A lightweight design method and lightweight structure suitable for plastic plate structures

Abstract

The present invention discloses a lightweight design method and lightweight structure suitable for plastic plate-like structures, comprising: dividing the geometric features of a carrier structure into structural areas based on historical matching data, configuring different supporting structures for the generated functional areas according to the matching scheme of the supporting structure; setting a pressure simulation monitoring mode, and performing a staged test on the pressure resistance of different functional areas, collecting statistics on the pressure test data of different functional areas, performing stability analysis on the pressure test data, and obtaining a pressure stability coefficient; if the pressure stability coefficient is greater than or equal to the pressure stability coefficient in the historical matching data, storing the matching scheme of the carrier structure and the supporting structure, the pressure test data, and the pressure stability coefficient to obtain the historical matching data; otherwise, adjusting the number and size of the pressure units in the plate-like area until the pressure stability coefficient is greater than or equal to the pressure stability coefficient in the historical matching data.

Description

Technical Field

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

[0002] With the development of science and technology and the increasing demand for lightweight plastics in the plastics industry, plastic sheets are gradually replacing traditional materials such as metal and glass due to their advantages such as low density, easy processing, and controllable costs. However, the lightweight design of plastic sheets still needs to address core issues such as strength, cost, and process feasibility. This is analyzed step by step from the following aspects: first, the optimized design and application of materials; second, the development and application of advanced manufacturing technologies; and third, the optimized design of product structure.

[0003] As we all know, both the optimized design and application of materials and the development and application of advanced manufacturing technologies are the basic means to achieve plastic lightweighting. However, neither of these two points can improve the lightweighting effect of existing target plastic panels in a short period of time. In addition, the stability of the materials in the experiment and the durability of subsequent long-term use must be considered. Even if the R&D team has developed a suitable improved plastic, it cannot be quickly used in production, which means it cannot meet the needs of current users.

[0004] Therefore, the current lightweight design of target plastic panels mainly relies on thin-walling + local reinforcement to achieve optimized product structure design. The main problem lies 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 hollow leaf vein design) rely on high-precision molds, which increases costs sharply.

[0005] In view of this, the present invention provides a lightweight design method and a lightweight structure suitable for plastic plate structures to solve the above problems. Summary of the Invention

[0006] The purpose of the present invention is to provide a lightweight design method and a lightweight structure suitable for a plastic plate structure, so as to solve the problems in the above-mentioned background technology.

[0007] In order to achieve the above object, the present invention provides the following technical solutions:

[0008] In a first aspect, the present invention provides a lightweight plastic plate structure, comprising:

[0009] The carrier structure is a target hollow shell having a first wall thickness; functional areas are divided inside the target hollow shell, and the functional areas include an edge area, a transition area, and a plate-shaped area;

[0010] Support structure, configure different stress support units for the target hollow shell in different functional areas, including:

[0011] Bionic units are vertically stacked between edge regions to improve the edge rigidity and connection stability of the target hollow shell;

[0012] Honeycomb units are vertically stacked in the transition area to relieve concentrated stress from the edge area to the plate area;

[0013] The compression-resistant unit is embedded in the plate-shaped area in the horizontal direction to construct a three-dimensional support frame and improve the spatial load-bearing capacity of the carrier structure.

[0014] As a preferred technical solution of the first aspect of the present invention, the bionic unit includes:

[0015] A plug-in plate, with a plurality of plug-in holes provided on the upper end surface;

[0016] The plug connectors respectively form male and female plug structures with the multiple plug holes;

[0017] Multiple meridian nodes are provided with a central axis meridian at the center, and the location of the meridian node 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 node are fixedly connected based on the derivative meridians.

[0018] As a preferred technical solution of the first aspect of the present invention, the honeycomb unit includes:

[0019] Honeycomb connection end, used to connect the target hollow shell in the transition area;

[0020] A honeycomb body, disposed between the two honeycomb connection ends;

[0021] A honeycomb array frame is vertically stacked inside the honeycomb body;

[0022] The honeycomb support unit is used to fix adjacent honeycomb array frames.

[0023] As a preferred technical solution of the first aspect of the present invention, the pressure-resistant unit includes:

[0024] The vertical pressure ring is a closed rectangular frame with an arc shape at the edge of the rectangular frame, and is fixed vertically along the height direction of the plate-shaped area;

[0025] The horizontal pressure ring is a closed rectangular frame with an arc shape at the edge of the rectangular frame. It is fixed vertically along the length of the plate-shaped area and is orthogonal to the vertical pressure ring to form a space frame.

[0026] The transverse pull rod is in the shape of a rod and is inserted along the length direction of the plate-shaped area to connect the vertical pressure ring and the transverse pressure ring, and is used for connecting adjacent transverse pressure rings.

[0027] In a second aspect, the present invention provides a lightweight design method suitable for a plastic plate structure, which is used to design the first aspect and includes the following steps:

[0028] Step S1: Divide the geometric features of the carrier structure into structural regions based on historical matching data, extract functional regions, and configure different support structures for the functional regions;

[0029] Step S2: Set the compression simulation monitoring mode, and conduct 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.

[0030] 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, compressive test data and compressive stability coefficient are stored to obtain the historical matching data; otherwise, the number and size of the compressive units in the plate-shaped area are adjusted until the compressive stability coefficient is greater than or equal to the compressive stability coefficient in the historical matching data.

[0031] As a preferred technical solution of the second aspect of the present invention, the logic of configuring different support structures for functional areas is:

[0032] Step S11: determining a target hollow shell with a first wall thickness based on the grid design model; using the inner edge interface of the target hollow shell as a reference plane, and a functional area with a second wall thickness in a direction perpendicular to the reference plane as an edge area, and modularly arranging the bionic units in the edge area;

[0033] Step S12: using the inner edge interface of the edge area as a reference plane, and the functional area having a third wall thickness in a direction perpendicular to the reference plane as a transition area, adjusting the support ratio of the honeycomb unit in the transition area, wherein the support ratio is the space occupied by the honeycomb support unit in the honeycomb array frame;

[0034] Step S13: configuring at least one pressure-resistant unit 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 in the plate-shaped area according to the load-bearing capacity.

[0035] As a preferred technical solution of the second aspect of the present invention, the modular layout logic of the bionic unit is:

[0036] According to the boundary position information of the edge area, the radial section information and the longitudinal section information of the meridian node are determined; based on the radial section information, the radial length of the meridian node is determined; based on the longitudinal section information, the depth value of the meridian node is determined.

[0037] taking the ratio of the maximum radial length to the depth value in the meridian segment as a first ratio; characterizing the meridian distribution pattern based on the first ratio;

[0038] If the first ratio is less than or equal to the expected threshold, then setting A meridian nodes and setting a central axis meridian at the center of each meridian node;

[0039] If the first ratio is greater than the expected threshold, A+B meridian nodes are set, and a central axis meridian is set at the center of each meridian node. Derivative meridians are built around the central axis meridian. The number of derivative meridians is determined based on the meridian distribution map, and the distribution of the derivative meridians is optimized.

[0040] As a preferred technical solution of the second aspect of the present invention, the adjustment logic of the transition region is:

[0041] Determine the expected scale spacing D1 of the transition area based on prior knowledge, and calculate the vertical distance from the transition area to the boundary position information as the first distance;

[0042] Marking a transition area where the first distance is less than the desired scale spacing D1 as a concentrated transition area, performing a concentrated drainage design on the honeycomb unit in the concentrated transition area, determining the size of the honeycomb cell in the honeycomb array frame to be M, filling the honeycomb cell with 2N honeycomb support units, wherein the honeycomb support unit 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;

[0043] The transition area where the first distance is greater than or equal to the expected scale spacing D1 is marked as a slow-release transition area, and a slow-release dredging design is performed on the honeycomb unit in the slow-release transition area. The size of the honeycomb cell in the honeycomb array frame is determined to be 2M, and N honeycomb support units of a sleeve unit structure are filled in the honeycomb cell.

[0044] As a preferred technical solution of the second aspect of the present invention, the design logic of the pressure-resistant unit is:

[0045] A compression layout diagram was constructed based on the compression unit, and finite element simulation analysis was used to determine the stress values and structural deformation trends of the vertical compression ring, transverse compression ring, and transverse tie rod under loading conditions.

[0046] According to the trend of stress 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.

[0047] 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 first to optimize the configuration of the compressive units and achieve the optimal determination of the number and size of vertical compression rings, transverse compression rings and transverse tie rods.

[0048] As a preferred technical solution of the second aspect of the present invention, the logic for obtaining the compressive stability coefficient is:

[0049] Extract matching schemes, compression test data, and compression stability coefficients of the carrier structure and the supporting structure based on historical matching data; number the matching schemes of the carrier structure and the supporting structure in advance, extract the historical matching scheme numbers, and form a matching feature data set;

[0050] 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 to extract feature influencing factors;

[0051] Construct a machine learning model, using the matching feature data in the matching feature dataset as the input of the machine learning model, and using the feature impact factor as the output of the machine learning model;

[0052] Obtain the influence degree of each characteristic influencing factor on the ultimate pressure value, normalize the influence degree and accumulate it to obtain the compressive stability coefficient;

[0053] The pressure resistance stability coefficient in the historical matching data is used as the prediction target, and the training goal is to minimize the sum of the prediction errors of all real-time pressure resistance stability coefficients; the machine learning model is trained until the sum of the prediction accuracy reaches convergence and the training is stopped.

[0054] In the above technical solution, the technical effects and advantages provided by the present invention are:

[0055] The present invention divides the carrier structure into functional areas and configures the support structure based on historical matching data. Combined with compressive simulation monitoring and stability analysis, it can perform hierarchical optimization configuration for different functional areas, dynamically evaluate and adjust the layout of compressive units, and achieve precise control and lightweight balance of the target plastic plate's compressive performance. At the same time, through the continuous accumulation and updating of matching data, a structural design closed loop of sustainable optimization and intelligent iteration is established, which significantly improves the stability, durability and design efficiency of the overall structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments described in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0057] Figure 1 It is a schematic diagram of the overall structure of the lightweight structure of the present invention.

[0058] Figure 2It is a schematic diagram of the overall structure of the lightweight structure with a hollow structure of the present invention.

[0059] Figure 3 It is a cross-sectional view of the lightweight structure of the present invention.

[0060] Figure 4 This is a schematic diagram of the cross-sectional connection of the lightweight structure of the present invention.

[0061] Figure 5 Schematic diagram of the structure of the bionic unit of the present invention.

[0062] Figure 6 Schematic diagram of the structure of the honeycomb unit of the present invention.

[0063] Figure 7 It is a structural schematic diagram of the special-shaped honeycomb unit of the present invention.

[0064] Figure 8 Schematic diagram of the structure of the pressure-resistant unit of the present invention.

[0065] Figure 9 This is a flow chart of a lightweight design method suitable for plastic plate structures according to the present invention.

[0066] Description of reference numerals:

[0067] 100, carrier structure; 110, edge region; 120, transition region; 130, plate-shaped region; 140, hollow region;

[0068] 200, support structure;

[0069] 210, bionic unit; 211, plug tray; 2111, plug hole; 212, plug connector; 213, meridian node; 214, central axis meridian; 215, derived meridian;

[0070] 220, honeycomb unit; 221, honeycomb connection end; 222, honeycomb body; 223, honeycomb array frame; 224, honeycomb support unit;

[0071] 230. Compression unit; 231. Vertical pressure ring; 232. Horizontal pressure ring; 233. Horizontal pull rod. DETAILED DESCRIPTION

[0072] 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 this disclosure will be more comprehensive and complete, and will fully convey the concepts of the example embodiments to those skilled in the art. The accompanying drawings are merely schematic illustrations of the present disclosure and are not necessarily drawn to scale. Identical reference numerals in the figures indicate identical or similar parts, and thus repeated descriptions thereof will be omitted.

[0073] In addition, the described features, structures or characteristics can be combined in any suitable manner in one or more example embodiments. 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 can 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.

[0074] Example 1

[0075] like Figure 3-4 As shown, the present invention provides a lightweight plastic plate 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.

[0076] The carrier structure 100 is a target hollow shell that is subjected to a shell extraction process according to a target plastic plate, and is used to provide a geometric profile and a load-bearing basis for the target plastic plate, and has a target hollow shell with a first wall thickness; different support structures 200 are selected inside the carrier structure 100 to adapt to the support as the functional area changes; the carrier structure 100 is provided with a functional area, and the functional area includes an edge area 110, a transition area 120 and a plate-shaped area 130; the support structure 200 is a reinforced support structure in the carrier structure 100 to implement a specific functional area, and is used to improve the overall mechanical properties, such as compression resistance, bending resistance, and impact resistance. The support structure 200 includes a bionic unit 210, a honeycomb unit 220 and a pressure-resistant unit 230; the details are as follows:

[0077] The edge region 110 is based on the inner edge boundary of the target hollow shell as a reference plane, the edge boundary line of the target hollow shell is located in the plastic plate and / or the hollowed-out region 140 on the plastic plate, and the functional region has a second wall thickness in a direction perpendicular to the reference plane. Local plane coordinates are arranged on the reference plane to determine the length direction and the height direction. Multiple bionic units 210 are evenly distributed in the length direction. The cross-sectional size of the bionic units 210 is configured according to the second wall thickness. The bionic meridian shape of the bionic units 210 is simulated in the height direction.

[0078] The bionic unit 210 is used to enhance the impact resistance of the corners. The full plastic panel is used to enhance the external bending stiffness and support strength to prevent the panel from sinking or bending when loaded. The upper and lower edge areas 110 are fixedly connected by the bionic unit 210 to improve the edge rigidity and connection stability. Figure 4 The columnar module simulating the plant meridians can be used as a 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. Multiple bionic units 210 are evenly distributed in the length direction. The cross-sectional size of the bionic unit 210 is configured according to the first width to simulate the natural plant stem or bone continuous support structure in the edge area 110.

[0079] Specifically, the bionic unit 210 includes:

[0080] The plug-in tray 211 includes: a plurality of plug-in holes 2111;

[0081] The plug connector 212 forms a male-female plug-in structure with multiple plug-in holes 2111 respectively; the application of the male-female plug-in structure not only allows the bionic unit 210 to be plugged into the edge area 110, but also allows multiple bionic units 210 to be firmly connected vertically to achieve modular connection.

[0082] Multiple meridian nodes 213 are provided with a central meridian 214 at the center thereof, and the location of the meridian node 213 is determined based on the central meridian 214; derivative meridians 215 are provided on the periphery of the central meridian 214, and the target hollow shell and the meridian node 213 are fixedly connected based on the derivative meridians 215;

[0083] Each meridian segment 213 constitutes an independently adjustable and supportable modular segment. Meridians are arranged on the meridian segment 213 according to their configuration. The meridians include central meridians 214 and derived meridians 215. The central meridians 214 are reinforced meridians such as thick ribs, and the derived meridians 215 are flexible meridians such as wavy ribs or through-holes, etc., to adjust local stiffness or buffering capacity.

[0084] It should be noted that the high-strength and lightweight columnar unit formed by the vertical combination of multiple bionic segments is suitable for use as edge reinforcement connectors, anti-collision support structures or functional support columns. Figure 4As shown, in this embodiment, the shape of the meridian is only illustrated as a circular meridian. A modular stacking and connection and plug-in design of multiple layers of meridian nodes 213 is adopted, presenting a highly biomimetic and engineering-feasible support structure. However, in actual application, the shape of the meridian is not fixed. It is constructed with reference to the meridian-vein force transmission mode of plant leaves in nature, and has the multi-objective performance of lightweight, high strength, and flexibility. Among them: the shape of the bionic unit 210 simulates the central axis structure of the main leaf vein of the plant, and is divided into several meridian nodes 213 to form a structural module segmented control unit. Different meridians are configured on each meridian node 213 according to its function and location, and its meridian shape is optimized according to the load distribution path. It can be straight, curved, S-shaped or forked; such as: enhanced high rigidity, buffered flexible connection, and connection type for plug-in.

[0085] The configuration logic of the meridian shape is as follows: multiple derivative meridians 215 extending from the central meridian 214 assist in the force conduction path, simulating the branching 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 leaf vein structure's geometric parameters, such as thickness, length, and bending radius, can be optimized and adjusted based on the load path or stress concentration areas. It can be connected to the bionic unit 210 through co-injection molding or plug-in assembly, improving the overall connection stiffness and flexible buffering capacity. The leaf vein structure and bionic unit 210 form a "fascia-membrane composite force distribution network" to share the structural stress concentration points and effectively prevent structural cracking or warping.

[0086] The transition region 120 is provided between the edge region 110 and the plate-shaped region 130. The inner edge interface of the edge region 110 is used as a reference plane. A functional region having a third wall thickness is provided along a 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 honeycomb units 220 are evenly distributed in the length direction. The cross-sectional size of the honeycomb units 220 is configured according to the third wall thickness. The height layout of the honeycomb units 220 is determined in the height direction.

[0087] Specifically, if Figure 6 As shown, the honeycomb unit 220 includes:

[0088] The honeycomb connection end 221 is the upper and lower boundary components of the honeycomb unit 220, which defines the size of the honeycomb unit 220 and seamlessly connects the transition area 120 to achieve module connection between the internal honeycomb array frame 223 and provide stable end force support;

[0089] The honeycomb body 222 is provided between the two honeycomb connection ends 221;

[0090] The honeycomb array frame 223 is vertically stacked in a plurality of honeycomb bodies 222 ; it is formed by integral injection molding or segmented plug-in connection, and has high compression and shear resistance, and high material utilization rate.

[0091] The honeycomb support unit 224 is used to fix the adjacent honeycomb array frame 223 to further enhance the out-of-plane support capability; it is a reinforcing rib, sleeve, cross support or transverse fixing rod, which plays the role of strengthening the connection between the honeycomb arrays, limiting deformation and evenly distributing the load.

[0092] It should be noted that the common honeycomb core adopts a hexagonal grid structure, but the honeycomb unit 220 in actual application is not limited to the shape thereof. Figure 6 As shown, this embodiment uses a circular honeycomb column as a specific form of expression, but in actual application, it can also be as shown in FIG. Figure 7 As shown, it is a special-shaped honeycomb column.

[0093] The honeycomb grid structure, specifically the honeycomb cells 220, are used within the transition region 120 of a lightweight plastic panel structure, suitable for areas that withstand vertical loads and require a smooth change in panel thickness. The dense arrangement of the honeycomb array achieves stress dispersion and uniform force transmission within the structure, while significantly reducing material usage and achieving lightweight design goals.

[0094] The plate-shaped area 130 is the main load-bearing area of the plastic plate. At least one pressure-resistant unit 230 is embedded in the plate-shaped area 130 according to the load-bearing requirements. In addition, the plate-shaped area 130 is integrated with heat conduction holes, heat sinks, and buffer materials to achieve multifunctional integration.

[0095] The anti-pressure unit 230 includes a vertical pressure ring 231, a horizontal pressure ring 232 and a horizontal pull rod 233, wherein the vertical pressure ring 231; Figure 8 As shown, where:

[0096] The vertical pressure ring 231 is in the shape of a closed ellipse or an approximately rectangular shape, and multiple vertical pressure rings 231 are arranged in the vertical direction of the upper and lower plate-shaped areas 130; they withstand the vertical pressure on the upper plate surface, that is, the vertical load, improve the overall compressive resistance of the structure, and prevent the plate surface from collapsing under pressure.

[0097] The transverse pressure ring 232 is in the shape of a closed ellipse or an approximately rectangular shape, and is along the transverse direction of the upper and lower plate-shaped areas 130, that is, the horizontal load; it is orthogonal or cross-sectional with the vertical pressure ring to form a spatial frame; it plays the role of dispersing the transverse component of force and assisting in bending resistance, thereby improving stability under transportation vibration or unbalanced load conditions.

[0098] The transverse tie rods 233 are slender rods that are inserted between the multiple vertical compression rings 231 and the transverse compression rings 232. They play a role in transverse restraint and tension sharing to prevent the structure from bulging or separating when loaded. They are arranged in pairs or symmetrically to stabilize the existing skeleton system.

[0099] It should be noted that: Figure 3 As shown, the compression unit 230 is suitable for the interior of the plastic plate-like member and is modularly arranged in the internal space of the plate-like area 130. By rationally arranging multiple units, a high-strength compression unit matrix is formed, which can not only bear high-intensity concentrated loads, but also has good anti-bending and anti-deformation properties.

[0100] When the plastic plate is a complete plate structure, such as Figure 1 As shown, the carrier structure 100 includes three parts: an edge region 110, a transition region 120, and a plate region 130. The plate region 130 is a complete plate. In this case, only the impact resistance of the corners of the edge region 110, the structural stress relief capability of the transition region 120, and the load-bearing capacity of the plate region 130 need to be considered. Bionic units 210 are provided in the edge region, and honeycomb units 220 are provided in the transition region 120. The layout of the honeycomb units 220 and bionic units 210 is determined based on a comprehensive assessment of the specific application scenario, load distribution, and process conditions. The compressive units 230 form a high-strength compressive unit matrix by rationally arranging multiple units. This matrix can bear high-intensity concentrated loads while also exhibiting excellent bending and deformation resistance.

[0101] When the plastic plate is a plate-shaped structure having at least one hollow area 140, such as Figure 2 As shown, the carrier structure 100 includes three parts, namely the edge area 110, the transition area 120, the plate-like area 130 and the hollow area 140; wherein: an edge is formed around the hollow area 140, and the edge area 110 and the transition area 120 are respectively arranged along the hollow area 140, extending to the plate-like area 130 through the transition area 120, and other functions are the same, but the plate-like area 130 here is a special-shaped plate, which is more suitable for actual application scenarios. The hollow area 140 can obtain more types of plastic plates. In this case, it is only necessary to consider the impact resistance of the corners of the edge area 110 and the stress deformation capacity of the edge area 110. According to the comprehensive evaluation of the specific application scenario, load distribution and process conditions, the layout of the honeycomb unit 220 and the bionic unit 210 is set. The compressive unit 230 forms a high-strength compressive unit matrix by reasonably arranging multiple units, which can not only bear high-strength concentrated loads, but also have good bending and anti-deformation properties.

[0102] Example 2

[0103] In the actual production process of the plastic plate-shaped lightweight structure described in Example 1, in order to ensure 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:

[0104] This embodiment adopts a multi-cavity combined mold layout to construct a target hollow shell with a first wall thickness, takes the target hollow shell as the carrier structure 100, and divides the edge area 110, the transition area 120 and the plate area 130 according to the degree of distance from the multi-cavity combined mold cavity; and through the reasonable configuration of the gate position and the cooling channel, the uniform molding and warpage control of the overall structure of the plastic part are achieved, ensuring that the connection accuracy between the support structure and the carrier structure meets the assembly requirements.

[0105] The bionic unit 210 in the edge area 110 adopts a segmented slider or insert design, and each meridian segment 213 realizes modular demolding through the corresponding slider insert unit. The central axis meridian 214 and the derived meridian 215 are consistent with the mold demolding direction according to the longitudinal expansion direction, thereby avoiding lateral core pulling and improving mold stability.

[0106] The honeycomb unit 220 in the transition area 120 has a periodic unit structure and is formed by an integrated cavity. Its honeycomb connection end 221 is located at the joint surface of the upper and lower molds, and its boundary contour is controlled by the insert provided in the mold. Vertically stacked honeycomb array frames 223 are provided in the honeycomb main body 222, and honeycomb support units 224 are arranged in the vertical direction on adjacent honeycomb array frames 223 to facilitate mold cavity exhaust and filling; if the honeycomb unit has an irregular structure, an auxiliary inclined top mechanism can be provided on its support unit to avoid molding interference.

[0107] The pressure-resistant unit 230 in the plate-shaped area 130 is a multi-layer nested space frame structure, in which the vertical pressure ring 231 and the horizontal pressure ring 232 are arranged orthogonally and are both arranged along the Z-axis direction, the main demolding direction of the mold, and are suitable for one-piece injection molding; the horizontal pull rod 233 is formed by a pre-embedded sliding core shaft or a lateral core pulling mechanism to ensure its penetration and structural integrity. If necessary, the module assembly can be carried out by insert replacement to improve the structural maintainability and mold processing flexibility.

[0108] Example 3

[0109] like Figure 9 As shown, the parts not described in detail in this embodiment are as described in Example 1. This embodiment provides a method for lightweight design of plastic plate structures, with a target plastic plate having functional zoning, and is particularly suitable for lightweight design of structures such as pallets, panels, panels, and bases; the method comprises the following steps:

[0110] Step S1: Divide the geometric features of the carrier structure 100 into structural regions based on historical matching data, extract functional regions, and configure different support structures 200 for the functional regions;

[0111] It should be noted that: the three-dimensional model of the target plastic plate is used as the target plastic plate, the target hollow shell subjected to shell extraction processing according to the target plastic plate, the target hollow shell having a first wall thickness is used as the carrier structure 100, and the support structure 200 for supporting the carrier structure 100;

[0112] Specifically, the logic of configuring different support structures 200 for functional areas is:

[0113] Step S11: Determine a target hollow shell having a first wall thickness based on the grid design model; use the inner edge interface of the target hollow shell as a reference plane, define a functional region having a second wall thickness in a direction perpendicular to the reference plane as an edge region 110, and modularize the bionic units 210 within the edge region 110;

[0114] It should be noted that the mesh design model is a 3D model that can read the target plastic sheet. Spatial data extraction is performed on the carrier structure 100 based on the mesh design model of the target plastic sheet. By identifying the mesh node set surrounding the internal cavity or non-solid area of the mesh 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, the boundary position information of the edge region 110 is determined by inferring inward from the outer boundary and the opening boundary.

[0115] The opening boundary position information is the hollow area 140 existing in the carrier structure 100. In principle, the corresponding stress requirements of the edge area 110 of the outer boundary and the opening boundary are different. The conventional setting is to set the scale of the edge area 110 accordingly. However, in the actual printing process, the operator uses different sizes of processing technology in the same mechanism, which places higher design requirements on the mold and the operator. In addition, although the edge stress demand and load corresponding to the hollow area 140 are greatly reduced compared to the outer boundary, there are still certain technical barriers in production. Therefore, in this embodiment, the technicians make unified settings for the edge area 110 and the bionic unit 210.

[0116] More specifically, the modular layout logic of the bionic unit 210 is:

[0117] According to the boundary position information of the edge area 110, the radial section information and the longitudinal section information of the meridian node 213 are determined; the radial length of the meridian node 213 is determined based on the radial section information; the depth value of the meridian node 213 is determined based on the longitudinal section information.

[0118] The ratio of the maximum radial length to the depth value in the meridian segment 213 is used as a first ratio; and the meridian distribution pattern is characterized based on the first ratio;

[0119] If the first ratio is less than or equal to the desired threshold, the meridian node 213 is relatively thick and has a small span, and A meridian nodes 213 are set, and a central axis meridian 214 is set at the center of each meridian node 213;

[0120] If the first ratio is greater than the desired threshold, the meridian node 213 has a larger structural span and a smaller depth. B meridian nodes 213 are set, and a central meridian 214 is set at the center of each meridian node 213. Derivative meridians 215 are constructed around the central meridian 214. The number of derivative meridians 215 is determined based on the meridian distribution map, and the distribution of the derivative meridians 215 is optimized.

[0121] The central axis meridian 214 and the derived meridian 215 are different expression states of the meridians. The meridian distribution map constructed based on the expression states of the meridians determines the expression states of the multiple meridians, and the expression degree is used to characterize the load-bearing pressure value of each meridian in each meridian node 213, where the numbers A and B are obtained by prior knowledge or machine learning models, and the sizes are manually adjusted based on actual conditions.

[0122] Step S12: Using the inner edge interface of the edge region 110 as a reference plane, and defining a functional region having a third wall thickness in a direction perpendicular to the reference plane as a transition region 120, adjusting the support ratio of the honeycomb unit 220 in the transition region 120, wherein the support ratio is the space occupied by the honeycomb support unit 224 in the honeycomb array frame 223;

[0123] It should be noted that a buffer zone is defined between the edge region 110 and the plate-shaped region 130 to form a transition region 120. The transition region 120 is used to mitigate stress gradient changes between the edge and the internal structure. The vertical distance from the grid cells within the transition region 120 to the boundary position information is calculated to adjust the support ratio of the honeycomb unit 220. The support ratio is the space occupied by the honeycomb support unit 224 within the honeycomb array frame 223; its width can be adjusted according to the structural support ratio.

[0124] Specifically, the adjustment logic of the transition area 120 is:

[0125] 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 the first distance;

[0126] The transition area 120 where the first distance is less than the desired scale spacing D1 is marked as a concentrated transition area, and 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. The honeycomb support unit 224 includes N cross-reinforcement rib unit structures and N sleeve unit structures. The N cross-reinforcement rib unit structures are staggered and distributed around the N sleeve unit structures.

[0127] The transition area 120 where the first distance is greater than or equal to the expected scale spacing D1 is marked as a slow-release transition area, and a slow-release dredging design is performed on the honeycomb unit 220 in the slow-release transition area. 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. The other parts retain cavities or are provided with flexible connection units to improve local flexibility and energy absorption capacity.

[0128] Through the differentiated honeycomb unit design, the transition area 120 can achieve stress concentration guidance or relief according to the local stress state, thereby improving the lightweight level and durability of the overall target plastic plate.

[0129] Step S13: configuring at least one pressure-resistant unit 230 in the remaining space of the cavity inside 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;

[0130] Specifically, the design logic of the pressure-resistant unit 230 is:

[0131] A compression layout diagram is constructed based on the compression unit, and 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;

[0132] According to the trend of stress 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.

[0133] 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 first to optimize the configuration of the compressive unit 230 and achieve the optimal determination of the number and size of the vertical pressure ring 231, the transverse pressure ring 232 and the transverse pull rod 233.

[0134] To illustrate this, an example is provided. A three-dimensional compression layout diagram of the complete plate-shaped region 130 and the compression unit 230 is established based on SolidWorks or ANSYS. The compression layout diagram includes a vertical compression ring 231, a transverse compression ring 232, and a transverse tie rod 233. The loading condition is to apply a vertical uniform load or a concentrated load to the compression layout diagram to simulate gravity, impact, or stacking pressure in actual use scenarios.

[0135] Through the finite element analysis module such as ANSYS Static Structural, the compression layout diagram is meshed and statically simulated to extract the stress value and structural deformation trend of each vertical compression ring 231, transverse compression ring 232 and transverse tie rod 233 under loading conditions. The structural deformation trend is simulated to obtain the displacement field, maximum deformation and stress concentration area distribution of each component node; the change in maximum deformation before and after the disturbance is used as an indicator of the change in compressive capacity, and the compressive capacity change quantity is established. and structural deformation trends The function relationship is used to calculate the sensitivity index of the structural unit, and then the degree of its adjustment impact is quantified to provide a data basis for subsequent optimization;

[0136] For each vertical pressure ring 231, transverse pressure ring 232 and transverse tie rod 233, a disturbance variable of ±10% size or quantity change is set, and the sensitivity of its influence on the change in the compressive capacity of the three-dimensional compressive layout diagram is recorded. The change in the compressive capacity is the ultimate load or stability. The formula for influencing sensitivity is:

[0137] ;

[0138] in, For the The sensitivity of each structural unit to the impact;

[0139] For the The change in compressive capacity caused by the adjustment of each structural unit is usually expressed as the change in ultimate load. It is a quantification of the change in the overall compressive capacity of the structure. In lightweight design, the compressive capacity can be expressed by meeting the maximum deformation threshold To judge whether the structure is qualified; for the disturbed structure (such as a pressure ring thickness reduced by 10%), the maximum displacement of the structure after disturbance , the maximum displacement and maximum deformation threshold are related by the function To characterize the indicator of the change in compressive capacity, the change in compressive capacity is defined as ;

[0140] For the The relative change degree of the structural quantity of each structural unit is expressed as the normalized change of the structural quantity. As a weighting factor for normalizing structural quantity units or setting influence sensitivity based on engineering experience;

[0141] For the The relative change degree of the structural size of each structural unit is expressed as the normalized change of the structural size. It is used as a weighting factor to normalize the structural quantity units or to set the sensitivity based on engineering experience.

[0142] The greater the sensitivity of the impact, the greater the impact of its adjustment on the system, and stability is prioritized; units with lower sensitivity are prioritized for optimization. Heuristic algorithms such as genetic algorithms or response surface optimization methods are used to iteratively optimize the parameters of low-sensitivity units on the premise of meeting the target compressive stability coefficient, and output the optimal configuration solution that meets the performance requirements, that is, the optimal number and size combination of vertical pressure rings 231, transverse pressure rings 232 and transverse tie rods 233.

[0143] Step S2: setting a compression simulation monitoring mode, and performing a staged test on the compression capacity of different functional areas, collecting compression test data of different functional areas, and performing stability analysis on the compression test data to obtain a compression stability coefficient;

[0144] Specifically, the logic for obtaining the compressive stability coefficient is as follows:

[0145] Extracting matching schemes, compression test data, and compression stability coefficients of the carrier structure 100 and the support structure 200 based on 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;

[0146] 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 to extract feature influencing factors;

[0147] Construct a machine learning model, using the matching feature data in the matching feature dataset as the input of the machine learning model, and using the feature impact factor as the output of the machine learning model;

[0148] Obtain the influence degree of each characteristic influencing factor on the ultimate pressure value, normalize the influence degree and accumulate it to obtain the compressive stability coefficient;

[0149] The pressure resistance stability coefficient in the historical matching data is used as the prediction target, and the training goal is to minimize the sum of the prediction errors of all real-time pressure resistance stability coefficients; the machine learning model is trained until the sum of the prediction accuracy reaches convergence and the training is stopped.

[0150] Step S3: If the pressure resistance stability coefficient is greater than or equal to the pressure resistance stability coefficient in the historical matching data, the matching scheme, pressure resistance test data and pressure resistance stability coefficient are stored to obtain the historical matching data; otherwise, the number and size of the pressure resistance units 230 in the plate-shaped area 130 are adjusted until the pressure resistance stability coefficient is greater than or equal to the pressure resistance stability coefficient in the historical matching data.

[0151] An embodiment of the present invention provides a method suitable for lightweight design of plastic plate structures, which is used to design a lightweight plastic plate structure provided by the above-mentioned embodiments of the present invention, and provides an embodiment of a specific method and process for the corresponding functions of each structure in a lightweight plastic plate structure, which will not be repeated here.

[0152] The above description is merely illustrative of certain exemplary embodiments of the present invention. It goes without saying that those skilled in the art will be able to modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and description are illustrative in nature and should not be construed as limiting the scope of protection of the claims.

Claims

1. A lightweight plastic plate 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, and the functional areas include 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: The bionic unit (210) is vertically stacked between the edge regions (110), and the meridian nodes (213), the central axis meridian (214) and the derived meridians (215) form a fascia-membrane composite force distribution network for improving the edge rigidity and connection stability of the target hollow shell; The honeycomb unit (220) is vertically stacked in the transition area (120), and the honeycomb support unit (224) is partitioned and configured according to the relationship between the vertical distance between the transition area and the edge area and the desired scale spacing, and a high-density concentrated dredging method is used for the area smaller than the desired scale spacing, and a low-density slow-release dredging design method is used for the area greater than or equal to the desired scale spacing; and the honeycomb support unit (224) is used to relieve the concentrated stress from the edge area (110) to the plate-shaped area (130); The compression unit (230) is embedded in the plate-shaped area (130) along the horizontal direction, and a three-dimensional support frame is constructed through a plurality of vertical compression rings (231), transverse compression rings (232) and transverse pull rods (233), thereby improving the spatial load-bearing capacity of the carrier structure (100); The type and parameters of each support unit in the support structure (200) are determined by historical matching data and a target compressive stability coefficient threshold.

2. A lightweight plastic plate 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) forms a male and female plug structure with the plurality of plug holes (2111); A plurality of meridian nodes (213) are provided with a central axis meridian (214) at the center thereof, 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. The lightweight plastic plate structure according to claim 1, characterized in that: The honeycomb unit (220) comprises: A honeycomb connection end (221) for connecting to the target hollow shell of the transition region (120); A honeycomb body (222) is disposed between the 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. The lightweight plastic plate 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 shape provided at the edge of the rectangular frame, and is fixed vertically along the height direction of the plate-shaped area (130); The horizontal pressure ring (232) is in the form of a closed rectangular frame, with an arc-shaped edge provided at the edge of the rectangular frame, and is fixed vertically 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 is inserted along the length direction of the plate-shaped area (130) to connect the vertical pressure ring (231) and the transverse pressure ring (232), and is used for connecting adjacent transverse pressure rings (232).

5. A method for lightweight design of plastic plate-like structures, used for designing a lightweight plastic plate-like structure according to any one of claims 1 to 4, characterized in that: The following steps are involved: Step S1: Based on historical matching data, the geometric features of the carrier structure (100) are divided into structural regions, and functional regions are extracted, wherein the functional regions include an edge region (110), a transition region (120), and a plate region (130); different support structures (200) are configured for the functional regions, wherein the support structures (200) include a bionic unit (210), a honeycomb unit (220), and a pressure-resistant unit (230), and the type and parameters of the support structures (200) are determined by the historical matching data and a target pressure-resistant stability coefficient threshold; Step S2: Set the compression simulation monitoring mode, and conduct 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 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; using an inner edge interface of the target hollow shell as a reference plane, a functional area 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) within the edge region (110); Step S12: using the inner edge interface of the edge region (110) as a reference plane, and a functional region having a third wall thickness in a direction perpendicular to the reference plane as a transition region (120), 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 for plastic plate structures according to claim 6, characterized in that: The modular layout logic of the bionic unit (210) is: Determining radial cross-sectional information and longitudinal cross-sectional information of the meridian node (213) based on the boundary position information of the edge region (110); determining the radial length of the meridian node (213) based on the radial cross-sectional information; and determining the depth value of the meridian node (213) based on the longitudinal cross-sectional information; The ratio of the maximum radial length to the depth value in the meridian segment (213) is used as a first ratio; and the meridian distribution pattern is characterized based on the first ratio; If the first ratio is less than or equal to the expected threshold, then 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 derivative meridians (215) are constructed along the periphery of the central meridian (214). The number of the derivative meridians (215) is determined based on the meridian distribution map, and the distribution of the derivative meridians (215) is optimized.

8. A lightweight design method for plastic plate structures according to claim 7, characterized in that: Adjustment logic of the transition area (120): Determine the expected scale spacing D1 of the transition region (120) based on prior knowledge, and calculate the vertical distance from the transition region (120) to the boundary position information as a first distance; A transition region (120) having a first distance less than the desired scale spacing D1 is marked as a centralized transition region, a centralized drainage design is performed on the honeycomb unit (220) in the centralized transition region, a size of a honeycomb cell in the honeycomb array frame (223) is determined to be M, 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) having a first distance greater than or equal to the desired scale spacing D1 is marked as a slow-release transition region, a slow-release dredging 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 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 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 are determined by finite element simulation analysis; According to the trend of stress 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 first to optimize the configuration of the compressive unit (230) and achieve the optimal determination of the number and size of the vertical pressure ring (231), the horizontal pressure ring (232) and the horizontal tie rod (233).

10. A lightweight design method suitable for plastic plate structures according to claim 9, characterized in that: The logic for obtaining the compressive stability coefficient is as follows: Extracting matching schemes, compression test data, and compression stability coefficients of the carrier structure (100) and the support structure (200) based on 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 to extract feature influencing factors; Construct a machine learning model, using the matching feature data in the matching feature dataset as the input of the machine learning model, and using the feature impact factor as the output of the machine learning model; Obtain the influence degree of each characteristic influencing factor on the ultimate pressure value, normalize the influence degree and accumulate it to obtain the compressive stability coefficient; The pressure resistance stability coefficient in the historical matching data is used as the prediction target, and the training goal is to minimize the sum of the prediction errors of all real-time pressure resistance stability coefficients; the machine learning model is trained until the sum of the prediction accuracy reaches convergence and the training is stopped.

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