Integrally Molded RV Body With Ribbed Composite Chassis

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Solution Overview

Problem

Conventional recreational vehicle bodies are constructed using a separate molding process for the cabin body and chassis, which increases labor and material costs and can result in corrosion issues with metal chassis.

Innovation Solution

An integrally molded recreational vehicle body where the base and chassis are molded together with a plurality of ribs, and utility members such as conduits are encapsulated within the layers to form a single, unified structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate molding processes are used for cabin body and chassis, then structural integrity can be achieved, but labor and material costs increase

Engineering Contradiction:

Improvemanufacturing costVSAvoidstructural complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the cabin body and chassis into a single integrally molded structure formed from one continuous layer of fiber-reinforced plastic. This merging eliminates the need for separate molding processes and assembly operations, directly reducing labor and material costs while maintaining structural integrity through the unified construction.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If metal chassis are used for support and rigidity, then structural strength is improved, but corrosion issues arise

Engineering Contradiction:

Improvechassis strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs fiber-reinforced plastic composite material to form both the cabin body and chassis in a single integral structure. This composite material provides the necessary structural strength and rigidity while inherently resisting corrosion, eliminating the problems associated with metal chassis without sacrificing mechanical properties.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If utility members are installed on the exterior or interior, then functionality is achieved, but protection and aesthetics are compromised

Engineering Contradiction:

Improveutility installationVSAvoidutility protection

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates utility members such as electrical wiring and piping within cavities and channels formed inside the integrally molded structure. This nesting approach allows utility members to be protected within the body itself, maintaining both functionality and aesthetic appearance by concealing them from external view and environmental exposure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250033550A1Integrally molded recreational vehicle body

Publication Date: 2025.01.30 SPIVAK PAUL

AI summary

A recreational vehicle body includes a base and a chassis integrally molded with the base, the chassis including a plurality of ribs that extend downward from the base. The recreational vehicle body includes one or more layers that are molded to integrally form the base and chassis. Moreover, the plurality of ribs forms a frame and one or more crossmembers within the frame.