SURFACE ELEMENT FOR A CAMPING VEHICLE OR MOBILE HOME

Abstract

The invention relates to a surface element, in particular a wall element, for a camping vehicle or a mobile home, in particular caravans, motorhomes, etc., as well as a method for its production.

Claims

1-6. (canceled)

7. A method for producing a surface element for a camping vehicle or a mobile home, comprising the following steps: a) producing a frame structure by applying a flowable, hardenable material in a desired form onto a base; b) hardening the flowable, hardenable material; c) connecting the finished frame structure with at least one top layer.

8. The method according to claim 7, wherein the desired form of the frame structure is introduced into a panel made of insulating material, the panel is subsequently connected with a top layer and then the flowable, hardenable material is introduced, into the incised spaces in the panel in order to produce a frame structure.

9. The method according to claim 7, wherein the flowable, hardenable material is sprayed, onto one of two top layers for producing the frame structure, flowable insulating material, is subsequently introduced into spaces of the frame structure, and then the second top layer is glued, onto the frame structure, so that the frame structure and the insulating material are arranged between the two top layers.

10. The method according to claim 7, wherein the flowable, hardenable material is applied onto a work base for producing the frame structure, subsequently the frame structure is connected, with a top layer, flowable insulating material, is subsequently introduced into spaces of the frame structure, and then the second top layer is applied onto the frame structure so that the frame structure and the insulating material are arranged between the two top layers.

11. The method according to claim 7, wherein the flowable, hardenable material is introduced or applied, respectively, via a casting process.

12. The method according to claim 7, wherein the frame structure is produced in at least two work steps, wherein different materials and/or different material thicknesses are preferably used for different frame structure sections in the corresponding work steps.

13. The method according to claim 7, wherein after the application of the second top layer onto the frame structure, the sandwich-like structure, consisting of two top layers, a frame structure and insulating material, is further processed by milling out window and door areas and/or incorporating an outer contour.

14. The method according to claim 7, wherein the flowable, hardenable material is one or more of plastic, fiber-reinforced plastic, natural-fiber-reinforced plastic, resin, and foam.

15. The method according to claim 7, wherein before applying the second top layer, the surface of the composite structure consisting of a frame structure and insulating material is calibrated, for example smoothed, machine-processed, etc.

16-20. (canceled)

Description

DESCRIPTION OF FIGURES

[0025] In the figures:

[0026] FIG. 1: shows the schematic procedure of a first embodiment of the method according to the invention for producing a surface element according to the invention;

[0027] FIG. 2: shows the schematic procedure of a second embodiment of the method according to the invention for producing a surface element according to the invention;

[0028] FIG. 3: shows the schematic procedure of a third embodiment of the method according to the invention for producing a surface element according to the invention;

[0029] FIG. 4: shows a top view of a frame structure of a surface element according to the invention.

DETAILED DESCRIPTION

[0030] FIG. 1 schematically shows the approach to an embodiment of the method according to the invention. In this embodiment, a large-sized panel 1 is initially produced from EPS or XPS (step a)). Now, the desired contours 2 of a frame structure are incised or milled out of the panel 1. The parts 3 not required are removed (step b)). Now a top layer 4 is glued thereon (step c)). The top layer 4 corresponds to the later outer shell or inner shell of a side wall of a camping vehicle in the case at hand. The composite structure 5 made of the top layer 4 and the incised panel 1 functions as a stencil 101 for the frame structure to be produced in the next step. Here, the hollow spaces 2 in the panel 1 are filled with flowable plastic (step d)). After the hardening of the plastic, the finished frame structure 6 is available. Now, the open surface is calibrated. Then, a second top layer 7 is glued thereon (step e)). This second top layer 7 later functions as an inner shell or outer shell of a side wall of a camping vehicle. After gluing on the second top layer, a finished sandwich-like composite is now available which corresponds to a surface element according to the invention in form of a wall element 100. This sandwich-like composite can now be processed further (for example by milling out windows and/or doors, incorporating an outer contour, etc.).

[0031] FIG. 2 schematically shows the procedure of another embodiment of the method. In this embodiment, flowable material 8 is initially applied in a desired form onto a work table from a dispensing device, so that a base frame structure 9 is initially formed. This base frame structure 9 already has a contour 10 for a door, for example (step a)).

[0032] Subsequently, additional structures 11 are applied onto the work table. The additional structures consist of a different flowable, hardenable material in this case. Polyurethane foam was used for the additional structures 11 in this case. Ultimately, a finished frame structure 12 is available (step b)).

[0033] Now, a top layer 13 is glued together with the frame structure 12 (step c)). Now, flowable insulating material 15 is introduced into the spaces 14 of the frame structure 12 (step d)). After the hardening of the frame structure 12, the open surface is calibrated. In the next step, a second top layer 16 is glued onto the frame structure 12.

[0034] Ultimately, another finished sandwich-like composite is available here, too, which corresponds to a surface element 100 according to the invention and can be processed further.

[0035] FIG. 3 shows a schematic illustration of the procedure of a third embodiment of the method. In this embodiment, one of two top layers 17 is initially fixed on a work surface and optionally adhered thereto via a vacuum (step a)).

[0036] Now, a base frame structure 18 is applied onto the top layer 17 via a dispensing device (step b)).

[0037] In another step of the method, additional structures 19 are applied to the top layer 17 (step c)). Ultimately, a finished frame structure 20 is available.

[0038] Now insulating material 21 is introduced into the spaces 14 of the finished frame structure 20 (step d)). The insulating material 21, however, is not introduced into door and window openings 22. After the hardening of the frame structure material, the surface is calibrated.

[0039] Now a second top layer 23 is glued onto the frame structure 20 (step e)). Ultimately, a finished sandwich composite is available which corresponds to a surface element 100 according to the invention. This sandwich composite can now be processed further (for example milling for windows and doors, outer contour).

[0040] FIG. 4 shows the frame structure 12 of the surface element produced in embodiment 2 of the method (FIG. 2). The frame structure 12 comprises a door section 10. The corners of the door section are not filled with stiffening corners, since the corners were sprayed following the contour of the door. The frame structure shown here is intended for use as a side wall of a camping vehicle in which a lift bed is to be arranged in the frontal upper area. In this area, a reinforcement of the frame structure 12 can be observed in the frame structure 12 in which several layers 25 of frame structure material are arranged over each other. Due to the layers 25, a good screwing possibility is provided for a lift bed.