Motorhome Front Mask Frame Structure for Crash Force Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing mobile home front masks are constructed as single-layer components, lacking the ability to absorb transverse or vertical forces effectively, leading to inconsistent safety structures and inadequate reinforcement, especially in crash or rollover scenarios, due to varying material thicknesses and processing qualities during manufacturing.
Innovation Solution
A fully integrated mobile home design where the front mask is attached to a supporting structure for the drive motor and front axle, incorporating a frame structure made of fiber-reinforced plastics, which enhances stability by forming a safety cell that can absorb forces and includes features like A-pillar and B-pillar elements for improved torsional strength and energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer front mask is used, then the device complexity is reduced, but the strength and ability to absorb forces in transverse or vertical directions deteriorates
Solution Approach 1:
The patent applies composite materials by constructing the front mask as a multi-layer structure combining a first fiber-reinforced plastic layer, a second fiber-reinforced plastic layer, and a foam core layer. This composite construction provides both transverse and vertical force absorption capabilities while maintaining structural integrity, directly resolving the contradiction between simple structure and high strength.
Solution Approach 2:
The patent introduces a third dimension by adding the foam core layer between two fiber-reinforced plastic layers, transforming the structure from a single-layer to a multi-layer sandwich construction. This dimensional enhancement enables the front mask to absorb forces in multiple directions (transverse and vertical) simultaneously, solving the strength limitation of single-layer designs.
2Ease of manufacture
If manual manufacturing of front masks is used, then the ease of manufacture is improved, but the manufacturing precision and consistency of material thickness deteriorates
Solution Approach 1:
The patent specifies precise parameter ranges for the foam core layer thickness (5-20 mm) and defines standardized dimensions for the fiber-reinforced plastic layers. These parameter specifications enable consistent manufacturing quality while maintaining ease of production through modular component assembly, resolving the contradiction between manual manufacturing flexibility and precision consistency.
3Strength
If additional reinforcement components are added to the front mask, then the strength is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the front mask structure itself: the multi-layer construction provides both structural strength and force absorption, while integrated guide elements for blackout blinds and pull-down beds combine safety reinforcement with functional features. This merging approach improves strength without proportionally increasing complexity, as the reinforcement and functional elements are integrated rather than added as separate components.
Data Source
AI summary
In a motorhome with a front mask (3) replacing the windshield and front body parts of the manufacturer of the underlying vehicle, wherein the front mask (3) is attached to a supporting structure for the drive motor and the front axle via retaining elements, a frame structure (12) is provided behind and on the front mask (3) and/or integrated into the front mask (3).