Integrated RV Floor Structure for Lightweight Seat Rail Attachment
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Solution Overview
Problem
Existing rail and carrier systems for recreational vehicles, such as campervans, are complex, requiring precise assembly and increasing unladen weight, leading to high costs and reduced payload capacity.
Innovation Solution
A method for producing an integrated floor with a lightweight board and profile body, featuring longitudinal openings in the cover layer and profile body for precise positioning of fastening devices, allowing for adjustable and variable seat attachment without the need for complex assembly devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex rail and carrier systems are installed in recreational vehicles, then seat attachment functionality is achieved, but device complexity and assembly difficulty increase significantly
Solution Approach 1:
The patent integrates the rail function directly into the floor structure by forming engagement protrusions on the underside of the floor panel and corresponding engagement recesses in the seat base. This merging of the rail system with the floor eliminates the need for separate, complex rail assemblies while maintaining seat attachment functionality.
Solution Approach 2:
The invention extracts the essential rail function from complex rail systems and implements it through simple geometric features (protrusions and recesses) formed directly on the floor panel. This extraction reduces device complexity while preserving the core functionality of seat attachment.
2Adaptability or versatility
If complex rail systems with multiple components are used, then seat positioning capability is achieved, but the number of components and assembly steps increase
Solution Approach 1:
The patent combines multiple functions (floor structure, rail system, and positioning mechanism) into a single integrated floor panel design. The engagement protrusions are formed directly on the floor underside, eliminating the need for separate rail components and simplifying assembly to a single integration step.
Solution Approach 2:
The engagement protrusions and recesses are pre-formed as integral features of the floor panel during manufacturing. This preliminary action ensures precise positioning capability is built into the floor structure itself, eliminating the need for complex assembly operations to achieve proper seat positioning.
3Adaptability or versatility
If traditional rail systems are installed, then seat attachment is enabled, but unladen weight increases reducing payload capacity
Solution Approach 1:
The invention extracts only the essential weight-bearing function from traditional rail systems and implements it through minimal geometric features (protrusions and recesses) formed on the floor panel. This extraction eliminates unnecessary rail components and their associated weight while maintaining seat attachment capability.
Solution Approach 2:
The patent applies local reinforcement only where needed - the engagement protrusions and recesses are formed with increased local thickness or density at specific attachment points. This local quality approach provides sufficient strength for seat attachment without adding weight to the entire floor structure.
4Manufacturing precision
If precise assembly devices and extreme positioning accuracy are required, then rail system functionality is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges the positioning function into the floor panel itself through pre-formed engagement protrusions and recesses. The precise positioning is achieved through the geometric design of these features during floor manufacturing, eliminating the need for separate positioning devices and complex assembly operations.
Solution Approach 2:
The engagement features are pre-formed with precise dimensions and positions during floor panel manufacturing. This preliminary action ensures accurate seat positioning is built into the floor structure itself, eliminating the need for complex assembly devices to achieve precise rail positioning during vehicle assembly.
Data Source
Figure 1~3
AI summary
Method for manufacturing a floor (2), in particular an integrated floor, for recreational vehicles (1), in particular for motorhomes and/or campervans, wherein the floor (2) comprises at least one lightweight panel (7).It is proposed that at least one lightweight panel (7) be formed with at least one profile body (8) and at least one lightweight foam (9), that the lightweight panel (7) be provided with a cover layer (10) on which, in the assembled state in which the floor (2) is installed in the recreational vehicle (1), a top surface (15) of the floor (2) is formed, that at least one longitudinal opening (16) be provided in the cover layer (10), and that the at least one longitudinal opening (16) of the cover layer (10) be positioned with respect to the at least one profile body (8) of the lightweight panel (7) such that access from the top surface (15) of the floor (2) into a profile space (20) of the profile body (8) is possible via the longitudinal opening (16) of the cover layer (10) and a longitudinal opening (18) of the profile body (8). Furthermore, a floor (2) and a recreational vehicle (1) are specified.