Vehicle Trim Sandwich Composite Load Floor
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Solution Overview
Problem
Load floors in vehicles often break or crack under heavy loads due to their lightweight construction, necessitating a trim component that is both lightweight and capable of withstanding significant loads without damage.
Innovation Solution
A trim component comprising a sandwich composite structure with glass fiber-reinforced thermoplastic skin layers and a honeycomb core, bonded using thermoplastic adhesive materials containing polyamide, which provides a strong and lightweight load-bearing surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials are used for load floors, then weight is reduced, but strength and load-bearing capacity deteriorate
Solution Approach 1:
The patent applies composite materials by combining thermoplastic adhesive material including polyamide with skin layers and core layers to create a sandwich structure. This composite construction achieves both lightweight properties and high strength, resolving the contradiction between weight reduction and load-bearing capacity. The adhesive material including polyamide specifically enhances bond strength between layers while maintaining overall structure lightness.
2Strength
If adhesive strength is increased to prevent layer separation, then bond strength improves, but risk of cracking under heavy loads increases
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the adhesive material to include polyamide, which changes the adhesive properties and bond characteristics. This compositional parameter change enables the adhesive to provide both strong bonding and flexibility, preventing layer separation while resisting cracking under heavy loads through enhanced molecular adhesion properties.
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 solution effectively distributes heavy loads across the surface, enhancing the trim component's strength and resistance to deflection while maintaining a lightweight design, as demonstrated by superior bond strength tests.
Implementation Method 1
a first thermoplastic adhesive material including a polyamide disposed between the first skin layer and the core layer to adhere the first skin layer to the first side of the core layer
Data Source
AI summary
A trim component for a vehicle interior includes first and second skin layers, a core layer sandwiched between the first and second skin layers with the core layer having first and second sides, a first thermoplastic adhesive material including a polyamide disposed between the first skin layer and the core layer to adhere the first skin layer to the first side of the core layer, and a second thermoplastic adhesive material including a polyamide disposed between the second skin layer and the core layer to adhere the second skin layer to the second side of the core layer.