Composite Railway Structural Element with Foam Core
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Solution Overview
Problem
The existing methods for producing structural elements of railway vehicles, such as longitudinal walls and floors, face challenges in achieving uniform rigidity, reducing the number of parts, and minimizing weight and aesthetic issues, as they often require complex assembly and use of metal materials with visible fasteners.
Innovation Solution
A method involving the use of composite material hollow sections connected by webs to form a closed section, with a foam core and ribs, allowing for a one-piece structural element with improved rigidity and reduced part count, using a matrix of thermosetting material mixed with continuous fibers, and eliminating visible fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal elements are assembled together by welding, riveting or bolting to form structural elements, then the structural element can be produced using conventional manufacturing methods, but the rigidity is reduced due to fixing elements passing through the elements and the number of parts increases
Solution Approach 1:
The patent merges multiple metal elements (leaf, door pillars, crosspieces, stretchers) into a single integrated structural element made from one piece of composite material. This eliminates the need for fixing elements like rivets, bolts, or welds that would compromise rigidity, while maintaining ease of manufacture through composite material forming processes.
Solution Approach 2:
The patent replaces traditional metal materials with composite materials (such as fiber-reinforced polymers) that provide equivalent or superior mechanical properties including rigidity and strength, while enabling monolithic construction without assembly fasteners.
2Strength
If reinforcing elements are added to increase rigidity, then the rigidity of the structural element is improved, but the number of parts increases further
Solution Approach 1:
The patent integrates reinforcing functions directly into the monolithic composite structure through strategic material distribution and structural design (such as varying fiber orientation, density, or layering within the composite) rather than adding separate reinforcing elements, thus maintaining uniform rigidity without increasing part count.
3Strength
If metal materials are used for structural elements, then the structural element has sufficient strength, but the mass of the structural element increases
Solution Approach 1:
The patent employs composite materials (such as carbon fiber reinforced polymers or glass fiber reinforced polymers) that offer high strength-to-weight ratios, providing equivalent or superior strength compared to metal while significantly reducing the mass of the structural element.
4Ease of manufacture
If fixing elements are used to assemble elements, then the structural element can be constructed from multiple parts, but the appearance is degraded due to visible fasteners
Solution Approach 1:
The patent creates a monolithic composite structure that eliminates the need for visible fasteners or joint lines, providing a smooth, continuous surface that enhances aesthetic appearance while maintaining manufacturing efficiency through integral forming processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a structural element with uniform rigidity, reduced mass, and a satisfactory aesthetic appearance, as it simplifies production and integrates reinforcing elements within the composite material, enhancing mechanical properties while adhering to fire safety standards.
Implementation Method 1
each being formed of an envelope encasing a foam core
Implementation Method 2
the composite material is formed from a matrix of thermosetting material mixed with continuous fibres
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
The element (1) has a beam (2) extending along longitudinal direction. A web (4) is extended perpendicularly to the longitudinal direction. The beam and the web are formed in a shell encasing a core (6) made of foam. The beam and a shell of the web are formed together as single piece for forming an envelope of the element. The envelope comprises a hollow profile made of a composite material extending in the longitudinal direction to form a case of the beam and in a direction perpendicular to the longitudinal direction to form the shell of the web.