WO2015081375A1

WO2015081375A1 - A modular vehicle body and method of construction thereof

Info

Publication number: WO2015081375A1
Application number: PCT/AU2014/001097
Authority: WO
Inventors: Paul John Campbell
Original assignee: Wenmay Pty Ltd
Priority date: 2013-12-05
Filing date: 2014-12-05
Publication date: 2015-06-11

Abstract

A method for producing a cabin for a land vehicle comprising: maintaining an inventory including one or more of each of a forward cabin module, an intermediate cabin module and a rear cabin module; upon receiving an order for a cabin module of a specified seating capacity retrieving a forward module, an appropriate number of intermediate modules and a rearward module from the inventory; fastening the modules to each other to thereby produce the cabin; wherein each of the cabins is of a composite structure and wherein the fastening of adjacent modules to each other includes the use of a structural adhesive so that welding is not required.

Description

A MODULAR VEHICLE BODY AND METHOD OF

CONSTRUCTION THEREOF

TECHNICAL FIELD

The present invention relates to a modular vehicle body for attachment to a vehicle chassis and to a method of producing such a vehicle body. More particularly, the invention relates to modular bus body sections of composite material construction, completely finished with all components fitted with some sections containing passenger seating.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

One approach to the production of a vehicle containing passenger seating, such as a moto bus, is to consider the bus body (or as it is equivalently referred to herein the "cabin") specifications. On the basis of the specification which will set out the required number of seats that are required for example, the cabin can then be prepared using conventional construction methods such as welding suitable steel members to form a frame work. For example, a monocoque steel framework ma be used to produce a bus cabin. Panels are welded on to the framework and windows, doors seats etc can then be installed in the final stages of construction.

A problem with producing a vehicle cabin according to the above described method is that the lead time is overiy long and specialized labor is required. Another problem is that there is little flexibility in the production of the cabins since they must all be produced "from scratch". There would be an advantage if the lead time could be considerably reduced.

It is known to manufacture a bus or coach from pre-fabricated steel sections (basic frames) that are welded together. This allows longer or shorter coaches to be more readily manufactured. The basic frames are attached to form the required coach length and are then fitted out with external and interna! paneling, windows, seating, ducting, electrics and the like. US application 2005/0161975 discloses method similar to that described above.

A disadvantage with this method is that the complexity of manufacture requires the basic frames to be fitted out and attached to the vehicle chassis at the factory. The completed coach/bus then needs to be driven or otherwise transported to the customer. For long distance or overseas customers, there is an enormous cost to transport the coach/bus to the final destination.

Transportatton in standard containers such as shipping containers or air containers, while being extremely efficient, is usually not possible due to the size of the completed customized vehicle.

Transporting the basic frames and all the fittings in shipping containers is possible but requires a high level of skills and expertise at the final destination to assemble and complete the fit out. This option is not available for remote destinations or destinations where only semi-skilled labor is available.

Even transporting fully fitted out frame moduies to remote locations is not usually a viable option as welding the moduies together is a specialist procedure. Welding is usually required to ensure that the frame modules do not twist of flex relative to each other.

Another disadvantage is that attaching the modules to the vehicle chassis can be a specialized procedure making such assembly unsuited for semi-skilled labor or for assembly in remote locations. Another disadvantage is that existing modules are manufactured from stee! members to provide the required stiffness and strength, but this results in the modules being heavy and thus more difficult to transport should this be required. The land vehicle to which these modules are attached needs to be heavier to be able to support the modules and often requires a larger more powerful engine. No attempts seem to have been made to manufacture modules from nonmeta!lic materials probable due to the problems with stiffness and problems with attachment of modules to each other and to a steel chassis.

It is an object of the present invention to provide a modular vehicle body for attachment to a vehicle chassis and to a method of producing such a vehicle body and which may overcome at least some of the above disadvantages or which is at least a useful alternative to those solutions that have hitherto been proposed.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a cabin for fastening to a chassis of a ground vehicle, such as a passenger bus, wherein the cabin includes;

a plurality of modules, each having a base and a cover over the base including walls and a roof, each of the modules being of a composite material construction and fastened to each other with structural adhesive.

Preferably the cabin includes a front panel. For example, the plurality of modules may include a forward one of said modules which has a forward panel.

Preferably the cabin includes a rear panel For example, the plurality of modules may include a rearward one of said modules which has a rear panel.

It is preferred that each cover of each said module is comprised of a single laminate formed in an inverted "U" shape. It is preferred that the cover include a core. Preferably the core is of a synthetic foam material.

Openings, such as windows or doorways may be formed in one or more of the sides of the cover.

The cover may be formed with one or more conduits therethrough. For example the conduits may be for conducting air from an air conditioning unit mounted to another of the modules.

Preferably leading and trailing edges of the cover are formed with flanges to assist in imparting rigidity to the cover.

Preferably, the flanges are shaped so that upon joining flanges of two adjacent modules together the flanges cooperate to present an T beam cross section to thereby assist in imparting strength to the joined modules.

Preferably each said bases comprises a single piece of moulded laminate. Preferably the moulded laminate is formed with a number of transverse and longitudinal strengthening members.

In a preferred embodiment of the invention the base includes a number of seat fixing members. Preferably the seat fixing members are disposed beneath an upper floor finish layer upon which the seats are located and fixed therethrough to the seat fixing members.

It is preferred that longitudinal members of the base are fastened to the vehicle chassis. Preferably the longitudinal members of the base are fastened to the vehicle chassis with a bolt assembly including a strain relief spring.

In a preferred embodiment of the present invention lateral ends of leading and trailing ends of the base are fitted with rigid bonding members to assist in the joining of one module to another. For example, the rigid members may comprise bonding e-p!ates.

Preferably lower opposed ends of the cover include a bottom flange for resting upon and fastening to opposed sides of the base. The opposed sides of the base may be formed with opposed side bonding flanges for location of the bottom flanges thereupon.

Bolts may be provided between the adjacent modules for clamping the modules together during drying of the structural adhesive.

In a preferred embodiment of the invention the cabin includes one or more air conditioning units. Preferably the forward panel is shaped to receive the one or more air conditioning units. For example, the forward panel may include a cutout in an upper portion thereof to accommodate part of the one or more air conditioning units.

Preferably the forward panel is formed with one or more conduits that correspond to one or more conduits of an adjacent module whereby the conduits of the forward panel are in communication with the air conditioner units.

In one embodiment of the invention the forward module includes a door with steps leading downward from a floor level of the module. Preferably the forward panel is shaped at one side to extend downward to a level corresponding to a lower limit of the steps.

Preferably the rearward panel is formed with recesses for tail lights. Preferably the rearward panel is formed with a window opening. Preferabl the rearward panel is formed with an air deflector.

In a preferred embodiment of the invention the rearward panel is fastened to an adjacent cabin module with structural adhesive. Similarly, it is preferred that the forward pane! is fastened to an adjacent cabin module with structural adhesive.

According to a further aspect of the present invention there is provided a cabin module for the production of a land vehicle cabin including;

a base of composite construction integrally formed with transverse and longitudinal strengthening members; and

a single piece cover having sides and a roof wherein lower edges of the sides are fastened along opposed sides of the base

According to another aspect of the present invention there is provided a method for producing a cabin for a land vehicle comprising:

maintaining an inventory including one or more of each of a forward cabin module, an intermediate cabin module and a rear cabin module;

upon receiving an order for a cabin module of a specifie seating capacity retrieving a forward module, an appropriate number of intermediate modules and a rearward module from the inventory;

fastening the modules to each other to thereby produce the cabin;

wherein each of the cabins is of a composite structure and wherein the fastening of adjacent modules to each other includes the use of a structural adhesive.

BRIEF DESCRIPTIO OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

Figure 1 is an exploded view of a cabin according to a preferred embodiment of the present invention mounted upon a bus chassis.

Figure 2 is a view of the front end of an intermediate cabin module according to a preferred embodiment of the present invention. Figure 3 is a view of the front, side and top of the cabin module of Figure

2.

Figure 4 is a view of a cover of the cabin module of Figure 2.

Figures 5 and 6 are diagrams showing the core and skin patches of the cover of Figure 4.

Figure 7 is a detail and cutaway view showing the joining of two adjacent cabin modules of the cabin of Figure 1.

Figure 8 is an exploded view showing the mounting of seats to a base of the cabin module of Figure 2.

Figure 9 is a view of the underside of the base of Figure 8.

Figure 9A is first cross section view of a portion of the base of Figure 9.

Figure 9B is a second cross section view of a portion of the base of Figure 9.

Figure 9C is a third cross section view of a portion of the base of Figure

9.

Figure 9D is a fourth cross section view of a portion of the base of Figure

9.

Figure 10 is an assembled top front and side vie of the seats and base of Figure 8.

Figure 11 is an assembled front underside and side view of the seats and base of Figure 8.

Figure 12 is a detail showing the spring loaded fastening assemb!y connecting the base to a member of the vehicle chassis.

Figure 13 is an exploded view showing an interconnection between adjacent cabin modules.

Figure 14 is a view of th rear, side and top of a forward cabin module according to a preferred embodiment of the present invention.

Figure 15 is a view of the side of the cabin module of Figure 14,

Figure 16 is an exploded view of a front panel and air conditioning unit assembly according to a preferred embodiment of the present invention.

Figure 17 is an exploded view of the rear of the assembly of Figure 16.

Figures 18 and 19 are diagrams showing the core regions and skin patches of the front panel of Figures 15 and 16. Figure 20 depicts a rearward cabin module with a rear pane! attached thereto.

Figures 21 and 22 are outer and inner views of the rear panel of Figure

20.

Figure 23 depicts a further cabin module containing only a single row of seats.

Figure 24 depicts steps in a method for producing a cabin for a !and vehicle according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to Figure 1 , there is depicted a cabin 1 according to a preferred embodiment of the present invention. The cabin 1 is designed for fastening to a chassis of a ground vehicle, such as a passenger bus chassis 2. The cabin 1 is comprised of a plurality of cabin modules 3a,..,, 3n wherein 3a is a forward cabin module, 3b is an intermediate cabin module and 3n is a rear cabin module.

The modules are formed from a lightweight composite construction made up of woven glass and foam core and infused with a vinyl ester resin. This composite structure does away with the need for the conventional heavy steel bod frames. The composite bodies can be about 10% lighter than steel and can be stronger than steel bodies.

Referring now to Figure 2, there is shown a front view of the intermediate cabin module 3b. Figure 3 is a view of the front, left hand side and top of the intermediate cabin module 3b. The intermediate cabin module 3b, and similarly each of the other modules, has a base 5 and an upper body shell in the form of a cover 7 over the base 5. The cover includes walls 9 and a roof 11.

As may be discerned from Figure 4, the cover 9 of each module is comprised of a single laminate formed in an inverted "U" shape. Openings, such as windows 15 or doorways 17 may be formed in one or more of the sides 9 of the cover 7. A window flange 8 is formed about the periphery of window 15

Conduits 19 are formed through the cover 7. In the present example the conduits 19 are arranged to conduct air from an air conditioning unit 23 mounted on a front panel 25 of the cabin 1.

Referring again to Figure 4, the leading and trailing edges of the cover 7 are formed with hoop flanges 21 ( see figure 7) to assist in imparting rigidity to the cover.

With reference to Figures 5 and 6, the intermediate module 3b, and similarly each of the other cabin modules 3, is of a composite material construction having a foam core 10a, 10b as indicated in Figure 5 and skin patches as shown in Figure 6. As will be explained in more detail, adjacent modules are fastened to each other with structural adhesive.

The hoop flanges 21 are shaped so that upon joining flanges 21 of two adjacent modules together, as shown in Figure 7, the flanges cooperate to present an T beam cross section 27. The Ύ beam cross section imparts rigidity to the cabin formed by the joined cabin modules.

Adhesive is applied between the flanges and when cured the modules are attached to each other in a strong and rigid manner and without the need for welding or the use of large numbers of bolts.

Referring now to Figures 8 to 11 , each base 5 comprises a single piece of moulded laminate 29. Preferably the moulded laminate 29 is formed with a number of transverse 31 and longitudinal 33 strengthening members.

The base also includes a number of seat fixing members 35. The seat fixing members are disposed beneath an upper floor finish layer 37 upon which seats 39 are located and fixed therethrough to the seat fixing members 35. Figures 9A to 9D are cross sectional detail views through the various cross sections indicated in Figure 9 indicating constructional details of the base and the attachment of the seats thereto in one particular preferred embodiment.

As shown in Figure 12, the iongitudinai strengthening members 33 of the base 5 are fastened to the vehicle chassis with a bolt assembiy 41 including a strain relief spring 43. This arrangement enables secure attachment of the light yet strong fibreg!ass modules to th steel chassis without placing damaging stress on the modules. Attachment of the modules to the chassis can be carried out using semi-skilled labour as no highly skilled attachment technique is required.

Referring to figure 13, lateral ends of the leading and trailing sides of the base are fitted with rigid bonding members in the form of composite plates 45 to assist in the joining of one module to another. The plates comprise rigid composite materia! to add rigidity and stiffness to the attached together modules. The plates are recessed into the end flanges of adjacent modules. Adhesive can be added to each side of the plate as well as over the edge flange of each adjacent module such that the modules can be glued to each other essentially over the entire surface of the flanges which gives a much stronger connection than with the use of fasteners only. A few clamping fasteners 51 are used to locate the composite plate 45 and become permanent fixings. The combination of the composite plates 45 and adhesive provides a high level of strength and rigidity to the modules.

Preferably lower opposed ends of the cover 7 include a bottom flange 47 (see Figure 4) which has an upper side that locates under the outer ends 49 (see figure 9) of leading and trailing sides of the base 5.

As shown in Figures 7 and 13 clamping bolts 51 are provided between the adjacent modules, e.g. modules 3a and 3b as shown in Figure 7, for clamping the modules together during drying of structural adhesive 52 (see Figure 13) that is disposed between the modules. Referring now to Figures 14 to 17, as previously mentioned the cabin 1 , i.e. the fully assembled bus body, includes a front module 3a which has a forward panel 25.

Referring to figures 16 and 17, the forward panel 25 is shaped to receive one or more air conditioning mounting units 23. More particularly, the forward panel 25 includes a cutout 53 in an upper portion thereof to accommodate part of the one or more air conditioning mounting units 23 which in turn receive an air conditioning unit 54.

The forward panel 25 is formed with conduits 55 that correspond to one or more conduits 9 of an adjacent module whereby the conduits of the forward panel are in communication with the air conditioner units 54 in use. The conduits 55 of the forward panel are coupled to the air conditioning unit 23 for circulation of cooled air from the air conditioning unit throughout the cabin. When the modules are glued together, the conduits align. Thus there is no requirement for installation of separate cooling ducts.

As illustrated in Figure 15, in the presently described exemplary embodiment the forward module includes a door 57 with steps 56 (shown in phantom outline) leading downward from a floor level of the module. The forward pane! 25 is shaped at one side with a tongue 59 to extend downward to a level corresponding to a lower limit of the steps 56.

With reference to Figure 18 and Figure 19, the forward panel 25 is of a composite construction with an inner core 24 of foam material, single skin fibreglass patches 26 and Sor core material 28. Soric is a polyester nonwoven material with a compression resistant hexagonal (XF, SF, L C) or random dot-printed (TF) ceil structure. These pressure-resistant cells, which are separated by channels, contain synthetic micro-spheres. The ceils do not absorb resin and therefore limit the total resin up-take. Since these cells are pressure resistant, they create thickness in the laminate even when pressure is applied by vacuum bag. The channels facilitate resin flow and form a pattern of cured resin with good mechanical properties and excellent bonding to the outer skins. Soric is manufactured by Lantor BV, whic has a website with contact details at http://www.lantor.nl.

As illustrated in Figure 20 the rearward cabin module 3n has a rear panel 63 fitted thereto.

As shown in Figures 21 and 22, which depict the inside and outside of the rear panel 63 respectively, the rear panel 63 is formed with recesses for tail fights and boot storage 65 and a window opening 67. Preferably the rearward panel is also formed with an air deflector 69 as shown.

The rearward pane! 63 is fastened to the rearmost cabin module 3n with structural adhesive. Similarly, forward panel 25 is fastened to the front cabin module 3a with structural adhesive.

Whil the various bus cabin modules 3a, 3b, 3n that have been described thus far have ail been of sufficient length to accommodate two rows of seats, other variations are possible. For example, Figure 23 illustrates an intermediate bus cabin module 3c which is of reduced length and suitable for a single row of seats. It will be realised that by using the shorter cabin module 3c in conjunction with the previously described modules 3a, 3b, 3n a greater flexibility is provided for production of a vehicle cabin of a desired seating capacity.

With reference to Figure 24 upon an order 70 for a specified vehicle cabin, .e.g. a bus body, being received a manufacturer determines the various modules that will be required to produce the desired cabin and selects them from an existing inventory 68 for assembly 72, wherein the forward cabin 3a, with front panel, is fastened with structural adhesive and clamping bolts to the next adjacent cabin module 3b. Any further intermediate modules or the rearward module 3n are similarly fastened together to form a finished cabin 1. The finished cabin 1 is then bolted to the chassis, using the previously described spring loaded fastening assembly, in order to form the finished vehicle. in the embodiment of the invention there is described a new fully composite 'Modular Series' bus body that can be configured to multiple lengths b simply adding on a module. The Lightweight composite construction is made up of several different types of woven glass/foam core and infused with Vinyl ester Resin. This composite construction does awa with conventional 'Steel Type' in current bus body frames. Several composite parts form the structure of each Module, and several modules form the body. The modules are joined by a structural adhesive and Hi Tensile Bolts. Once the body is complete it is then mounted on the truck chassis.

Alternatively, the modules are small enough and lightweight enough to be shipped anywhere in the world for attachment to each other and to the vehicie chassis. The attachment of the modules to each other uses structural adhesive and relatively few bolts to hold the parts together for the adhesive to set. The modules are fully fitted out before leaving the factory. At the destination, the gluing together of the modules is simple and requires no specialized equipment such as welding or fabrication equipment. The gluing can be done by semi-skilled labor and can be done at remote locations. Also, the attachment of the modules to the chassis can be done using the strain relief bolts which again does not require a high degree of specialized knowledge.

The modules can be manufactured for use in areas of unrest by making the modules bullet resistant and biast resistant.

The modules can be pre manufactured to contain about 90% of the completed module requirements. Then the final 10% of the fit out can be completed based on the customer's specialized requirements regarding number of seats etc. This allows a customers specialized order to be completed within about 7 days as opposed to more than 5 weeks for a conventional steel manufacture. In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in an of its forms or modifications withi the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Throughout the specification and claims if present, unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims

The claims defining the invention are as follows:

1. A cabin for fastening to a chassis of a ground vehicle, such as a passenger bus, wherein the cabin includes:

a plurality of modules, each having a base and a cover over the base including wails and a roof each of the modules being of a composite materia! construction and fastened to each other with structural adhesive.

2. A cabin according to claim 1 , including a front panel fastened to a forward one of said modules.

3. A cabin according to claim 1 or claim 2 including a rear panel fastened to rearward one of said modules.

4. A cabin according to any one of the preceding claims wherein each cover of each said module is comprised of a single laminate formed in an inverted "U" shape.

5. A cabin according to claim 4, wherein openings, such as windows or doorways are formed in one or more of the sides of each cover of each said module.

6. A cabin according to any one of claims 4 to 5, wherein each said cover is formed with one or more conduits therethrough.

7. A cabin according to claim 6, including an air conditioning unit wherein the conduits are in Gommunication with the air conditioning unit for conducting air from the air conditioning unit through the cabin.

8. A cabin according to any one of the preceding claims wherein the leading and trailing edges of the cover are formed with flanges to assist in imparting rigidity to the cover.

9. A cabin according to claim 8, wherein the flanges are shaped so that upon joining flanges of two adjacent modules together the flanges cooperate to present an T beam cross section to thereby assist in imparting strength to the joined modules.

10. A cabin according to any one of the preceding claims, wherein each said of the bases includes a single piece of moulded laminate.

11. A cabin according to claim 11 , wherein the moulded laminate is formed with a number of transverse and longitudinal strengthening members.

12. A cabin according to claim 11 , wherein the base includes a number of seat fixing members.

13. A cabin according to claim 12, wherein the seat fixing members are dtsposed beneath an upper floor finish layer upon which the seats are located and fixed therethrough to the seat fixing members.

14. A cabin according to any one of claims 11 to 13, wherein longitudinal members of the base are fastened to the vehicle chassis.

15. A cabin according to claim 14, wherein the longitudinal members of the base are fastened to the vehicle chassis with a bolt assembly including a strain relief spring.

16. A cabin according to any one of the preceding claims, wherein lateral ends of leading and trailing ends of the base are fitted with rigid bonding members to assist in the joining of one module to another,

17. A cabin according to claim 16, wherein the rigid members comprise bonding plates.

18. A cabin according to any one of the preceding claims, wherein lower opposed ends of the cover include a bottom flange for resting upon and fastening to opposed sides of the base.

19. A cabin module for the production of a land vehicle cabin including: a base of composite construction integrally formed with transverse and longitudinal strengthening members; and

20. A method for producing a cabin for a land vehicle comprising:

upon receiving an order for a cabin module of a specified seating capacity retrieving a forward module, an appropriate number of intermediate modules and a rearward module from the inventory;

fastening the modules to each other to thereby produce the cabin;