Transportable Case Composite Wall Impact Protection
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Solution Overview
Problem
Existing transportable cases are either lightweight and prone to damage or heavy and costly, failing to provide a balance between protection and efficiency in transportation and storage.
Innovation Solution
A transportable case with walls comprising an inner layer of microcellular foam and an outer layer of self-reinforced polymer woven composite, bonded together and moulded into a shape defining a cavity for receiving an item, offering improved durability and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic or metal boxes with foam layers are used, then protection against impacts is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining microcellular foam (inner layer) with self-reinforced polymer woven composite (outer layer). This composite structure provides enhanced impact protection through the foam's energy absorption capabilities while the woven composite adds structural strength, achieving superior protection at reduced weight compared to traditional plastic or metal boxes.
Solution Approach 2:
The patent implements local quality by using different materials for different functional requirements: the inner microcellular foam layer provides shock absorption and cushioning where impact energy needs to be dissipated, while the outer self-reinforced polymer woven composite provides structural integrity and surface protection. This localized material assignment optimizes both protection and weight.
2Strength
If traditional layered self-reinforced polymer is used, then structural strength is improved, but manufacturing temperature and pressure increase
Solution Approach 1:
The patent uses a composite material system where microcellular foam is combined with self-reinforced polymer woven composite. This specific combination allows for lower manufacturing temperatures and pressures because the microcellular foam structure provides inherent cushioning that reduces the need for high-energy bonding processes, while still achieving the required structural strength through the woven composite's architectural properties.
Solution Approach 2:
The patent applies parameter changes by modifying the manufacturing conditions (temperature and pressure) to lower values. The unique combination of microcellular foam and self-reinforced polymer woven composite enables bonding and moulding at reduced thermal and mechanical energy input, making the manufacturing process more energy-efficient while maintaining structural integrity.
3Reliability
If robust materials like plastic or metal are used, then durability is improved, but transportation cost and energy efficiency worsen
Solution Approach 1:
The patent employs composite materials (microcellular foam inner layer + self-reinforced polymer woven composite outer layer) that provide high durability and hardwearing properties. The self-reinforced woven composite offers exceptional strength-to-weight ratio, ensuring the case is robust and long-lasting, while the lightweight construction significantly reduces transportation energy requirements compared to traditional heavy-duty plastic or metal cases.
Solution Approach 2:
The patent applies the anti-weight principle by using lightweight materials (microcellular foam and self-reinforced polymer woven composite) that counterbalance the need for heavy construction. The case achieves sufficient durability and protection without requiring excessive weight, thereby improving transportation energy efficiency and reducing logistics costs.
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 case is hardwearing yet lightweight, providing effective protection against impacts while minimizing transportation costs and energy consumption, with the ability to be formed at lower temperatures and pressures.
Implementation Method 1
Microcellular foam is a specific type of polymer foam comprising a large number of very small bubbles uniformly distributed therethrough
Implementation Method 2
the self-reinforced polymer woven composite instead comprises a fabric or sheet formed from woven or interlocking threads or yarns of stretched polymer fibres
Implementation Method 3
The first layer and the second layer are bonded together and moulded into a shape
Implementation Method 4
the first layer and the second layer are bonded together and moulded into a shape defining a cavity
Data Source
AI summary
A transportable case for containing an item, the transportable case having at least one wall comprising a first layer, formed of microcellular foam and a second layer, formed of self-reinforced polymer woven composite, covering at least part of the first layer. The first layer and the second layer are bonded together and moulded into a shape defining a cavity for receiving at least part of the item, the first layer being an inner layer that is closer to the cavity than the second layer.