Concrete-Faced Container Module with Integrated Twist-Lock Corners
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Solution Overview
Problem
Existing container modules for temporary or permanent human habitation are not adequately fireproof or soundproof, and they lack durability during seismic activities due to metal components weakening under thermal stress, and they are not efficiently designed for easy handling and transportation.
Innovation Solution
A method for manufacturing a container module by forming at least four panels with a concrete core facing inward and an external metal plate facing outward, where twist-lock elements are integrated into each corner for secure handling and assembly, and the panels are welded together to create a rectangular parallelepiped structure, enhancing fire resistance and soundproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal containers are used for module construction, then ease of manufacture and transport is improved, but fire resistance and seismic durability deteriorate
Solution Approach 1:
The container module employs a composite structure combining metal external plates with concrete core panels. The metal plates provide structural strength and ease of manufacture, while the concrete core provides fire resistance and seismic durability. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Reliability
If concrete is added to shipping containers for fireproofing, then fire resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The container is divided into modular panels, each consisting of an external metal plate and a concrete core. These standardized panels can be manufactured independently and then assembled, reducing overall manufacturing complexity compared to monolithic concrete container construction.
Solution Approach 2:
The concrete cores and metal plates are prepared as separate pre-manufactured components before final assembly. This preliminary preparation allows for optimized manufacturing processes for each material type and simplifies the final assembly process.
3Reliability
If twist-lock elements are added to corners for secure handling, then handling reliability is improved, but device complexity increases
Solution Approach 1:
The twist-lock elements are integrated directly into the corner structures of the container panels during manufacturing. This merging of the locking mechanism with the structural corners eliminates the need for separate attachment processes and reduces overall device complexity.
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
The method results in a durable, fire-resistant, and soundproof container module that is easier to manufacture, transport, and assemble, with improved stress distribution and handling capabilities, making it suitable for both temporary and permanent human habitation.
Implementation Method 1
curing the concrete and thereby forming a rigid connection between the external plate and the concrete
Implementation Method 2
the panels are welded together to create a rectangular parallelepiped structure
Data Source
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AI summary
Disclosed is a method for manufacturing a container module (1). The method comprises the steps of: forming at least four container panels (2) by means of the following steps: placing a casting frame (3) on or around an external plate (4) to form a casting mould (5), pouring concrete (6) into the casting mould (5), curing the concrete (6) and thereby forming a rigid connection between the external plate (4) and the concrete (6), assembling the at least four container panels (2) and optionally further panels to form the container module (1) as a rectangular parallelepiped, wherein the concrete (6) is facing inwards and the external plate (4) is facing outwards, and wherein a twist-lock element (7) is provided in each corner of the container module (1). A container module (1) comprising a number of container panels (2) together forming a rectangular parallelepiped is also disclosed along with use of a container module (1).