Mass Transit Door Leaf Deep-Drawn Polymer Layers
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Solution Overview
Problem
Mass transportation vehicle door leaves require a balance between robustness and lightness, and existing manufacturing methods are cumbersome and weight-heavy.
Innovation Solution
A door leaf configuration featuring outer and inner layers made in one piece through deep-drawing or thermoforming of planar sheet polymer material, with a core material filling the space between for added stiffness, insulation, and protection, reducing the number of parts and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-part construction with frame and panels is used, then structural robustness is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the frame and panels into a single integrated door leaf constructed from one piece of formed material. This eliminates the need for separate frame and panel components, reducing the number of connections and overall weight while maintaining structural robustness through the continuous formed structure.
Solution Approach 2:
The patent employs composite materials by combining a formed base structure with an integrated panel layer. This composite construction provides both structural strength from the formed base and additional robustness from the panel, while the integration of these layers reduces weight compared to traditional separate frame and panel constructions.
2Strength
If traditional multi-part construction with frame and panels is used, then structural robustness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the frame and panels into a single integrated door leaf constructed from one piece of formed material. This eliminates the need for separate frame and panel components, reducing the number of connections and overall weight while maintaining structural robustness through the continuous formed structure.
Solution Approach 2:
The patent segments the door leaf into distinct functional zones within a single formed structure, allowing different regions to serve specific purposes (structural support, panel coverage, connection points) while being manufactured as one integrated piece, thereby reducing assembly complexity.
3Strength
If traditional gluing, riveting or welding methods are used to fasten panels to frame, then connection strength is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent merges the frame and panels into a single integrated door leaf constructed from one piece of formed material. This eliminates the need for separate frame and panel components, reducing the number of connections and overall weight while maintaining structural robustness through the continuous formed structure.
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 solution simplifies production, reduces weight, and enhances the door leaf's robustness and insulation properties while maintaining structural integrity and aesthetic appeal.
Implementation Method 1
at least the one of the outer and inner door leaf layers is made by deep-drawing or thermoforming a planar sheet polymer material
Implementation Method 2
at least the one of the outer and inner door leaf layers is made by deep-drawing or thermoforming a planar sheet polymer material
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a door leaf device being configured and provided for use in a wagon (2) of a mass transportation vehicle, having an outside face (16), an inside face (17), a height and a width and comprising an outer door leaf layer (10; 10') at least partially forming the outside face (16) and an inner door leaf layer (11; 11') at least partially forming the inside face (17), the outer and inner door leaf layers (10, 11; 10', 11') being arranged with respect to one another so as to form an inner space (13) therebetween. It is provided that at least one of the outer and inner door leaf layers (10, 11; 10', 11') substantially extends over the height and/or the width of the door leaf device (1; 1') and is formed in one piece. The invention further relates to a method for the production of a door leaf device.