Vehicle Roof Air-Conditioning Plastic Support Frame
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Solution Overview
Problem
Existing rooftop air-conditioning systems for vehicles are heavy due to metal support frames, which adversely affect vehicle behavior and are difficult to mount and maintain, especially when components are made of plastic.
Innovation Solution
The air-conditioning system uses a plastic support frame divided into multiple parts connected via detent or plug-type connections, reducing weight and simplifying mounting and maintenance, with optional reinforcing elements for increased stiffness and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal support frames are used for the air-conditioning system, then structural strength and stability are ensured, but the weight of the system increases significantly
Solution Approach 1:
The patent changes the material parameter from metal to plastic (polymer) for the support frame components. This material substitution fundamentally alters the weight-to-strength ratio, reducing overall system weight while maintaining adequate structural strength through optimized plastic component design and geometry.
Solution Approach 2:
The patent employs composite construction by combining plastic material with strategic metal reinforcements or mounting elements. The support frame itself is made of plastic, but metal elements are used where high strength is required, creating a hybrid structure that optimizes both weight and strength requirements.
2Stability of the object's composition
If the support frame is made as a single piece, then structural integrity is improved, but manufacturing complexity and cost increase due to large injection molds required
Solution Approach 1:
The patent divides the support frame into multiple separate plastic components that can be manufactured using smaller, more economical injection molds. These segmented components are then assembled together using connection elements, achieving the same structural integrity as a single-piece design while significantly reducing manufacturing complexity and mold size requirements.
Solution Approach 2:
The patent introduces connection elements as intermediary components that join the segmented support frame parts. These connection elements act as mediators, providing the necessary mechanical linkage and structural continuity between separate plastic components, thereby achieving overall structural integrity without requiring a single large molded piece.
3Weight of moving object
If plastic components are used for the air-conditioning system, then weight is reduced and manufacturing is simplified, but the difficulty of mounting and maintenance increases
Solution Approach 1:
The patent incorporates reversible or adjustable connection mechanisms that allow the plastic components to be easily assembled and disassembled. The connection elements are designed to facilitate simple mounting operations and enable straightforward maintenance access, transforming static plastic components into dynamically adjustable assemblies that are as easy to service as metal systems.
Data Source
AI summary
An air-conditioning system for a vehicle may include at least one of a condenser module including a condenser housing and a condenser, the condenser arranged in the condenser housing, and an air-conditioning module including an air-conditioning housing and an evaporator, the evaporator arranged in the air-conditioning housing. The air-conditioning system may also include a plastic support frame including a plurality of parts, the support frame configured to support at least one of the condenser module and the air-conditioning module, and to hold at least one of the condenser module and the air-conditioning module on a vehicle roof. The air-conditioning system may also include at least one detent housing connection. The air-conditioning system may also include at least one of at least one detent support connection and at least one plug-type support connection including a securing element.