SAFETY CAB FOR A MOBILE HOME OR CAMPER WITH DEFORMATION ELEMENTS

Abstract

The invention relates to a safety cabin for a mobile home or motor home comprising a part of the safety cabin arrangeable behind the driver compartment, with walls of the safety cabin comprising at least one layer of a fibre-reinforced plastic woven fabric and/or non-woven fabric. One layer comprises plies following one another along a transverse direction here. Plies directly following one another comprise different fibre orientations here. The layer in the lateral external walls in a front region of the cabin, in relation to an intended main travel direction, preferably comprises at least three to nine plies. In a rear region of the cabin, in relation to an intended main travel direction, the layer in the lateral external walls preferably comprises one to five plies. Additionally, an intermediate wall is present at a transition from the front region of the cabin to the rear region of the cabin arranged transversely to a longitudinal direction of the cabin, with the intermediate wall comprising a layer including three to nine plies. Similarly, the invention relates to a manufacturing method for the safety cabin according to the invention.

Claims

1. A safety cabin (1) for a mobile home or motor home (2) comprising a part of the safety cabin (1) arrangeable behind a driver compartment (4) characterized in that walls (9, 23, 24, 25) of the safety cabin (1) comprise at least one layer of a fibre-reinforced plastic woven fabric and/or non-woven fabric, wherein a layer comprises plies following one another along a transverse direction, wherein plies directly following one another comprise different fibre orientations with respect to one another, wherein the layer in the lateral external walls (23) in a front region (6) of the cabin, in relation to an intended main travel direction, preferably comprises at least three to nine plies, wherein the layer in the lateral external walls (24) in a rear region (7) of the cabin, in relation to an intended main travel direction, preferably comprises one to five plies, wherein an intermediate wall (9) is present at a transition from the front region (6) of the cabin to the rear region (7) of the cabin arranged transversely to a longitudinal direction of the cabin, wherein the intermediate wall (9) comprises a layer including preferably three to nine plies.

2. The safety cabin (1) according to claim 1, characterized in that more plies are included in the front region (6) than in the rear region (7).

3. The safety cabin (1) according to claim 1, characterized in that the fibre reinforcement is selected from the group comprising carbon fibres, aramide fibres and/or glass fibres.

4. The safety cabin (1) according to claim 1, characterized in that the plastic non-woven fabric and/or woven fabric is a hybrid non-woven fabric and/or woven fabric which comprises a mixed fibre reinforcement of carbon fibres and aramide fibres.

5. The safety cabin (1) according to claim 1, characterized in that in the layer in the front region (6) of the cabin, a hybrid woven fabric and/or non-woven fabric is included, which i. comprises four plies, wherein the fibre orientations of the plies following one another each differ by an angle of 30° or ii. comprises six plies, wherein the fibre orientations of the plies following one another each differ by an angle of 18° or iii. comprises seven plies, wherein the fibre orientations of the plies following one another each differ by an angle of 15°.

6. The safety cabin (1) according to claim 1, characterized in that in the layer in the rear region (7) of the cabin, a hybrid woven fabric and/or non-woven fabric is included, which i. comprises two plies, wherein the fibre orientations of the plies following one another each differ by an angle of 90° or ii. comprises three plies, wherein the fibre orientations of the plies following one another each differ by an angle of 45°.

7. The safety cabin (1) according to claim 1, characterized in that two external plies made of glass fibre-reinforced plastic are included in the layer, which finish the layer at two opposing external surfaces, wherein the fibre orientation of each external ply preferably differs by 90° from the ply therebelow and/or the other external ply.

8. The safety cabin (1) according to claim 1, characterized in that each ply of the layer comprises a thickness of roughly 0.3 mm.

9. The safety cabin (1) according to claim 1, characterized in that the walls (9, 23, 24, 25) of the safety cabin comprise at least one foam material, preferably a hard foam, in particular extruded polystyrene hard foam (XPS).

10. The safety cabin (1) according to claim 9, characterized in that the walls (9, 23, 24, 25) of the safety cabin (1) comprise at least two layers of a fibre-reinforced plastic woven fabric and/or non-woven fabric, wherein a foam material layer is preferably positioned between the layers.

11. The safety cabin (1) according to claim 10, characterized in that the foam material layer comprises a hard foam material and comprises a thickness of roughly 30 mm.

12. The safety cabin (1) according to claim 10, characterized in that the two layers of the fibre-reinforced plastic woven fabric and/or non-woven fabric comprise a ply structure, which is symmetrical in relation to the fibre orientation, with respect to a symmetry plane lying between the layers.

13. The safety cabin (1) according to claim 1, characterized in that the fibre reinforcement of the hybrid non-woven fabric and/or woven fabric is included with a weight proportion of between 40% and 60% and in particular roughly 50% of aramide fibres, wherein carbon fibres are also included and wherein the weight proportions relate to the total weight of the fibre reinforcement.

14. The safety cabin (1) according to claim 1, characterized in that a front (6) and/or a rear (7) region comprises an extension of at least 1.5 m in the longitudinal direction of the safety cabin (1).

15. The safety cabin (1) according to claim 1, characterized in that a chassis of the safety cabin (1) is included, wherein the chassis comprises: at least one foamed profile comprising hybrid woven fabric and/or non-woven fabric as the longitudinal (12) and/or transverse beam (13); at least one panel including hybrid woven fabric and/or non-woven fabric to form a preferably aerodynamic configuration of the regions of the chassis not included by the profiles; at least one layer of the hybrid woven fabric and/or non-woven fabric.

16. The safety cabin (1) according to claim 15, characterized in that the chassis comprises, in a lateral edge region at least in sections along the circumference, at least one deformation element, preferably comprising a honeycomb structure (20) made of carbon fibre-reinforced plastic and/or at least one foamed profile comprising hybrid woven fabric and/or non-woven fabric, wherein the deformation element is preferably present with at least one panel.

17. The safety cabin (1) according to claim 15, characterized in that the chassis comprises at least one rear axle and/or at least one drive unit.

18. The safety cabin (1) according to claim 1, characterized in that the safety cabin (1) comprises at least one battery, at least one fuel cell and/or at least one water tank, with battery, fuel cell and/or water tank preferably being housed in a protective box (21, 22) in the front (6) and/or in the rear (7) region of the cabin.

19. The safety cabin according to claim 18, characterized in that the protective box (22) in the front region (6) is delimited externally at least in sections by at least one deformation element, which in particular comprises a honeycomb structure (20) made of carbon fibre-reinforced plastic and/or at least one foamed profile comprising hybrid woven fabric and/or non-woven fabric, wherein the protective box (22) is preferably connected to a longitudinal (12) and/or transverse beam (13) of the chassis.

20. The safety cabin (1) according to claim 1, characterized in that the interior region (5) comprises at least one seating area (15) installed counter to in particular the main travel direction wherein the seating area (15) comprises a carbon fibre-reinforced hybrid woven fabric and/or non-woven fabric, which is preferably directly connected to the chassis.

21. The safety cabin (1) according to claim 1, characterized in that the safety cabin (1) comprises furniture, in particular at least one seating area (15), a bench, a cupboard and/or bathroom-partition wall, wherein the furniture, observing load path calculations, is fixedly connected by a fibre-reinforced plastic to the chassis and/or to the safety cabin (1).

22. The safety cabin (1) according to claim 1, characterized in that the lateral external walls (23, 24) of the cabin comprise beams arranged in a framework-like manner and made of carbon fibre-reinforced plastic profiles, in particular longitudinal (12) and transverse beams (13), between which the layers of the fibre-reinforced plastic woven fabric are arranged, wherein the beams (12, 13) are preferably arranged along probable load paths in the case of an accident.

23. A manufacturing method for a safety cabin (1) for a mobile home or motor home (2) comprising at least one part of the safety cabin arrangeable behind a driver compartment (4), comprising the manufacture of a layer of a fibre-reinforced plastic woven fabric and/or non-woven fabric for a wall (9, 23, 24, 25) of the safety cabin (1), characterized in that a plurality of plies of a fibre-reinforced plastic woven fabric and/or non-woven fabric are laminated to form one layer, wherein the plies are arranged in the transverse direction of the layer, wherein plies directly following one another comprise different fibre orientations with respect to one another, wherein the layer of a lateral external wall (23) for a front (6) region of the cabin, in the main travel direction, comprises at least three to nine plies, wherein the layer of a lateral external wall (24) for a rear region (7) of the cabin, in the main travel direction, comprises one to five plies, wherein more plies are included in the front region (6) than in the rear region (7) and wherein a layer intended for an intermediate wall (9) in the transverse direction of the cabin comprises three to nine plies.

24. The manufacturing method according to claim 23, further comprising the following steps: laminating two external plies made of glass fibre-reinforced plastic onto the layer, which finish the layer at two opposing external surfaces, wherein the fibre orientation of each external ply preferably differs by 90° from the ply therebelow and/or the other external ply.

25. The manufacturing method according to claim 23, further comprising the following steps: connecting at least two layers of a fibre-reinforced plastic woven fabric and/or non-woven fabric to a wall (9, 23, 24, 25) or to a wall region of the safety cabin (1), wherein a foam material layer is preferably positioned between the layers, wherein the two layers of the fibre-reinforced plastic woven fabric and/or non-woven fabric, in relation to the fibre orientation, comprise a symmetrical ply structure with respect to a symmetry plane located between the layers.

26. The manufacturing method according to claim 23, further comprising the following steps: connecting a wall (23) or a wall region of the front region (6) with a wall (24) or a wall region of the rear region (7) to a lateral external wall or to a wall region of a lateral external wall;

27. The manufacturing method according to claim 23, comprising the manufacture of a chassis of the safety cabin (1), comprising the following steps: providing at least one foamed profile comprising hybrid woven fabric and/or non-woven fabric for a longitudinal (12) and/or transverse beam (13); preferably connecting longitudinal beam (12) and transverse beam (13) Preferably aerodynamic cladding of the regions of the chassis, not included by the profiles, with at least one panel including hybrid woven fabric; preferably inserting at least one layer of the hybrid woven fabric and/or non-woven fabric.

28. The manufacturing method according to claim 27, wherein the carbon fibre-reinforced plastic profile can be manufactured by a pultrusion process.

29. The manufacturing method according to claim 26, comprising the following steps: mounting the lateral external walls (23, 24) or wall regions of the lateral external walls on the chassis to form an external wall of the safety cabin (1) preferably inserting the intermediate wall (9) at a transition from the front region (6) of the cabin to the rear region (7) of the cabin in the transverse direction of the cabin. preferably mounting a ceiling element for a roof of the safety cabin.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0329] FIG. 1 shows a three-dimensional representation of a mobile home with safety cabin in an external view.

[0330] FIG. 2 shows a three-dimensional sectional representation of the mobile home with safety cabin without the front external wall.

[0331] FIG. 3 shows a three-dimensional sectional representation of the mobile home with safety cabin without the front external wall, with essential elements of the internal equipment.

[0332] FIG. 4 shows a three-dimensional representation of the mobile home with safety cabin without the front external wall, with a sectional representation of the rear external wall and a partition shown, in the transverse direction.

[0333] FIG. 5 shows a three-dimensional representation of the mobile home with safety cabin without the front external wall, with a sectional representation of the rear external wall without partition shown, in the transverse direction.

[0334] FIG. 6 shows a three-dimensional sectional representation of the mobile home without further parts of the safety cabin, with longitudinal and transverse beams in the floor region of the cabin.

[0335] FIG. 7 shows a three-dimensional sectional representation of the mobile home with the chassis.

[0336] FIG. 8 shows a three-dimensional sectional representation of the safety cabin from a front perspective.

[0337] FIG. 9 shows a three-dimensional sectional representation of the safety cabin from a rear perspective.

[0338] FIG. 10 shows the mobile home or motor home in a top view.

[0339] FIG. 11a shows the structure of one embodiment of a wall in the cross-section.

[0340] FIG. 11b shows the structure of a second embodiment of a wall in the cross-section.

[0341] FIG. 11c shows the structure of a third embodiment of a wall in the cross-section.

[0342] FIG. 12 shows the structure of a multi-axial hybrid non-woven fabric.

[0343] FIG. 13 shows the manufacturing process of a multi-axial non-woven fabric.

DETAILED DESCRIPTION OF THE IMAGE

[0344] FIG. 1 shows a three-dimensional representation of a mobile home 2 with safety cabin 1 in an external view. The safety cabin 1 with the external regions 3 is located behind the driver compartment 4.

[0345] FIG. 2 shows a three-dimensional sectional representation of the mobile home 2 with safety cabin 1 without the front external wall. The interior region 5 is clearly visible.

[0346] FIG. 3 shows a three-dimensional sectional representation of the mobile home 2 with safety cabin 1 without the front external wall, but including essential internal equipment. In this way, essential safety-relevant features and primarily deformation elements of the cabin 1 can be discerned. The interior region 5 is e.g. divided by a partition in the transverse direction 9 into a front 6 and a rear region 7. The front region 6 is the passenger region during the journey, while in the rear region 7 the bathroom and a bed are housed (see FIG. 2). The seating area counter to the travel direction 15 in the front region 6, which is connected via a connector 18 to the safety cabin, is clearly visible. A stabilising angular element 8 is introduced in a corner region of the cabin 17 above the seating area to increase safety in an unobtrusive manner and appearing to be part of the interior furniture.

[0347] FIG. 4 shows a three-dimensional representation of the mobile home 2 with safety cabin 1 without the front external wall and the interior furniture with a sectional representation of the rear external wall, with the partition being shown in the transverse direction 9. The layers of glass fibre-reinforced plastic 11 and carbon and/or aramide-fibre reinforced plastic 10 introduced into the external regions 3 and in the partition in the transverse direction 9, which significantly increase the safety of the cabin 1, are visible in the drawing. Since the interior furniture is now shown in this figure, the stabilising angular element 8 can also be clearly discerned in the corner region of the cabin 17.

[0348] FIG. 5 shows in principle the same representation of the safety cabin 1 as FIG. 4, but without the partition being represented in the transverse direction 9, whereby the introduced layers of glass fibre-reinforced plastic 11 and carbon and/or aramide-fibre reinforced plastic 10 in the external regions 3 of the safety cabin 1 are even more clearly discernible.

[0349] FIG. 6 shows a three-dimensional sectional representation of the mobile home 2 without further parts of the safety cabin 1, with two longitudinal 12 and four transverse beams 13 in the floor region of the cabin 1. They preferably consist of carbon and/or aramide fibre-reinforced plastic and are preferably connected both to the chassis 14 and to the upper structure of the safety cabin 1.

[0350] FIG. 7 shows a three-dimensional sectional representation of the mobile home 2 with the chassis 14 without longitudinal 12 and transverse beam 13.

[0351] FIG. 8 shows a three-dimensional sectional representation of the safety cabin 1. On one side, the interior region 5 is illustrated and on the other side an external region 3 is illustrated. The intermediate wall 9 divides the safety cabin 1 into two regions. The front region 6 of the safety cabin 1 comprises, inter alia, a seating area 15 counter to the main travel direction, with this seating area preferably being connected via a connector 18 to the chassis. The chassis of the safety cabin 1 comprises a protective box 22. The protective box 22 is preferably configured such that it is surrounded from two sides each by a longitudinal beam 12 comprising preferably a honeycomb 20 and from a further side by a transverse beam 13. The longitudinal beams 12 are preferably configured as foamed profiles comprising hybrid woven fabric and/or non-woven fabric. The protective box 22 is arranged in the front region 6 of the safety cabin 1 and provides a space for a battery and/or a fuel cell with a hydrogen tank. A protective box 21 is also present in the rear region 7. Unlike the front protective box 22, it is not integrated in the chassis. The protective box 21 is configured such that the region to be protected is surrounded by a frame or a framework-like structure of longitudinal and transverse beams, which are connected to the beams (12, 13) of the chassis.

[0352] FIG. 9 shows a three-dimensional sectional representation of the safety cabin 1. In this case, the tail of the safety cabin 1 is in focus. The rear region 7 of the safety cabin can be seen. The rear region 7 comprises a protective box 21. A transverse beam 13 is attached above the protective box 21, which comprises a honeycomb structure 20 made of carbon fibre-reinforced plastic along the circumference. Additionally, the honeycomb structure 20 is included in the edge regions of the chassis.

[0353] The mobile home or motor home 2 is represented in a top view in FIG. 10. The safety cabin 1 is divided by an intermediate wall 9 into a front 6 and a rear region 7. Additionally, a deformation element 16 is present between the driver compartment 4 and the front region 6 of the safety cabin 1. The external walls of the front region 23 and the intermediate wall 9 and the deformation element 16 preferably comprise a hybrid woven fabric and/or non-woven fabric with 3 to 9 plies per cover layer. The external walls of the rear region (24, 25), in contrast, preferably comprise a hybrid woven fabric and/or non-woven fabric with 1 to 5 plies per cover layer.

[0354] FIGS. 11a, 11b and 11c illustrate the structure of an external wall in the cross-section. In this case, the wall is divided into 3 sections. One outer cover layer, in relation to the safety cabin, one inner cover layer, in relation to the safety cabin, and one hard foam ply (XPS) arranged between both cover layers. The external and internal cover layers include, in FIG. 11a, in each case two GFP non-woven fabrics, which each enclose a hybrid non-woven fabric (CFP) from one side. The hybrid non-woven fabric (CFP) is laminated here by three standardised biaxial hybrid non-woven fabrics (CFP) with a fibre alignment of (0°/90°; +/−45°, 90°/0°) with respect to a multi-axial non-woven fabric. The GFP non-woven fabrics have a fibre orientation of (0°/90° or 90°/0°). The structure of the internal cover layer is identical to the external cover layer, except for the arrangement of the fibre orientations of the standardised biaxial non-woven fabric. The fibre orientations of the internal cover layer are here mirror-inverted with respect to the fibre orientations of the external cover layer such that the hard foam ply (XPS) is considered to be a mirror plane or a symmetry plane. FIGS. 11b and 11c differ from FIG. 11a in the number of the laminated biaxial hybrid non-woven fabrics (CFP) and in their fibre orientations.

[0355] FIG. 12 shows the structure of a multi-axial hybrid non-woven fabric. By laminating a plurality of unidirectional non-woven fabrics, the multi-axial non-woven fabric comprises a fibre orientation of (0°/−15°/−30°/−45/°−60°/−75°/−90°).

[0356] FIG. 13 illustrates the manufacturing process of a multi-axial non-woven fabric. The arrow demonstrates the production direction here which the 0° fibre orientation defines.

LIST OF REFERENCE NUMERALS

[0357] 1 safety cabin [0358] 2 mobile home or motor home [0359] 3 external region [0360] 4 driver compartment [0361] 5 interior region [0362] 6 front region [0363] 7 rear region [0364] 8 stabilising angular element [0365] 9 partition in the transverse direction [0366] 10 carbon and/or aramide fibre-reinforced plastic [0367] 11 glass fibre-reinforced plastic [0368] 12 longitudinal beam [0369] 13 transverse beam [0370] 14 chassis [0371] 15 seating area counter to travel direction or main travel direction [0372] 16 deformation element between driver compartment and interior region [0373] 17 corner region of the cabin [0374] 18 connector [0375] 20 honeycomb structure [0376] 21 protective box in the rear region [0377] 22 protective box in the front region [0378] 23 lateral external wall in the front region [0379] 24 lateral external wall in the rear region [0380] 25 external wall at the rear of the safety cabin