop tests, then reliability during transport is improved, but weight increases and automation capability is lost

Engineering Contradiction:

Improvereliability during transportVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The locking mechanism is divided into multiple independent locking elements (first locking element, second locking element, third locking element) that can engage with corresponding locking receptacles at different positions. This segmentation allows the locking system to distribute forces across multiple points, maintaining reliability without requiring heavy reinforcement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lid is designed with movable characteristics allowing it to shift position during impact, and the locking mechanism includes elements that can engage/disengage dynamically. The spring element provides dynamic response to impact forces, allowing the system to adapt to drop conditions without rigid reinforcement

Inventive Principle:

Principle #15Dynamics

2Reliability

If reinforcement measures (strapping, metal bars) are added to pass drop tests, then reliability during transport is improved, but device complexity increases

Engineering Contradiction:

Improvereliability during transportVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple locking functions are merged into a single integrated locking mechanism. The first, second, and third locking elements work together as one system, combining the functions of multiple locks into a unified structure that reduces overall complexity compared to using separate reinforcement measures

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The locking mechanism serves multiple functions: it locks the lid in the closed position, provides impact resistance during drop tests, and allows for both automated and manual operation. This multi-functionality eliminates the need for separate reinforcement systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple locking configurations are provided, then reliability under load is improved, but device complexity increases

Engineering Contradiction:

Improvereliability under loadVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking mechanism is segmented into multiple locking elements (first, second, third locking elements) that can engage independently with corresponding receptacles. This segmentation provides multiple locking configurations without requiring a complex overall structure, as each element is relatively simple

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different locking elements are positioned at different locations (front, rear, side) of the lid, providing localized locking at specific points. This local quality approach ensures reliable locking under various load conditions while keeping each individual locking element simple in design

Inventive Principle:

Principle #3Local quality

4Weight of moving object

If lightweight plastic construction is used, then weight is reduced, but strength during drop tests worsens

Engineering Contradiction:

ImproveweightVSAvoidstrength during drop tests

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The load carrier combines plastic construction with a metal spring element in the locking mechanism. This composite approach maintains the lightweight advantage of plastic while incorporating metal where high strength and elasticity are needed for drop test resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The spring element in the locking mechanism is pre-loaded to provide cushioning against impact forces before they occur. This beforehand cushioning allows the lightweight plastic construction to withstand drop tests by absorbing impact energy through the elastic deformation of the spring

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP4606724A1Load carrier

Publication Date: 2025.08.27 VOLKSWAGEN AG

Figure 1a~1b
Figure 2

AI summary

The invention relates to a load carrier (1) comprising a container part (2) designed to receive components and a lid (3) which can be releasably locked in a closed position (5) by at least one locking mechanism (4), and the locking mechanism (4) can be transferred between an unlocked state and a locked state (6) for this purpose. The unlocked state of the locking mechanism (4) can be provided by an unlocking configuration of the locking mechanism (4), and the locked state (6) of the locking mechanism (4) can be provided by at least two locking configurations of the locking mechanism (4).