Unitary RV Slide-Room Shell Molded via Vacuum Resin Transfer
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Solution Overview
Problem
Traditional slide-room configurations in recreational vehicles are prone to water leakage due to gaps between panel members and irregularities in the surface, leading to increased manufacturing variances and aesthetic issues, resulting in higher warranty costs and reduced fit and finish.
Innovation Solution
A method for forming a fiberglass slide-room shell using a molding apparatus with mandrels and a vacuum-assisted resin transfer process, creating a one-piece unitary construction with an integrally formed flange that eliminates the need for separate fasteners and reduces surface irregularities, enhancing sealing and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate panel construction with mechanical fasteners is used, then ease of manufacture is improved, but manufacturing precision deteriorates due to gaps and surface irregularities between panels
Solution Approach 1:
The patent merges multiple separate panels into a single unitary molded structure. The slide room assembly is formed as one integrated piece with continuous surfaces, eliminating the need for separate panel assembly, mechanical fasteners, and caulking operations. This resolves the contradiction by achieving both ease of manufacture (single molding operation) and manufacturing precision (continuous surfaces without gaps).
Solution Approach 2:
The molding apparatus uses segmented mandrels that can be assembled and disassembled. The mandrels are divided into multiple sections that form the mold cavity when assembled, allowing the mold itself to be segmented for ease of manufacture while producing a non-segmented unitary product with high manufacturing precision.
2Ease of manufacture
If traditional separate panel construction is used, then ease of manufacture is improved, but reliability deteriorates due to water leakage through joints
Solution Approach 1:
By combining all panels into a single unitary molded structure, the patent eliminates the joints and seams that cause water leakage in traditional constructions. The continuous molded surface provides inherent water resistance without requiring additional sealing operations, thus improving reliability while maintaining ease of manufacture through the single-step molding process.
3Ease of manufacture
If traditional separate panel construction with flanges and brackets is used, then ease of manufacture is improved, but device complexity increases due to multiple components
Solution Approach 1:
The patent merges the slide room panels, flanges, brackets, and sealing surfaces into a single unitary molded component. This integration eliminates the complexity of assembling multiple separate parts while maintaining ease of manufacture through the efficient single-step molding process. The molded structure includes all necessary features as integral parts of the unified design.
4Ease of manufacture
If traditional separate panel construction is used, then ease of manufacture is improved, but insulation performance deteriorates due to thermal bridges at joints
Solution Approach 1:
By combining all panels into a single continuous molded structure, the patent eliminates thermal bridges at panel joints and fastener locations. The uninterrupted insulation material throughout the unitary structure provides superior thermal performance compared to traditional assembled panels, while the single-step molding process maintains ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces water leakage, improves the fit and finish, and enhances insulation by eliminating leak paths and surface irregularities, resulting in a more aesthetically pleasing and cost-effective slide-room assembly.
Implementation Method 1
vacuum-assisted resin transfer process
Data Source
AI summary
A slide-room for installation in a recreational vehicle or other structure is disclosed. The slide-room comprises a shell, which can be constructed from fiberglass. The shell comprises an end wall, a ceiling, a floor, two opposing side walls, and a flange extending from the end wall, wherein the end wall, the ceiling, the floor, the side walls and the flange comprise a one-piece, unitary construction. Also disclosed are methods for molding composite components, such as slide-room. In one specific implementation, the shell for a slide-room is formed from fiberglass using a vacuum-assisted resin transfer process. During the vacuum-assisted resin transfer process, a mold apparatus can include a perimeter seal system to inhibit resin from flowing into spaces between mating components of the mold. The perimeter seal system can include clamp seal assemblies and/or vacuum seal assemblies.