Truck Deck Gate Composite Structure for Weight Reduction
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Solution Overview
Problem
Existing deck gates for trucks face issues with strength, corrosion resistance, abrasion resistance, fatigue life, impact resistance, weight lightening, low-temperature resistance, and heat resistance, particularly due to high costs and weight, and are prone to malfunctioning in adverse weather conditions.
Innovation Solution
A deck gate design featuring a core layer made of resins and a skin layer with reinforced fibers, arranged on both surfaces, manufactured using the VA-RTM process, with a finishing unit and hinge units for enhanced protection and durability, comprising a sandwich-panel structure with specific thickness ratios and materials like glass, carbon, or aramid fibers and epoxy or polyester resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum-type deck gates are used to improve corrosion resistance and durability, then reliability is improved, but cost increases
Solution Approach 1:
The patent uses a composite structure combining foam core layer (for lightweight) with skin layers containing reinforced fibers (for strength and corrosion resistance). This composite approach achieves aluminum-like durability while using lower-cost materials and reducing overall weight.
Solution Approach 2:
The patent optimizes the thickness ratio of outer skin:core layer:inner skin to be 1:5 to 7:1, and controls fiber content at 40-70 weight% and resin content at 30-60 weight%. These parameter optimizations ensure structural integrity while minimizing material costs.
2Strength
If traditional steel and wood wick structure is used to maintain structural integrity, then strength is maintained, but weight increases
Solution Approach 1:
The patent applies different material properties to different layers: the core layer uses foam for lightweight properties, while the skin layers use reinforced fibers for strength. This local differentiation achieves structural integrity without excessive weight.
Solution Approach 2:
The sandwich-panel structure combines foam core with fiber-reinforced skin layers, creating a composite material system that provides both strength and weight reduction compared to traditional solid steel or wood constructions.
3Strength
If thicker skin layers are used to improve impact resistance, then strength is improved, but weight increases
Solution Approach 1:
The patent optimizes the thickness ratio of outer skin:core layer:inner skin to be 1:5 to 7:1, achieving impact resistance through optimized distribution rather than uniform thickness increase, thereby minimizing weight.
Solution Approach 2:
The fiber-reinforced skin layers provide high impact resistance per unit thickness due to the reinforced fibers (glass, carbon, or aramid), allowing thinner skin layers compared to unreinforced structures.
4Reliability
If reinforced fiber content is increased to improve strength and durability, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent specifies fiber content at 40-70 weight% and resin content at 30-60 weight%, optimizing durability while maintaining manufacturability through controlled parameter ranges rather than extreme values.
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 provides a lightweight, durable deck gate with improved impact strength, low permanent deformation, and resistance to corrosion, abrasion, fatigue, and extreme temperatures, while reducing weight and maintaining structural integrity.
Implementation Method 1
VA-RTM process
Data Source
AI summary
Disclosed herein is a truck, a deck gate for truck, and a method for manufacturing thereof. According to the present invention, the deck gate for truck has excellent impact strength, low plastic deformation rate, excellent molding property and thermal resistance, and reduces weight. Also, the deck gate for truck according to the present invention reduces weight of about 23% in comparison with a conventional steel and wood type deck gate for truck.