DE2558300A1 - IMPROVED MANUFACTURING PROCESS FOR BODY BODIES FOR TRANSPORT MEANS - Google Patents

Description

Patent attorneys WILCKEN & LAUFER DR. HUGO WILCKEN DIPL.-ING. THOMAS »WILCKEN · DIPL.-CHEM. DR. WOLFGANG LAUFER LOBECK LÜBECK MUNICH

1) TADA HISA KAWAMATA

Rua Pirassununge, 484 - Sao Paulo (Brazil)

2) CARLOS JORGE FREIRB ANTUNES

Rua Bento de Matos, 133/33 Sao Paulo (Brazil)

3) CARLOS DE BRITO ANTUNES

Rua Augusta, 2110/11 Sao Paulo (Brazil)

Improved manufacturing process for body structures for means of transport

The invention relates to an improved manufacturing method for body structures or car bodies for means of transport or Transport units such as trucks, vans, trailers, railroad cars and other means of transport that are also made up isothermal heat protection systems or cooling systems exist. Transport units of this type usually consist of a synthetic material and appear as a uniform construction, such as from shell construction. However, these body structures or car bodies are made of separate panels or Assembled parts that are attached to a support structure and which are assembled and locked by means of special fastening devices.

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2 * LÜBECK 1 · Breil »Strafie 52-54 - Telephone {0451) 75888 * I MUNICH · * · Prinireflentansfrae · 74 · Telephone (089) 4773«

: Homburg 138119-204 · Bank «,: Commerzbank Lübeck (BLZ 23040022) Account no. 3W187 · Deuts * «Bank MOndien (BLZ 70070010) Account no. 65/05432

It is known that the conventional car bodies described above have a number of disadvantages. These consist mainly of the complex production method of the car body, whereby a large amount of waste material arises, many and different devices and operations for the production of the individual panels or parts are required and also is the production of a Support structure required for the car body. There are also additional materials, devices, and manufacturing processes for the assembly of the individual parts of the conventional car bodies required.

It is also known that the car bodies assembled in the construction described above do not have a rigid structure and therefore, when using these car bodies, there are clearances, grooves and other irregularities, especially on poor roads in the structure, requiring constant and costly repairs.

The present invention was therefore based on the object of an improved method for the production of body structures and in particular To develop car bodies for means of transport or transport units of the type described above, the car bodies not as are conventionally assembled from plates or similar separate components, but a complete and practically self-supporting uniform construction is created (if necessary in shell construction), which in simple and rational Way can be made.

In the following description preferred embodiments

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of the method according to the invention with reference to the accompanying drawings explained in detail. -.

FIG. 1 is a perspective view of the separate components of FIG external mold for the manufacture of the car body according to the invention.

Figure 2 is a perspective view of the assembled components of the outer mold.

Fig. 3 is a perspective view of the internal and complementary Mold for the manufacture of the car body according to the invention.

Figures 4 and 5 show the successive stages of the composition the outer and inner forms into a single common car body structure.

FIGS. 6 and 7 are cross-sectional and longitudinal sectional views along FIG Lines A-A and B-B of Fig. 5, wherein the car body ^ Kit in the molding stage for the production of the car body structure is located.

Fig. 8 is a perspective view of the car body structure showing has already been extracted from the corresponding forms.

Figures 9 and 10 are perspective views with partial sectional views the outer and inner forms for the manufacture of the roof or the cover for the car body according to the Invention.

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11 is a cross-sectional view of that in FIGS. 9 and 10 Shapes shown, which are assembled in a suitable manner for the molding process for making the roof or the cover.

Figure 12 is an overall view of the process of the invention completed car body.

From the figures listed above it can be seen that the in novel Well-made car body for means of transport is made of two separate parts, namely a main body, which consists of the floor and the side walls and represents a single self-supporting part (see Fig. 8) and a roof part for the car body. Both the main body and the roof part are made with a single pair of moldings that vary in size and configuration desired Own shape. The main body and the roof part are then assembled in a simple manner and result in a single, unitary one and self-supporting structure as seen in FIG.

From Figs. 1 and 2 it can be seen that. the outer shape for the manufacture of the car body according to the invention from separate Plates consists, for example, of the bottom 1 and the sides 2, which consist of a plastic or a plastic material. The bottom 1 consists of a plate 3, which has a rectangular or other desired shape, and which has an inner surface indicates, which is provided with ribs 4 or other details, depending on how the external configuration of the bottom part is desired. The outer surface of the plate is also not shown here Provided ribs, which, however, have the task of reinforcement

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sit. The plate 3 has at the free edge a surrounding band 5 with a beveled surface at an angle of 45, which in a Surface and a peripheral flange 6 ends, which is provided with mounting holes or openings 7. The bottom plate 1 is at the Inside subjected to a non-stick treatment and then with a layer 8 made of a plastic mixture of glass fibers (fiberglass) and coated synthetic resins, which is spread only over the surface of the plate 1, the inclined edge or the inclined band 5 and the peripheral flange 6 remain free.

The side plates 2 each consist of a rectangular or equivalent plate and have reinforcing ribs on the outside 10. At the points where the side doors for the car body are provided there are rectangular openings 11 provided on the inner side of the plate with outwardly stepped frames 12 and 13, the first step being the intended thickness of the wall of the car body owns. The plate 9 has a lower edge 14 which is bevelled in an inclined surface of 45 and to which a peripheral and horizontal flange 15 is connected, with fastening openings in is provided at certain intervals. The side edges are also bevelled in identically inclined surfaces 16 and also have in spaced apart fastening openings 17. The upper Edge forms a double edge or a double end edge, the inner part 18 of the upper surface being inclined and the lower part is graded and is provided with small openings for filling or injection. The outer and horizontal part 20 has fastening openings 21. In the same way, the side plates 2 are given a surface non-stick treatment subjected on its inner side and then lined with a layer 22. This layer consists of Fiberglass and synthetic resins covering the entire area of the

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Plate 9 to be distributed. Also becomes the lower and stepped part of the upper inner edge 18 as well as the inner step 13 of the frame 11, which surrounds the door, coated with the mixture.

The bottom plate 1 and the side plates 2 are used for the formation of the Outer shape assembled, in which the side plates 2 are arranged orthogonally to the bottom plate 1, the inner and beveled edges 14 and the flat and peripheral edges 15 can be precisely adjusted via the inclined edge 5 and the peripheral edge 6. The panels are assembled using screws, which are inserted into the mating openings with each adjacent pair of the side panels 2 being orthogonal to each other and the side beveled edges 16 are opposite. The assembly is done by identical Screws 23 through the mating openings 17 as seen in FIG.

As can be seen from Fig. 3, the inner shape is made of a single one Part made of plastic material and has essentially the shape of a prism-like rectangular box 24, the lower outer surface is provided with ribs 25 or other protruding formations corresponding to the parts, as they are for the inner surface of the floor of the car body are provided. The sides are with exactly corresponding openings 11 for the doors the outer shape provided with identical rectangular openings 26 extending through the thickness of the lower or side wall. A surrounding band 27 with an inclined surface, which is provided with injection openings 28 and extends around the free edge to which a flat and horizontal peripheral edge 29 adjoins, which is provided with fastening openings 3O. The inner shape is

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and is used for lifting and is formed by angle iron plates. In in the same way, the inner shape is given a non-stick treatment on the outside subjected and provided with a layer 32, which consists of fiberglass and synthetic resin, this mixture over the entire Area of the bottom and the side surfaces is distributed as well as on the inclined band or edge 27 and the peripheral edge 29. Only the opening edge 26, which corresponds to the doors, only remains free.

In order to assemble the mold structure for the main body, the inner form raised by means of the frame 31 and inserted into the outer form (see Fig. 4), which is suspended and directly from peripheral edge 29 over the corresponding edge 20 of the side panels 2 will be carried. Is fastened by means of the screws 23 through the matching Openings 30 and 21 of the two parts (see Fig. 5). As can be seen from FIGS. 6 and 7, a chamber 33 is thereby formed which has the thickness or diameter of the walls to be produced. This chamber 33 is then filled with the filler material 34, which is polyurethane foam (rigid polyurethane foams) and glass fibers are filled, which are introduced through the injection openings 28 and 19 of the inner mold will.

The inner trim coatings remain during the solidification process of the bottom 8 and the side walls 22 of the outer mold as well as the outer coating 32 of the inner mold firmly to the introduced material 34 adhere, as the layered material does not adhere to the corresponding surfaces due to the non-stick treatment. As a result, these cladding layers form the outer cladding or lining or the outer covering of the walls of the main body of the car body produced by the method of the invention.

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Before injecting or filling the filler material within the Main body shape can be the chamber 33 with a plurality of wooden support plates 35 or a metal or other suitable material (see Fig. 7). Different lines 36 can also be used for the later installation of necessary devices, electrical and signal lines and the like. These support plates 35 and the lines 36 are located within the walls of the Car body.

After complete solidification of the filled or injected into the mold Material are first removed the screws 23 that hold the inner shape to the outer shape and then the inner shape taken out. Then the screws 23 that hold the side walls and bottom of the outer mold together are removed the parts are taken apart. This gives the main body 37 of the car body (see FIG. 8), which consists of the bottom part and the Side panels consists of one piece and has the appropriate openings for the installation of the doors.

To make the roof part of the main body of the car body will be two forms used. From Fig. 9 it can be seen that the outer shape is made of a single piece of plastic material and one Has bottom plate 39, which is provided on its inner surface with projections 40, which are then present on the outer surface of the roof part meant to be. The side parts 41 form a slightly curved frame which forms a narrow stepped edge on which a surface and a Connect the horizontal edge 42, with fastening openings 43. This shape is given a surface non-stick treatment on its inner surface and then with an inner layer 44 made of a plastic mixture made of fiberglass and synthetic resins, which is distributed over the entire surface of the bottom plate 14 and the side plate 41. Edge parts 45 are arranged on the side.

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The complementary and inner shape (see Fig. 10) consists of one rectangular plate 46 with reinforcing ribs 47 on the outer Surface is provided and also has stepped edges 48 with injection openings 49. This is followed by a surface and a horizontal one peripheral edge 50, which has fastening openings 51. A surface non-stick treatment is carried out on the inner surface of this plate and then a layer 52 of a plastic mixture of glass fibers and synthetic resins is applied and that is this Mixture distributed over the area formed by the removable frame 53 and in a level directly after the injection openings 49. These The inner shape also has one or more inner projections 54, into which narrow plates 55 are later inserted in order to close the light boxes 56 wear. These are connected to one another by straight lines 57 through which the electrical lines are to be passed.

To produce the roof part of the car body, the inner shape is over the outer shape is set and the peripheral edges 50 and 42 are arranged opposite one another. The two parts are connected to one another by means of the screws 58 which go through the corresponding openings 51 and 43 (see Fig. 11). This creates a chamber 59 within the two molds which is then filled with the filler material 60. The filler material 60 consists of rigid polyurethane foam and fiberglass and is through the injection openings 49 are filled. This filling material completely surrounds the light boxes 56 and conduits 57 and other support devices that may be located within the mold.

During the solidification, the inner liner 44 remains the outer form and the outer cladding layer 52 of the inner form due to the non-stick treatment firmly adhere to the filler material 60 and thereby

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it forms the outer cladding of the roof part. After complete To solidify, the screws 58 are removed and the inner form is lifted off so that the roof part is then removed can be. The previously used light boxes and cables are embedded in the filling material and the free ends are located on the inner surface of the inner side of the roof part.

The car body produced by the method according to the invention is finally obtained by placing the roof part 61 on the main part 37 (see Fig. 12), with the free edges exactly be arranged opposite and the two parts by means of glue or other adhesive based on fiberglass or synthetic Resins are firmly bonded together. This gives a firm and rigid connection between the roof part and the main body of the car body and the four existing structural difficulties are no longer present here.

The doors 62 of the car body can be used in a procedure similar to that described above for the manufacture of the main body and the Roof part are produced by means of two molds made of plastic material, which are not shown here. The doors must of course have the appropriate shapes to fit into the exposed door frames. In the same way, the the outer sides of a surface non-stick treatment and a coating, so that the mixture of fiber- glass and synthetic resin form the outer cladding of the doors that will be installed later. Can also be used before injecting of the filling material, various holding devices, hinges, and the like are inserted within the mold, so that they

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be embedded in the door body.

Patent claims: - 12 -

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Claims (8)

■ 4%. Claims 1 J Process for the production of body structures or car boxes for means of transport or transport units, such as trucks, delivery vans, trailers, railroad cars and other means of transport, which also consist of isothermal heat protection systems or cooling systems or can contain them, characterized in that the body structure or the car body is made of two separate parts, namely the main body, which consists of the bottom part and the side walls and forms a single self-supporting structure, and the matching roof part, the main body and roof part each made individually by means of a pair of molds is in the desired size and shape and the two parts are then assembled into a rigid and rigid self-supporting structure. 2. The method according to claim 1, characterized in that that the outer shape of the pair of molds for producing the main body from two separate plates for the bottom (1) and the Side walls (2) can be formed, both of which are made up of panels (3, 9) assemble, which have inner surfaces that are provided with ribs (4) or other details that may be desired outer relief of the main body correspond, and the outer reinforcing ribs CfO), with such plates along the entire periphery of the base plate (3) and on the lower edge of the Side plates (9) are surrounded by a band or edge (5, 14) which ο
have a 45 slope and run out in a flat and horizontal outer edge (6, 15) for facing and fastening by means of screws (23), which are connected through matching openings (7). -13- 609831/0256 can be brought, the plates (9) of the side plates (2) still have vertical side edges (16), which are also shown in are beveled at an angle of 45 and to the other neighboring Side plates can be attached, these also by means of screws (23) through matching openings (17) go, can be fastened together, and the upper ones form a double edge, the inner part (18) of the upper Face is inclined and the lower one is stepped, and likewise with is provided with small openings (19), the outer one being flat and horizontal and having fastening openings (21), the Side plates (2) with right-angled openings (11) in the inner Surface are provided with outwardly stepped frame in two stages (12, 13), with all panels, the bottom part (1) and the side parts (2) be subjected to an internal surface non-stick treatment and then a cladding with a layer (8, 22) made of a plastic mixture of glass fiber and synthetic resins, the be distributed over the inner surfaces. 3. The method according to claims 1 and 2, characterized in that the inner shape of the pair of molds for producing the main body is made from a single part, which consists of a substantially prismatic box (24) with ribs (25) and other external relief according to the desired inner relief, which is desired for the main body, and side parts, which exactly the openings (11) for doors and the outer one Shape correspond, with openings (26) rectangular shape, which are also along the diameter or the thickness of the bottom and of the lower wall and also extend through the diameter or the thickness of the lower or the bottom wall, wherein such a box extends in its free end into a surrounding band or a surrounding edge (27) with an inclined surface and 609831/0256 _ ₁₄ _ Injection openings (28), on which a peripheral flat and horizontal edge (29) connects with fastening openings (30) above the corresponding outer edge (20) of the side plates (2) of the outer mold, whereby this is completely inserted into the interior of an outer mold can be, and the inner shape also with an inner frame (31) is equipped for reinforcement and lifting, and with these parts are also subjected to a surface non-stick treatment and finally coated with a layer (32) of a mixture of fiberglass and synthetic resins over the entire exterior Surface is distributed, but not to the places and surfaces to be applied to the outer shape. 4. Process according to Claims 1 to 3, characterized in that that the inner mold is used in a suspended form within the outer mold, the chamber (33) formed between them with filling material (34) Filled in solid urethane foam and fiberglass is passed through the injection ports (19 and 18) of the inner mold and the Side walls of the outer mold are injected, with plates (35), some ducts (36) and the like inserted inside the filler are used for lamps, electrical wires, other devices and signal wires, with the cladding layers (8) of the floor and the cladding layers (22) both of the outer shape and that of the outer cladding (32) of the inner mold firmly adhere to the filler material (34) and thereby due to the previous surface non-stick treatment, form the outer lining of the parts of the main body thus produced. 5. Process according to Claims 1 to 4, characterized in that that in the manufacture of the roof part for the main body of the car body according to the invention, the outer shape of a single part is made and consists of a base plate (39) with an inner surface, which has a relief (40) corresponding to the relief that for the - 15 - 609831/02 5 6 outer surface of the roof tile is seen, and the extending Side parts have a weak curve shape, the latter having a slight gradation of the edge and into an outer flat one and-horizontal edge (42) merges, the fastening openings (43) has and outer brackets (45), while the inner form consists of a plate (46) with reinforcing ribs (47) and brackets on the outer surface, and which also has a stepped edge (48) with injection openings (49) which merge into a flat, peripheral and horizontal edge (50) with fastening openings (51) to the corresponding edge (42) of the outer shape, and screws (58), and wherein layers (44) and (52) made of a plastic mixture of glass fibers and synthetic resins are coated on the later outer surfaces, and in the chamber (60) my panels (55) can be used as a carrier for the light boxes (56) and for straight tubes (57), which later serve as tubes for electrical lines. 6. The method according to claims 1 to 5, characterized in that the inner shape is placed over the outer shape is, the intermediate chamber (59) with the filler material (60) made of the later rigid urethane foam and filling glass fibers introduced through the injection ports (49) of the inner mold, the filler material being all Parts such as the light boxes (56) and the lines (57) and the other support devices within the mold surrounds so that during the firfc » dMt inner: \ Zprt4 ctoTrtt rtttofr itert (44) and. Layer (52) of the outer and inner shapes firmly attached to the filler material (60) stick due to the previous surface non-stick treatment, whereby they form the outer cladding of the roof part. " - 16 - 60SS31 / 0256 7. The method according to claims 1 to 6, characterized in that the roof part (61) is placed on the main body or the main structure (37) and these are connected to one another by means of a suitable adhesive, for example an adhesive based on glass fiber and plastic resin. 8. The method according to claims 1 to 7, characterized in that the doors (62) of the car body are also each made by a pair of molds which are also closed by the addition of the peripheral flat edges. be and are coated by a surface non-adhesive treatment with layers of a synthetic mixture based on fiberglass and synthetic resins by means of screws and wherein the respective surfaces of the molds that are directed inwards, so that these layers after the injection of the filling material Based on urethane foams and fiberglass, these form the outer cladding layers, and previously various installation devices and additional devices for locks, brackets, hinges and the like were also used in the filler material and remain embedded in the door body after hardening. 609831/0 256 Blank page