Rail Vehicle Floor with Cork Insulation Layer
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Solution Overview
Problem
Current rail vehicle floors face challenges such as high stress, inadequate moisture resistance, excessive weight, complex installation, and increased construction height due to multi-layered structures, which compromise their heat-insulating, sound-insulating, and fire-retardant properties while being costly and labor-intensive to produce.
Innovation Solution
A four-layer floor structure consisting of a first metal layer, a cork-based filling layer, a second metal layer, and a wear layer, manufactured as a single, one-piece panel, which reduces development costs and installation complexity, enhances moisture resistance, and eliminates thermal bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a multi-layer floor structure with local supports and plywood panels is used, then heat insulation and sound insulation properties are improved, but construction height increases and device complexity increases
Solution Approach 1:
The patent combines multiple floor panels into a single integrated floor structure that covers the entire passenger compartment floor in one piece, eliminating the need for multiple separate panels and local supports. This merging approach maintains insulation properties while reducing construction height and simplifying the overall structure.
Solution Approach 2:
The patent uses composite materials consisting of a metal base layer, a filling layer with insulating material (such as cork or foam), and a wear-resistant top layer. This composite structure provides both thermal insulation and structural integrity in a single integrated panel, avoiding the need for multiple layers and supports.
2Temperature
If a multi-layer floor structure with local supports and plywood panels is used, then heat insulation and sound insulation properties are improved, but device complexity and installation effort increase
Solution Approach 1:
The patent combines multiple floor panels into a single integrated floor structure that covers the entire passenger compartment floor in one piece, eliminating the need for multiple separate panels and local supports. This merging approach maintains insulation properties while reducing construction height and simplifying the overall structure.
Solution Approach 2:
The patent uses composite materials consisting of a metal base layer, a filling layer with insulating material (such as cork or foam), and a wear-resistant top layer. This composite structure provides both thermal insulation and structural integrity in a single integrated panel, avoiding the need for multiple layers and supports.
3Temperature
If a multi-layer floor structure with cavities filled with insulating material is used, then heat insulation is improved, but moisture resistance deteriorates
Solution Approach 1:
The patent uses composite materials consisting of a metal base layer, a filling layer with insulating material (such as cork or foam), and a wear-resistant top layer. This composite structure provides both thermal insulation and structural integrity in a single integrated panel, avoiding the need for multiple layers and supports.
Solution Approach 2:
The patent employs porous insulating materials such as cork or foam that inherently resist moisture penetration while maintaining thermal insulation properties. These materials do not require additional cavity structures, eliminating the risk of moisture accumulation.
4Strength
If plywood panels with wear layer are used, then wear resistance is improved, but weight increases
Solution Approach 1:
The patent uses composite materials consisting of a metal base layer, a filling layer with insulating material (such as cork or foam), and a wear-resistant top layer. This composite structure provides both thermal insulation and structural integrity in a single integrated panel, avoiding the need for multiple layers and supports.
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 results in a lightweight, easy-to-install, and cost-effective floor that is highly insulating, resistant to moisture, and provides inherent strength, reducing production and installation efforts while maintaining necessary safety and durability standards.
Implementation Method 1
cork or a composite material with cork as a filling layer, as the advantageous properties of cork (low weight, elastic, shock-absorbing, good thermal insulation properties, moisture resistance, fungus resistance, fire-retardant properties) can be optimally exploited
Implementation Method 2
the advantageous properties of cork (low weight, elastic, shock-absorbing, good thermal insulation properties, moisture resistance, fungus resistance, fire-retardant properties) can be optimally exploited
Data Source
AI summary
The invention relates to a floor (F) for rail vehicles consisting of a four-layer structure of a first metal layer (1), a filling layer (2), a second metal layer (3) and a wear layer (4), which are undetachably connected to one another. According to the invention, the floor (F) is made in a single piece and covers the entire floor of the passenger space of a rail vehicle.