Load Structure Panel Coating for Mud and Water Protection
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Solution Overview
Problem
Existing load structures in vehicles are heavy and costly, and they often require additional protection against weather elements like mud and water, which adds weight and expense.
Innovation Solution
A load structure with a honeycomb paper core coated with glass and a polyurethane layer, featuring a moisture-resistant barrier layer and an over rim coating, which provides protection from weather elements while reducing weight and cost.
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 barrier function directly into the load structure panel by integrating a moisture-resistant barrier layer and over-rim coating into the panel itself, eliminating the need for separate floor mats or protective coverings while maintaining protection from mud and water
Solution Approach 2:
The load structure panel is designed to perform multiple functions simultaneously: it provides structural support, incorporates moisture-resistant barrier layers for protection, and includes over-rim coatings for edge protection, all in a single integrated component that replaces multiple separate protective elements
2Object-affected harmful factors
If a layer of thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but weight and cost increase
Solution Approach 1:
The patent uses composite material construction with a honeycomb paper core, glass coating layer, and polyurethane barrier layer that collectively provide moisture and weather resistance without requiring heavy vinyl or thermoplastic olefin coatings, achieving protection through material composition rather than thick protective layers
Solution Approach 2:
The patent changes the approach from applying heavy protective coatings to using lightweight barrier layers with specific moisture-resistant properties, transforming the protection mechanism from surface coating to integrated barrier construction that provides equivalent protection with reduced weight
3Object-affected harmful factors
If a layer of thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but cost increases
Solution Approach 1:
The patent employs composite materials including honeycomb paper core, glass coating, and polyurethane barrier layers that provide effective weather protection through material properties rather than expensive heavy-duty coatings, reducing overall material and manufacturing costs
Solution Approach 2:
The patent utilizes cost-effective materials such as honeycomb paper core and polyurethane coatings that provide adequate protection at lower cost compared to expensive vinyl or thermoplastic olefin layers, achieving economical weather resistance
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 proposed load structure effectively protects against mud and water while minimizing weight and cost, offering a durable and efficient solution for vehicle applications.
Implementation Method 1
a polyurethane layer that provides a moisture-resistant barrier
Implementation Method 2
a honeycomb paper core coated with glass and a polyurethane layer
Data Source
AI summary
A method of manufacturing a load structure may include forming a panel having a first side and a second side, clearing a fill passage through the panel, providing a tool having a first tool portion, a second tool portion, and a cavity disposed between the first and second tool portions, connecting a fill busing to the tool, the fill bushing includes a flange, disposing the panel within the cavity, disposing the fill bushing within the fill passage, connecting an injection gun to the fill bushing, and injecting a material through the fill busing and the fill passage such that one of the first side or the second side of the panel is at least partially covered with the material, the fill bushing is arranged within the fill passage to block the coating from contacting the other one of the first side or the second side.