Foldable Roof Superstructure for Light Vans
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Solution Overview
Problem
Existing solutions for expanding vehicle space, such as mobile homes, often compromise vehicle drivability, maneuverability, and safety due to altered weight distribution and increased aerodynamic drag, making them impractical for light vans under 3,500 kg, which face stringent weight and operational restrictions.
Innovation Solution
A foldable superstructure mounted on the vehicle's roof, featuring downwardly foldable auxiliary floors and sideboards, which unfold to create additional floor space while maintaining the vehicle's original dimensions, using light composite materials and a pantographic mechanism for proportional lifting, ensuring stability and minimal weight addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If permanent extension of the vehicle is used to expand space, then the usable area is increased, but the weight distribution and aerodynamic drag are negatively affected
Solution Approach 1:
The superstructure is designed to be foldable and movable rather than permanent, allowing it to be deployed only when needed for additional space. This dynamic configuration enables the vehicle to maintain its original aerodynamic profile during transport while providing expanded space when parked or stationary.
Solution Approach 2:
Instead of extending the vehicle horizontally which increases aerodynamic drag, the invention utilizes the vertical dimension by placing the superstructure on the roof. This dimensional transition allows space expansion without significantly increasing the vehicle's frontal area or length, thereby minimizing aerodynamic penalties.
2Volume of moving object
If frame chassis with new superstructure is used, then the living space is considerably enlarged, but the vehicle weight exceeds passenger car category
Solution Approach 1:
The superstructure is divided into separable components including the main superstructure body, auxiliary floors, and sideboards that can be independently folded or removed. This segmentation allows the space-expanding elements to be detached when not needed, keeping the base vehicle within passenger car weight limits.
Solution Approach 2:
The auxiliary floors and sideboards are designed to be removable and storable, allowing the vehicle to operate in its original weight category when these components are folded away or removed. The components can be recovered and deployed when additional living space is required.
3Area of moving object
If wall cutting and reinforcement with steel sections is used, then the habitable space is expanded, but the structural strength and weight distribution are compromised
Solution Approach 1:
Instead of cutting into the vehicle's side walls which compromises structural integrity, the invention expands space by utilizing the roof dimension. The superstructure is mounted on the roof where it does not interfere with the load-bearing walls, preserving the original structural strength while still providing expanded habitable space.
4Volume of moving object
If expanded vehicle dimensions are used, then the living space is increased, but the maneuverability and parking ability are impaired
Solution Approach 1:
The superstructure transitions from an extended state providing large living space to a folded state that restores the vehicle's original compact dimensions. This dynamic transformation enables the vehicle to maneuver through city streets and park in standard spaces when the superstructure is folded, while providing expanded living space when parked.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The foldable superstructure for vehicles (21) comprises a floor (1), fitted on both sides with downwardly foldable auxiliary floors (2, 2'), having drop sideboards (3, 3') movably fitted thereon. The drop sideboards (3, 3') are movably connected with the main sideboards (4, 4'), wherein their height is longer by the height of the storage space of the superstructure in its unfolded configuration, as the width of the auxiliary floors (2, 2') together with the height of the drop sideboards. The main sideboards (4, 4') are movably connected with the roof (5) with their other side, wherein the front panel (10') is foldable to the inside and connected with the front lower panelling (12) and the front panel (10) is foldable to the inside and connected with the front upper panelling (13), the rear panel (9') is foldable to the inside and connected with the rear lower panelling (11), and the rear panel (9) is foldable to the inside and connected with the rear upper panelling (14), the front triangular panels (16, 16') and the rear triangular panels (15, 15') for closing the folded superstructure are removable or mounted, foldably inward the superstructure, to the auxiliary floors (2, 2') and equipped with fast clamping pawls positioned on their sides. In order to unfold or fold the superstructure, the roof (5) can be firmly connected with the telescopic tube (6), which has a firmly fixed nut at its bottom, in which the threaded rod (7) moves, being rotatably mounted in the floor of the vehicle and fitted in the protective tube (8). The front supporting legs (17, 17') and the rear supporting legs (18, 18') can also be hingedly attached on the vehicle (21) sides, wherein a part of the side wall of the vehicle (21) in the kitchen area is formed by the tiltable wall (24).