Hybrid Plastic-Metal Bulk Containers for Lower Noise and Weight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional metal containers for bulk material are acoustically noisy, prone to deformation and corrosion, heavy, and increase fuel consumption due to high friction, necessitating a more durable and efficient alternative.
Innovation Solution
A hybrid plastic-metal construction where the container's floor and walls are made of plastic, supported by a metal frame with spaced-apart members, minimizing metal usage while maintaining rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal is used to form the container, then rigidity and durability are improved, but noise levels increase, weight increases, and susceptibility to corrosion increases
Solution Approach 1:
The container employs a composite construction combining metal frame members with plastic cladding or lining. The metal frame provides the necessary rigidity and structural strength, while the plastic material covers the metal surfaces to reduce noise generation during material loading and protect against corrosion. This composite approach allows simultaneous achievement of structural integrity and noise reduction that neither material could achieve alone.
2Reliability
If metal is used to form the container, then durability is improved, but weight increases and fuel consumption increases
Solution Approach 1:
The container uses a composite structure where the metal frame provides structural durability and load-bearing capacity, while the plastic cladding or lining reduces the overall weight compared to a fully metal construction. The plastic material is sufficient to provide durability against corrosion and minor impacts without requiring the full thickness and weight of metal walls, achieving a favorable weight-to-durability ratio.
3Strength
If metal is used to form the container, then structural strength is improved, but payload capacity decreases
Solution Approach 1:
The composite construction with metal frame and plastic cladding reduces the overall mass of the container structure compared to a fully metal container. This weight reduction directly increases the payload capacity of the vehicle, allowing more bulk material to be transported. The metal frame maintains sufficient structural strength to handle the increased payload while the plastic components keep the structure lightweight.
4Stability of the object's composition
If metal is used to form the container, then rigidity is improved, but friction increases and tipping becomes impeded
Solution Approach 1:
The plastic cladding or lining on the metal frame creates a smoother surface with lower friction coefficients compared to bare metal. This plastic surface allows bulk materials to slide more easily during the tipping operation, reducing the angle required for complete discharge. The metal frame underneath maintains the container's rigidity and structural integrity throughout the tipping motion.
5Reliability
If a protective plastic liner is added to a metal container, then corrosion resistance is improved, but complexity and cost increase, and mass increases
Solution Approach 1:
The container integrates plastic cladding or lining as an essential structural component rather than an optional protective liner. This integrated composite design provides corrosion resistance as a inherent feature of the construction rather than an added protective layer. The plastic and metal components work together as a unified structure, reducing overall complexity compared to assembling separate metal container and liner components.
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
A container (104) for holding bulk material is disclosed. The container comprises a floor (203) and walls (204, 205, 206) formed of plastic, and a frame (202) supporting the floor and the walls, wherein the frame comprises a plurality of spaced-apart metal frame members separated by open areas, and the floor and walls are attached to the frame members and span the open areas to bound a volume suitable for holding bulk material.