Residence Module Wall Reinforcement for Longitudinal Crash Loads

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Solution Overview

Problem

Recreational vehicles lack structural rigidity and crash energy absorption capacity, particularly in the longitudinal direction, due to partial and visible connections between wall surfaces, which compromises safety in collisions and rollovers.

Innovation Solution

Incorporating stiffening profiles made of lightweight materials, such as fiber composites, inside the wall surfaces at connection points to transmit forces continuously in the longitudinal direction, maintaining the external geometry and enhancing overall structural strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional profiles are used to connect wall surfaces, then connection is achieved, but longitudinal rigidity is insufficient and appearance is compromised

Engineering Contradiction:

Improvelongitudinal rigidityVSAvoidexternal geometry

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The stiffening profile is inserted into a recess formed in the wall surfaces, nesting the structural element within the existing geometry. This allows the profile to provide longitudinal rigidity while remaining hidden, thus improving strength without compromising the external appearance of the vehicle body.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The stiffening profile acts as an intermediary element between the wall surfaces, transmitting forces continuously in the longitudinal direction. By being inserted into the recess, it mediates the connection between wall panels while maintaining a smooth external geometry, resolving the contradiction between structural requirements and aesthetic appearance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If multiple profile sections are used consecutively, then connection coverage is improved, but structural continuity is reduced

Engineering Contradiction:

Improveconnection coverageVSAvoidforce transmission continuity

Core Design Contradiction:

Area of stationary objectVSStability of the object's composition

Solution Approach 1:

Multiple profile sections are merged by inserting their adjoining ends into one another, creating a continuous stiffening structure. This combining approach maintains force transmission continuity while still providing extensive connection coverage along the vehicle body, resolving the contradiction between coverage area and structural stability.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If lightweight materials are used for wall surfaces, then vehicle weight is reduced, but structural strength is compromised

Engineering Contradiction:

Improvevehicle weightVSAvoidoverall structural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The solution uses composite construction by combining lightweight wall surface materials with stiffening profiles made of appropriate materials. The profile is inserted into the lightweight wall structure to provide the necessary structural strength and longitudinal rigidity, thus achieving both weight reduction and structural integrity through material composition rather than relying on a single material type.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP3828031B1Leisure vehicle with residence module

Publication Date: 2023.08.30 ERWIN HYMER GRP SE

AI summary

In a recreational vehicle with a living body, in particular a motorhome (2) or caravan, with wall surfaces (5) made of flat panel elements and/or lightweight materials, wherein stiffening profiles (9) are attached to the inside and/or inserted into the wall surface (5) at the connections of the wall surfaces (5) to each other, the stiffening profiles (9) can transmit forces continuously in the longitudinal direction over their ends.