Tubular structural profile and construction system
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Solution Overview
Problem
Current structural elements, particularly in the packaging and furniture industries, face challenges in achieving a rigid and lightweight structure using recyclable materials like cardboard, as they often require additional materials for reinforcement and specialized tools for assembly and disassembly, leading to logistical and environmental issues.
Innovation Solution
A tubular structural profile is created by folding and cutting a sheet of semi-rigid material, featuring orthogonal sheets and diagonal inner portions with tabs and slots for closure, allowing for a self-sustaining structure without external reinforcements, enabling easy assembly and disassembly without specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional reinforcement elements (metal bolting, plastic clips, foams, rigid profiles) are incorporated to achieve structural strength and stiffness, then the structural stability and strength are improved, but the device complexity and material diversity increase, making the structure difficult and expensive to recycle
Solution Approach 1:
The structural profile is segmented into distinct functional zones: outer contour sheets provide the primary structure, while inner diagonal sheets provide reinforcement. These segments are connected through folding lines that allow relative movement, enabling the structure to achieve strength through geometric configuration rather than additional fastening elements.
Solution Approach 2:
The invention merges the reinforcement function directly into the profile structure by integrating inner diagonal sheets within the hollow body formed by outer contour sheets. This eliminates the need for separate reinforcement elements like metal bolting or plastic clips, as the diagonal sheets themselves provide the necessary structural strength while maintaining a single-material construction suitable for recycling.
2Ease of manufacture
If specialized tools and techniques are used for assembly and disassembly of structural elements, then the ease of manufacture is improved, but the ease of operation deteriorates due to the need for specialized tools and the logistical complexity of transporting and dismantling furniture
Solution Approach 1:
The profile incorporates folding lines that enable dynamic transformation between a compact flat state for transport and an expanded three-dimensional structure for use. The same folding mechanism that simplifies assembly also facilitates disassembly, allowing the structure to be collapsed back into a compact form without requiring specialized tools, thus improving both ease of manufacture and ease of operation.
3Strength
If a closed tube structure is used as the base material for structural elements, then the structural strength and stiffness are improved, but the ease of manufacture deteriorates because it requires a closed tube as base material plus additional braces, rather than being formed from a single sheet
Solution Approach 1:
The invention transitions from a two-dimensional sheet layout to a three-dimensional tubular structure through strategic folding. The sheet is folded along predetermined lines to create the hollow body of the profile, with inner diagonal sheets folded at angles greater than 90 degrees to form the reinforcement structure. This dimensional transformation allows a simple flat sheet to become a complex three-dimensional structure with inherent strength and stiffness.
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 solution provides a lightweight, rigid, and recyclable structural profile that enhances structural stability and minimizes environmental impact by eliminating the need for additional materials and tools, optimizing operational costs and logistical efficiency in packaging, furniture, and product display.
Implementation Method 1
manufactured from the folding and cutting of a sheet of semi-rigid and foldable material
Implementation Method 2
whose outer contour comprises 4 substantially orthogonal sheets joined in folding lines, and an inner portion, located diagonally joining two opposite folding lines
Implementation Method 3
at least one tab (7) are positioned, which coincides with at least one slot (8) located on the third opposite folding line, allowing that during the fold, the tubular structural profile is closed by the coincidence of both third folding lines and both internal diagonal sheets (5, 6), and the insertion of the at least one tab (7) in its corresponding slot (8)
Implementation Method 4
with high vending, compressive and torsion stiffness
Implementation Method 5
semi-rigid and foldable material
Data Source
AI summary
A tubular structural profile and construction system, produced by cutting and folding a semi-rigid and foldable sheet, having four orthogonal layers joined at fold lines and two internal diagonal layers joining two opposing fold lines. The sheet has six rectangular sections. The cutting lines are positioned for at least one tongue, which coincides with at least one slot located on an opposing fold lines, such that, during the folding, the profile is closed of the coming together of fold lines and both internal diagonal layers, and by means of the insertion of at least one tongue on its corresponding slot, and wherein, in addition, the profile of the formed system can have at least one break in the second external layers and in the two internal diagonal layers, which permit the creation of an engaging area for transverse structural profiles.