Lightweight design method suitable for plastic plate-shaped structure and lightweight structure

Abstract

The invention discloses a lightweight design method suitable for a plastic plate-shaped structure and a lightweight structure, and the method comprises the steps: carrying out the structural region division of geometric features of a carrier structure based on historical matching data, and configuring different supporting structures for functional regions generated through division according to the matching scheme of the supporting structures; setting a compression resistance simulation monitoring mode, carrying out hierarchical testing on the compression resistance of different functional areas, carrying out statistics on compression resistance test data of different functional areas, carrying out stability analysis on the compression resistance test data to obtain a compression resistance stability coefficient, and if the compression resistance stability coefficient is greater than or equal to the compression resistance stability coefficient in historical matching data, determining that the compression resistance is greater than or equal to the compression resistance stability coefficient in the historical matching data. If yes, the matching scheme of the carrier structure and the supporting structure, the compression resistance test data and the compression resistance stability coefficient are stored, historical matching data are obtained, and otherwise, the number and the size of the compression resistance units in the plate-shaped area are adjusted till the compression resistance stability coefficient is larger than or equal to the compression resistance stability coefficient in the historical matching data.

Description

Technical Field

[0001] The present invention relates to the technical field of plastic lightweight design, and particularly to a lightweight design method and a lightweight structure suitable for plastic plate-like structures. Background Art

[0002] With the development of technology and the increasing demand for lightweight in the plastic industry, plastic plates gradually replace traditional materials such as metals and glasses due to their advantages of low density, easy processing, and controllable cost. However, the lightweight design of plastic plates still needs to solve core problems such as strength, cost, and process feasibility. It is gradually analyzed from the following aspects: one is the optimized design and application of materials, the second is the development and application of advanced manufacturing technologies, and the third is the optimized design of product structures; As is well known, both the optimized design and application of materials and the development and application of advanced manufacturing technologies are basic means to achieve plastic lightweighting. However, neither of these two points can improve the lightweight effect of the existing target plastic plates in a short time, and the stability of materials in experiments and the durability of long-term use need to be considered. Even if the R & D team has developed suitable improved plastics, they cannot be quickly used in production, that is, they cannot meet the current needs of users; Therefore, the current lightweight design of target plastic plates mainly relies on thinning + local reinforcement to optimize the product structure. The main problems lie in how to balance performance, cost, and sustainability while reducing weight. The process window of thin-wall injection molding is narrow, and the yield affects the cost; complex bionic units (such as hollowed-out vein designs) rely on high-precision molds, resulting in a sharp increase in cost.

[0003] In view of this, the present invention provides a lightweight design method and a lightweight structure suitable for plastic plate-like structures to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a lightweight design method and a lightweight structure suitable for plastic plate-like structures to solve the problems in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions: In the first aspect, the present invention provides a plastic plate-like lightweight structure, including: The carrier structure is a target hollow shell with a first wall thickness; functional regions are divided inside the target hollow shell, and the functional regions include an edge region, a transition region, and a plate-like region; A support structure, different stress support units are configured for the target hollow shell in different functional regions, including: Bionic units, vertically stacked between the edge regions, are used to improve the edge rigidity and connection stability of the target hollow shell; Honeycomb cells, vertically stacked within the transition region, are used to relieve the concentrated stress from the edge region to the plate-like region; Compressive units, horizontally embedded in the plate-like region, are used to construct a three-dimensional support framework and improve the spatial load-bearing capacity of the carrier structure.

[0006] As a preferred technical solution of the first aspect of the present invention, the bionic unit includes: A plug-in disk, with multiple plug-in holes provided on its upper end face; Plug-in joints, respectively forming a male-female plug-in structure with the multiple plug-in holes; Multiple meridian nodes, with a central axis meridian provided at their centers, and the position of the meridian nodes is determined based on the central axis meridian; derivative meridians are provided on the periphery of the central axis meridian, and the target hollow shell and the meridian nodes are fixedly connected based on the derivative meridians.

[0007] As a preferred technical solution of the first aspect of the present invention, the honeycomb cell includes: A honeycomb connection end, used to connect the target hollow shell in the transition region; A honeycomb main body, arranged between two honeycomb connection ends; A honeycomb array frame, vertically stacked within the honeycomb main body; A honeycomb support unit, used to fix adjacent honeycomb array frames.

[0008] As a preferred technical solution of the first aspect of the present invention, the compressive unit includes: A vertical compression ring, in the shape of a closed rectangle-like frame, with an arc shape provided at the edge of the rectangle-like frame, and vertically fixedly installed along the height direction of the plate-like region; A horizontal compression ring, in the shape of a closed rectangle-like frame, with an arc shape provided at the edge of the rectangle-like frame, and vertically fixedly installed along the length direction of the plate-like region; it orthogonally forms a space frame with the vertical compression ring; A horizontal tension rod, in the shape of a rod, horizontally penetrates and connects the vertical compression ring and the horizontal compression ring along the length direction of the plate-like region, and is used for connecting adjacent horizontal compression rings.

[0009] In a second aspect, the present invention provides a lightweight design method suitable for plastic plate-like structures, used for the design of the first aspect, including the following steps: Step S1: Based on historical matching data, perform structural region division on the geometric features of the carrier structure, extract functional regions, and configure different support structures for the functional regions; Step S2: Set a compressive simulation monitoring mode, conduct staged tests on the compressive capacities of different functional regions, statistically analyze the compressive test data of different functional regions, and perform stability analysis on the compressive test data to obtain a compressive stability coefficient. Step S3: If the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the historical matching data, store the matching scheme, compressive test data, and compressive stability coefficient to obtain the historical matching data. Otherwise, adjust the number and size of the compressive units in the plate-shaped area until the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the historical matching data.

[0010] As a preferred technical solution of the second aspect of the present invention, the logic of configuring different support structures for the functional areas is as follows: Step S11: Determine the target hollow shell with the first wall thickness based on the grid design model; take the inner edge interface of the target hollow shell as the reference plane, and the functional area with the second wall thickness in the vertical direction along the reference plane is the edge area, and modularize the bionic units in the edge area; Step S12: Take the inner edge interface of the edge area as the reference plane, and the functional area with the third wall thickness in the vertical direction along the reference plane is the transition area, and adjust the support ratio of the honeycomb units in the transition area, where the support ratio is the occupied space of the honeycomb support units in the honeycomb array frame; Step S13: Configure at least one compressive unit in the remaining space area inside the inner cavity of the target hollow shell according to the load distribution, and adjust the number and size of the compressive units in the plate-shaped area according to the bearing capacity.

[0011] As a preferred technical solution of the second aspect of the present invention, the modular layout logic of the bionic units is as follows: According to the boundary position information of the edge area, determine the radial cross-sectional information and longitudinal cross-sectional information of the meridian node; based on the radial cross-sectional information, determine the radial length of the meridian node; based on the longitudinal cross-sectional information, determine the depth value of the meridian node, Take the ratio of the maximum radial length to the depth value in the meridian node as the first ratio; characterize the meridian distribution mode based on the first ratio; If the first ratio is less than or equal to the expected threshold, set A meridian nodes and set a central meridian at the center of each meridian node; If the first ratio is greater than the expected threshold, set A + B meridian nodes, set a central meridian at the center of each meridian node, build derivative meridians along the periphery of the central meridian, determine the number of derivative meridians based on the meridian distribution map, and optimize the distribution of the derivative meridians.

[0012] As a preferred technical solution of the second aspect of the present invention, the adjustment logic of the transition area: Based on prior knowledge, determine the expected scale spacing D1 of the transition area, and calculate the vertical distance from the transition area to the boundary position information as the first distance; Mark the transition region with the first distance less than the expected scale spacing D1 as the concentrated transition region, conduct a concentrated diversion design for the honeycomb cells in the concentrated transition region, determine the size of the honeycomb cells in the honeycomb array frame as M, and fill 2N honeycomb support units in the honeycomb cells. The honeycomb support units include N cross-reinforcing rib unit structures and N sleeve unit structures, and distribute the N cross-reinforcing rib unit structures staggered around the N sleeve unit structures; Mark the transition region with the first distance greater than or equal to the expected scale spacing D1 as the slow-release transition region, conduct a slow-release diversion design for the honeycomb cells in the slow-release transition region, determine the size of the honeycomb cells in the honeycomb array frame as 2M, and fill the honeycomb support units with N sleeve unit structures in the honeycomb cells.

[0013] As a preferred technical solution of the second aspect of the present invention, the design logic of the compression-resistant unit is: Based on the compression-resistant unit, construct a compression-resistant layout diagram, and use finite element simulation analysis to measure the stress values and structural deformation trends of the vertical compression ring, horizontal compression ring, and horizontal tie rod under loading conditions; According to the stress value and the change trend of the deformation amount, extract the sensitivity of each structural unit to the overall bearing capacity as a quantitative index for adjusting the influence degree. The higher the sensitivity, the greater the influence on the overall structure after adjustment; With the goal of minimizing the change in the overall sensitivity, and on the premise of meeting the target compression-resistant stability coefficient, preferentially adjust the parameters of the structural units with lower sensitivity to optimize the configuration of the compression-resistant unit and achieve the optimal determination of the quantity and size of the vertical compression ring, horizontal compression ring, and horizontal tie rod.

[0014] As a preferred technical solution of the second aspect of the present invention, the acquisition logic of the compression-resistant stability coefficient: Based on the historical matching data, extract the matching scheme of the carrier structure and the support structure, the compression-resistant test data, and the compression-resistant stability coefficient; pre-number the matching scheme of the carrier structure and the support structure, extract the historical matching scheme number, and form a matching feature data set; Extract the compression-resistant test data of each group of matching schemes. The compression-resistant test data includes: ultimate pressure value, deformation curve, and failure mode; conduct feature engineering processing on the compression-resistant test data and extract feature influence factors; Construct a machine learning model, use the matching feature data in the matching feature data set as the input of the machine learning model, and the machine learning model uses the feature influence factor as the output of the machine learning model; Obtain the influence degree of each feature influence factor on the ultimate pressure value, and normalize and accumulate the influence degree to obtain the compression-resistant stability coefficient; Taking the compressive stability coefficient in the history matching data as the prediction target, and minimizing the sum of the prediction errors of all real-time compressive stability coefficients as the training target; training the machine learning model until the sum of the prediction accuracies reaches convergence and then stopping the training.

[0015] In the above technical solution, the technical effects and advantages provided by the present invention are as follows: Through the functional area division and support structure configuration of the carrier structure based on the history matching data, combined with compressive simulation monitoring and stability analysis, the present invention can perform hierarchical optimization configuration for different functional areas, dynamically evaluate and adjust the layout of compressive units, and achieve precise control of the compressive performance of the target plastic plate and lightweight balance; at the same time, by continuously accumulating and updating the matching data, a closed-loop structure design for sustainable optimization and intelligent iteration is established, significantly improving the overall structural stability, durability and design efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings.

[0017] Figure 1 Schematic diagram of the overall structure of the lightweight structure of the present invention.

[0018] Figure 2 Schematic diagram of the overall structure of the lightweight structure with a hollow structure of the present invention.

[0019] Figure 3 Cross-sectional view of the lightweight structure of the present invention.

[0020] Figure 4 Schematic diagram of the cross-sectional connection of the lightweight structure of the present invention.

[0021] Figure 5 Schematic diagram of the structure of the bionic unit of the present invention.

[0022] Figure 6 Schematic diagram of the structure of the honeycomb unit of the present invention.

[0023] Figure 7 Schematic diagram of the structure of the special-shaped honeycomb unit of the present invention.

[0024] Figure 8 Schematic diagram of the structure of the compressive unit of the present invention.

[0025] Figure 9 Flowchart of a lightweight design method suitable for plastic plate-like structures of the present invention.

[0026] Description of reference numerals: 100, carrier structure; 110, edge region; 120, transition region; 130, plate-shaped region; 140, hollow region; 200. Support structure; 210, bionic unit; 211, plug-in plate; 2111, plug-in hole; 212, plug-in connector; 213, meridian node; 214, central axis meridian; 215, derived meridian; 220, honeycomb unit; 221, honeycomb connection end; 222, honeycomb body; 223, honeycomb array frame; 224, honeycomb support unit; 230, compression unit; 231, vertical compression ring; 232, transverse compression ring; 233, transverse pull rod. DETAILED DESCRIPTION

[0027] Example embodiments will now be described more fully with reference to the accompanying drawings. However, example embodiments can be implemented in a variety of forms and should not be construed as limited to the examples set forth herein; rather, these example embodiments are provided so that the description of the present disclosure will be more comprehensive and complete and the concepts of the example embodiments will be fully conveyed to those skilled in the art. The accompanying drawings are only schematic illustrations of the present disclosure and are not necessarily drawn to scale. The same reference numerals in the figures represent the same or similar parts, and thus their repeated description will be omitted.

[0028] In addition, the described features, structures or characteristics may be combined in one or more example embodiments in any suitable manner. In the following description, many specific details are provided to provide a full understanding of the example embodiments of the present disclosure. However, those skilled in the art will appreciate that the technical solutions of the present disclosure may be practiced while omitting one or more of the specific details, or methods, components, steps, etc. In other cases, well-known structures, methods, implementations or operations are not shown or described in detail to avoid obscuring various aspects of the present disclosure.

[0029] Example 1 like Figure 3-4 As shown, the present invention provides a plastic plate-like lightweight structure, including a carrier structure 100 with a support structure 200; the carrier structure 100 is a load-bearing platform at the upper and lower ends, and the support structure 200 is a mechanical functional unit. The support structure 200 is arranged on the carrier structure 100 as needed according to the stress requirements of different functional areas on the carrier structure 100, reflecting the structure-function matching principle.

[0030] The carrier structure 100 is a target hollow shell obtained by shelling a target plastic plate, which is used to provide the geometric profile and bearing foundation of the target plastic plate, and is a target hollow shell with a first wall thickness; different support structures 200 are selected and adapted to support inside the carrier structure 100 according to the change of functional areas; functional areas are arranged inside the carrier structure 100, and the functional areas include an edge area 110, a transition area 120 and a plate area 130. The support structure 200 is a reinforcement support structure in the carrier structure 100 for specific functional areas, which is used to improve the overall mechanical properties, such as compressive, bending and impact resistance. The support structure 200 includes a bionic unit 210, a honeycomb unit 220 and a compressive unit 230; specifically as follows: For the edge area 110, taking the inner edge interface of the target hollow shell as the reference plane, the edge demarcation line of the target hollow shell is located within the plastic plate and / or the hollowed-out area 140 on the plastic plate. It is a functional area with a second wall thickness in the direction perpendicular to the reference plane. Local plane coordinates are arranged on the reference plane to determine the length direction and the height direction. A plurality of bionic units 210 are evenly distributed in the length direction, and the cross-sectional size of the bionic unit 210 is configured according to the second wall thickness. The bionic meridian shape of the bionic unit 210 is simulated in the height direction; The bionic unit 210 is used to enhance the impact resistance of the corners. It adopts the entire plastic plate surface to enhance the external bending stiffness and support strength, and prevent the plate surface from sagging or bending under load. The bionic units 210 are fixedly connected between the upper and lower edge areas 110 to improve the edge rigidity and connection stability; such as Figure 4 The columnar module that simulates the plant meridians in the figure can be used as the connecting column between the edge areas 110. The bionic meridian shape of the bionic unit 210 is determined according to the height value between the edge areas 110. A plurality of bionic units 210 are evenly distributed in the length direction, and the cross-sectional size of the bionic unit 210 is configured according to the first width. The continuous support structure of natural plant stems or bones is simulated in the edge area 110.

[0031] Specifically, the bionic unit 210 includes: A plug-in disk 211, including: a plurality of plug-in holes 2111; A plug-in joint 212, which respectively forms a male-female plug-in structure with a plurality of plug-in holes 2111; the application of the male-female plug-in structure not only enables the bionic unit 210 to be plugged into the edge area 110, but also enables a plurality of bionic unit 210 units to be stably connected vertically, realizing modular connection.

[0032] A plurality of meridian nodes 213, with a central axis meridian 214 arranged at the center thereof, and the position of the meridian node 213 is determined based on the central axis meridian 214; a derivative meridian 215 is arranged on the periphery of the central axis meridian 214, and the target hollow shell and the meridian node 213 are fixedly connected based on the derivative meridian 215; Each meridian segment 213 forms an independently adjustable and supportable module segment. According to the configured meridians on the meridian segment 213, the meridians include a central axis meridian 214 and derivative meridians 215. The central axis meridian 214 is an enhanced meridian such as a thick rib, and the derivative meridians 215 are flexible meridians such as wavy rib patterns or through-hole types, etc., for adjusting local stiffness or buffering capacity. It should be noted that: By combining vertical multi-segment bionic segments, high-strength and lightweight columnar units are formed, which are suitable for use as edge reinforcement connectors, anti-collision support structures or functional support columns. For example Figure 4 As shown, in this embodiment, only the circular meridian is used to illustrate the meridian shape. By using a modular stacking and connecting plug-in design of multiple meridian segments 213, a highly bionic and engineering-realizable support structure form is presented. However, in actual applications, the meridian shape is not fixed. Referring to the force transmission mode of the veins - leaf veins in nature, a multi-objective performance of lightweight, high strength, and flexibility is achieved. Among them: The shape of the bionic unit 210 simulates the central axis structure of the main leaf vein of a plant, dividing several meridian segments 213 to form a structural module segmented control unit. On each meridian segment 213, according to its function and location, different meridians are configured, and the meridian shape is optimized according to the load distribution path, which can be straight, curved, S-shaped or bifurcated; such as: enhanced high rigidity, buffer flexible connection, connection type for plugging.

[0033] The configuration logic of the meridian shape is as follows: Multiple derivative meridians 215 extending from the central axis meridian 214 assist the force transmission path, simulating the branched radial structure of real plant leaf veins. Each leaf vein structure extends radially and connects to the internal support frame or edge frame of the carrier structure 100. The geometric parameters of the leaf vein structure, such as thickness, length, and bending radius, can be optimized and adjusted according to the load path or stress concentration area; it can be connected to the bionic unit 210 by co-injection molding in one piece or by plugging, improving the overall connection stiffness and flexible buffering capacity; a "rib - film composite force - dividing network" is formed between the leaf vein structure and the bionic unit 210, sharing the structural stress concentration points and effectively avoiding structural rupture or warping.

[0034] The transition region 120 is set between the edge region 110 and the plate - like region 130. Taking the inner edge interface of the edge region 110 as the reference plane, it is a functional region with a third wall thickness in the direction perpendicular to the reference plane. Local planar coordinates are laid out on the reference plane to determine the length direction and height direction. A plurality of honeycomb units 220 are evenly distributed in the length direction, and the cross - sectional size of the honeycomb units 220 is configured according to the third wall thickness, and the height layout of the honeycomb units 220 is determined in the height direction. Specifically, as Figure 6 shown, the honeycomb unit 220 includes: The cellular connection end 221 is the upper and lower boundary member of the cellular unit 220, which defines the size of the cellular unit 220 and seamlessly connects the transition region 120 to achieve module connection between the internal cellular array frames 223 and provide stable end force support; The cellular main body 222 is arranged between two cellular connection ends 221; The cellular array frame 223 is vertically stacked in the cellular main body 222 in multiple layers; it is formed by integral injection molding or segmented plugging, with high compressive and shear resistance performance, and high material utilization rate.

[0035] The cellular support unit 224 is used to fix adjacent cellular array frames 223 and further enhance the out-of-plane support ability; it is a reinforcing rib, sleeve, cross support or transverse fixing rod, which plays a role in strengthening the connection between cellular arrays, restricting deformation and evenly dispersing loads.

[0036] It should be noted that: the common cellular core adopts a hexagonal grid structure, but the cellular unit 220 shown in actual applications is not limited to this shape, such as Figure 6 shown, in this embodiment, the circular cellular column is taken as the specific manifestation form, but in actual applications, it can also be as Figure 7 shown, an irregular cellular column.

[0037] As long as it is a cellular grid, specifically, the cellular unit 220 is used in the transition region 120 of the plastic plate-like lightweight structure and is applicable to the area that bears vertical loads and needs to keep the change of the plate thickness stable. Through the dense arrangement of the cellular array, the stress dispersion and uniform force transmission inside the structure are realized, and at the same time, the material consumption is greatly reduced, achieving the lightweight design goal.

[0038] The plate-like area 130 is the main load-bearing area of the plastic plate. At least one compressive unit 230 is embedded in the plate-like area 130 according to the bearing needs. In addition, heat conduction holes, heat sinks, and buffer materials are integrated on the plate-like area 130 to achieve a high degree of multi-function integration; The compressive unit 230 includes a vertical pressure ring 231, a horizontal pressure ring 232, and a horizontal tension rod 233. The vertical pressure ring 231; as Figure 8 shown, where: The vertical pressure ring 231 is in a closed elliptical or approximately rectangular shape, and multiple vertical pressure rings 231 are arranged along the vertical direction of the upper and lower plate-like areas 130; it bears the vertical pressure on the upper plate surface, that is, the vertical load, improves the overall compressive resistance of the structure, and prevents the plate surface from collapsing under pressure.

[0039] The horizontal compression ring 232 is in a closed elliptical or approximately rectangular shape. Along the horizontal direction of the upper and lower plate-like regions 130, that is, the horizontal load; it is orthogonal or intersects with the vertical compression ring to form a spatial framework; it plays the role of dispersing the horizontal component force and assisting in bending resistance, and improves the stability under transportation vibration or eccentric load conditions.

[0040] The horizontal tie rod 233 is in a slender rod shape and is inserted and connected between multiple vertical compression rings 231 and horizontal compression rings 232; it plays the role of horizontal restraint and tension sharing, preventing the structure from bulging or separating under load; it is arranged in pairs or symmetrically to stabilize the existing skeleton system.

[0041] It should be noted that: as Figure 3 shown, the compression unit 230 is applicable to the inside of the plastic plate-like member, and is modularly arranged in the internal space of the plate-like region 130. By reasonably arranging multiple units, a high-strength compression unit matrix is formed, which can not only bear high-strength concentrated loads, but also has good bending resistance and anti-deformation characteristics.

[0042] When the plastic plate is a complete plate-like structure, as Figure 1 shown, the carrier structure 100 includes three parts, namely the edge region 110, the transition region 120, and the plate-like region 130; among them: the plate-like region 130 is a complete plate. In this case, only the corner impact resistance of the edge region 110, the stress relief ability of the transition region 120, and the load-bearing capacity of the plate-like region 130 need to be considered. The bionic unit 210 is set in the edge region, and the honeycomb unit 220 is set in the transition region 120. According to the comprehensive evaluation of specific application scenarios, load distribution, and process conditions, the layout of the honeycomb unit 220 and the bionic unit 210 is set. The compression unit 230 forms a high-strength compression unit matrix by reasonably arranging multiple units, which can not only bear high-strength concentrated loads, but also has good bending resistance and anti-deformation characteristics.

[0043] When the plastic plate is a plate-like structure with at least one hollow region 140, as Figure 2As shown in the figure, the carrier structure 100 includes three parts, namely the edge area 110, the transition area 120, the plate-like area 130 and the hollowed-out area 140. Among them: An edge is formed around the hollowed-out area 140. The edge area 110 and the transition area 120 are respectively arranged along the hollowed-out area 140 and extend to the plate-like area 130 through the transition area 120. Their other functions are the same, but here the plate-like area 130 is a special-shaped plate, and this situation is more applicable to the actual application scenario. The hollowed-out area 140 can obtain more types of plastic plates. In this case, it is necessary to consider not only the impact resistance of the corners of the edge area 110, but also the stress deformation ability of the edge area 110. According to the specific application scenario, load distribution and process conditions, a comprehensive evaluation is carried out to set the layout of the honeycomb unit 220 and the bionic unit 210. The compressive unit 230 is composed of a plurality of units arranged reasonably to form a high-strength compressive unit matrix, which can not only bear high-strength concentrated loads, but also have good bending resistance and anti-deformation characteristics.

[0044] Embodiment 2 For the plastic plate-like lightweight structure described in Embodiment 1, during the actual production process, to ensure the structural accuracy and assembly reliability, the support structure 200 corresponding to each functional area needs to be highly coordinated with the mold structure. The specific mold implementation method is as follows: In this embodiment, a multi-cavity combined mold cavity layout is used to construct a target hollow shell with a first wall thickness. Taking the target hollow shell as the carrier structure 100, the edge area 110, the transition area 120 and the plate-like area 130 are divided according to the distance from the multi-cavity combined mold cavity; and by reasonably configuring the gate position and the cooling channel, uniform molding and warpage control of the overall structure of the plastic part are realized, and the connection accuracy between the support structure and the carrier structure is ensured to meet the assembly requirements.

[0045] The bionic unit 210 in the edge area 110 adopts a segmented slider or insert design. Each meridional segment 213 realizes modular demolding through the corresponding slider insert unit. The central axis meridian 214 and the derived meridians 215 are consistent with the mold demolding direction according to the longitudinal unfolding direction, thereby avoiding side core pulling and improving the mold stability.

[0046] Since the honeycomb unit 220 in the transition area 120 has a periodic unit structure, it is formed by an integrated cavity. Its honeycomb connection end 221 is located at the upper and lower mold joint surface, and its boundary contour is controlled by an insert provided in the mold. A honeycomb array frame 223 is vertically stacked inside the honeycomb body 222, and honeycomb support units 224 are arranged vertically between adjacent honeycomb array frames 223 to facilitate mold cavity exhaust and filling; if the honeycomb unit has a special-shaped structure, an auxiliary lifter mechanism can be set in its support unit to avoid molding interference.

[0047] The compressive unit 230 in the plate-shaped region 130 is a multi-layer nested space frame structure, in which the vertical compression ring 231 and the horizontal compression ring 232 are arranged orthogonally and are both arranged along the main demolding direction Z-axis of the mold, suitable for integral injection molding; the horizontal tie rod 233 is formed by a pre-embedded sliding mandrel or a side core-pulling mechanism to ensure its penetration and structural integrity. When necessary, the insert replacement method can be considered for module assembly to improve the structural maintainability and mold processing flexibility.

[0048] Embodiment 3 As Figure 9 shown, the parts not described in detail in this embodiment are as described in Embodiment 1. This embodiment provides a lightweight design method suitable for plastic plate-shaped structures, a target plastic plate with functional zoning, especially suitable for the lightweight design of structures such as trays, plates, panels, and bases; including the following steps: Step S1: Based on the historical matching data, perform structural area division on the geometric features of the carrier structure 100, extract the functional areas, and configure different support structures 200 for the functional areas; It should be noted that: taking the three-dimensional model of the target plastic plate as the target plastic plate, the target hollow shell obtained by performing shelling on the target plastic plate, taking the target hollow shell with the first wall thickness as the carrier structure 100, and the support structure 200 for supporting the carrier structure 100; Specifically, the logic of configuring different support structures 200 for the functional areas is as follows: Step S11: Determine the target hollow shell with the first wall thickness based on the grid design model; taking the inner edge interface of the target hollow shell as the reference plane, the functional area with the second wall thickness in the direction perpendicular to the reference plane is the edge area 110, and modularize the bionic unit 210 within the edge area 110; It should be noted that: the grid design model is a three-dimensional model that can read the target plastic plate; based on the grid design model of the target plastic plate, spatial data extraction is performed on the carrier structure 100. By identifying the set of grid nodes around the internal cavity or non-solid area of the grid design model, the inner edge interface of the target hollow shell corresponding to the outer boundary and the opening boundary is extracted; after obtaining the outer boundary and the opening boundary, deduce inward from the outer boundary and the opening boundary to determine the boundary position information of the edge area 110.

[0049] The position information of the opening boundary is the hollow area 140 existing in the carrier structure 100. In principle, the corresponding stress requirements for the outer boundary and the edge area 110 of the opening boundary are different. The conventional setting is to set the scale of the edge area 110 correspondingly. However, during the actual printing process by the operator, different-size processing technologies are adopted in the same mechanism, which requires higher design requirements for the mold and the operator. In addition, although the corresponding edge stress requirements and loads of the hollow area 140 are greatly reduced compared with the outer boundary, there are still certain technical barriers in production. Therefore, in this embodiment, the technical personnel make a unified setting for the edge area 110 and the bionic unit 210.

[0050] More specifically, the modular layout logic of the bionic unit 210 is as follows: According to the boundary position information of the edge area 110, determine the radial cross-section information and longitudinal cross-section information of the meridional segment 213; based on the radial cross-section information, determine the radial length of the meridional segment 213; based on the longitudinal cross-section information, determine the depth value of the meridional segment 213. Take the ratio of the maximum radial length to the depth value in the meridional segment 213 as the first ratio; based on the first ratio, characterize the meridional distribution mode. If the first ratio is less than or equal to the expected threshold, the structure of the meridional segment 213 is relatively thick and has a small span. Set A meridional segments 213, and set a central axis meridian 214 at the center of each meridional segment 213. If the first ratio is greater than the expected threshold, the structure of the meridional segment 213 has a large span and a small depth. Set B meridional segments 213, and set a central axis meridian 214 at the center of each meridional segment 213. Build derivative meridians 215 along the periphery of the central axis meridian 214. Determine the number of derivative meridians 215 based on the meridional distribution map, and optimize the distribution of the derivative meridians 215. The central axis meridian 214 and the derivative meridians 215 are different manifestation states of the meridians. Based on the meridional distribution map constructed by the manifestation states of the meridians, determine the manifestation states of the multiple meridians, and use the manifestation degree to characterize the load-bearing pressure value of each meridian in each meridional segment 213, where the quantities of A and B are obtained from prior knowledge or a machine learning model and are adjusted manually according to the actual situation.

[0051] Step S12: Taking the inner edge interface of the edge area 110 as the reference plane, the functional area with the third wall thickness in the vertical direction of the reference plane is the transition area 120. Adjust the support ratio of the honeycomb unit 220 in the transition area 120, where the support ratio is the occupied space of the honeycomb support unit 224 in the honeycomb array frame 223. It should be noted that a buffer zone is set between the edge region 110 and the plate-like region 130 to form a transition region 120. The transition region 120 is used to relieve the stress gradient change between the edge and the internal structure. The vertical distance from the grid unit in the transition region 120 to the demarcation position information is calculated to adjust the support ratio of the honeycomb unit 220. The support ratio is the proportion of the honeycomb support unit 224 in the honeycomb array frame 223; its width can be adjusted according to the structural support ratio.

[0052] Specifically, the adjustment logic of the transition region 120 is as follows: Based on prior knowledge, the expected scale spacing D1 of the transition region 120 is determined, and the vertical distance from the transition region 120 to the demarcation position information is calculated as the first distance; The transition region 120 with the first distance less than the expected scale spacing D1 is marked as the concentrated transition region. In the concentrated transition region, a concentrated guidance design is carried out for the honeycomb unit 220. The size of the honeycomb cell in the honeycomb array frame 223 is determined as M, and 2N honeycomb support units 224 are filled in the honeycomb cell. The honeycomb support unit 224 includes N cross-reinforcing rib unit structures and N sleeve unit structures. The N cross-reinforcing rib unit structures are staggered around the N sleeve unit structures; The transition region 120 with the first distance greater than or equal to the expected scale spacing D1 is marked as the slow-release transition region. In the slow-release transition region, a slow-release guidance design is carried out for the honeycomb unit 220. The size of the honeycomb cell in the honeycomb array frame 223 is determined as 2M, and the honeycomb support unit 224 with N sleeve unit structures is filled in the honeycomb cell, and the other parts are reserved as cavities or provided with flexible connection units to improve the local flexibility and energy absorption capacity.

[0053] Through the differential honeycomb unit design, the transition region 120 can realize stress concentration guidance or slow release according to the local stress state, so as to improve the lightweight level and durability of the overall target plastic plate.

[0054] Step S13: At least one compressive unit 230 is configured in the remaining space region of the internal cavity of the target hollow shell according to the load distribution, and the number and size of the compressive units 230 are adjusted in the plate-like region 130 according to the bearing capacity; Specifically, the design logic of the compressive unit 230 is as follows: Based on the compressive unit, a compressive layout diagram is constructed, and the stress values and structural deformation trends of the vertical compression ring 231, the horizontal compression ring 232, and the horizontal tie rod 233 under the loading condition are measured by finite element simulation analysis; According to the stress value and the change trend of the deformation amount, the sensitivity of each structural unit to the overall bearing capacity is extracted as a quantitative index for adjusting the influence degree. The higher the sensitivity, the greater the influence on the overall structure after adjustment; With the goal of minimizing the change in overall sensitivity, on the premise of meeting the target compressive stability coefficient, the parameters of the structural units with lower sensitivity are preferentially adjusted to optimize the configuration of the compressive unit 230, so as to achieve the optimal determination of the quantity and size of the vertical compression rings 231, the horizontal compression rings 232 and the horizontal tie rods 233.

[0055] A sample is provided for illustration. Based on SolidWorks or ANSYS, a three-dimensional compressive layout diagram of the complete plate-like area 130 and the compressive unit 230 is established. The compressive layout diagram includes the vertical compression rings 231, the horizontal compression rings 232 and the horizontal tie rods 233; the loading condition is to apply a vertical uniform load or a concentrated load to the compressive layout diagram to simulate the gravity, impact or stacking pressure in the actual use scenario; Through a finite element analysis module such as ANSYS Static Structural, the compressive layout diagram is meshed and statically simulated, and the following are extracted: the stress values and the structural deformation trends of each vertical compression ring 231, horizontal compression ring 232 and horizontal tie rod 233 under the loading condition. The structural deformation trend is obtained through simulation calculation of the displacement field, the maximum deformation amount and the stress concentration area distribution of each component node; the change in the maximum deformation amount before and after perturbation is used as an indication of the change in compressive capacity, and the change amount of compressive capacity is established and the structural deformation trend of the functional relationship. The sensitivity index of the structural unit is calculated by this function, and then its adjustment influence degree is quantified, providing a data basis for subsequent optimization; Set the perturbation variables of ±10% size or quantity change for each vertical compression ring 231, horizontal compression ring 232 and horizontal tie rod 233, and record their influence sensitivity on the change amount of the compressive capacity of the three-dimensional compressive layout diagram. The change amount of compressive capacity is the ultimate load or stability. The formula for the influence sensitivity is: ; Among them, is the influence sensitivity of the th structural unit; is the change amount of compressive capacity caused by the adjustment of the th structural unit, usually represented by the change value of the ultimate load , which is a quantification of the change in the overall compressive capacity of the structure. In lightweight design, the compressive capacity can be judged whether the structure is qualified by meeting the maximum deformation threshold ; for the perturbed structure (such as a 10% reduction in the thickness of a certain compression ring), the maximum displacement , an indication quantity characterizing the change in compressive capacity is represented by a functional relationship between the maximum displacement and the maximum deformation threshold, and the change in compressive capacity is defined as ; ; is the relative change degree of the structural quantity of the th structural unit. The relative change degree is the normalized expression of the change quantity of the structural quantity, which is used as a weight factor affecting the sensitivity set by normalizing the structural quantity unit or engineering experience; is the relative change degree of the structural size of the th structural unit. The relative change degree is the normalized expression of the change quantity of the structural size, which is used as a weight factor affecting the sensitivity set by normalizing the structural quantity unit or engineering experience.

[0056] The greater the influence sensitivity, the greater the impact of its adjustment on the system, and it is preferred to maintain stability; the units with smaller sensitivity are preferably included in the optimization. Using heuristic algorithms such as genetic algorithms or response surface optimization methods, under the premise of meeting the target compressive stability coefficient, the parameters of the low-sensitivity units are iteratively optimized to output the optimal configuration scheme that meets the performance requirements, that is, the optimal quantity and size combination of the vertical compression ring 231, the horizontal compression ring 232, and the horizontal tie rod 233.

[0057] Step S2: Set the compressive simulation monitoring mode, conduct staged tests on the compressive capacities of different functional areas, statistically analyze the compressive test data of different functional areas, and perform stability analysis on the compressive test data to obtain the compressive stability coefficient; Specifically, the acquisition logic of the compressive stability coefficient: Extract the matching scheme, compressive test data, and compressive stability coefficient of the carrier structure 100 and the support structure 200 based on historical matching data; pre-number the matching schemes of the carrier structure 100 and the support structure 200, and extract the historical matching scheme numbers to form a matching feature dataset; Extract the compressive test data of each group of matching schemes. The compressive test data includes: ultimate pressure value, deformation curve, and failure mode; perform feature engineering processing on the compressive test data to extract feature influence factors; Construct a machine learning model, use the matching feature data in the matching feature dataset as the input of the machine learning model, and the machine learning model takes the feature influence factor as the output of the machine learning model; Obtain the influence degree of each feature influence factor on the ultimate pressure value, and normalize and accumulate the influence degree to obtain the compressive stability coefficient; Taking the compressive stability coefficient in the history matching data as the prediction target and minimizing the sum of the prediction errors of all real-time compressive stability coefficients as the training target; training the machine learning model until the sum of the prediction accuracies reaches convergence and then stopping the training.

[0058] Step S3: If the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the history matching data, store the matching scheme, the compressive test data, and the compressive stability coefficient to obtain the history matching data; otherwise, adjust the quantity and size of the compressive units 230 within the plate-shaped area 130 until the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the history matching data.

[0059] An embodiment of the present invention provides a lightweight design method suitable for plastic plate-like structures, which is used to design a plastic plate-like lightweight structure provided in the above embodiments of the present invention. An embodiment of the specific method and process of the corresponding functions of each structure in the plastic plate-like lightweight structure is provided here and will not be elaborated further.

[0060] Only some exemplary embodiments of the present invention have been described by way of illustration above. Undoubtedly, for those of ordinary skill in the art, without departing from the spirit and scope of the present invention, the described embodiments can be modified in various different ways. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the protection scope of the claims of the present invention.

Claims

1. A plastic plate-shaped lightweight structure, characterized in that: include: The carrier structure (100) is a target hollow shell having a first wall thickness; functional areas are divided inside the target hollow shell, the functional areas comprising an edge area (110), a transition area (120) and a plate-shaped area (130); The support structure (200) configures different stress support units for the target hollow shell in different functional areas, including: A bionic unit (210) is vertically stacked between the edge regions (110) and is used to improve the edge rigidity and connection stability of the target hollow shell; The honeycomb unit (220) is vertically stacked in the transition area (120) and is used to relieve the concentrated stress from the edge area (110) to the plate-shaped area (130); The compression-resistant unit (230) is embedded in the plate-shaped area (130) along the horizontal direction, and is used to construct a three-dimensional support frame to improve the spatial load-bearing capacity of the carrier structure (100).

2. A plastic plate-shaped lightweight structure according to claim 1, characterized in that: The bionic unit (210) comprises: A plug-in plate (211), the upper end surface of which is provided with a plurality of plug-in holes (2111); The plug connector (212) and the plurality of plug holes (2111) respectively form a male and female plug structure; A plurality of meridian nodes (213) are provided at the center of which a central axis meridian (214) is provided, and the location of the meridian node (213) is determined based on the central axis meridian (214); a derived meridian (215) is provided on the periphery of the central axis meridian (214), and the target hollow shell and the meridian node (213) are fixedly connected based on the derived meridian (215).

3. A plastic plate-shaped lightweight structure according to claim 1, characterized in that: The honeycomb unit (220) comprises: A honeycomb connection end (221) for connecting to a target hollow shell in a transition region (120); A honeycomb body (222) is arranged between two honeycomb connection ends (221); A honeycomb array frame (223) is vertically stacked inside the honeycomb body (222); The honeycomb support unit (224) is used to fix adjacent honeycomb array frames (223).

4. A plastic plate-shaped lightweight structure according to claim 1, characterized in that: The pressure-resistant unit (230) comprises: The vertical pressure ring (231) is in the form of a closed rectangular frame, with an arc-shaped portion provided at the edge of the rectangular frame, and is vertically fixedly installed along the height direction of the plate-shaped region (130); The transverse pressure ring (232) is in the form of a closed rectangular frame, with an arc-shaped portion at the edge of the rectangular frame, and is vertically fixedly installed along the length direction of the plate-shaped area (130); and is orthogonal to the vertical pressure ring (231) to form a spatial frame; The transverse pull rod (233) is rod-shaped and penetrates and connects the vertical pressure ring (231) and the transverse pressure ring (232) along the length direction of the plate-shaped area (130), and is used for connecting adjacent transverse pressure rings (232).

5. A method suitable for lightweight design of plastic plate-like structures, used for designing a plastic plate-like lightweight structure as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: Step S1: dividing the geometric features of the carrier structure (100) into structural regions based on historical matching data, extracting functional regions, and configuring different support structures (200) for the functional regions; Step S2: Set the compression simulation monitoring mode, and perform a staged test on the compression capacity of different functional areas, collect the compression test data of different functional areas, perform stability analysis on the compression test data, and obtain the compression stability coefficient. Step S3: If the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the historical matching data, the matching scheme, the compressive test data and the compressive stability coefficient are stored to obtain the historical matching data; otherwise, the number and size of the compressive units (230) in the plate-shaped area (130) are adjusted until the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the historical matching data.

6. A lightweight design method suitable for plastic plate-like structures according to claim 5, characterized in that: The logic of configuring different support structures (200) for functional areas is: Step S11: determining a target hollow shell having a first wall thickness based on a grid design model; taking an inner edge interface of the target hollow shell as a reference plane, a functional region having a second wall thickness in a direction perpendicular to the reference plane as an edge region (110), and modularly arranging the bionic unit (210) in the edge region (110); Step S12: taking the inner edge interface of the edge region (110) as a reference plane, and the functional region having a third wall thickness in a direction perpendicular to the reference plane as a transition region (120), and adjusting the support ratio of the honeycomb unit (220) in the transition region (120), wherein the support ratio is the space ratio of the honeycomb support unit (224) in the honeycomb array frame (223); Step S13: configuring at least one pressure-resistant unit (230) in the remaining space area of ​​the internal cavity of the target hollow shell according to the load distribution, and adjusting the number and size of the pressure-resistant units (230) in the plate-shaped area (130) according to the load-bearing capacity.

7. A lightweight design method suitable for plastic plate-like structures according to claim 6, characterized in that: The modular layout logic of the bionic unit (210) is: Determine radial section information and longitudinal section information of the meridian node (213) based on the boundary position information of the edge region (110); determine the radial length of the meridian node (213) based on the radial section information; determine the depth value of the meridian node (213) based on the longitudinal section information, Taking the ratio of the maximum radial length to the depth value in the meridian node (213) as a first ratio; characterizing the meridian distribution pattern based on the first ratio; If the first ratio is less than or equal to the expected threshold, A meridian nodes (213) are set, and a central axis meridian (214) is set at the center of each meridian node (213); If the first ratio is greater than the expected threshold, A+B meridian nodes (213) are set, and a central meridian (214) is set at the center of each meridian node (213), and derived meridians (215) are built around the central meridian (214). The number of derived meridians (215) is determined based on the meridian distribution map, and the distribution of the derived meridians (215) is optimized.

8. A lightweight design method suitable for plastic plate-like structures according to claim 7, characterized in that: The adjustment logic of the transition area (120) is: Determine the expected scale spacing D1 of the transition area (120) based on prior knowledge, and calculate the vertical distance from the transition area (120) to the boundary position information as a first distance; The transition area (120) where the first distance is less than the expected scale spacing D1 is marked as a concentrated transition area, a concentrated drainage design is performed on the honeycomb unit (220) in the concentrated transition area, the size of the honeycomb cell in the honeycomb array frame (223) is determined to be M, and 2N honeycomb support units (224) are filled in the honeycomb cell, wherein the honeycomb support unit (224) includes N cross-reinforced rib unit structures and N sleeve unit structures, and the N cross-reinforced rib unit structures are staggered and distributed around the N sleeve unit structures; A transition region (120) in which the first distance is greater than or equal to the expected scale spacing D1 is marked as a slow-release transition region, a slow-release drainage design is performed on the honeycomb unit (220) in the slow-release transition region, the size of the honeycomb cell in the honeycomb array frame (223) is determined to be 2M, and N honeycomb support units (224) of a sleeve unit structure are filled in the honeycomb cell.

9. A lightweight design method suitable for plastic plate-like structures according to claim 8, characterized in that: The design logic of the pressure-resistant unit (230) is: A compression layout diagram is constructed based on the compression unit, and a finite element simulation analysis is used to determine the stress values ​​and structural deformation trends of the vertical compression ring (231), the transverse compression ring (232) and the transverse tie rod (233) under loading conditions; According to the trend of stress value and deformation, the sensitivity of each structural unit to the overall bearing capacity is extracted as a quantitative indicator of the adjustment impact. The higher the sensitivity, the greater the impact on the overall structure after adjustment. With the goal of minimizing the overall sensitivity change, and on the premise of meeting the target compressive stability coefficient, the parameters of the structural units with lower sensitivity are adjusted preferentially to optimize the configuration of the compressive unit (230) and achieve the optimal determination of the number and size of the vertical compression ring (231), the transverse compression ring (232) and the transverse tie rod (233).

10. A lightweight design method suitable for plastic plate-like structures according to claim 9, characterized in that: The logic for obtaining the compressive stability coefficient is: Extracting the matching scheme, compression test data and compression stability coefficient of the carrier structure (100) and the support structure (200) based on the historical matching data; numbering the matching schemes of the carrier structure (100) and the support structure (200) in advance, extracting the historical matching scheme numbers, and forming a matching feature data set; Extract the compression test data of each matching solution, including the ultimate pressure value, deformation curve and failure mode; perform feature engineering on the compression test data and extract feature influencing factors; A machine learning model is constructed, wherein the matching feature data in the matching feature data set is used as the input of the machine learning model, and the feature impact factor is used as the output of the machine learning model; Obtain the influence degree of each characteristic influencing factor on the ultimate pressure value, normalize and accumulate the influence degree to obtain the compressive stability coefficient; The stress resistance stability coefficient in the historical matching data is used as the prediction target, and minimizing the sum of the prediction errors of all real-time stress resistance stability coefficients is used as the training target. The machine learning model is trained until the sum of the prediction accuracies converges and the training is stopped.

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