Sandwich intermediate frame for camper cabins with integrated systems accommodation

Abstract

Intermediate frame: A sandwich composite intermediate frame consisting of an insulating core and fiber-reinforced cover layers, which serves as an adapter between a base vehicle and a standardized camper cabin.

Description

1. Technical area

[0001] The invention relates to vehicle construction and, in particular, to the development of a sandwich composite subframe that serves as a connecting element between a base vehicle (e.g., Iveco Daily, Mercedes Sprinter) and a standardized camper cabin. In addition to the possibility of using the same cabin on different base vehicles, the subframe offers other significant advantages. 2. State of the art

[0002] In conventional camper systems, living cabins are often individually coupled to vehicle-specific steel subframes. This results in the following disadvantages: • High development and manufacturing costs: A separate living cabin solution must be designed for each base vehicle. • Increased weight and unfavorable center of gravity: Steel subframes have a high dead weight and increase the center of gravity of the vehicle, which impairs driving dynamics. • Limited thermal insulation: Conventional materials provide inadequate protection in extreme temperatures. • Limited system integration: Technical systems such as tanks, batteries or electronics are often housed in the living cabin, which reduces the usable interior space. • Low flexibility: The living cabin is usually designed for a specific vehicle and cannot be used universally on different base vehicles. 3. Technical problem

[0003] The aim is to develop an adapter solution that meets the following goals: • Standardization of the living cabin: A uniform camper living cabin should be able to be used on different base vehicles. • Vehicle-specific adaptability: A specific adapter subframe should be manufactured for each base vehicle, which mounts the living cabin safely and stably. • Weight reduction: The use of a lightweight sandwich composite should significantly reduce the overall weight. • Optimized center of gravity: The subframe is designed to integrate heavier components in such a way that the vehicle's center of gravity is improved. • Improved thermal insulation: The structure must protect sensitive systems and the living space against extreme temperatures. • Efficient system integration: Tanks, battery systems, control electronics and other components are to be housed in an insulated cavity in the intermediate frame. • Additional cold protection: Integrated underfloor heating above the tanks is intended to provide additional protection at low temperatures. • Cost efficiency and scalability: The separation of standardized living cabin and adaptable intermediate frame significantly reduces development and manufacturing costs. • Improved off-road and fording capabilities: A boat-hull-like design increases stability and usability in rough terrain. • Increased security: A central, protected integration of all technical systems ensures reliable connections and safe operation. 4. Solution to the task

[0004] This task is solved by a sandwich composite intermediate frame, which serves as a flexible connecting element between the base vehicle and the standardized camper cabin. The intermediate frame is characterized by the following features: a) Material and structure: • Sandwich composite: The intermediate frame consists of a lightweight, insulating core (e.g. high-strength foam) and two fiber-reinforced cover layers (e.g. made of glass or natural fibers). • Weight reduction: The use of this material significantly reduces the overall weight. b) Optimized center of gravity: • Heavy technical components are integrated within the subframe, which lowers the vehicle's center of gravity and improves driving dynamics. c) Improved thermal insulation: • The material combination of the sandwich composite offers excellent insulation properties and protects the technical systems and the interior of the living cabin from extreme temperatures. d) Integrated system accommodation: • An insulated cavity is created in the intermediate frame in which tanks, battery systems and control electronics are safely housed. e) Universal application (adaptability): • A custom-fit (adapter) intermediate frame is manufactured for each base vehicle, which allows the standardized living cabin to be mounted universally. f) Cost efficiency and manufacturing scaling: • By separating the living cabin from the vehicle-specific intermediate frame, development, production and assembly can be made significantly more efficient. g) Additional cold protection: • An integrated underfloor heating system, installed below the tanks housed in the intermediate frame, provides additional protection against low temperatures and increases thermal comfort. h) Improved off-road and fording depth characteristics: • The design of the intermediate frame is similar in shape to a boat hull, which results in better stability and greater safety when traveling through water or rough terrain. i) Increased security and system integration: • The central, protected integration of all technical systems in the intermediate frame ensures stable connections and reliable operation. 5. Example

[0005] A practical example of the invention comprises the following steps: 1. Manufacturing the intermediate frame (adapter): ◯ An intermediate frame made of sandwich composite is manufactured, consisting of an insulating core and two fiber-reinforced cover layers. ◯ An insulated cavity is created within the intermediate frame in which tanks, battery systems and control electronics are integrated. ◯ Underfloor heating will be installed beneath the tanks to provide additional protection against the cold. 2. Adaptation to base vehicles: ◯ For a base vehicle such as the Iveco Daily, precise fastening points and connection points are developed on the subframe. ◯ For a Mercedes Sprinter or another model, an adjustment is made so that the intermediate frame acts as an adapter and is precisely tailored to the respective vehicle. 3. Assembly of the standardized living cabin: ◯ The uniformly constructed camper cabin is attached to the base vehicle via the adapter intermediate frame. ◯ The living cabin remains unchanged, while the intermediate frame takes care of the individual adjustment. 4. Result: ◯ Measurements and tests according to DIN EN ISO standards confirm a significant reduction in total weight, an optimized center of gravity, improved thermal insulation and increased protection against the cold thanks to the integrated underfloor heating. ◯ In addition, tests demonstrate improved off-road and fording depth characteristics as well as increased safety through central system integration. 6. Advantages of the invention (in order of importance) 1. Weight reduction: ◯ Use of lightweight sandwich composite significantly reduces the overall weight. 2. Optimized center of gravity: ◯ Integration of heavy components in the subframe lowers the center of gravity and improves driving stability. 3. Improved thermal insulation: ◯ The sandwich construction offers excellent protection against extreme temperatures. 4. Integrated system accommodation: ◯ Tanks, battery systems and control electronics are housed in an insulated cavity, which keeps the interior of the living cabin clear. 5. Universal application (adaptability): ◯ The intermediate frame is adapted to the specific vehicle and thus enables the universal installation of the same camper cabin on different base vehicles. 6. Cost efficiency and manufacturing scaling: ◯ Separation of standardized living cabin and individually adapted adapter reduces development, production and assembly costs. 7. Additional cold protection through integrated underfloor heating: ◯ The underfloor heating integrated in the intermediate frame below the tanks improves protection against low temperatures. 8. Improved off-road and fording depth characteristics: ◯ The boat-hull-like design offers greater stability and safety when traveling through water or rough terrain. 9. Increased security and system integration: ◯ The central integration of all technical systems ensures stable connections and reliable operation.

[0006] The attached drawings illustrate: 1. The cross-section of the intermediate frame with the insulating core and the fiber-reinforced cover layers. 2. The integrated cavity for accommodating tanks, battery systems and control electronics. 3. The positioning of the underfloor heating below the tanks. 4. The adapter concept, which represents the connection between the base vehicle and the standardized living cabin. Parts list 1 longitudinal member 2 bottom boxes 3 water tanks 4 vehicle frame 5 Water-bearing tank heating 6 cabins

Claims

[1] Intermediate frame: A sandwich composite intermediate frame consisting of an insulating core and fiber-reinforced cover layers, which serves as an adapter between a base vehicle and a standardized camper cabin. [2] Integrated system accommodation: Intermediate frame according to claim 1, in which tanks, battery systems and control electronics are integrated in an insulated cavity. [3] Underfloor heating to optimize cold protection: An intermediate frame according to claim 1, wherein underfloor heating is provided beneath the integrated tanks to provide additional protection against low temperatures. [4] Vehicle-specific adaptation: Intermediate frame according to claim 1, wherein the adapter is specifically adapted to the conditions of the respective base vehicle (e.g. Iveco Daily, Mercedes Sprinter) so that the same standardized living cabin can be used universally. [5] Overall system for universal integration: A system for assembling a camper living cabin, comprising an adapter-shaped intermediate frame according to one of claims 1 to 4 and a standardized living cabin, wherein the intermediate frame serves as a connecting element between the base vehicle and the living cabin.

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