Rotational Molded Cabin Panel Integrating Air Ducts
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Solution Overview
Problem
Current air conditioning solutions for working machine cabs require complex and costly insulated sheet metal consoles with long intake and exhaust ducts, leading to high temperatures, increased space requirements, and inefficient airflow, as well as high installation costs and increased machine height.
Innovation Solution
A rotationally molded plastic panel serves as a structural component of the cabin, integrating air ducts and forming a receiving space for the air conditioning unit, reducing duct length and eliminating the need for complex insulation, while allowing for efficient air circulation and attachment of vehicle fittings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If welded insulated sheet metal consoles with long ducts are used in the engine compartment, then air conditioning function is achieved, but airflow losses increase and space requirements increase
Solution Approach 1:
The patent combines the air conditioning unit, air lines, and structural support functions into a single integrated plastic panel component. The air conditioning unit is mounted directly on the panel, and the air lines are formed as integral parts of the panel structure, eliminating the need for separate long ducts and reducing airflow losses.
Solution Approach 2:
The patent relocates the air conditioning unit from the traditional engine compartment position to a new position within the vehicle body structure, specifically integrating it into the plastic panel that forms part of the vehicle's structural framework. This dimensional repositioning shortens the air line length significantly.
2Ease of manufacture
If welded insulated sheet metal consoles are used, then air conditioning function is achieved, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent merges multiple functions (structural support, air conditioning housing, air line routing, and mounting support) into a single plastic panel component manufactured in one rotational molding process, eliminating the need for welding, insulation materials, and multiple assembly steps required by traditional sheet metal consoles.
Solution Approach 2:
The patent changes the manufacturing method from traditional welded sheet metal construction to rotational molding of plastic, which allows for integral formation of complex three-dimensional structures with built-in air lines and mounting features, significantly simplifying manufacturing and reducing costs.
3Temperature
If air conditioning unit is placed in engine compartment, then air conditioning function is provided, but thermal insulation requirements increase
Solution Approach 1:
The patent extracts the air conditioning unit from the high-temperature engine compartment environment and relocates it to a thermally more favorable position within the vehicle body structure, where it is integrated into the plastic panel assembly away from direct engine heat exposure, thereby reducing thermal insulation requirements.
4Ease of manufacture
If retrofittable on-roof solutions are used, then air conditioning function is achieved, but machine height increases and costs increase
Solution Approach 1:
The patent integrates the air conditioning unit and all necessary air lines into the existing vehicle body structure through the plastic panel, eliminating the need for separate on-roof installations. This integration approach reduces overall machine height while providing equivalent air conditioning functionality at lower cost.
Data Source
Figure 1
Figure 2~3
AI summary
A control station (1) for a work vehicle equipped with a cabin (2) is described, with a plastic covering serving as a support (3) for fittings (4) and with air lines (10, 11) for air conditioning the cabin (2). In order to create advantageous climate control conditions in the cabin, it is proposed that the support (3) be a structural component for the cabin (2) and thus form part of the cabin inner wall (6) and the cabin outer wall (7) of a cabin wall, and that the support (3) is rotationally molded in integral construction, wherein the support (3) comprises the cabin inner wall (6) and, spaced apart from it, the cabin outer wall (7), formed integrally with the cabin inner wall (6) and forming a trough-shaped receiving space for an air conditioning unit (9), and wherein at least two integrally formed passages forming air ducts (10, 11) are provided between the cabin inner wall (6) and the receiving space of the cabin outer wall (7).