# US 12,179,677 B2 · Composite material vehicle cargo compartment construct

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- Number: US 12,179,677 B2
- Document ID: US12179677B2
- Status: Granted
- Kind: B2
- Application number: 17/792,512
- Filed: 2021-01-15
- Published: 2023-02-23
- Granted: 2024-12-31
- Earliest claimed: 2020-01-15
- Assignees: Teijin Automotive Technologies, Inc.
- Applicants: Continental Structural Plastics, Inc.
- Inventors: Hugh C. Foran; Eric J. Haiss; Matthew Plauman
- Web page: https://patentgrep.com/patent/US12179677B2

## CPC

- B60R 13/01: Liners for load platforms or load compartments
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/08: of synthetic resin
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/325: {comprising polycycloolefins}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 29/08: Corrugated paper or cardboard
- B62D 29/00: Superstructures, {understructures, or sub-units thereof,} characterised by the material thereof {(B62D33/044, B62D33/048 take precedence)}
- B62D 29/043: {Superstructures (B62D25/161 takes precedence)}
- B62D 33/02: Platforms; Open load compartments {(flat wagons including posts or standards B61D3/08)}
- B62D 33/023: Sideboard or tailgate structures {(vehicle side panels in general B62D25/02)}
- B62D 33/044: {built up with profiles of constant elongated shape, e.g. extruded, mechanically interconnected by coupling members, e.g. by clamping, riveting or bolting}
- B62D 33/046: {built up with flat self-supporting panels; Fixed connections between panels (B62D29/045, B62D33/048 take precedence)}
- B32B 2250/03: 3 layers
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2264/101: Glass
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2266/0278: Polyurethane
- B32B 2266/126: Aerogel, i.e. a supercritically dried gel
- B32B 2307/102: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/516: mono-axially
- B32B 2307/7246: Water vapor barrier
- B32B 2307/732: Dimensional properties
- B32B 2605/00: Vehicles
- B32B 2605/08: Cars
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)

## Abstract

A vehicle cargo construct including a floor, a plurality of side wall panels extending from the floor, and an end wall panel extending from the floor between the plurality of side wall panels. The floor has an exterior surface and an oppositely opposed interior surface. Each of the plurality of side wall panels has an exterior surface and an oppositely opposed interior surface. The has an exterior surface and an oppositely opposed interior surface. Each of the floor, the plurality of side wall panels, and the end wall panel are formed of a composite sandwich panel material formed including an open area core defining a plurality of pores disposed between a backing sheet and a surface sheet formed of a sheet molding composition (SMC) reinforced with unidirectional fibers.

## Claims

### Claim 1

A vehicle cargo construct comprising:
a floor having an exterior surface and an oppositely opposed interior surface;
a plurality of side wall panels extending from said floor, each of said plurality of side wall panels having an exterior surface and an oppositely opposed interior surface; and
an end wall panel extending from said floor between said plurality of side wall panels, said end wall panel having an exterior surface and an oppositely opposed interior surface;
each of said floor, said plurality of side wall panels, and said end wall panel being formed of a composite sandwich panel material comprising an open area core defining a plurality of pores disposed between a backing sheet and a surface sheet formed of a sheet molding composition (SMC) reinforced with unidirectional fibers wherein the backing sheet is wrapped around the open area core and joined to the surface sheet along all edges of the composite sandwich material with an elastomeric gasket therebetween to fully enclose the open area core and inhibit moisture from entering an interior of the composite sandwich material.

### Claim 2 (depends on 1)

The vehicle cargo construct of claim 1 wherein the exterior surface of said floor is defined by the surface sheet of said composite sandwich panel material and the oppositely opposed interior surface of said floor is defined by the backing sheet of said composite sandwich panel material.

### Claim 3 (depends on 1)

The vehicle cargo construct of claim 1 wherein the exterior surface of each of said plurality of side wall panels is defined by the surface sheet of said composite sandwich panel material and the oppositely opposed interior surface of each of said plurality of side wall panels is defined by the backing sheet of said composite sandwich panel material.

### Claim 4 (depends on 1)

The vehicle cargo construct of claim 1 wherein the exterior surface of said end wall panel is defined by the surface sheet of said composite sandwich panel material and the oppositely opposed interior surface of said end wall panel is defined by the backing sheet of said composite sandwich panel material.

### Claim 5 (depends on 1)

The vehicle cargo construct of claim 1 further comprising a second end wall panel extending from said floor between said plurality of side wall panels, said second end wall panel having an exterior surface and an oppositely opposed interior surface.

### Claim 6 (depends on 1)

The vehicle cargo construct of claim 1 wherein the surface sheet of the composite sandwich panel material is 0.5 to 4 mm thick.

### Claim 7 (depends on 1)

The vehicle cargo construct of claim 1 further comprising a plurality of cap sections positioned along an upper edge of each of said plurality of side wall panels and said end wall panel.

### Claim 8 (depends on 1)

The vehicle cargo construct of claim 1 further comprising a bed liner positioned on the exterior surface of said floor.

### Claim 9 (depends on 1)

The vehicle cargo construct of claim 1 wherein the open area core of said composite sandwich panel material is an array having a pattern of at least one shape of: hexagonal, circular, rhomboidal, triangular, parallelogram quadrilateral, or regular quadrilateral.

### Claim 10 (depends on 1)

The vehicle cargo construct of claim 1 wherein the open are core of said composite sandwich panel material is formed of at least one of thermoplastic and aluminum.

### Claim 11 (depends on 1)

The vehicle cargo construct of claim 1 wherein the backing sheet of said composite sandwich panel material is formed of any one of: sheet molding compound (SMC), thermoplastic sheet, dicyclopentadiene (DCPD), or overmolded polyurethane (PU).

### Claim 12 (depends on 1)

The vehicle cargo construct of claim 1 wherein the SMC material of the surface sheet is reinforced with unidirectional carbon fibers.

### Claim 13 (depends on 1)

The vehicle cargo construct of claim 1 wherein the surface sheet is adhered to a first face of the open area core by a first adhesive layer and wherein the backing sheet is adhered to a second face of the open area core by a second adhesive layer.

### Claim 14 (depends on 1)

The vehicle cargo construct of claim 1 wherein said composite sandwich panel material has a cloth embedded in a first adhesive layer between the surface sheet and the first face of the open area core.

### Claim 15 (depends on 14)

The vehicle cargo construct of claim 14 wherein at least one of the first adhesive layer and said second adhesive layer of said composite sandwich panel material contacts an interior volume of the open area core.

### Claim 16 (depends on 1)

The vehicle cargo construct of claim 1 wherein said composite sandwich panel material has a fill in the pores of the open area core, the fill being at least one of a sound dampening foam, a fire retardant, or a phase change material.