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Pop-up Camper Trims Weight, Adds Versatility
Sylvan’s pop-up employs extruded aluminum parts to keep weight down without adding complexity
Terry Costlow, Contributing Editor -- Design News, May 14, 2008
A pop-up trailer from Sylvan Sport addresses the present economic condition, making extensive use of aluminum to reduce fuel consumption while providing versatility so only one trailer is needed. The trailer is being showcased at ET ’08, an aluminum extrusion technology show held every four years.
The company, based in Cedar Mountain, NC developed a trailer that folds out large enough to sleep four and allow adults to stand up inside. The surfaces that sit horizontally when the trailer is used as a camper can be folded up so the trailer can carry bicycles or motorcycles. It can also be configured as a simple wagon-like trailer that can haul mulch, lumber or other materials.
The pop-up is made largely with extruded aluminum, which keeps its weight down to about 700 lbs. That’s light enough to be pulled by many four-cylinder vehicles.
Some of the components offer sophisticated functionality. “The inside of the corner post is designed as a bearing for the telescopic tube used to raise the roof,” says Todd Haase, engineering program manager at Hydro Aluminum of Sidney, OH, the extruder that fabricates the parts used for the frame.
However, he says most of the parts are fairly standard components. “There are 12 extrusions for the trailer. Most of them are stock tubes, which minimizes the tooling costs,” Haase says.
Those frame elements are designed so the trailer can be assembled quickly. “It’s easy to attach the bumper; we fabricate a groove so it can be attached with a T-nut," he says.
Though aluminum is a dominant material, plastics and steel are also used. Steel inserts at joints in the frame add strength, while plastics are used for low cost and weight. Simplifying the integration of these elements is a key aspect of design. “It takes only four bolts on the rear frame to marry the steel brackets to the extrusions so you have a strong frame,” Haase says.
Designing components for multiple functions also helps keep size down. For example, the tailgate folds down to become a step for the camper mode. Tabletops can also be used to create a bed,” Haase notes.
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 Sylvan's pop-up employs extruded aluminum parts to keep weight down without adding complexity. |
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