EPP Roof Top Air Conditioner Structure for Lightweight Vehicle Mounting
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Solution Overview
Problem
Existing roof top air conditioner units for vehicles, particularly recreational vehicles, face challenges in achieving both stability and reduced weight while ensuring a reliable and robust configuration for the unit and its coupling to the vehicle.
Innovation Solution
The use of expanded polypropylene (EPP) for the roof top air conditioner unit, incorporating stabilizing and connecting elements molded directly into the EPP structure, which are optionally made of metal, to enhance stability and provide a reliable connection to the vehicle, thereby reducing weight and improving overall stability and coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional materials and construction methods are used for roof top air conditioner units, then structural strength and stability are maintained, but weight reduction is limited
Solution Approach 1:
The patent applies composite materials by integrating metal stabilizing and connecting elements within the EPP foam structure. The EPP material provides lightweight properties while the embedded metal elements (such as aluminum or steel profiles, nuts, and fasteners) provide structural strength and stability. This composite approach allows the housing to achieve both weight reduction and maintained structural integrity.
2Ease of manufacture
If separate stabilizing and connecting elements are used, then assembly flexibility is maintained, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges the stabilizing and connecting elements directly into the EPP foam structure during the molding process. The metal elements are positioned and fixed within the foam before final curing, creating an integrated structure where the housing and stabilizing/connecting elements form a single unified component. This eliminates separate assembly steps and reduces manufacturing complexity.
Solution Approach 2:
The stabilizing and connecting elements are pre-positioned and fixed within the EPP foam structure during the molding process itself. This preliminary action ensures that when the housing is removed from the mold, the metal elements are already in their correct positions and orientations, ready for final assembly without requiring additional positioning or adjustment steps.
3Stability of the object's composition
If stabilizing and connecting elements are added as separate components, then structural stability is improved, but assembly time and installation complexity increase
Solution Approach 1:
The stabilizing and connecting elements are combined with the housing structure during the molding process, creating a pre-assembled unit. The metal elements are embedded within the EPP foam, forming a unified structure that maintains stability while eliminating the need for separate assembly operations during installation.
Solution Approach 2:
The stabilizing and connecting elements are pre-installed and secured within the EPP foam structure before the housing is removed from the mold. This preliminary positioning ensures that when the unit is installed on the vehicle, the stabilizing elements are already in place, significantly reducing installation time and complexity.
4Weight of moving object
If EPP material is used for the housing, then weight is reduced, but structural rigidity may be compromised
Solution Approach 1:
The patent uses EPP foam as the base material for the housing to achieve weight reduction, while embedding metal stabilizing and connecting elements within the foam structure. The EPP provides lightweight insulation properties, while the metal elements (such as aluminum or steel profiles) provide the necessary structural rigidity and stability. This composite construction maintains both weight benefits and structural requirements.
Data Source
AI summary
A roof top air conditioner unit for a vehicle, in particular a recreational vehicle, wherein the roof top air conditioner at least in part is made of expanded polypropylene (EPP). At least one stabilizing and/or connecting element of the roof top air conditioner unit is mold in the section of the roof top air conditioner unit made of EPP. Furthermore, the present invention refers to a method for producing, assembling and installing such roof top air conditioner units and a vehicle having such a roof top air conditioner assembly.