Preparation method of reinforced magnesium alloy lightweight cargo container

Abstract

The invention relates to design and manufacturing of light-weight metal containers, in particular to a preparation method of an enhanced magnesium alloy light-weight cargo container. The magnesium alloy lightweight cargo container is composed of a main framework, wall plates, a bottom plate, a top plate and a door. The main framework is formed by welding hollow profiles with a plurality of slots; inserting strips which are made of high-strength steel or high-strength composite materials and are connected together are inserted into inner cavities of the corner hollow profiles. The hollow profile is made of high-strength magnesium alloy; a plurality of metal elements containing rare earth are added into the magnesium alloy. The alloy with the components is prepared into a bar material in a semi-continuous casting mode after being subjected to protective smelting; after casting is completed, homogenization heat treatment, surface oxide layer removal, preheating before extrusion, fixed-length cutting after extrusion, back fire heat treatment and surface temporary protective coating or moisture-proof / rust-proof wrapping are carried out for standby application.

Description

Technical Field

[0001] The invention relates to the design and manufacture of a lightweight metal container, and in particular to a method for preparing a lightweight cargo container made of a reinforced magnesium alloy. Background Art

[0002] Containers, the primary function of containers is to load goods for transportation. It can load goods of various types, shapes and sizes into a standardized box, which is convenient for conversion and intermodal transport between different modes of transportation (such as sea, air, rail, road, etc.), and improves transportation efficiency. Containers also have the function of protecting goods. Its sturdy steel structure can withstand external impact, extrusion and adverse weather conditions, protecting goods from damage, moisture and loss. In addition, containers can realize the unitization and standardization of cargo transportation. It makes the loading, unloading, handling and storage of goods more convenient and efficient, and reduces labor costs and operation time.

[0003] Containers must have certain strength, rigidity and specifications. They are large cargo containers specially used for turnover. When using containers to transport goods, goods can be loaded directly at the shipper's warehouse and unloaded at the consignee's warehouse. When changing vehicles or ships in the middle, there is no need to take the goods out of the box for reloading. It can be seen that containers are a great mechanical creation. The greatest success of containers lies in the standardization of their products and the entire transportation system established by them. It can be standardized to enable a behemoth with a load of dozens of tons, and on this basis, gradually realize a logistics system that matches ships, ports, routes, roads, transfer stations, bridges, tunnels, and multimodal transport around the world. This is indeed one of the great miracles created by mankind in history. At present, containers use metal materials as raw materials and are made through cutting, welding, grinding, painting and other processes. The shortcomings of existing products are: 1. Steel materials are easy to rust and corrode, and the production anti-rust requirements are high; the anti-rust coating is damaged by bumps during the handling and installation process, and the anti-rust ability decreases. 2. The finished product is heavy and the efficiency of loading goods is low. 3. The product life cycle is short and the maintenance cost is high.

[0004] With the development of the times and the continuous improvement of the transportation industry, the industry is paying more and more attention to the entire life cycle and maintenance and use costs of containers. It has become an inevitable trend to improve the use efficiency of products, extend the use cycle, reduce maintenance costs, reduce their own weight, and improve the efficiency of loading goods, and adopt new materials and new structures.

[0005] On September 24, 2024, a search was conducted in the Chinese Patent Publication Database with "container and magnesium and cuttings and light and lifting" as the abstract keywords, and the option of allowing synonym expansion was checked, but no relevant literature was found.

[0006] On September 24, 2024, an abstract search for "container and magnesium and cuttings and light and lifting" was conducted on China National Knowledge Infrastructure, and no relevant literature was found.

[0007] On September 24, 2024, a search was conducted on the website of the United States Patent and Trademark Office for "Container with Magnesium with Cutting with Lightwith Hoisting", and no relevant literature was found; the search URL was https: / / ppubs.uspto.gov / pubwebapp / .

[0008] On September 24, 2024, a search was conducted on the Korean Patent Office for "Container and Magnesium and Cutting and Light and Hoisting" at the search URL http: / / eng.kipris.or.kr / enghome / main.jsp. A document was found that is not related to this patent. The document is: SYSTEMS AND METHODS FOR FORMINGA LAYER ONTO A SURFACE OF A SOLID SUBSTRATE AND PRODUCTS FORMED THEREBY.

[0009] On September 24, 2024, a search was conducted on WIPO’s https: / / patentscope2.wipo.int / for “Container and Magnesium and Cutting and Light and Hoisting”.

[0010] On September 24, 2024, a search was conducted on the Japan Patent Office website https: / / www.j-platpat.inpit.go.jp / for "Container and Magnesium and Cutting and Light and Hoisting", but no relevant literature was found.

[0011] The conception of this patent is completely different.

[0012] Among them: the defects of these technologies are: 1. Steel materials are easy to rust and corrode, and the production anti-rust requirements are high; the anti-rust coating is damaged during transportation and installation, and the anti-rust ability is reduced. 2. The finished product is heavy and the loading efficiency is low. 3. The product life cycle is short and the maintenance cost is high. Summary of the invention

[0013] Purpose of the invention: To provide a method for preparing a reinforced magnesium alloy lightweight cargo container with better effect. The specific purpose can be seen in the multiple substantial technical effects in the specific implementation part.

[0014] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0015] Option 1: A lightweight cargo container made of reinforced magnesium alloy; the core is the mechanical structure;

[0016] Solution 2: A method for preparing a lightweight cargo container made of a reinforced magnesium alloy; the core is the preparation method;

[0017] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0018] Solution 1:

[0019] A reinforced magnesium alloy lightweight cargo container, characterized in that the cargo container is composed of a main frame, a wall plate, a bottom plate, a top plate and a door;

[0020] The main frame is welded from a hollow profile with multiple slots, and connected inserts made of high-strength steel or high-strength composite materials are inserted into the inner cavity of the corner hollow profiles;

[0021] The hollow profile is magnesium alloy;

[0022] Insertion-type reinforcement strips are provided in multiple slots of the main frame;

[0023] The wall panels, bottom panels and top panels are assembled and welded from hollow profiles and panels, including corrugated panels and honeycomb panels;

[0024] The main frame, the wall panels, the bottom panel and the top panel form a hexahedral structure as a whole, and one or more openings are arranged on any one side of the hexahedral structure;

[0025] The opening may be completely open, or may be closed by a door manufactured using the same standards and materials as the container body.

[0026] A further technical solution of the present invention is that the inserted insert is a reinforced insert structure, which is firmly connected at the eight top corners of the container;

[0027] Lifting holes are provided on the connections or welded joints at each corner, in the end and side directions of the container, and at the ends of the upper longitudinal beam and the upper long cross beam.

[0028] A further technical solution of the present invention is that the eight vertices formed by the reinforced insert structure are provided with vertices and top plate sheaths welded from high-strength steel plates;

[0029] The top corner roof sheathing structure is as follows: the end guard plate and the side guard plate are arranged at right angles, and the end guard plate and the side guard plate are each welded to the bottom lower roof plate;

[0030] Includes square stack centering holes 77 on the bottom lower top plate;

[0031] Circular holes matching the size and position of the lifting holes of the reinforcing insert structure are arranged on each of the side guard plates and the bottom lower top plate;

[0032] It also includes a sheath 45, which is welded with a block structure. The sheath 45 is cylindrical, and the diameter of the sheath 45 is the same as that of the circular hole. The length of the sheath 45 is adapted to the depth of the lifting hole of the reinforcing insert structure.

[0033] The top plate, guard plate and sheath are connected into a whole by welding.

[0034] A further technical solution of the present invention is that it also includes an insert 42, which is connected to the reinforcing insert structure and the corner reinforcing corner 43 in a centering manner, and the hanging hole is a reference for assembly centering.

[0035] A further technical solution of the present invention is that the main frame includes columns, upper long cross beams, upper longitudinal beams, top plate longitudinal supports, lower long cross beams, lower longitudinal beams, side wall transverse supports and longitudinal supports, end transverse supports and longitudinal supports, and bottom plate transverse supports and longitudinal supports.

[0036] A further technical solution of the present invention is that more than zero welding wings are arranged on the profile of the main frame, and when there are multiple welding wings, they are located on different sides of the profile.

[0037] A further technical solution of the present invention is that the material of the inserted strip is high-strength steel or fiber-reinforced composite material.

[0038] A further technical solution of the present invention is that the inserted insert is an insert with an inclined surface or an insert without an inclined surface; and both sides of the inserted insert are provided with hanging holes or are not provided with hanging holes.

[0039] A further technical solution of the present invention is that the panels of the wall panels, bottom panels, top panels and doors are any one or more of magnesium alloy panels, magnesium alloy corrugated panels and magnesium alloy honeycomb panels.

[0040] A further technical solution of the present invention is that as much dry quartz powder or river sand as possible is poured into the gap between the inserted strip and the inner cavity of the profile, that is, the slot, and the end of the slot is blocked with asbestos yarn or asbestos cloth.

[0041] Option 2:

[0042] A method for preparing a reinforced magnesium alloy lightweight cargo container, characterized in that the magnesium alloy lightweight cargo container is composed of a main frame, a wall plate, a bottom plate, a top plate and a door;

[0043] The main frame is welded from hollow profiles with multiple slots;

[0044] The hollow profile is magnesium alloy;

[0045] The magnesium alloy is added with a plurality of metal elements including rare earth;

[0046] The content of some elements is as follows: La, Ce or La+Ce 0.10-0.35%wt, yttrium (Y) 0.15-4.5%wt, gadolinium (Gd) 0.0-2.5%wt, aluminum (Al) 0.0-6.5%wt, zinc (Zn) 0.60-6.0%wt, manganese (Mn) 0.20-45%wt, tin (Sn) 0.0-1.5%wt; the balance is magnesium alloy;

[0047] The alloy of the above composition is made into rods by semi-continuous casting after protective melting; after casting, it is subjected to homogenization heat treatment, removal of surface oxide layer, preheating before extrusion, cutting to length after extrusion, post-annealing heat treatment, temporary surface protective coating or moisture-proof / rust-proof packaging, and standby.

[0048] A further technical solution of the present invention is that the profile is extruded by a horizontal extruder in a hot state, and the extrusion ratio is controlled between 8 and 120, which is a reinforced and rigid hot extruded profile; the extrusion temperature is determined comprehensively based on the composition of the rod and the parameters of the extruder, and the extrusion speed is controlled to be above 2.5 meters / minute. In addition to normal traction, additional cooling measures are applied at the discharge port of the extruder. The cooling measures are to use bottled industrial-grade high-pressure nitrogen through a pressure reducing valve, and spray it at a certain angle and flow rate to a certain side of the outlet profile to achieve a faster cooling speed to ensure that the extruded profile is not oxidized, smooth / straight, has no surface damage, and has no excessive distortion or bending deformation.

[0049] A further technical solution of the present invention is that the main frame is welded from 12 edge magnesium alloy profiles, each edge cavity is penetrated with an ultra-high strength steel or fiber composite material insert to connect / weld the overall structure, and each side is also provided with transverse and longitudinal magnesium alloy profiles as support.

[0050] A further technical solution of the present invention is that the inserted strips are firmly connected at each corner of the container, and are connected by welding or gluing to form an integral structure; if carbon fiber or other high-performance fiber composite material strips are used as the strips, a gluing method is required, and standard-sized lifting holes are provided on the welding or connecting joints at each corner in the end and side directions of the container, at the ends of the upper longitudinal beam and the upper long cross beam. The strip welding is carried out after the welding of the magnesium alloy structure of the container body is completed, and the strip welding positions need to be machined at both ends of the four long cross beam profiles in advance; finally, local grinding, polishing, passivation and painting are performed.

[0051] A further technical solution of the present invention is that insert-type insert strips are arranged in the inner cavities of multiple profiles of the main frame;

[0052] The wall panels, bottom panels and top panels are assembled and welded from hollow profiles and plates;

[0053] The main frame, the wall panels, the bottom panel and the top panel form a hexahedral structure as a whole, and one or more openings are arranged on any one side of the hexahedral structure;

[0054] The opening may be completely open, or may be closed by a door manufactured using the same standards and materials as the container body.

[0055] The present invention adopting the above technical scheme has the following beneficial effects compared with the prior art: the main frame of the patent is welded by hollow profiles with multiple closed cavities, all edges of the main frame are provided with inserted ultra-high strength steel or carbon fiber composite material reinforcement structures, and the wall panels are assembled and welded by hollow profiles and plates with closed cavities. The container can be used for constant temperature containers, powder lightweight cargo containers (such as the transportation of coal, concentrate, raw grains and processed grain products), accommodation containers, etc.; it is suitable for truck container flatbeds, railway container flatbeds, air transport, and ocean container cargo ships for loading and use. The container's own weight is reduced by 35% to 50%, which can significantly increase the payload, realize green, energy-saving and environmentally friendly transportation, reduce carbon emissions, and improve economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In order to further illustrate the present invention, the following is further described in conjunction with the accompanying drawings:

[0057] Figure 1 The main frame diagram;

[0058] Figure 2 It is a schematic diagram of the cross section of the column profile: with adjacent side welded wings;

[0059] Figure 3 magnesium alloy profiles for the columns and high-strength steel or composite inserts;

[0060] Figure 4 It is a schematic diagram of the upper and lower longitudinal beams and long cross beam insertions;

[0061] Figure 5 It is a structural diagram of the support section without welded wings;

[0062] Figure 6 It is a braced section with welded wings on one side;

[0063] Figure 7 It is a braced section with welded wings on both sides;

[0064] Figure 8 This is a cross-section of the upper long beam: the lower part has welded wings;

[0065] Fig. 9 It is the middle cross beam section: with welded wings on both sides;

[0066] Fig.10 It is the lower long beam section: the upper part has welded wings;

[0067] Fig.11 It is a schematic diagram of the horizontal and longitudinal beam insertions;

[0068] Fig.12 For the support bar profile section: no welded wings;

[0069] Fig.13 For the support bar profile section: with welded wings on one side;

[0070] Fig.14 For the support bar section: with welded wings on both sides;

[0071] Fig.15 To enhance the schematic diagram of the insert location and weld joint;

[0072] Fig.16 and Fig.17 for Fig.15 A magnified view of the local structure;

[0073] Fig.18 It is a schematic diagram of the welding relationship between the long cross beam of the chassis and the longitudinal support or column profile;

[0074] Fig.19 This is a schematic diagram of the welding details at the top corner;

[0075] Fig. 20 It is a schematic diagram of the welding position of each insert;

[0076] Fig.21 This is a schematic diagram of a container with double-side doors (2 doors);

[0077] Fig. 22 This is a schematic diagram of multiple doors on the side (6 doors);

[0078] Fig.23 It is a top-opening container;

[0079] Fig.24 Schematic diagram for composite material cutting design;

[0080] Fig.25 It is a schematic diagram of the connection relationship of the composite material insert reinforcement;

[0081] Fig.26 reinforce the structural high-strength steel top plate and jacket for composite inserts / high-strength steel inserts;

[0082] Fig. 27 Schematic diagram of inserts (ultra-high strength steel) and blocks: from left to right: column insert No. 1; column insert No. 2; upper and lower longitudinal beam inserts; upper and lower long cross beam inserts; and blocks.

[0083] Among them: 1. Column; 2. Middle support; 3. Upper longitudinal beam; 4. Upper long cross beam; 5. Top plate longitudinal support; 6. Upper top plate; 7. End door; 8. End door control mechanism; 9. Side wall; 10. Side wall transverse support; 11 Lower long cross beam; 12 Top angle welding structure; (for stacking positioning structure and hoisting structure); 13. Column profile outer wall; 14. Column profile No. 1 slot; 15. Column profile inner rib; 16. Column profile side welding wing; 1 7. Slot 1 for column profile; 18. Welding wings on both sides of column profile; 19. Slot No. 2 for column profile; 21 Lifting hole; 22. Column insert No. 2; 23. Column insert No. 1; 24. Insert insert; 41. Top corner of container; 42. Inlay; 43. Corner reinforcement corner; 44. Side guard plate; 45. Cover; 50. Door operating lever self-locking head; 51. Door operating lever; 75. Top corner stacking centering surface; 77. Square hole in the middle of the stacking surface. DETAILED DESCRIPTION

[0084] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. In the description of the present invention, it should be noted that the orientation or position relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", "top", "bottom", etc. is based on the orientation or position relationship shown in the accompanying drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or a metallurgical connection; it can be directly connected, or indirectly connected through an intermediate medium, or it can be a connection between two or more components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0085] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0086] This patent provides a variety of parallel solutions. The different expressions are improved solutions or parallel solutions based on the basic solution. Each solution has its own unique characteristics. In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other. The fixing method not described in the text can be any fixing method such as riveting, bolting or gluing.

[0087] A reinforced magnesium alloy cargo container and a method for manufacturing the same. The lightweight container is made of a high-strength deformable magnesium alloy and a small amount of ultra-high-strength steel or fiber composite material for reinforcement and stiffening. The structure consists of five parts: a main frame, a wall panel, a bottom panel, an end panel, a top panel and a door.

[0088] The various components constituting the main frame include columns, upper long crossbeams, upper longitudinal beams, top plate longitudinal supports, lower long crossbeams, lower longitudinal beams, side wall transverse supports and longitudinal supports, end transverse supports and longitudinal supports, bottom plate transverse supports and longitudinal supports, door frames, etc. The cross-sectional shapes and sizes of the magnesium alloy profiles of different components are different according to functions, stress conditions, connection methods and geometric positions.

[0089] The pillars and other structures are made of high-strength magnesium alloy profiles, and high-strength or ultra-high-strength steel inserts are inserted into the internal cavity of the pillar profiles. The cross-section design of each profile is as follows: Figure 2-Figure 14 As shown:

[0090] The reinforcing insert structure is characterized by: (1) being made of the same ultra-high strength material, such as ultra-high strength steel or fiber-reinforced composite material; (2) each insert is firmly connected at each corner of the container, such as by welding, to form an integral structure; if carbon fiber or other high-performance fiber composite strips are used as inserts, a gluing method is required; (3) standard-sized lifting holes are provided on the welded joints at each corner, in the end and side directions of the container, at the ends of the upper longitudinal beam and the upper long cross beam; (4) the insert welding is carried out after the magnesium alloy structure of the container body is welded, and the insert welding positions need to be machined at both ends of the four long cross beam profiles in advance; and finally, local grinding, polishing, passivation and painting are performed.

[0091] The eight top corners formed by the welding / gluing structure of the inserts are provided with top corner roof plate sheaths welded from high-strength steel plates. The top plate is made of 8-25mm thick steel plates, with a square stacking positioning hole at the center. The guard plate is made of 3-15mm thick high-strength steel plates, with a round hole matching the size and position of the insert hoisting hole at the center, and a sheath of the same material with the same diameter as the round hole. The thickness of the sheath is 3-8mm, and the length is adapted to the depth of the hoisting hole after the inserts are welded and glued. The top plate, guard plate and sheath are connected into a whole by welding. It should be noted that these welds are performed in situ after the welding / gluing of the inserts is completed. Afterwards, grinding, polishing, passivation and painting are carried out for final protection. The top plate, guard plate, sheath and their relative positions are as follows Fig.26 shown.

[0092] Example 1: As a standard container for standard gauge railway flatbed cars, a standard container for road trucks, and a container used for transporting bulk goods such as general non-bulk steel and non-coarse block ore, ultra-high strength steel 40Cr, in hot-rolled state or in a quenched and tempered state after rolling, is used as a cutting strip and assembled and manufactured in the following order:

[0093] (1) AZ32M magnesium alloy semi-continuous casting rods are selected and subjected to homogenization heat treatment to prepare various profiles, plates, corrugated plates and / or honeycomb plates, such as column profiles, beam profiles, etc., and the preparatory work is carried out such as precise cutting, processing of welding grooves, cutting of windows for insert welding, and plates for sealing welding windows. The outer wall thickness of each profile is 3.5-5.0 mm, and the internal rib thickness is 2.5-3.5 mm. The original plate thickness of the corrugated plate is 1.5-3.5 mm, and the structural thickness after being pressed into the corrugated plate is 55-75 mm. The magnesium alloy panel thickness of the honeycomb plate is 1.5-2.5 mm, and the original foil thickness of the honeycomb core is 0.02-0.06 mm. The material can be selected from conventional aluminum alloy. The total thickness of the structure of the honeycomb plate is 10-25 mm. The appearance dimensions of each profile are defined by the container design drawings; the appearance dimensions of the magnesium alloy plate, magnesium alloy corrugated plate, and magnesium alloy honeycomb plate are also defined by the container design drawings. The welding material, i.e. the welding wire, is made of AZ31B magnesium alloy hot extruded welding wire, or is made of hot extruded material that is completely homogeneous with the profile or plate.

[0094] (2) After the above 40Cr inserts are accurately cut, pre-drill lifting holes at the determined positions at both ends of the long beam, with a diameter slightly smaller than the final lifting holes;

[0095] (3) Insert the prepared insert into the corresponding inner hole of the profile and adjust the length of the exposed head; the welding material of the insert shall be selected in accordance with the numbering requirements of the national standard for 45Cr steel welding.

[0096] (4) Pour as much dry quartz powder or river sand as possible into the gap between the insert and the profile cavity, and block the end with asbestos yarn or asbestos cloth to prevent the powder from leaking out;

[0097] (5) According to the above assembly and welding process, the magnesium alloy container body is assembled and welded; the TIG process is used, and after sufficient cooling after welding, inspection and calibration are carried out;

[0098] (6) Solder the inserts in the following order:

[0099] (a) The column inserts and long beam inserts are as follows: Figure 7 Welding is carried out in the relative positions shown, and the welding of the 8 top corner lifting holes and the stacking centering structure is completed in sequence, requiring full penetration.

[0100] (b) The relative position of the welding between the column insert No. 2 and the insert in the middle of the long beam insert is as follows: Fig.26 .

[0101] (7) Weld the top and bottom square top plates (container stacking contact, centering and reversing positioning devices) with the same material as the inserts, and open a square positioning hole in the middle of the top plate; trim the lifting holes and positioning holes.

[0102] (8) Grind, polish and passivate all external surfaces, and then paint and print after thorough drying.

[0103] Embodiment 2: This embodiment is applied to a container with a side door. Fig.21 and Fig. 22 shown.

[0104] (1) Prepare various magnesium alloy profiles and process the ends. At the same time, prepare basic materials such as inserts, inserts, top plates, and guard plates. Except for the side walls and doors, the rest are the same as in Example 1;

[0105] (2) Assemble and weld the main frame, inserts and panels, and assemble and weld the two end walls, including strengthening the longitudinal support strips;

[0106] (3) Assemble and weld the left and right side walls according to the design requirements. The two side doors can be set in the middle of the length direction of the side walls, and the door size is based on the design requirements. The door operating levers can be set for each door or multiple doors according to the design requirements. Multiple groups of doors or multiple doors can also be set, and they do not necessarily have to be set as double doors.

[0107] (4) Inspection, calibration, polishing, painting, printing

[0108] Embodiment 3: It is a top-opening container. This embodiment is suitable for loading fine powders that are not easy to flow. The unloading method is a tipping or overturning pouring mode, such as Fig.23 shown.

[0109] Example 4: Carbon fiber composite material as reinforcement insert

[0110] Magnesium alloy structure cargo containers are made of carbon fiber composite materials, basalt fiber composite materials, or S glass fiber composite materials as reinforcing inserts, and the inserts are finally aligned, bonded and cured after being inserted into the corresponding profile cavity, and are integrated with the magnesium alloy profile welding frame. The lifting holes are made by fiber winding, and it is absolutely forbidden to use mechanical drilling methods to process the lifting holes. Plastic blocks of the same material as the composite matrix polymer material are used as inserts, and the inserts are connected to the inserts and corner reinforcement corners in the same way as the inserts. The lifting holes are the centering reference.

[0111] The magnesium alloy container reinforced with composite material inserts will further reduce the weight by 120-250kg compared with the container with high-strength steel inserts.

[0112] The stacking centering mechanism at the eight corner tops is made of high-strength steel. It uses upper and lower top plates, end guard plates and side guard plates welded to the top plates, and cylindrical sleeves welded to the guard plates and closely bonded to the wall of the lifting holes. The top plates and guard plates are connected to the composite material plug connection mechanism by bonding.

[0113] Embodiment 5: A reinforced magnesium alloy cargo container and a manufacturing method thereof, using high-strength magnesium alloy profiles and plates, and welding and assembling them into the above-mentioned lightweight cargo container, the specific method is as follows:

[0114] Step 1: Prepare high-strength magnesium alloy: Select high-quality advanced magnesium alloy and use mature technology to prepare dense cast bars with dimensions matching the design requirements of the profile in step 2, such as using a semi-continuous casting method, and then undergo pre-heat treatment, such as homogenization heat treatment, to prepare the internal microstructure for hot extrusion or rolling;

[0115] Step 2: Prepare profiles, plates, corrugated plates or honeycomb plates: prepare magnesium alloy profiles by hot extrusion, and prepare magnesium alloy plates by hot rolling or hot extrusion + hot rolling; make some plates into corrugated plates and / or honeycomb plates; accurately cut profiles and plates according to the size specifications of the required lightweight cargo container; customize the high-strength steel inserts and homogeneous high-strength steel inserts for reinforcement, stacking top plates and positioning square holes in the center of the top plates according to design parameters;

[0116] Step three, assembly and welding: Assemble and weld the profiles, plates and corrugated plates cut in step two on a steel workbench. First, insert high-strength steel inserts into the columns and upper and lower long beams and longitudinal beams, assemble and weld them into the main frame, and then assemble and weld the magnesium alloy structure in the order of columns, beams, side door frames, and finally bottom plates, side wall panels, front and rear end panels (including end door frames); then weld the ends of the high-strength steel inserts to form a hanging structure with eight corner welded steel structures, forming lifting holes on both sides and both ends, stacking top plates at the top and bottom, and square positioning holes in the center; then install each door that has been assembled and welded individually into place through the hinge rivet structure;

[0117] Step 4: Protective treatment of the insert: First, grind and polish the welded joints and processed holes of the insert, use commercial or homemade passivation liquid for spraying or brushing passivation, clean with water, blow with dry gas, dry, and apply anti-rust paint; pour dried alumina fine powder, quartz powder, or ground river sand fine powder, or any other dry powder that does not chemically react with the insert steel and magnesium alloy profile into the gap between the insert and the magnesium alloy profile cavity where the insert is located;

[0118] Step 5. Overall protection: After completing the welding and assembly, check the form and position tolerances, make local shape corrections as needed, drill holes (bolt holes or rivet holes) at the locations that need to be installed and opened, grind and polish all the inner and outer surfaces and side edges of the container structure, as well as all the outer surfaces of the door leaves, passivate them, use putty to level and polish the locations that need to be leveled, then spray primer, spray topcoat and print, then spray protective paint, topcoat and spray or print patterns and text; install doors and other plug-ins after all paints are fully dry.

[0119] Embodiment 5: Its main structure is divided into a main frame, a reinforcement structure, a bottom plate, side walls and front and rear end plates, a top plate and a plurality of double-leaf doors, and these structures are manufactured by melting welding; wherein the reinforcement structure is formed by inserting a strip structure made of ultra-high-strength steel into the interior of the main frame profile, and welding it separately to be inlaid with the main frame.

[0120] Example 7: Corrugated boards and / or honeycomb boards are used in the side walls, end walls or top / bottom panel walls. The corrugated boards are made by cutting magnesium alloy hot-rolled plates or extruded plates into a certain length and hot pressing or cold pressing in a special mold to form the required corrugated boards with a certain overall thickness, width and length.

[0121] Embodiment 8: A honeycomb panel using a magnesium alloy panel is used in the side wall, end wall or top / bottom panel wall. The honeycomb panel is composed of two plates of the same length and width and the same or different thicknesses, each of which is passivated on one side and then coated with glue, with the two glue-coated surfaces facing each other, and a honeycomb core is pasted in the middle. The honeycomb core can be a honeycomb core made of magnesium alloy, aluminum alloy or other materials with certain heat resistance. The magnesium alloy or aluminum alloy honeycomb core can be a bonded honeycomb core or a welded honeycomb core; the welding method can be brazing or fusion welding.

[0122] Embodiment 9: The main frame is made of a high-strength magnesium alloy through hot extrusion into a hollow profile, the cross-sectional size and shape of the hollow profile are specially designed according to the specific position and function of the profile in the main frame, especially the force characteristics, and have different overall sizes and structural details, including the shape of the inner cavity, the internal rib structure and the corresponding arc transition;

[0123] Embodiment 10: It is a closed frame, embedded in the twelve corners of the main frame, and connected by welding at eight corners; each edge is composed of an insert inserted into the cavity of the edge profile; the insert is made of ultra-high strength steel, which is hot-rolled, heat-treated (such as quenching and tempering) and machined at the end; the welding process can be arc welding (such as TIG, MIG) or laser welding, and local annealing heat treatment (such as electromagnetic induction heating annealing) is performed after welding, and then two sides of the eight corners are punched (see Figure 4 ).

[0124] Embodiment 11: A welded insert reinforcement system, wherein the weld positions are arranged as follows: the lower portions of both ends of the long cross beam insert are welded to the top end surface of column insert No. 1; the two end surfaces of the longitudinal beam insert are welded to the side surfaces of the end portions of column insert No. 2; the inclined surfaces of the end portions of the column insert are welded to the inclined surfaces of the inserts; and the right-angle surfaces of the inserts are welded to the inward-facing side surfaces of both ends of the long cross beam inserts.

[0125] Example 12: In addition to the inner hole, internal ribs, outer wall and other structures of the profile, a welding wing is provided on the side of the wall panel (such as corrugated board, honeycomb board, etc.) that needs to be connected by welding in the direction of the inner wall. The thickness of the welding wing matches the thickness of the plate (such as corrugated board, honeycomb board, etc.) to be welded and connected. Usually, its thickness can be 0.5 to 2.0 mm larger than the plate to be connected, and the height can be 2 to 10 times the thickness. The length is consistent with the length of the profile, but adaptive processing and modification must be performed before welding to meet the requirements of the overall wall panel.

[0126] Embodiment 13: After the welding and assembly are completed, the entire container structure and its door panels are subjected to shape and position correction, grinding and polishing, chemical passivation, and spraying with two or more layers of organic paint for permanent protection to ensure that the container can be in long-term safe service.

[0127] Embodiment 14: The core of this embodiment is a structure in which a reinforcement part is inserted into the middle of a hollow profile, which can greatly increase the strength of the container. A reinforced magnesium alloy lightweight cargo container, characterized in that the cargo container is composed of a main frame, a wall panel, a bottom panel, a top panel and a door;

[0128] The main frame is welded from hollow profiles with multiple slots;

[0129] The hollow profile is magnesium alloy;

[0130] Insert strips are provided in a plurality of slots of the main frame;

[0131] The wall panels, bottom panels and top panels are assembled and welded from hollow profiles and plates with slots;

[0132] The main frame, the wall panels, the bottom panel and the top panel form a hexahedral structure as a whole, and one or more openings are arranged on any one side of the hexahedral structure;

[0133] The opening may be completely open, or may be closed by a door manufactured using the same standards and materials as the container body.

[0134] In general, the main frame of this patent is welded from hollow profiles with multiple closed cavities, all edges of the main frame are equipped with inserted ultra-high-strength steel or carbon fiber composite material reinforcement structures, and the wall panels are assembled and welded from hollow profiles and plates with closed cavities. The container can be used for constant temperature containers, powder lightweight cargo containers (such as the transportation of coal, concentrate, raw grains and processed grain products), accommodation containers, etc.; it is suitable for truck container flatbeds, railway container flatbeds, and ocean container ships for loading and use. The container's own weight is reduced by 30-40%, which can significantly increase the payload, achieve green, energy-saving and environmentally friendly transportation, reduce carbon emissions, and improve economic and social benefits.

[0135] Example 15: La 0.10 wt%, yttrium (Y) 4.5% wt, gadolinium (Gd) 2.5% wt, aluminum (Al) 6.5% wt, zinc (Zn) 0.60% wt, manganese (Mn) 0.20% wt, tin (Sn) 1.5% wt; the remainder is magnesium alloy;

[0136] Example 16: La+Ce 0.35% wt, yttrium (Y) 0.15 wt, gadolinium (Gd) 0.5% wt, aluminum (Al) 5% wt, zinc (Zn) 6.0% wt, manganese (Mn) 45% wt, tin (Sn) 0.5% wt; the remainder is magnesium alloy;

[0137] Example 17: Ce 0.2% wt, yttrium (Y) 0.3% wt, gadolinium (Gd) 1% wt, aluminum (Al) 4% wt, zinc (Zn) 4% wt, manganese (Mn) 8% wt, tin (Sn) 1% wt; the balance is magnesium.

[0138] Container material structure strength index and unit mass table

[0139] Container material / structure tensile / bending strength table

[0140]

[0141] Note 1: Q235 is a commonly used steel material for standard containers

[0142] Note 2: AZ80M is a modified and upgraded version of the high-strength magnesium alloy AZ80

[0143] Note 3: 40Cr is a commonly used ultra-high strength low alloy steel

[0144] Note 4: Welding refers to the welding process that is particularly suitable for this alloy

[0145] The basic principle, main features and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the protection required.

Claims

1. A method for preparing a reinforced magnesium alloy lightweight cargo container, characterized in that: The magnesium alloy lightweight cargo container consists of a main frame, wall panels, bottom panels, top panels and doors; The main frame is welded from hollow profiles with multiple slots; The hollow profile is magnesium alloy; The magnesium alloy is added with metal elements including at least aluminum, zinc, manganese, zirconium, and especially rare earths; the alloy of the above components is made into rods by semi-continuous casting after protective smelting; after casting, it is subjected to homogenization heat treatment, removal of surface oxide layer, preheating before extrusion, cutting to length after extrusion, post-annealing heat treatment, temporary surface protective coating or moisture-proof / rust-proof packaging, and standby.

2. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 1, characterized in that: The profile is extruded by a horizontal extruder in a hot state, and the extrusion ratio is controlled between 8 and 120. It is a reinforced hot extruded hollow profile. The extrusion temperature is determined by the composition of the rod and the parameters of the extruder. The extrusion speed is controlled at more than 2.5 meters per minute. In addition to normal traction, additional cooling measures are applied at the discharge port of the extruder. The cooling measures are to use bottled industrial-grade high-pressure nitrogen through a pressure reducing valve and spray it at a certain angle and flow rate on one side of the outlet profile to achieve a faster cooling speed to ensure that the extrusion is not oxidized, smooth / straight, without surface damage, and without excessive distortion or bending deformation.

3. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 1, characterized in that: The main frame is welded from 12 edge magnesium alloy profiles. Ultra-high-strength steel or fiber composite material inserts are inserted into the inner cavity of each edge and connected / welded to form an overall structure. Each side is also provided with transverse and longitudinal magnesium alloy profiles as reinforcement support.

4. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 1, characterized in that: The inserted strips are firmly connected at each corner of the container, and are connected by welding or gluing to form an integral structure; if carbon fiber or other high-performance fiber composite strips are used as strips, gluing method is required. On the welded joints at each corner, on the end and side of the container, on the ends of the upper longitudinal beam and the upper long cross beam, standard-sized lifting holes are set. The strip welding is carried out after the welding of the magnesium alloy structure of the container body is completed. The strip welding positions need to be machined at both ends of the four long cross beam profiles in advance; finally, local grinding, polishing, passivation and painting are carried out.

5. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 1, characterized in that: Insertion strips are arranged in multiple slots of the main frame; the wall panels, bottom panels and top panels are assembled and welded from hollow profiles and plates with slots; the main frame, wall panels, bottom panels and top panels form a hexahedral structure as a whole, and one or more openings are arranged on any one side of the hexahedral structure; The opening may be completely open, or may be closed by a door manufactured using the same standards and materials as the container body.

6. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 5, characterized in that: The inserted inserts are reinforced insert structures that are securely connected at the eight top corners of the container; Lifting holes are provided on the welded joints at each vertex, in the end and side directions of the container, and at the ends of the upper longitudinal beam and the upper long cross beam.

7. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 5, characterized in that: The eight vertices formed by the reinforced insert structure are provided with vertices and top plate sheaths welded from high-strength steel plates; The top corner roof sheathing structure is as follows: the end guard plate and the side guard plate are arranged at right angles, and the end guard plate and the side guard plate are each welded to the bottom lower roof plate; A square stack centering hole (77) is included on the bottom lower top plate; Circular holes matching the size and position of the lifting holes of the reinforcing insert structure are arranged on each of the side guard plates and the bottom lower top plate; It also includes a sheath (45), which is welded into a block structure to form the top corner of the container. The sheath (45) is cylindrical and has the same diameter as the circular hole. The length of the sheath (45) is adapted to the depth of the lifting hole of the reinforcing strip structure. The top plate, guard plate and sheath are connected into a whole by welding.

8. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 5, characterized in that: It also comprises an insert (42), which is centrally connected with the reinforced insert structure and the corner reinforced corner (43), and the hanging hole is the reference for assembly centering.

9. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 5, characterized in that: The contents of some elements are as follows: La, Ce or La+Ce 0.10-0.35% wt, yttrium (Y) 0.15-4.5% wt, gadolinium (Gd) 0.0-2.5% wt, aluminum (Al) 0.0-6.5% wt, zinc (Zn) 0.60-6.0% wt, manganese (Mn) 0.20-45% wt, tin (Sn) 0.0-1.5% wt; the balance is magnesium.

10. The method for preparing a reinforced magnesium alloy lightweight cargo container according to claim 5, characterized in that: The insert strips are made of high-strength steel and fiber-reinforced composite materials.

Images