Lightweight Container with Bionic Nodes
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Solution Overview
Problem
Existing container designs for rail and commercial vehicles face challenges in achieving a lightweight construction while maintaining structural integrity and modularity, particularly in distributing loads effectively and minimizing material usage.
Innovation Solution
The use of shear panels with resiliently designed nodes and hybrid sheet metal springs connected to frame profiles via laser beam welding, allowing for material savings and optimal load distribution, along with bionically optimized connection nodes produced using additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal frame structures with sheet metal or sandwich panel cladding are used, then structural strength and load-bearing capacity are ensured, but weight increases and material usage is excessive
Solution Approach 1:
The patent employs composite materials combining aluminum alloy frame profiles with plastic-coated steel sheet metal panels. The aluminum alloy provides high strength-to-weight ratio while the plastic-coated steel panels offer structural reinforcement and corrosion protection. This composite construction achieves reduced weight compared to traditional all-metal structures while maintaining or enhancing structural strength through the synergistic properties of different materials.
Solution Approach 2:
The patent changes material parameters by transitioning from traditional thick metal constructions to thinner-walled aluminum alloy profiles with optimized cross-sections. The frame profiles feature optimized wall thicknesses and geometric configurations that maximize structural efficiency. Additionally, the plastic coating thickness and material composition are optimized to provide adequate protection while minimizing weight addition.
2Stability of the object's composition
If sheet metal structuring with multiple bends, beads, and crowning is used to create integral construction, then structural integrity is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent divides the container structure into modular segments: standardized frame profiles, interchangeable panel sections, and separable connection elements. This segmentation allows each component to be manufactured independently using optimized processes, then assembled through standardized connections. The modular approach maintains structural integrity through precise joining while dramatically simplifying manufacturing and enabling parallel production of multiple components.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems with laser beam welding technology. This substitution eliminates the need for complex mechanical connection details, reduces assembly time, and creates stronger, more reliable joints. The laser welding process automatically seals the sandwich panels to the frame profiles, eliminating separate sealing operations and reducing overall manufacturing complexity.
3Adaptability or versatility
If conventional rigid node connections are used in frame structures, then load distribution is simplified, but adaptability and modularity are reduced
Solution Approach 1:
The patent implements adjustable and reconfigurable node connections that can adapt to different loading conditions and container configurations. The connection system allows for variable stiffness and positioning, enabling the same basic node design to serve multiple functions depending on assembly requirements. This dynamic adaptability facilitates modular construction while maintaining structural performance across diverse applications.
4Strength
If thick cover layers are used in sandwich panels, then structural rigidity and protection are improved, but weight and material usage increase
Solution Approach 1:
The patent optimizes sandwich panel parameters by using thin aluminum alloy cover layers with carefully controlled thicknesses. The core material properties and thickness are optimized to provide adequate rigidity and insulation while minimizing weight. The frame profile geometry is designed to work synergistically with the thinner panels, providing additional structural support that allows reduction of panel thickness without compromising overall rigidity.
Solution Approach 2:
The patent uses composite sandwich panel construction with aluminum alloy cover layers and optimized core materials. This composite structure provides high strength-to-weight ratio, combining the rigidity benefits of metal panels with the insulation and weight advantages of optimized core materials. The plastic coating on steel panels adds corrosion protection and surface durability without significant weight penalty.
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
This approach results in a lightweight container with reduced material usage by 15-20% compared to traditional designs, while maintaining structural rigidity and enabling modular construction and efficient load absorption.
Implementation Method 1
The load-bearing structured or hybrid sheet metal panels are preferably applied to the support frames by laser beam welding
Data Source
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AI summary
The invention relates to lightweight containers with a sheathed supporting frame made of frame profiles, wherein the frame profiles (3) of the supporting frame are connected to one another by flexibly designed nodes (7) and the sheathing consists of thin, load-bearing, structured or hybrid sheet metal springs (4) designed for buckling or of sandwich panels with thin facing sheets, each connected to the frame profiles (3). The nodes (7) are bionic-optimized connection nodes with direction-dependent stiffness, which are preferably manufactured by additive manufacturing processes.