Foldable Transport Containers With Hybrid Panels
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Solution Overview
Problem
Existing transport containers are either too heavy or lack sufficient structural strength, limiting their load-carrying capacity and storage space, while also having surfaces that can accumulate dirt and potentially damage goods due to protrusions or indentations.
Innovation Solution
The development of hybrid panels with a core structure, such as honeycomb or alveolar, covered by protective layers and enhanced with overmolded frames that provide structural functions, made from materials like thermoplastic, reinforced resin, or concrete, which are lighter and stronger, allowing for increased load capacity and internal space without protrusions or indentations that can damage goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional transport containers are used, then structural strength is sufficient, but weight is too heavy
Solution Approach 1:
The patent employs composite panel structures combining a core material (such as honeycomb structure, alveolar structure, or foam) with protective layers (such as metal sheets, plastic sheets, or wooden panels). This composite construction achieves optimal strength-to-weight ratio, making the container 5-10% lighter while maintaining or enhancing structural strength by 30-60% compared to traditional solid construction
Solution Approach 2:
The patent applies different materials and structures to different parts of the container based on local requirements. The core provides lightweight structural support, while protective layers are applied specifically where strength and durability are needed. Overmolded frames are added at specific locations to enhance structural functions without adding weight throughout the entire container
2Object-affected harmful factors
If traditional container walls are used, then structural strength is maintained, but surface protrusions can accumulate dirt and damage goods
Solution Approach 1:
The patent uses smooth protective layers (metal sheets, plastic sheets, or wooden panels) that completely cover the core structure, creating a flat, continuous surface without protrusions or indentations. This smooth surface prevents dirt accumulation and eliminates potential damage points for stored goods, while the layered construction maintains structural strength
Solution Approach 2:
The patent integrates the protective layers with the core structure to form a unified panel system. The protective layers are bonded to the core, merging the smooth surface function with the structural support function into a single integrated component, eliminating the need for separate surface treatments
3Quantity of substance
If container design is optimized for strength, then load capacity increases, but internal storage space decreases
Solution Approach 1:
The lightweight composite construction (5-10% weight reduction) allows for increased payload capacity while maintaining structural integrity. The hollow core structures provide structural strength without the weight penalty of solid walls, effectively increasing both load capacity and internal storage space by 5-10%
Solution Approach 2:
The patent divides the wall structure into a core component and protective layer component, allowing the core to be optimized for lightweight structural support while the protective layers provide surface functionality. This segmentation enables optimal use of material, maximizing internal space without compromising strength
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 hybrid panels result in transport containers that are 5-10% lighter and 30-60% stronger than traditional ones, capable of carrying 5-10% more load with 5-10% additional storage space, featuring flat surfaces that prevent dirt accumulation and minimize risk of damage to goods.
Implementation Method 1
channels are provided in the surface of the article to guide the flow of the overmoulding material, in addition holes may be provided across the article to enable flow of the overmoulding material
Implementation Method 2
gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure and permitting an even flow pattern to exist, encapsulating or sandwiching the said porous structure
Implementation Method 3
gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure
Implementation Method 4
effectively equalizing cavity pressure and permitting an even flow pattern to exist
Implementation Method 5
formation thereby of the injection molding component and joining of the injection molding component to the basic component, wherein upon closure of the molding tool before the injection molding material is injected, the entire region, formed by the basic component, of the wall of the injection molding cavity is formed by the narrow side of the basic component
Data Source
AI summary
The present invention relates to a hybrid panel, comprising a panel comprising: a core, a first protecting layer on a first side of said core and a second protecting layer on a second side of said core; said panel defining an outside geometry thereof; and an overmolded portion which overlays at least a part of said panel, thereby changing said geometry of said panel at said part of said panel.