Pickup Truck Floor Pan Reinforcement Assembly
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Solution Overview
Problem
Pickup truck floor pans, especially those made of aluminum, are prone to distortion and cracking under heavy loads due to material susceptibility, affecting durability and user satisfaction.
Innovation Solution
A reinforcement assembly with a bridge spanning a cross member channel and tabs extending outboard to suspend the reinforcement from the cross member, secured by fasteners, is integrated with a urethane isolator and weld flanges to support the floor pan beads, enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum floor pan is used to increase payload capacity, then payload capacity is improved, but susceptibility to deformation under heavy loads increases
Solution Approach 1:
The patent employs a composite reinforcement assembly consisting of a bridge structure, tabs, and side walls that work together to strengthen the aluminum floor pan. The bridge spans the channel to provide load distribution, while the tabs and side walls create a composite structural system that resists deformation, allowing the aluminum pan to maintain both light weight and enhanced strength.
Solution Approach 2:
The reinforcement assembly is segmented into distinct functional components: a bridge for spanning the channel, tabs for suspension from the cross member, and side walls for structural support within the channel. This segmentation allows each component to perform its specific function optimally while collectively addressing the deformation issue.
2Strength
If reinforcement assembly is added to the floor pan, then resistance to deformation is improved, but device complexity increases
Solution Approach 1:
The reinforcement assembly merges multiple structural elements (bridge, tabs, side walls) into a single integrated component that is installed as one unit between the floor pan and cross member. This combining approach provides comprehensive reinforcement while maintaining relatively simple installation and structural organization.
Solution Approach 2:
The reinforcement assembly acts as an intermediary structural element between the aluminum floor pan and the cross member, mediating the load transfer and preventing direct contact between heavy loads and the floor pan beads. This intermediary structure protects the floor pan from deformation without requiring fundamental changes to the existing truck bed design.
Data Source
AI summary
A reinforcement assembly is provided for a pickup truck bed. The reinforcement is assembled to a cross member that supports the pickup truck bed. The reinforcement includes a bridge spanning a channel defined by the cross member. The reinforcement assembly is suspended on tabs that are received in recesses defined by a front weld flange and a rear weld flange. A urethane isolator is utilized to secure the cross member to a frame component.