Vehicle Load Structure with Over Rim Coating for Weather Protection

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Solution Overview

Problem

Existing load structures in vehicles face challenges in providing protection from weather elements like mud and water while minimizing weight and cost, as conventional methods such as floor mats and adhesive thermoplastic olefin layers are either heavy or expensive.

Innovation Solution

A load structure with a honeycomb paper core, a polyurethane coating, and a moisture-resistant over rim coating, optionally with a carpeted A-side and a concealed B-side, featuring a barrier layer to prevent resin penetration and a fill passage for efficient resin injection, which reduces weight and cost while maintaining protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a floor mat is added over the load structure to protect from weather elements, then protection from mud and water is improved, but weight increases

Engineering Contradiction:

Improveprotection from weather elementsVSAvoidweight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent combines the protective coating and the load structure panel into a single integrated component. The moisture-resistant coating is applied directly to the panel, merging the protection function with the structural function, thereby eliminating the need for separate floor mats while maintaining weather protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a thin film moisture-resistant coating applied to the panel surface. This thin film provides the necessary protection from water and mud while adding minimal weight compared to traditional floor mats.

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If a layer of thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but cost and weight increase

Engineering Contradiction:

Improveprotection from weather elementsVSAvoidcost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective moisture-resistant coating that can be applied directly to the panel. This coating provides necessary protection at a lower cost compared to expensive materials like thermoplastic olefin or vinyl, while maintaining adequate durability for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses a composite structure combining the panel material with a moisture-resistant coating. This composite approach provides weather protection through material composition rather than requiring expensive adhesive bonding of separate layers.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If a layer of thermoplastic olefin or vinyl is adhesively bonded to the panel for protection, then protection from weather elements is improved, but weight increases

Engineering Contradiction:

Improveprotection from weather elementsVSAvoidweight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses a thin film moisture-resistant coating applied directly to the panel surface. This thin film provides the necessary protection from water and mud while adding minimal weight compared to traditional floor mats or thick adhesive layers.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

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 proposed load structure effectively protects against weather elements, is lightweight, cost-effective, and easy to clean, with a reversible design that maintains functionality and integrity under wet and dry conditions.

Implementation Method 1

The panel is then coated with a polyurethane coating that provides a cosmetic, cleanable, and waterproof surface

Methodology Applied

Scientific EffectMoisture barrier: Absorption (physical)

Implementation Method 2

The panel may include an over rim coating on at least a portion of the second side, and a barrier layer on the second side to prevent resin from penetrating the panel

Methodology Applied

Scientific EffectBarrier layer: Physical Containment

Data Source

PatentEP3578355B1Method of manufacturing a load structure

Publication Date: 2022.11.23 GEMINI GROUP

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Figure 5~7

AI summary

A method of manufacturing a load structure may include first forming a panel (12) having a first side and a second side. The method may then include trimming the panel, including clearing a fill passage through the panel from the first side to the second side. The method may then include applying an over rim coating on the second side of the panel via an over rim tool by which a resin (214) may be injected through the fill passage to the second side. The method may further include performing final trimming of the panel, and finally performing final assembly to form the load structure.