Cover for air conditioning device for vehicle, and method for manufacturing same
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Solution Overview
Problem
Existing air conditioning device covers for vehicles are heavy due to stainless steel plates and require low productivity processes like welding and bonding of heat insulating materials, and fiber-reinforced plastic sandwich panels require costly thermal processing and cutting for curved shapes.
Innovation Solution
A cover made of a foamed material core with a fiber-reinforced plastic surface, where the core is elastically deformed into a curved shape using a molding die, eliminating the need for additional heat insulating materials and costly thermal processing, and using a vacuum impregnation molding method to impregnate fibers with resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a stainless steel plate with reinforcing members and heat insulating material is used for the cover, then the cover has sufficient strength and heat insulation, but the total weight becomes large and productivity decreases due to welding and bonding processes
Solution Approach 1:
The patent uses a composite structure consisting of a foam core material for heat insulation and a fiber reinforced plastic surface member for strength and lightweighting. This composite material approach replaces the traditional stainless steel plate with reinforcing members, achieving both strength requirements and weight reduction simultaneously.
2Strength
If a stainless steel plate with reinforcing members and heat insulating material is used for the cover, then the cover has sufficient strength and heat insulation, but productivity decreases due to welding and bonding processes
Solution Approach 1:
The patent merges the heat insulating material and the surface member into a single integrated structure. The foam core material serves as both the heat insulation layer and the structural base, while the fiber reinforced plastic surface member provides both strength and aesthetic finish. This eliminates the need for separate welding and bonding processes, significantly improving productivity.
3Shape
If thermal processing or cutting work is performed on the core material to obtain a curved shape, then the cover achieves the required curved shape, but productivity decreases and costs run up
Solution Approach 1:
The patent changes the physical state and properties of the core material by using a foamed material that can be easily deformed into curved shapes without requiring thermal processing or cutting. The foam structure allows for flexible shaping while maintaining structural integrity, eliminating the need for costly and time-consuming thermal processing or cutting operations.
4Shape
If a molding die with a curved shape is used to obtain the curved shape, then the cover achieves the required curved shape, but costs run up due to the expensive die
Solution Approach 1:
The patent changes the approach to achieving curved shapes by using a foamed core material that can be deformed into the required shape without requiring a specially designed curved molding die. This eliminates the need for expensive custom dies while still achieving the desired curved shape, significantly reducing manufacturing 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 solution results in a lightweight cover with improved productivity and increased withstand load, eliminating the need for additional heat insulating materials and reducing production costs by avoiding thermal processing and using a less expensive molding die.
Implementation Method 1
the core is elastically deformed into a curved shape
Implementation Method 2
impregnating the fibers with the resin by injecting the resin into a sealed space formed between the molding die and the core by vacuuming
Implementation Method 3
demolding the cover from the molding die after the resin is cured
Data Source
AI summary
A cover for an air conditioning device for a railway vehicle is a cover for an air conditioning device for a vehicle, which covers an air-conditioner main body. The cover includes a core made of a foamed material having heat insulating property, and a surface member made of a fiber reinforced plastic, which covers entire surfaces of the core. The core is deformed into a curved shape by elastic deformation.