Insulated Vehicle Box Panel With Integrated Cable Gland Routing
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Solution Overview
Problem
The routing of electrical cables in conventional box bodies of commercial vehicles adds complexity and cost to the manufacturing process due to the need for routing through interfaces between structural layers, which can also compromise thermal insulation.
Innovation Solution
Integrating a cable passage in the core layer that extends from the inner to the outer cover layer, utilizing a cable gland for routing cables, and incorporating a cable entry point that prevents moisture ingress and thermal bridge formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cables are routed through interfaces between structural layers, then cables can be connected to electrical devices, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The cable passage is integrated directly into the core layer structure, merging the cable routing function with the thermal insulation core layer. This eliminates the need for separate routing operations through multiple structural layer interfaces, thereby reducing manufacturing complexity while maintaining electrical connectivity functionality
2Loss of energy
If cables are routed through interfaces between structural layers, then electrical connectivity is achieved, but thermal insulation properties deteriorate
Solution Approach 1:
The core layer acts as an intermediary structure that provides both thermal insulation and integrated cable passage. The cable passage is formed within the porous structure of the core layer, allowing cables to pass through without compromising the overall thermal insulation performance, as the passage is integrated into the insulating material itself rather than creating separate thermal bridges
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
Facilitates easier, quicker, and more cost-effective assembly of box bodies by eliminating the need for interface routing, while maintaining thermal insulation and preventing moisture ingress.
Implementation Method 1
a core layer (12) provided between the inner and outer cover layers (11, 10), which comprises a plastic (13) having a plurality of pores for gas
Implementation Method 2
typically made of a plastic, especially a foamed plastic. The inner and/or outer layers themselves can be multi-layered as needed. Foamed core layers or core layers with a high air content, in particular, can provide a high degree of thermal insulation for the cargo space
Data Source
Figure 1
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Figure 2B
AI summary
Described and illustrated is a panel (6) for forming a box body (1) of a commercial vehicle (N), in particular a truck, trailer or semi-trailer, comprising an outer structural cover layer (10), an inner structural cover layer (1011) and a core layer (12) provided between the inner cover layer (11) and the outer cover layer (10), comprising a plastic (13) having a plurality of pores for gas. In order to make the box body easier, faster and more cost-effective to manufacture, it is provided that a cable gland (9) extending at least substantially from the inner cover layer (11) to the outer cover layer (10) is provided in the core layer (12).