Thermoplastic Fiberglass Vehicle Shell Assembly for Faster Body Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing vehicle housings, such as those for recreational vehicles and box trailers, are time-consuming, labor-intensive, and require multiple cutting, welding, and riveting steps, leading to inefficiencies and inexact processes.
Innovation Solution
A method involving the use of continuous sheets of pliable fiberglass material, bonded with a composite core, which are folded and thermoplastically welded to form a shell that provides thermal insulation, structural strength, and can be used to create interior cabinetry, eliminating the need for framing and reducing assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stick-and-tin or laminated wall construction methods are used, then structural strength and thermal insulation are achieved, but the manufacturing process becomes time-consuming and labor-intensive with multiple cutting, welding, and riveting steps
Solution Approach 1:
The patent combines multiple separate components (framing structure, insulation material, and exterior panels) into a single pre-assembled envelope unit. This integration eliminates the need for sequential assembly steps including cutting, welding, and riveting, thereby significantly reducing manufacturing time and labor requirements while maintaining structural integrity and thermal insulation performance.
Solution Approach 2:
The envelope is pre-assembled and pre-insulated before being installed on the chassis. All structural framing, insulation installation, and panel attachment are completed in advance as a single unit, allowing for streamlined final assembly on the vehicle chassis and eliminating time-consuming on-site construction steps.
2Stability of the object's composition
If traditional framing and panel assembly methods are used, then structural stability is achieved, but the manufacturing process requires significant labor inputs and assembly space
Solution Approach 1:
The patent merges the framing structure, insulation layer, and exterior panels into a single integrated envelope component. This consolidation reduces the number of separate manufacturing operations required and simplifies the assembly process, while the internal framing structure within the envelope maintains structural stability.
Solution Approach 2:
The envelope utilizes a streamlined shell structure that provides structural stability through its integrated design rather than requiring extensive separate framing. The pre-formed envelope shell reduces manufacturing complexity while maintaining the necessary structural integrity for vehicle application.
3Strength
If separate assembly of walls and floor is performed, then structural integrity is maintained, but the manufacturing process is inexact and time-consuming
Solution Approach 1:
The patent combines the floor panel and wall structures into a single pre-assembled envelope unit with integrated joints and connections. This integration ensures precise alignment and fit between structural components is achieved during manufacturing, eliminating variability and inexactness that would occur with separate field assembly operations.
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
This approach allows for a faster, more precise manufacturing process that reduces labor requirements and provides a durable, thermally-insulative, and structurally strong vehicle housing with integrated cabinetry, enhancing efficiency and quality.
Implementation Method 1
thermoplastically welded to form a shell
Implementation Method 2
provides thermal insulation, structural strength
Data Source
AI summary
An over-the-road vehicle. The vehicle comprises a chassis, and an envelope supported on the chassis. The envelope comprises a first continuous sheet of material folded over to form a front wall, a back wall, an overhead panel, and at least a portion of a floor panel. The envelope also includes a second continuous sheet of material forming a left side panel, and a third continuous sheet of material forming a right side panel. The left side panel is thermoplastically welded onto the first sheet of material on a left side of the chassis. Similarly, the right side panel is thermoplastically welded onto the first sheet of material on a right side of the chassis. Each of the first, second, and third sheets of material is fabricated from at least one malleable fiberglass sheet and a thermoplastic core. A method of fabricating an envelope for a vehicle is also provided herein.