International Journal of Scientific Research and Engineering Development

This paper presents the design, development, and performance evaluation of an insulated air-conditioned (AC) cabin capable of maintaining interior temperatures between 25°C and 30°C under extreme ambient conditions up to 80°C. The system was designed for use in automotive, industrial, and defense environments, where thermal comfort and energy efficiency are essential. A dual-layer insulation system consisting of 30–40 mm of polyurethane foam (PUF) and 8 mm of reflective bubble foil was implemented. Thermal load analysis, including conduction, radiation, and occupant heat gain, was conducted to determine the cooling requirement. Experimental testing under a polycarbonate shed environment showed that the insulation reduced the total cooling load to approximately 0.6 kW, enabling the use of a compact 1 TR rooftop AC unit. The insulated cabin achieved interior comfort within the desired range with a low compressor duty cycle of 25–35%, confirming high thermal efficiency. The study demonstrates a practical approach to integrating insulation materials with optimized HVAC design for maintaining comfortable conditions in high-temperature environments.

C.A.Jagadish, K.Siva, Arunkumar T, Deva S, Hariprasath V S,"Development of a Thermal Insulated AC Cabin for Extreme Temperature Conditions" International Journal of Scientific Research and Engineering Development, V9(2): Page(669-674) Mar-Apr 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.