WO2021195690A1

WO2021195690A1 - Vehicle body improvements

Info

Publication number: WO2021195690A1
Application number: PCT/AU2021/000030
Authority: WO
Inventors: Grant Christopher REYNOLDS
Original assignee: WarpForge Limited
Priority date: 2020-04-01
Filing date: 2021-03-31
Publication date: 2021-10-07

Abstract

The present disclosure relates to a cargo area for mounting to the frame or chassis of a vehicle. In one aspect, the cargo area comprises a deck panel comprising at least one fibre reinforced composite panel, and at least one metallic mounting plate secured to a bottom surface of the deck panel at least, the or each mounting plate providing a substantially continuous planar mounting surface for supporting at least a mounting arrangement for securing the cargo tray to the vehicle.

Description

VEHICLE BODY IMPROVEMENTS

PRIORITY DOCUMENTS

[0001] The present application claims priority from Australian Provisional Patent Application No. 2020901008 titled “VEHICLE BODY IMPROVEMENTS” and filed on 1 April 2020, the content of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to a cargo area for mounting to the frame or chassis of a vehicle.

BACKGROUND

[0003] Commercial vehicles such as light trucks (also known as utility vehicles or pick-up trucks), medium trucks or box trucks (also known as Pantech trucks) feature cargo or freight areas in the form of cargo beds, trays, or boxes, configured to mount to the chassis or frame of the vehicle. These cargo areas are typically manufactured from steel or aluminium alloys.

[0004] In use, these cargo areas are susceptible to sliding or impact loads which can result in dents, deformations, scratches and abrasions, which are unsightly, can lead to rust, make it difficult to load and unload cargo, and in a worst case scenario lead to failure of the cargo area or damage to the cargo being carried.

[0005] Many steel and aluminium cargo trays are strengthened with ribs or corrugations that extend along their length and even transversely, which can make it difficult to precisely mount the cargo trays to various vehicles and in many cases require vehicle specific adapters to secure the cargo trays to the vehicle mounting members.

[0006] It is against this background that the present disclosure has been developed.

SUMMARY

[0007] According to a first aspect, there is provided a cargo tray for mounting to a vehicle, the cargo tray comprising a deck panel comprising at least one continuous planar mounting surface configured to at least support a mounting arrangement for securing the cargo tray to the vehicle. [0008] In one form, the cargo tray further comprises at least one mounting plate secured to a bottom surface of the deck panel, the or each mounting plate providing a continuous planar mounting surface.

[0009] In one form, the deck panel comprises planar top and bottom surfaces.

[0010] In one form, the or each mounting plate comprises planar top and bottom surfaces.

[0011] In one form, the or each continuous mounting surface is substantially planar, and is continuous in terms of its planarity.

[0012] In one form, the cargo tray further comprises at least one mounting plate secured to an upper surface of the deck panel. One or more mounting plates secured to the upper surface of the deck panel might be used to secure items such as toolboxes, drop sides, a tail gate or tie down points to the deck panel.

[0013] In one form, the deck panel comprises at least one fibre reinforced composite panel.

[0014] In one form, the deck panel comprises a single fibre reinforced composite panel. In an alternative, it comprises a plurality of fibre reinforced composite panels joined together.

[0015] In one form, the or each mounting plate is metallic.

[0016] In one form, the or each mounting plate is secured to the bottom surface of the deck panel by an adhesive.

[0017] In one form, the or each mounting plate comprises a plurality of holes for receiving fasteners.

[0018] In one form, the cargo tray further comprises a headboard secured with respect to one end of the deck panel.

[0019] In one form, the headboard comprises at least one fibre reinforced composite panel

[0020] In one form, the headboard comprises a single fibre reinforced composite panel. In an alternative, it comprises a plurality of fibre reinforced composite panels joined together.

[0021] In one form, the cargo tray further comprises a rollover protection structure.

[0022] In one form, the rollover protection structure is internally moulded as part of the headboard. [0023] In one form, the deck panel and headboard are formed as a unitary component.

[0024] In one form, the cargo tray further comprises edge capping extending around its perimeter.

[0025] In one form, the cargo tray further comprises dropsides and a tailgate secured with respect to the deck panel.

[0026] In one form, the deck panel comprises at least one continuous mounting surface configured for securement of the dropsides and tailgate thereto.

[0027] In one form, the cargo tray further comprises a canopy secured with respect to the deck panel .

[0028] In one form, the deck panel comprises at least one continuous mounting surface configured for securement of the canopy thereto.

[0029] In one form, the cargo tray further comprises a cargo box secured with respect to the deck panel.

[0030] In one form, the deck panel comprises at least one continuous mounting surface configured for securement of the cargo box thereto.

[0031] According to a further aspect, there is provided a cargo tray for mounting to a light vehicle comprising a deck panel and a headboard made from a fibre reinforced composite.

[0032] In one form, the deck panel comprises a continuous mounting surface configured to at least support a mounting arrangement for securing the cargo tray to the vehicle.

[0033] According to a further aspect, there is provided a canopy for mounting to a light vehicle comprising a body made from a fibre reinforced composite, to which one or more doors can be attached to provide an enclosure.

[0034] According to a further aspect, there is provided a cargo box for mounting to a light vehicle comprising a body made from a fibre reinforced composite, to which one or more doors can be attached to provide an enclosure.

[0035] In one form, the body comprises a continuous mounting surface configured to at least support a mounting arrangement for securing the cargo tray to the vehicle. [0036] According to a further aspect, there is provided a cargo tray for mounting to a vehicle, the cargo tray comprising a deck panel comprising a fibre reinforced composite panel, and at least one metallic mounting plate secured to a bottom surface of the deck panel at least, the or each mounting plate providing a continuous planar mounting surface for supporting at least a mounting arrangement for securing the cargo tray to the vehicle.

[0037] In one form, the cargo tray further comprises at least one mounting arrangement secured with respect to the or each mounting plate.

[0038] In one form, the cargo tray comprises a pair of parallel, lengthwise extending mounting plates.

[0039] In one form, there is at least one mounting arrangement secured with respect to the or each mounting plate.

[0040] In one form, the deck panel comprises a sandwich-structured composite.

[0041] In one form, the deck panel comprises a core panel sandwiched between a pair of skin panels.

[0042] In one fonn the or each fibre reinforced composite panel comprises a carbon fibre.

[0043] In one form, the or each fibre reinforced composite panel comprises a glass fibre.

[0044] In one form, the or each fibre reinforced composite panel comprises an aramid fibre.

[0045] For ease of description, a cargo tray is described below in its usual assembled position as shown in the accompanying drawings, aid tenns such as front, rear, upper, lower, top, bottom, horizontal, longitudinal etc., may be used with reference to this usual position. However, the cargo tray may be manufactured, transported, sold, or used in orientations other than that described and shown here.

[0046] The present invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the present invention is not unnecessarily obscured.

BRIEF DESCRIPTION OF DRAWINGS

[0047] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein: [0048] Figure 1 is a top perspective view of a cargo deck and headboard, according to an embodiment;

[0049] Figure 2 is a bottom perspective view of the cargo deck and headboard of Figure 1;

[0050] Figure 3 is a top perspective view of the headboard as shown in Figure 1 ;

[0051] Figure 4 is a top perspective view of the cargo deck as shown in Figure 1 ;

[0052] Figure 5 is a top perspective view of a cargo tray including the cargo deck and headboard of

Figure 1;

[0053] Figure 6 is a bottom perspective view of the cargo tray of Figure 5;

[0054] Figure 7 is a top perspective view of a light truck including a cargo tray, according to an embodiment,

[0055] Figure 8 is a top perspective view of a cargo tray for a medium truck, according to an embodiment;

[0056] Figure 9 is a top perspective view of a dual cab track including a cargo tray and canopy, according to an embodiment; and

[0057] Figure 10 is a top perspective view of a portion of a box truck including a cargo box, according to an embodiment.

[0058] In the following description, like reference characters designate like or corresponding parts throughout the figures

DESCRIPTION OF EMBODIMENTS

[0059] Referring now to Figures 1 to 6, there is shown a cargo tray 1 for mounting to a vehicle of the type commonly known as a utility or pick-up truck, the cargo tray 1 comprising a deck panel 100 comprising a continuous mounting surface configured to at least support a mounting arrangement 305 for securing the cargo tray 1 with respect to the vehicle.

[0060] The deck panel 100 comprises a lightweight, fibre reinforced composite panel which features capping 120 extending around its perimeter. This capping comprises a ‘C’ or parallel flange cross- sectional shape for fitment over and around an edge of the deck panel 100. The capping 120 is metallic, and serves to protect the edge of the composite deck panel 100 from damage

[0061] As best shown in Figure 2, the cargo tray 1 further comprises two mounting plates 110 secured to the underside of and extending along the length of the deck panel 100, each of the mounting plates 110 comprising one of the continuous mounting surfaces, which as shown in Figure 6 and as will be discussed in greater detail below, is configured to at least support a mounting arrangement for securing the cargo tray 1 to the vehicle.

[0062] It can also be seen that an optional licence plate mount 130 may be secured to the underside of the deck panel 100. While in the embodiment shown the mounting plates 110 and the license plate mount 130 are secured to the underside of the deck panel 100 by an adhesive, it will be appreciated that in an alternative embodiment they may be secured through the use of fasteners, or a combination of fasteners and an adhesive In yet a further embodiment, the mounting plates 110 and license plate mount 130 may be moulded as part of the deck panel 100.

[0063] The mounting plates 110, license plate mount 130 and capping 120 are made from a metal such as steel, stainless steel or aluminium.

[0064] Referring again to Figure 1 , it can be seen that the cargo tray 1 further comprises a headboard 200 secured with respect to one end of the deck panel 100. The headboard 200 may be tapered to the shape of the vehicle and features a mesh section 240 in order to maintain visibility from the cabin of the vehicle. Like the deck panel 100, the headboard 200 is made from four lightweight, fibre reinforced composite panels 210, 220, 230 bonded together around the mesh section 240, with capping 120 around its perimeter.

[0065] As shown in Figures 3 and 4, the deck panel 100 and headboard 200 are two separate structures that are fabricated separately and then secured together. As shown in Figures 1 and 3, the headboard structure 200 also features an internal support panel 260 configured to mate with an upper surface of the deck panel 100, and as shown in Figures 2 and 4, the deck panel 100 features a complementary outer support panel 140 configured to mate with the headboard 200 such that when the deck panel 100 and headboard 200 are secured together, the inner and outer support panels 140, 260, as well as angled cappping 122 act to maintain a perpendicular relationship between the pair.

[0066] While in the embodiment shown, the deck panel 100 and headboard 200 are secured together through the use of an adhesive, it will be appreciated that in an alternate embodiment they can also be adhered through the use of fasteners or a combination thereof. In a further alternative embodiment, deck panel 100 and headboard 200 may be co-fabricated as a unitary component.

[0067] Referring now to Figures 5 and 6, where there is shown a cargo tray including the cargo deck and headboard of Figure 1 , configured to be mounted to a vehicle via vehicle specific mounts 305 secured to the mounting plates 110. As best shown in Figure 6, the mounting plates 110 provide a continuous mounting surface to be used for a variety of mountings and accessories. In the embodiment shown, mounting plates support a filler neck 302 and associated fuel hoses 301 for connection to the vehicle. Tire mounting plates also support mudguards 303, side tie downs 304, tail light brackets 306, light protectors 307 and drop sides 308 via respective drop side hinges 309. It will be appreciated that depending on the vehicle configuration and user preference, the position, number and size of the various mountings and accessories secured to the mounting plates 110 will vary, and that the continuous mounting surface provided by the mounting plates 110 accommodates this requirement. As can also be seen in Figures 5 and 6, the cargo tray also features a tailgate 310 secured to the rear capping 120 via hinges 311. It will be appreciated that in an alternative embodiment the tailgate hinges may also be secured to the mounting plates 110.

[0068] Wide in the embodiment shown, the mounting plates 110 are blank plates, and it is up to an end user or installer of the cargo tray to secure the various mounts and accessories to the mounting plates, it will be appreciated that in an alternative version, the mounting plates 110 may feature an array of pilot or tapped holes, or in a further alternative, the mounting plates may feature pre-drilled and tapped holes for specific vehicles, as an OEM component.

[0069] The cargo tray may be optionally fitted with a rollover protection structure intended to protect the driver of the vehicle in the event that the vehicle overturns or experiences a rollover. The rollover protection structure may be in the form of bars or structural elements externally attached to the cargo tray 1, alternatively the bars or structural elements may be moulded within the headboard 200. In yet a further embodiment, the headboard may be the rollover protection structure.

[0070] It will be appreciated that the above disclosure can be applied to vehicles of different dimensions, and that cargo trays of various lengths, widths and heights may also be configured. For instance, Figure 8 teaches a cargo tray 500 for a medium truck, Figure 9 teaches a cargo tray and accompanying canopy 600 for a dual cab truck, and Figure 10 teaches a cargo box 700 for a box truck.

[0071] The canopy 600 of Figure 9 is formed from a fibre reinforced composite. The doors 602 of the canopy 600 are also formed from a fibre reinforced composite. [0072] The cargo box 700 of Figure 10 is formed from a fibre reinforced composite. The doors 702 of the cargo box 700 are also formed from a fibre reinforced composite.

[0073] Different composite parts or panels can be produced with different composites depending on the requirements of their given applications. A composite can be varied by variation of the kind, weight or weave direction of its fibre, and/or by variation of the resin, and/or by the use of a core and the type of core where used. For example, if it is a highly loaded area such as a deck panel 100, then the composition of the composite from which it is formed is designed to handle that, or if it is more important that a part is light than it is strong, such as might be the case for the roof of a box 700 or a canopy 600, then the composite from which it is formed is designed accordingly.

[0074] It will be appreciated that by virtue of the flat bottom surface of the mounting plates 110, that a continuous planar mounting surface is provided to be used for any mounting or accessory, providing the flexibility to adapt the cargo tray to a variety of vehicles and to support a variety of mountable accessories and sub components.

[0075] The basis for all of these is the arrangement of deck panel 100 and mounting plates 110. In this respect it is possible to provide a ‘modular’ system based upon the deck panel, from which the user can build up a cargo tray as required, and which they can adapt to a vehicle of their choosing.

[0076] It will further be appreciated that the above disclosure teaches a cargo area having reduced weight by virtue of the fibre reinforced composite structure, which improves the power to weight ratio, handling characteristics, and fuel efficiency of the vehicle, while also reducing braking distances, when compared with existing prior art solutions. It will also be appreciated that by reducing the weight of the cargo area, an increased cargo or payload weight may be transported.

[0077] It will also be appreciated that the above disclosure teaches a cargo area having improved impact and wear resistance, improved impact energy absorption characteristics when compared with existing prior art solutions. The cargo area will also be more dimensionally stable, will not be susceptible to corrosion, and may be able to deliver an increased internal cargo area when compared with existing prior art solutions.

[0078] Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers. [0079] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art fonns part of the common general knowledge.

[0080] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims

1. A cargo tray for mounting to a vehicle, the cargo tray comprising a deck panel comprising at least one continuous planar mounting surface configured to support at least a mounting arrangement for securing the cargo tray with respect to the vehicle.

2. The cargo tray as claimed in claim 1, further comprising at least one mounting plate secured to a bottom surface of the deck panel at least, the or each mounting plate providing the or each continuous planar mounting surface.

3. The cargo tray as in either of the preceding claims, wherein the tray comprises a pair of parallel, elongate, lengthwise extending mounting plates.

4. The cargo tray as in any one of the preceding claims, wherein the deck panel comprises at least one fibre reinforced composite panel

5. The cargo tray as in any one of claims 2 through 4, wherein the or each mounting plate is metallic.

6. The cargo tray as in any one of claims 2 through 5, wherein the or each mounting plate is secured to the bottom surface of the deck panel by an adhesive.

7. The cargo tray as in any one of claims 2 through 6, wherein the or each mounting plate comprises a plurality of holes for receiving fasteners.

8. The cargo tray as in any one of the preceding claims, further comprising a headboard secured with respect to one end of the deck panel.

9. The cargo tray of claim 8, wherein the headboard comprises at least one fibre reinforced composite panel.

10. The cargo tray as in any one of the preceding claims, further comprising a rollover protection structure.

11 . The cargo tray of claim 10, wherein the rollover protection structure is internally moulded as part of the headboard.

12. The cargo tray as in any one of claims 8 through 11, wherein the deck panel and headboard are formed as a unitary component.

13. The cargo tray as in any one of the preceding claims, wherein the deck panel comprises planar top and bottom surfaces.

14. The cargo tray as in any one of the preceding claims, wherein the or each continuous planar mounting surface is continuous in terms of its planarity.

15. The cargo tray as in any one of the preceding claims, further comprising edge capping extending around its perimeter.

16. The cargo tray as in any one of the preceding claims, further comprising dropsides and a tailgate secured with respect to the deck panel.

17. The cargo tray as in any one of the preceding claims, further comprising a canopy secured with respect to the deck panel.

18. The cargo tray as in any one of the preceding claims, further comprising a cargo box secured with respect to the deck panel.

19. A cargo tray for mounting to a vehicle, the cargo tray comprising a deck panel comprising at least one fibre reinforced composite panel, and at least one metallic mounting plate secured to a bottom surface of the deck panel at least, the or each mounting plate providing a substantially continuous planar mounting surface for supporting at least a mounting arrangement for securing the cargo tray to the vehicle.

20. The cargo tray of claim 19, comprising a pair of parallel, lengthwise extending mounting plates, each comprising a continuous planar mounting surface.