Modular Deck System with Interlocking Planks for Variable Cargo Beds
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Solution Overview
Problem
Existing cargo decks are not universally compatible with various sizes of cargo beds, limiting their versatility for different vehicles.
Innovation Solution
A modular deck system comprising interlocking planks and a rail assembly that can be customized to fit different cargo bed sizes, with hook members for secure interlocking and a slider assembly to expand the deck surface, supported by rail capture members and leg members for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cargo deck is designed for a specific cargo bed size, then it provides stable support and secure fit, but it cannot be used with other cargo bed sizes
Solution Approach 1:
The deck is divided into multiple individual planks that can be independently selected and combined. Each plank has standardized dimensions and interlocking features, allowing them to be assembled in different configurations to match various cargo bed widths and lengths without requiring custom-designed deck structures for each bed size.
Solution Approach 2:
The planks are designed with universal interlocking features (notches and tabs) that work across all plank combinations. This universal design allows the same plank components to serve multiple cargo bed configurations, eliminating the need for size-specific deck designs while maintaining structural integrity.
2Adaptability or versatility
If multiple planks are used to cover larger cargo beds, then versatility is improved, but the interlocking mechanism complexity increases
Solution Approach 1:
The deck is segmented into discrete planks with standardized interlocking interfaces. Each plank contains integrated notches and tabs that enable simple end-to-end connection, allowing multiple planks to be assembled into longer decks for larger cargo beds through repetitive, straightforward joining operations rather than complex integrated structures.
Solution Approach 2:
Multiple planks are combined using standardized interlocking features that merge them into a continuous deck surface. The notches and tabs on adjacent planks engage to create a unified structure, allowing scalable deck assembly for various cargo bed sizes without increasing the complexity of individual connection mechanisms.
3Productivity
If planks are made longer to span cargo bed width, then fewer planks are needed, but interlocking reliability decreases
Solution Approach 1:
The deck is segmented into multiple shorter planks rather than using few long planks. This segmentation creates more interlocking joints distributed along the deck length, with each joint providing structural support and load distribution. The increased number of connection points enhances overall interlocking reliability while the standardized simple joints maintain quick assembly.
Data Source
AI summary
A deck system for a vehicle having a cargo bed. The deck system includes a deck body that extends across at least a portion of the cargo bed. The deck body includes a plurality of planks, each plank having an upper surface, a lower surface, and first and second opposing edges, each first edge configured to interlock with the second edge of another plank. The plurality of planks are coupled together via their interlocking edges to form the deck body. The deck system may also include a rail assembly configured to be coupled to side rails of the cargo bed and to the deck body for supporting the deck body above the cargo deck. The first edge of each plank has at least one first hook member and the second edge of each plank has at least one second hook member, the at least one second hook member configured to engage with the at least one first hook member of another plank.