DESCRIPTION
"FREE STANDING BODY FOR TRUCKS"
Technical field
The present invention concerns a free standing body for trucks particularly suitable to create all those set-ups that require an equipped vehicle bed such as vans for markets, vans for particular types of transport, motorhomes, caravans, etc.
Background Art
As it is known, nowadays all the body shops that produce trucks with capacity up to 35/40 q must structure the truck and then develop the body or box. In fact, the body shops purchase the cabin and bed from the vehicle manufacturer and then modify the bed to make it suitable to house the box, for example to obtain a motorhome or create a set-up for a market trader for use at outdoor markets. In particular, the bed must be reinforced and widened and if necessary also lengthened so that the box can then be structured and built.
Currently to obtain a bed of the required size, the body shops prepare iron or aluminium perimeter profiles that are fastened to the bed supplied by the vehicle manufacturer; they then close the structure created with curtain wall panels of various types according to the load to which the bed will be subjected and/or to the final use, as in the case of a motorhome.
Once the bed has been structured, the side walls are created using vertical uprights to which the curtain wall panels are fastened, welded or using rivets or mastic adhesive, to make up the box which is then closed at the top with roofing.
The box structure assembly starts from the base, trying to stiffen the structure so that it can withstand the stress to which it is subjected and in particular the torsion. Currently, it is the vehicle that must be structured and reinforced for its final use.
Furthermore, on vans with chassis, a counterframe is made on which to rest the body; the counterframe is fastened to the girders of the vehicle's structure therefore a base structure must be made and fastened to the counterframe and then the body can be developed vertically. The construction system briefly described and currently adopted has revealed a number of problems.
A first problem encountered is due to the fact that the welds that join the portions of the profiles and above all the panels, are often not fully watertight and therefore they often allow water to seep through, which then ruins the wood panels.
A second problem is caused by the fact that to structure a vehicle it is necessary to make compromises as regards the materials used, in order to comply with the weight limit allowed for the completed vehicle.
Another problem is due to the fact that the work and welding to add the profiles to make the new bed are performed on existing sheet metal and the vehicle has already been treated against rust, salt spray etc. by the vehicle manufacturer; this operation therefore creates unprotected areas that could lead to the corrosion and wear of the materials, thus shortening the vehicle's useful life.
In fact, a modified vehicle has a maximum life of ten years due to the formation of rust which leads to the creation of holes and consequently the structure is more likely to give way and collapse in a shorter time.
Another series of problems encountered are caused by the structural failure caused by stress and vibrations and above all by the tension created by the incorrect distribution of weight on the bed.
The tension due to torsion and the stress caused by the weights, subject the vehicle structure to continuous strain; when the body is subjected to torsion and bending, if the forces are distributed in a balanced manner the structure tends to return to its initial conditions, but if the
forces are not well balanced, a part of the stress load is reset while the remaining part remains and the structure remains subjected to stress. As time passes, with the repetition of heavy loading and unloading operations, the stress on the structure continues to increase and may cause it to fail and therefore not to respond adequately and correctly when subjected to strain; consequently, the structure no longer withstands the stress and therefore, for example, while braking round a bend, with the addition of other forces applied to the vehicle, the structure may no longer resist and it may collapse. As these types of stress are repeated the structure is subjected to wear and tends to fail making the vehicle no longer safe and reliable.
Another problem encountered is caused by the curtain wall panels that come easily unglued since, at present, metal tubular elements are fitted between the polystyrene section in order to add structural strength to the panels; when the external covering is applied however, the glue used behaves differently with the insulating material and with the tubular elements, therefore in a short time, the covering may come unstuck, allowing the water and humidity to penetrate deteriorating the underlying panel.
In a similar way, this also happens with the panels that form the walls of motorhomes, where wood strips are used instead of the metal tubular elements with the result that, if the material becomes unstuck and consequently there are infiltrations, the wall deteriorates losing structural strength as well as thermal and acoustic insulation capacity.
Another problem is caused by the fact that over time the insulating capacity of the profiles and panels, when secured by means of screws, may be reduced; being subjected to stress and loads, they may become loose with the result that the structure tends to move and change its set-up to the point that, sometimes, they may become disengaged making the panel come out of its seat with unpleasant and dangerous consequences and damage to the structure and the objects contained inside.
In addition to the explanations so far, other problems encountered are due to the fact that the time required to create the structures is quite long, labour costs are high due to the many processing operations carried out and costs for materials (sheet metal for the base, profiles, etc.), welding and painting are also high; above all, once the body has been completed, it cannot be modified, and when the cabin with the bed have to be changed, the entire vehicle must be changed and the body must be constructed and equipped once again, with considerable purchasing and running costs.
Disclosure of Invention
The aim of the present invention is essentially to solve the problems of the known technique by overcoming the difficulties described above by means of a free standing body for trucks that can completely change the construction concept of bodies or boxes.
A second aim of the present invention is to have a free standing body for trucks that allows the construction of a box that is independent from the vehicles onto which it will be secured.
A third aim of the present invention is to have a free standing body for trucks that can be connected in a simple, practical, fast and easy way to the vehicle's bed. Another aim of the present invention is to have a self bearing body for trucks that has a simple structure with a reduced number of pieces required to construct it, so that it is very practical and flexible.
A further aim of the present invention is to have a self bearing body for trucks obtained by means of a series of standardised elements.
A further but not final aim of the present invention is to produce a free standing body for trucks, which is easy to manufacture and works well.
These aims and others besides, which will better emerge over the course of the present description, are essentially achieved by means of free standing body for trucks, as outlined in the claims below.
Brief Description of Drawings
Further characteristics and advantages will better emerge in the detailed description of a free standing body for trucks, according to the present invention, provided in the form of a non- limiting example, with reference to the accompanying drawings, in which:
- figure 1 shows, schematically and from a perspective view, a free standing body for trucks according to the present invention;
- figure 2 shows, schematically and from a perspective view, the free standing body for trucks in figure 1 in a different condition;
figure 3 shows, schematically and from a top-down perspective view, a component of the body in figure 1 ;
- figure 4 shows, schematically and from a bottom-up perspective view, the component of the body in figure 3;
figure 5 shows, schematically and from a perspective view, the inside of the component of the body in figure 3;
- figure 6 shows, from a perspective view, a component of the body in figure 1 ;
- figures 7, 8, 9 each show, schematically and from a perspective view, a coupling that belongs to the body according to the present invention;
- figure 10 shows, schematically, the outline of a base structural profile of the body in figure 1;
- figure 11 shows, schematically, the outline of a base structural profile related to an access to the body in figure 1 ;
- figure 12 shows, schematically, the outline of a panel connection profile for the body to an access to the body in question;
- figure 13 shows, schematically, the outline of a structural profile of the component of the body in figure 5;
- figures 14 and 15 show, schematically, the outline of a profile for the door frames and for the doors, respectively, of the body in figure 1 ;
- figures 16 and 17 each show, schematically, the outline of a profile with hinge for the doors of the body in figure 1.
With reference to the aforesaid figures, and in particular Figure, n.l denotes a free standing body for trucks as a whole, according to the present invention.
The free standing body for trucks in question allows to completely reverse the construction method with respect to what has been done so far, in fact, the body or box is created independently from the cabin and bed; the latter are involved later since the body is secured to the bed and the cabin once it has been completed, using the holes drilled in the bed and on the back of the cabin by the manufacturer without the need to carry out any other work. With this invention it is the body that structures the vehicle and not vice versa, as has been occurring so far.
Best Mode for Carrying Out the Invention
The free standing body 1 for trucks is essentially made up of a structural frame made of a series of metal load bearing profiles 2, preferably made of aluminium alloy, that are shaped to house the special joining elements that allow them to be joined together and which are arranged to fit floor and curtain wall panels 6.
More in detail, the coupling elements 3, 4 and 5 are essentially of three types, as will be explained later on, and are made of metal, in particular aluminium alloy and are manufactured using moulds and the die-casting technique; they are therefore manufactured in single blocks or made of steel or stainless steel sheet metal obtained by means of moulds and the deep drawing method that entails the creation of two or more parts (shells), internal and external that are later welded together to form a single block that is empty inside.
Furthermore, according to the present invention the panels 6 for the floor, curtain wall and doors of the body are made up of extruded aluminium alloy tubular elements duly shaped with interlocking system and bilaminated with different types of materials including aluminium, stainless steel, fibreglass or Kevlar when deemed necessary to meet load bearing or aesthetic requirements.
Alternatively the panels 6 are made of a honeycomb structure (core) and they are covered with deferent types of material including aluminium, stainless steel, fibreglass or Kevlar, which - when adequately engaged to the profiles of the frame or of the doors - create a single structure that is light, resistant to loads, bending, torsion and wear.
Furthermore, the panels 6 are of the type with a closed honeycomb polycarbonate structure but also made of materials with equivalent characteristics. They have insulating capacity and in the configuration where the body requires thermal insulation, the honeycomb is filled with insulating material.
The panel is then covered with different types of materials such as metal ones (steel or aluminium) plastic ones, fibreglass, etc.
The floor is made of the same type of panels used for the walls but they are thicker.
In particular the bottom side of the floor panel is covered with a stainless steel plate that offers significant protection to the structure against corrosion and wear due to salt, sea salt, etc. and the upper part can also be covered, thus becoming a structural element and conferring to the floor a significant resistance.
The panels 6 previously described are much lighter than those used so far in the commonly known technique, therefore they make it possible to maintain the overall weight of the body low.
In accordance with the present embodiment and as mentioned previously, the structural frame is made up of different profiles 2 including the said base profile 20, shown in figure 10, which
features a particular configuration made up of a central block 210 that has a cross-shaped hollow seat 211 designed to engage a corresponding cross-shaped connection element as will be explained later.
In more detail, the cross shape of the central block 210 allows the profile to be resistant to torsion, compression and bending, and in addition it can be joined to the other profiles by means of joining elements to obtain a linear structure. The hollow seat 211 can be used to seat piping or cabling.
According to the present embodiment, the base profile 20 features a recess 212 to engage a side skirt profile that creates a protective band around the perimeter of the vehicle against sprays as well as having an aesthetic function, a series of shaped ducts 213 in which to insert one or more threaded pawls onto which load retaining hooks or externally other connection profiles can be engaged to obtain a base grid frame structure. In detail, the shaped duct 213 is envisaged to house and secure other profiles also to create orthogonal structures (in this way for example, soft top vans will no longer require a counterframe).
The base profile 20 also features two ducts 213 on one side and two on the adjacent side. Furthermore, the central block 210 features some holes 214 near the shaped ducts 213 that can be threaded to secure a curtain wall element or a support plate. The block 210 also envisages an access 215 having the function of cable gland and a first projection 216 that creates a base for a floor panel.
Finally the profile 20 includes a projection 22 that confers an L-shape to the profile as shown in figure 10 and in figure 1 1. In more detail, the profile 20 shown in figure 1 1 features the projection 22 with a hollow seat 220 to house the hydraulic pipes or cable gland, and a second projection 226 parallel to the first one 216 that features knurling at the top to generate friction. Furthermore, the projections 216 and 226 create an area designed to engage and secure a floor
panel. Similarly, the profile 20, shown in figure 10, features, in the L-shaped projection 22, a first hollow seat 220 and a second hollow seat 225 designed to house piping or cabling and on the first hollow seat 220 there is a projection 226 parallel to the projection 216 that creates an area designed to house a floor panel. Furthermore, the projection 226 is fitted at the upper end with a shaped duct 213 perpendicular to the projection. Finally, the projection 22 ends with a U-shaped guide 224 to engage a vertical curtain wall panel 6 as shown in figure 6.
The free standing body for trucks according to the present invention comprises a panel connection profile 23 envisaged to connect and secure pairs of panels to create the external curtain wall of the body. The connection profile 23 is made up of a pair of U-shaped guides 230 with the base 231 of the U in common, as shown in figure 12. In particular, the inside of the guide features internal vertical walls 232 of the U with knurling to increase friction and therefore the grip of the panels inserted.
In addition to the explanations so far, the body comprises a C-shaped profile 25 shown in figure 5 and more in detail in figure 13, which is designed as upright to create the vertical part of the frame and the "roof top" in vans that transport goods or the alcove of motorhomes. According to the present embodiment, the C-shaped profile 25 features a U- shaped guide 250 at each end configured essentially like the one of the connection profile 23 and close to the base of the U-shaped guide 250, the profile 25 comprises a hollow seat 251 arranged to house hydraulic pipes or to act as gable gland.
Furthermore, inside of the curved part of the C-shaped profile, there is a shaped duct 252 similar in terms of shape and function to the ducts 213 of the profile 20.
In particular, a pair of grooves 253 is positioned on the outside of the curved part of the C-shaped profile 25, which are not visible from the outside because they are closed by a small removable plate 254. When it is necessary to slide in accessories, cables, etc., the small plate 254 that closes the groove is removed by simply taking it with pliers and lifting it; if a small piece must be inserted, then it is sufficient to make a small hole or slot of the required size. Likewise for the internal duct 252.
The duct 252 is present on the entire external perimeter of the floor and ceiling and arranged, when transporting goods, to house rings, belts or load retainers and likewise for the roof. In motorhomes or in set-ups for market traders it becomes an element to fasten containers, furniture, etc. In addition, the C-shaped profile 25 features other hollow seats 255, 256 and 257 designed for inserting cabling, piping and connections.
The profiles 2 comprise a perimeter profile 26 for door frames, shown in figure 14, that is made up of a shaped element 260 that features at one end a pair of recesses 260a that have the task of interacting with the base of the U-shaped guide on the C-shaped profile 25 and on the panel connection profile 23 by fitting into the guide to create the perimeter ledge of the door.
Furthermore, the profile 26 features a hollow seat 261 having the function of cable gland.
In addition, as shown in figure 15, there is a first profile 27 that features at one end a U-shaped guide 270 that has the internal walls knurled to create friction when it engages a panel. Furthermore, profile 27 features a hollow seat 271 to house an
L-shaped connection square to secure a pair of profiles 27 to each other and obtain the door frame.
Finally, at the opposite end to the U-shaped guide, an orthogonal projection 272 is envisaged, which features an indenture 273 designed to house a water and air seal.
The profiles 2 also include profile 28 with hinge, shown in figure 16, used in the door frame, which has a configuration very similar to the profile in figure 14 featuring a shaped element 280 with a pair of recesses 280a and a hollow seat
281 but it is fitted with a pintle 282 positioned orthogonally to the hollow seat 281 , which is designed to house a rotation pin for the door. In more detail, the said shaped element 280 with the pair of recesses 280a is envisaged to fit into the U-shaped guide of the C-shaped profile 25 or of the profile 23 to create the door ledges.
Similarly, a second profile 29, shown in figure 17, has a shape similar to the profile 27 featuring, at one end, a U-shaped guide 290 that has knurled internal walls, a hollow seat 291 , and an orthogonal projection 292 that features an indenture 293 but it features, at the end without the projection 292, a pintle 294. The profile 29 is designed to be coupled with the profile 28 as the two pintles
282 and 294 mutually engage and are connected by a rotation pin. In this way a hinge is created along the length of the door, which when combined with the pair of recesses 280a ensures that the door does not give way, unlike the hinges currently used where the doors tend to give way and rotate limiting the capacity and efficiency of the closure. As a whole it becomes an integral structure.
The profiles 2 are preferably made of anodised aluminium to avoid the wear and corrosion due to the presence of salt on the roads, sea salt and/or other air pollutants.
In accordance with the present invention, the connection elements are essentially three and, as shown in figures 7, 8 and 9 respectively, they are made up of a base coupling 3 , a top roof coupling 4 and a halberd coupling 5.
The base coupling 3, as suggested by the definition, is used to connect to each other the base profiles 20 that create the perimeter of the base of the frame for the floor of the body and features a complex configuration made up of a central block 30 with the shape of a parallelepiped from where on each of the two internal and adjacent sides 3 1 a and 31 b juts out an internally hollow cross shaped element 32 designed to fit in the corresponding seat 21 1 of the base profile 20, shown in figure 6. A triangular element 33 divided internally in two hollow sectors 33a and 33b is designed to be positioned on the upper side of the central block 30 to make the piece lighter. The triangular element 33 is positioned with the base of the triangle almost in line with the internal edge of the parallelepiped. Both the parallelepiped 30 and the triangular element 33 are externally coupled to each other to create a continuous slightly rounded surface that is aesthetically pleasant and at the same time streamlined and aerodynamic, as shown in figure 1 .
A sheet 34 is placed above the triangular element 33 with the shape of a segment of a circle with the edge facing inwards and positioned on the internal edge of the parallelepiped. Two L-shaped couplings 35 that jut out from the sheet 34 and have the function of engaging a C-shaped profile 25.
In addition to the explanations so far, the said parallelepiped central block features a hole 36 through both internal sides and has the function of cable gland.
Furthermore, the floor of the body is designed to touch the triangular element 33 and rest on the portion of the upper side of the parallelepiped 30 not occupied by the triangular element 33 and touching the lower portion of the sheet 34 not in contact with the triangular element.
The joint on the top roof 4 is essentially made up of a block 40 with the shape of a segment of a sphere with internal walls 40a and 40b from which, from the edge, a first pair of couplings jut out 41 positioned reciprocally orthogonally and having an L-shape with the L positioned horizontally while, on the lower side, at the base of the segment, a second pair of couplings 42 jut out once again L-shaped but with the L positioned vertically and reciprocally orthogonally, as shown in figure 8. Furthermore, perpendicularly to each coupling 42 of the second pair there is a third coupling 43 with the shape of a vertical L.
All the couplings 41 , 42 and 43 of the roof joint 4 are designed to engage the C- shaped profiles 25.
The third halberd coupling, shown in figure 9, connects the lower part of the alcove of a motorhome or that of a roof top of a van.
The halberd coupling 5 features an arched central element 50 from which a pair of arched sectors 51 jut out positioned in parallel to each other and designed to house a curtain wall panel 6, as shown in figure 3. In addition, the halberd coupling 5 features a first pair of L-shaped couplings 52 positioned at the ends of the arched element 50 where the diameter is smaller. In particular, one coupling has the L vertically positioned while the other one has the L horizontally positioned.
The coupling 5 envisages a second pair of couplings 53 positioned orthogonally to each coupling 52 of the first pair and a third pair of couplings 54 each of
which is positioned parallel to those of the second pair 53. According to the present invention, there is a second halberd coupling that features, in addition to the previous one, a fourth pair of couplings positioned one parallel to and one perpendicular to the pair of couplings 54. The said coupling is designed to engage the vertical panel of the side of the roof top or alcove if the door is near the uprights.
As previously mentioned, the base coupling 3 in question envisages that the cross shaped element 32 is housed in the corresponding seat 211 of the base profile 20 to create the base of the frame, creating a square or rectangular perimeter according to the final size of the body to be created; it also allows however to create an internal grid, orthogonally securing the other base profiles 20. Furthermore, similarly, recesses can be created in the base of the frame to house steps, for example, in a motorhome or niches for wheel arches. Once the base of the frame is completed, the C-shaped profiles 25 that make up the vertical structure of the body are secured to the couplings 35 of the base coupling.
The roof joints 4 are engaged above the vertical profiles for the rear part, while for the front part the halberd couplings 5 are engaged, to create the roof top or alcove, as they allow creating a front projection as shown in figure 1. A C-shaped profile 25 is engaged on each halberd coupling 5, positioned perpendicularly to the vertical one and a roof joint 4 is engaged on the free end; the said roof joint 4 in turn houses an orthogonal profile 25 on the same level to create the floor of the alcove or roof top and a vertical one to which a roof joint 4 is engaged to create the perimeter of the roof, joining the front and rear couplings once again with the C-shaped profiles 25.
The base couplings 3 house the panels that have the task of forming the floor while the profiles 25 engage, by means of the U-shaped guide 250 the curtain wall panels of the vertical walls, roof top and top roof.
If a rounded profile is required at the front of the alcove or roof top it is sufficient to use the halberd couplings instead of the joints on the bottom roof, with a duly curved shaped panel to obtain a streamlined shape of the alcove or roof top. In the same way, wavy portions can be created on the top roof using the halberd couplings and curved panels.
The couplings are mutually secured to the profiles by interference and are locked using adhesives, mastic or silicone and the profiles are secured to the panels in the same way.
According to the present invention, the body envisages openings closed by hatches or doors made of panels framed by profiles 27 and 29, while the rebates are obtained with the profiles 26 and 28.
In accordance with the present invention, the number of types of profiles, connection elements and panels is limited but depending on how they are coupled, different configurations can be obtained in terms of shape and size of the body and/or box.
After the predominantly structural description above, the operation of the invention in question will now be outlined.
When a user requires a vehicle such as a motorhome or a van for markets or similar, it is sufficient to have the body set-up according to personal requirements and have it installed on a cabin with a bed, simply securing it by means of fastening elements such as screws or nuts and bolts or brackets.
If, for whatever reason, the user intends to change the mechanical part of the vehicle, it is sufficient to detach the body and install it on a new vehicle without having to create a new one as currently occurs because the vehicle is adapted and modified according to the final set-up. Thus the present invention achieves the aims set.
The free standing body for trucks in question, completely changes the concept of construction of bodies and boxes, in fact it allows the box to be created independently from the vehicle on
which it will be installed, therefore the vehicle can be replaced without having to make the box again.
Advantageously, the body allows the customer to interchange a flatbed truck with a cowl chassis truck as required, without having to build a new body each time, as currently occurs, with consequent savings as regards the set-up of the vehicles. Furthermore, the free standing body can be connected to the bed of vehicle in a simple, practical, fast and easy way that does not require structural operations to adapt the vehicle as with the known technique.
In particular, the body, according to the present invention, features a simple structure made of a limited number if pieces which are standardised, making it is very flexible and practical. In fact, the connection elements in question make it possible to connect in a simple, practical, fast and easy way two or more metal profiles, vertical or horizontal.
Furthermore, the connection elements feature a simple and particularly flexible structure that allows to secure profiles with different configurations and section, with a limited overall size and a pleasant and neat appearance.
In addition to what has been explained so far, this type of body offers different advantages: first of all the assembly system to form the structural frame as the profiles are joined together with connection elements that confer rigidity and, at the same time, elasticity and strength to the structure without having to resort to welding; weldings, in view of the natural characteristics of a truck are systematically subjected to continuous torsion and vibrations with the inevitable result that cracks or fissures form in the parts joined by welding, which compromise stability and safety.
Furthermore this leads to water infiltrations in the panels and to the deformation of entrance doors, etc.
Furthermore, the assembly system with connection elements combined with the use of panels with a honeycomb core and / or bilaminated tubular elements, ensures a considerable reduction of the loads that weigh on the truck.
The free standing body creates a reverse situation to all current construction systems whereby the operations illustrated previously with the addition of material become obsolete, because the free standing body according to the present invention will be the linking element between the bed and the cabin creating a single block between the bed, cabin and body.
The assembly system allows to reduce the costs of production and installation of the body with consequent lowering of the final price to customers for several reasons.
The first reason is related to the time required to construct the body, which is much less compared to the time currently necessary. Another reason is due to the fact that the materials used have a much higher quality than the average used nowadays by all the body shops; the quality is about 30% higher but despite an increase in the cost of materials, there is a total saving, given that the construction time is shorter, by about 70%, and the cost of labour is reduced by about 50%. Furthermore, as the materials are of better quality, this leads to savings due to the fact that less maintenance is required.
The assembly and installation of the truck is designed as DIY kit and can be sent directly to the body shop, or it can be sent already assembled to the body shop and easily mounted on the truck.
Advantageously, with the profiles and connection elements in question there is great construction flexibility because, when there is the need to change a cabin and its bed, it is sufficient to remove the screws that secure the body to the bed and cabin and install it on the new vehicle; it is not necessary to eliminate everything as used to happen with bodies used to transport goods or those set-up for market traders or with the boxes of motorhomes of the known technique.
A further but not final advantage of the present invention is that it proves remarkably easy to use and to manufacture and works well.
Naturally, further modifications or variants may be applied to the present invention while remaining within the scope of the invention that characterises it.