Modular Composite Truck Bed Assembly for High Strength, Low Weight

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Solution Overview

Problem

Existing utility truck bed assemblies lack a reinforced modular design that integrates metal and composite reinforcements within a thermoformed thermoplastic or fiber-reinforced structure, leading to inefficiencies in weight, strength, and noise reduction.

Innovation Solution

A modular assembly for utility truck bodies featuring metal and/or composite reinforcements encapsulated within a thermoformed thermoplastic or fiber-reinforced thermoset floor structure, with minimal welding and permanent adhesive use, allowing for integral and aerodynamic sidepack compartments that are removably or permanently attachable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal and composite reinforcements are added to the truck bed assembly, then strength and load-bearing capacity improve, but weight increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoidassembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs composite materials by encapsulating metal and composite reinforcements within a thermoformed thermoplastic or fiber-reinforced thermoset floor structure. This creates a hybrid composite assembly that leverages the high strength-to-weight ratio of both traditional metals and modern composite materials, achieving superior load-bearing capacity while minimizing weight penalty through optimized material distribution and integration.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement elements are nested within the floor structure through encapsulation. The metal and composite reinforcements are embedded inside the thermoformed thermoplastic or fiber-reinforced thermoset matrix, creating a nested configuration where the reinforcement elements are contained within the floor structure. This nesting approach integrates strength enhancement without adding external weight.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If modular components are used for sidepack compartments, then adaptability and ease of installation improve, but manufacturing complexity increases

Engineering Contradiction:

Improvemodular attachment capabilityVSAvoidassembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The sidepack compartments are designed as modular, separable units that can be independently manufactured and then assembled to the truck bed floor. This segmentation allows for simplified manufacturing of individual components, easy installation and removal, and flexibility in configuration. The modular design breaks down the complex assembly into manageable segments that can be produced using standard manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular sidepack compartments are designed with universal attachment capabilities that allow them to be installed on various truck bed configurations. The standardized interface and attachment mechanism enable these compartments to serve multiple functions and be adapted to different applications, reducing the need for custom-designed components for each specific use case.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If aerodynamic features are incorporated into sidepacks, then drag reduction and noise reduction improve, but manufacturing complexity increases

Engineering Contradiction:

Improvedrag and noiseVSAvoidsidepack structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Aerodynamic features are incorporated into the sidepack design through curved and streamlined shapes that reduce air resistance and turbulence. The use of curved surfaces instead of sharp edges and flat panels helps to smooth airflow around the sidepacks, reducing drag and wind noise. This curvature principle is integrated into the modular sidepack structure to achieve aerodynamic performance.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Ease of repair

If minimal welding and permanent adhesive are used, then ease of repair and modularity improve, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidattachment alignment

Core Design Contradiction:

Ease of repairVSManufacturing precision

Solution Approach 1:

Traditional welding and permanent adhesive bonding are replaced with mechanical attachment systems such as clips, fasteners, or interlocking mechanisms. This substitution enables easy disassembly, repair, and replacement of components without requiring specialized welding equipment or adhesive application expertise. The mechanical attachment system maintains structural integrity while significantly improving ease of repair and modularity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12043320B2Truck body assembly and methods of making and using same

Publication Date: 2024.07.23 ALTEC INDS

AI summary

An assembly for utility truck bodies having metal and/or composite reinforcement(s) and/or foam reinforcements and/or honeycomb reinforcement/and/or wood reinforcements encapsulated within a thermoformed thermoplastic, or thermoset or fiber-reinforced thermoset walking surface floor structure of the truck bed assembly or other composite floor structure with attachable components and junctions, e.g., sidepack(s), and methods of making the same are provided.