Polymeric Deck Panel Ribbed Structure for Vehicle Bed

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Solution Overview

Problem

Vehicle bodies with beds require enhanced structural reinforcement to withstand cargo loading without increasing mass or compromising manufacturability, as traditional metallic elements are heavy and costly to produce.

Innovation Solution

A polymeric deck panel with a ribbed section implemented across a corrugated section, featuring adjacent ridges and valleys with ribs extending continuously between and across crossbeams, providing consistent longitudinal rigidification and structural reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metallic body elements are used, then structural strength is improved, but weight increases and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidbody weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameter from traditional metal to polymeric material, fundamentally altering the weight-to-strength ratio. The polymeric deck panel achieves comparable structural strength through material selection while significantly reducing body weight, directly resolving the contradiction between strength and weight.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction by integrating ribs, corrugated sections, and reinforcement elements into the polymeric deck panel. This composite approach within the polymeric material system enhances structural strength to match or exceed traditional metallic elements while maintaining the weight advantage of polymers.

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional metallic body elements are used, then structural reinforcement is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural reinforcementVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges multiple structural components (deck panel, ribs, corrugated sections, reinforcement elements) into a single integrated polymeric body element. This consolidation eliminates the need for separate metal components and assembly operations, reducing manufacturing complexity and cost while maintaining structural reinforcement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing approach from traditional metal forming and assembly to polymeric molding processes. This parameter change enables more cost-effective production through streamlined manufacturing operations, reducing both material and labor costs associated with traditional metallic body elements.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If polymeric body elements are used, then weight is reduced and manufacturing cost is reduced, but structural reinforcement may be compromised

Engineering Contradiction:

Improvebody weightVSAvoidstructural reinforcement

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses composite material design within the polymeric system, combining the deck panel with integrated ribs and corrugated sections to achieve structural reinforcement comparable to metal while maintaining weight reduction benefits.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs curved and corrugated geometries in the polymeric deck panel design. These curved structures enhance structural reinforcement through geometric strength while maintaining the lightweight polymeric construction, resolving the contradiction between weight reduction and structural reinforcement.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Strength

If complex rib structures are added to polymeric deck panel, then structural integrity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidstructural complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the rib structures, corrugated sections, and reinforcement elements into a single integrated polymeric component molded as one piece. This integration maintains structural integrity while reducing device complexity by eliminating the need for multiple separate parts and assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11235817B2Vehicular body structure

Publication Date: 2022.02.01 TOYOTA JIDOSHA KK

AI summary

A vehicular body structure includes a polymeric deck panel. The deck panel includes an adjacent ridge and valley with a leg shared therebetween, a crossbeam footprint crosswise to the adjacent ridge and valley, and a rib extending along the adjacent ridge and valley. Outside the crossbeam footprint, the rib extends along the ridge, approaching the crossbeam footprint, the rib extends along the leg into the valley, and across the crossbeam footprint, the rib extends along the valley.