GB2317858A - Vehicle body structure - Google Patents

Abstract

A vehicle body structure comprises a space frame (31 figure 3) formed from modules 10, 20, 21 and 22 made of composite material with a number structural elements, eg 11 and 12, and a number of integral connection means including joining members 11A, 11B, 14B and 16B and complementary recesses 12A, 14A, 15A, 15B and 16A in abutting modules. Body panels (13 figure 1) may be fixed or moulded between the structural elements of the modules. The joining members and recesses may be joined by adhesive bonding or mechanical fixing and the joining members may be spigots. Vehicle systems may be sub-assembled within the modules before the space frame is assembled.

Description

A Vehicle Bodv This invention relates to vehicle body assemblies and in particular to vehicle body assemblies made of composite plastics materials.

It is common to produce vehicle bodies from many separate metal pressings which are later joined together, usually by welding. A body assembly made of composite plastics materials offers advantages, for example in substantial weight-saving. Current composite body assembly techniques rely on adhesively bonding large components of the structure along long bond lines.

It is an object of this invention to provide an improved body assembly for a vehicle made from composite plastics materials.

According to the invention there is provided a body assembly for a vehicle comprising a structural space frame formed by joining together a number of modules made of a composite plastics material, each of said modules including a number of structural elements joined together to form said module and having a number of connection means formed as an integral part thereof, wherein each of said connection means comprises a joining member for engagement with a complementary recess in an abutting module.

Body panels may be fixed between the structural elements of the modules and body panels in mutual abutment between abutting modules may be adhesively bonded together.

Vehicle systems may be sub-assembled into the modules before assembly of the space frame.

A joining member and a recess may joined by adhesive bonding or a joining member may be interconnected with a recess by a mechanical fixing.

The invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 is an isometric view of part of a body assembly in accordance with the invention; Figure 2 is a side view of part of a vehicle body before assembly in accordance with the invention; Figure 3 is a side view of a part assembled vehicle including a body assembly in accordance with a first aspect of the invention; and Figure 4 is a side view of part of a vehicle body in accordance with a second aspect of the invention after assembly.

Vith reference to Figure 1, part of a module 10 of a modular body assembly is shown and comprises a pair of corresponding, opposite and spaced apart structural elements in the form of space frame pillars 11 each including joining members in the form of protruding spigots 11A, 11B and a pair of structural elements in the form of pillars 12 each including a complementary cavity in the form of a recess 12A.

The pillars 11, 12 are made of a composite plastics material and a floor panel 13 is moulded integrally with the pillars 12 by resin transfer moulding. The floor panel 13 is used to hold the pair of pillars 12 spaced apart and has a joining edge 13A between the pillars 12.

In Figure 2 the module 10 of Figure 1 is shown fully in a side view with further modules 20, 21, 22 situated around it before assembly into a space frame. The further modules 20, 21, 22 are made of the same composite plastics material as the first module 10 and are configured in a similar manner.

A front module 20 comprises space frame members 14 which include recesses 14A and spigots 14B. Recess 14A is complementary to, and lined up with, spigot 1 1B and spigot 14B is complementary to and lined up with recess 12A at the front of the first module in the direction of arrow A (shown in Figures 1 and 2).

A roof module 21 comprises space frame members 15 which include recesses 15A, 15B which are complementary to and lined up with spigots 11A of the first module 10.

A rear module 22 comprises space frame members 16 which include recesses 16A and spigots 16B. Recess 16A is complementary to, and lined up with, spigot 11B and spigot 16B is complementary to and lined up with recess 12A at the rear of the first module 10.

Figure 3 shows a part assembled vehicle 30 which comprises a space frame 31 manufactured by assembling the space frame modules 10, 20, 21, 22 shown in figure 2. The space frame 31 forms the structural member onto which the rest of the vehicle is assembled.

The modules 10, 20, 21, 22 are assembled into the space frame 31 by bringing their pillars 11, 12, 14, 15, 16 into abutment such that the corresponding spigots 11A, 14B, 16B and recesses 12A, 14A, 15A, 15B, 16A interconnect, the joints being further strengthened by adhesively bonding the spigots into the recesses. At key areas such as the crash zone included in the front module 20, the joint between the spigots 11B, 14B and their corresponding recesses 14A, 12A is further strengthened by additional mechanical fixings such as bolts (not shown separately).

Body panels, typified by floor panel 13, are moulded in a single operation with the pillars 11, 12, 14, 15, 16 by resin transfer moulding and come into abutment along their respective joining edges 13A. To further strengthen the structural integrity of the space frame 31, the body panels 13 are bonded to each other along their respective joining edges 13A.

The vehicle 30 includes sub-assemblies in the form of a seat 32, a steering mechanism 33, a powertrain 34, front suspension 35 and rear suspension 36. To aid modular assembly, some of the sub-assemblies are assembled into the modules 10, 20, 21, 22 before assembly into the space frame 31. One example of such construction is the sub-assembly of the power train 34 and front suspension 35 onto the front module 20 before it is joined to the first module 10.

In this manner, a high strength modular vehicle body assembly is provided which is made of a composite plastics material and is suitable for use as the main structural member of the vehicle.

Figure 4 shows a space frame 40 similar to the space frame 31 of Figure 3 and serves to demonstrate the flexibility of this approach to modular construction by the addition of an extra centre section 41 to enlarge the passenger compartment. Further flexibility is provided by the possibility to use disconnectable snap-fit fixings integrated with the spigots which could take the form, for example, of a barbed member (not shown separately) biased into connection with a captive cavity (not shown) in the main recess of a pillar.

Claims (7)

1. A body assembly for a vehicle comprising a structural space frame formed by joining together a number of modules made of a composite plastics material, each of said modules including a number of structural elements joined together to form said module and having a number of connection means formed as an integral part thereof, wherein each of said connection means comprises a joining member for engagement with a complementary recess in an abutting module.

2. A body assembly according to claim 1 wherein body panels are fixed between the structural elements of the modules.

3. A body assembly according to claim 2 wherein body panels in mutual abutment between abutting modules are adhesively bonded together.

4. A body assembly according to any preceding claim wherein vehicle systems are sub-assembled into the modules before assembly of the space frame.

5. A body assembly according to any preceding claim wherein a joining member and a recess are joined by adhesive bonding.

6. A body assembly according to any preceding claim wherein a joining member is interconnected with a recess by a mechanical fixing.

7. A body assembly substantially as described herein with reference to the accompanying drawings.