Composite ULD Weight Reduction via Laminate Segmentation
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Solution Overview
Problem
The increasing energy costs have highlighted the need for lightweight unit load devices (ULDs) in the cargo container industry, as existing all-aluminum ULDs are heavy and inefficient, necessitating a reduction in weight while maintaining structural integrity and meeting various ULD standards.
Innovation Solution
The development of ULDs using composite laminates, including materials like Kevlar/epoxy, carbon/epoxy, and S-Glass/epoxy, configured to meet specific geometry and loading requirements, with a frame structure comprising unit beam members and connectors, and a design that incorporates a greater number of strips at the top and bottom portions for enhanced strength and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If all-aluminum ULDs are used, then structural integrity and strength are maintained, but weight is excessive and energy efficiency deteriorates
Solution Approach 1:
The patent applies composite materials (carbon fiber reinforced polymers, glass fiber reinforced polymers, or aramid fiber reinforced polymers) to replace traditional all-aluminum construction. This composite material system provides equivalent or superior structural integrity and strength while achieving weight reduction of less than 50% compared to conventional aluminum ULDs, directly resolving the contradiction between weight reduction and strength maintenance
2Weight of moving object
If composite laminate materials are used, then weight is reduced and energy efficiency improves, but manufacturing complexity and production difficulty increase
Solution Approach 1:
The patent divides the ULD structure into discrete composite laminate components including frame members, bulkheads, and panels. Each component can be manufactured separately using composite fabrication techniques, then assembled into the complete ULD. This segmentation approach manages manufacturing complexity by breaking down the complex composite construction into manageable segments while maintaining the weight reduction benefits
Solution Approach 2:
The patent utilizes autoclave curing parameters and composite layup configurations to optimize manufacturing. By controlling curing temperature, pressure, and fiber orientation parameters, the patent achieves consistent structural properties and quality standards for composite components, making the manufacturing process more predictable and manageable despite the inherent complexity of composite materials
3Weight of moving object
If lightweight composite structure is implemented, then weight-to-cost ratio improves, but fire resistance and safety requirements become more challenging to meet
Solution Approach 1:
The patent modifies the chemical composition parameters of the polymer matrix and incorporates fire-retardant additives into the composite material formulation. These parameter changes enable the lightweight composite structure to achieve required fire resistance ratings and safety certifications, addressing the harmful factor of fire risk while maintaining weight reduction benefits
Data Source
AI summary
A lightweight cargo container and methods of use, assembly, and repair are disclosed herein. Individual panels, frame components, base, and joints may be customized with composite materials to further improve strength-to-weight ratio. Some embodiments provide for a simplified manufacturing and assembly of cargo container, through standardization, while improving cost, time-to-produce, durability, and strength-to-weight ratios. The embodiments described herein provide a significant weight savings for all cargo containers, modern present-day composite containers included.