Modular Vehicle Sandwich Panels with Pultruded Beams
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Solution Overview
Problem
Multi-passenger vehicles face challenges in balancing weight and structural integrity due to the use of rigid frames and malleable panels, which lead to deformation and breakage during crashes or rollovers, resulting in insufficient residual space for passengers and increased Gross Vehicle Weight.
Innovation Solution
A modular vehicle design featuring sandwich-type side panels coupled to structural joiners with pultruded beams, integrated into a chassis with channels, using a bonding agent for enhanced structural integrity and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel plates or heavy durable materials are appended to the frame and panels to increase structural integrity, then the vehicle becomes excessively heavy, increasing Gross Vehicle Weight
Solution Approach 1:
The patent employs composite sandwich panels consisting of lightweight outer shells (aluminum or fiberglass) bonded to a rigid core material (foam, honeycomb, or balsa wood). This composite structure provides the necessary structural integrity and crash resistance without the excessive weight of solid steel plates, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent changes the material parameters by transitioning from solid heavy materials to composite structures with optimized density and strength characteristics. The sandwich panel design allows adjustment of core material type, thickness, and density to achieve the precise balance between structural integrity and weight reduction required for bus construction.
2Stability of the object's composition
If the frame is made rigid and panels are made of malleable materials, then the vehicle structure deforms and breaks during crashes, reducing residual space for passengers
Solution Approach 1:
The sandwich panel construction combines rigid outer shells with a rigid core material to create a structure that maintains its shape and integrity during impact. This composite structure prevents the deformation and breakage associated with traditional malleable panels, preserving residual space and reducing passenger injury risk during crashes and rollovers.
Solution Approach 2:
The rigid core material in the sandwich panels acts as a pre-engineered cushioning structure that absorbs and distributes impact forces before they can deform the outer shell or penetrate the passenger compartment. This beforehand cushioning protects passengers during crash events.
3Weight of moving object
If sandwich type panels are used to reduce weight, then they may insufficiently provide structural support, resulting in deformation and breakage upon impact
Solution Approach 1:
The patent uses composite sandwich panels with rigid core materials (foam, honeycomb, or balsa wood) bonded between rigid outer shells. This composite construction provides sufficient structural support for bus applications while maintaining weight reduction benefits, overcoming the limitation of insufficient structural support in traditional sandwich panels.
Solution Approach 2:
The patent applies sandwich panel construction specifically to non-structural or semi-structural components where weight reduction is most beneficial, while maintaining traditional rigid frame structures for primary load-bearing elements. This localized application of sandwich panels achieves weight reduction without compromising overall structural support capability.
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 modular vehicle configuration increases residual space while reducing Gross Vehicle Weight and improving structural integrity, providing a safer and more efficient passenger compartment.
Implementation Method 1
using a bonding agent for enhanced structural integrity
Data Source
AI summary
A passenger compartment of the modular vehicle, such as a bus, includes a roof panel and sandwich-type side panels coupled to structural joiners to form the passenger compartment. The side panels and the joiners may include pultruded beams for increased structural integrity. A chassis of the vehicle has channels integrated therein for coupling of the side panels and passenger compartment to the chassis. This coupling to the chassis channel may also include the use of a bonding agent.