Method of manufacturing a single-shell structure of a land vehicle using a modular mold system

Abstract

Disclosed herein are land vehicles, modular systems for forming a unibody structure of a land vehicle, and methods of forming a unibody structure of a land vehicle using a modular system. In certain embodiments, land vehicles are provided as cargo vehicles and / or utility vehicles. The land vehicles include a unibody structure that supports a plurality of wheels to allow the vehicle to move relative to an underlying ground surface when the land vehicle is in use.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and interest in U.S. Provisional Application No. 62 / 957,577, filed January 6, 2020, entitled “SYSTEMS AND METHODS FORMANUFACTURING LAND VEHICLES”. The entire contents of that application are incorporated herein by reference. Technical Field

[0003] This invention generally relates to land vehicles and methods of manufacturing land vehicles, and more specifically, to multi-purpose vehicles and freight vehicles, and methods of manufacturing multi-purpose vehicles and freight vehicles. Background Technology

[0004] Current systems and methods for manufacturing multi-purpose vehicles and freight vehicles have numerous shortcomings and limitations. For these reasons, further improvements are still needed in this technological field. Summary of the Invention

[0005] The present invention may include one or more of the following features and combinations thereof.

[0006] According to one aspect of the invention, a land vehicle may include a monocoque structure supporting multiple wheels to enable movement of the vehicle relative to the ground below when in use. The monocoque structure may be a single-piece, integral structure not supported by an internal chassis. The monocoque structure may include a front body defining a cab and a rear floor located behind the front body. The monocoque structure may have a composite construction such that each of the front body and the rear floor is formed of one or more composite materials.

[0007] In some embodiments, the single-shell structure may not include metallic materials. The single-shell structure may include a core and a shell at least partially surrounding the core. The core may be formed of one or more lightweight, low-density materials, and the shell may be formed of resin and glass fiber. The core may contain balsa wood. The core may contain plastic. The single-shell structure may include a laminate that at least partially covers the shell.

[0008] In some embodiments, the monocoque structure may include a central section disposed between the front body and the rear floor. The vehicle may include a cargo box at least partially defined by the central section and the rear floor, the cargo box having a roof and multiple sidewalls. Each of the central section, the multiple sidewalls, and the roof may be formed of one or more composite materials, and each of the central section, the multiple sidewalls, and the roof may be free of metallic materials. The cargo box volume may be 650 cubic feet, 1000 cubic feet, or 1200 cubic feet. Furthermore, in some embodiments, the vehicle's weight limit may be between 10,001 pounds and 14,000 pounds. Further, in some embodiments, the land vehicle may include a refrigeration unit at least partially housed in the cargo box, the refrigeration unit being configured to cool the cargo box.

[0009] In some implementations, the vehicle may not include an internal combustion engine. The height of the rear floor above the ground can be between 22 inches and 28 inches.

[0010] According to another aspect of the invention, a modular system for forming a monocoque structure of a land vehicle may include a front body mold unit, a rear floor mold unit, and a plurality of intermediate mold units. The front body mold unit may include a front body mold cavity whose dimensions and shape correspond to the front body of the monocoque structure defining the cab. The front body mold unit may have an opening at its rear end to establish a fluid connection between the front body mold cavity and another component of the system. The rear floor mold unit may include a rear floor mold cavity whose dimensions and shape correspond to the rear floor of the monocoque structure located behind the front body. The rear floor mold unit may have an opening at its front end to establish a fluid connection between the rear floor mold cavity and another component of the system. The dimensions of each of the plurality of intermediate mold units may be used to position it between the front body mold unit and the rear floor mold unit. Each of the plurality of intermediate mold units may include an intermediate mold cavity whose dimensions and shape correspond to the intermediate portion of the monocoque structure located between the front body and the rear floor. Each of the multiple intermediate mold units may have a front opening at its front end to establish a fluid connection between the intermediate mold cavity and the front body mold cavity, and a rear opening at its rear end to establish a fluid connection between the intermediate mold cavity and the rear bottom plate mold cavity.

[0011] In some implementations, the front end of each of the plurality of intermediate mold units can be configured to be directly connected to the rear end of the front body mold unit. The rear end of each of the plurality of intermediate mold units can be configured to be directly connected to the front end of the rear floor mold unit. When any of the intermediate mold units is directly connected to the front body mold unit and the rear floor mold unit, the front body mold cavity, the intermediate mold cavity, and the rear floor mold cavity can be fluidly connected to each other in an adjacent arrangement to establish a continuous monocoque structure mold cavity. One or more composite materials can be introduced into the continuous monocoque structure mold cavity to form the monocoque structure as a single-piece integral structure.

[0012] In some implementations, the rear end of the front body mold unit can be configured to connect directly to the front end of the rear floor mold unit. When the front body mold unit is directly connected to the rear floor mold unit, the front body mold unit and the rear floor mold unit can be fluidly connected to each other in an adjacent arrangement to establish a continuous monocoque structure mold cavity. One or more composite materials can be introduced into the continuous monocoque structure mold cavity to form the monocoque structure as a single-piece integral structure.

[0013] In some embodiments, the plurality of intermediate mold units may include a first intermediate mold unit having a first length, a second intermediate mold unit having a second length, and a third intermediate mold unit having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length. The dimensions of the first intermediate mold unit may be used to form the intermediate portion of a monocoque structure included in a vehicle with a storage volume of 650 cubic feet, the dimensions of the second intermediate mold unit may be used to form the intermediate portion of a monocoque structure included in a vehicle with a storage volume of 1000 cubic feet, and the dimensions of the third intermediate mold unit may be used to form the intermediate portion of a monocoque structure included in a vehicle with a storage volume of 1200 cubic feet.

[0014] According to another aspect of the invention, a land vehicle may include a monocoque structure supporting multiple wheels to enable the vehicle to move relative to the ground below when in use. The monocoque structure may be a single-piece, integral structure not supported by an internal chassis. The monocoque structure may include a front body defining a cab, a rear floor plate located behind the front body, and an intermediate portion disposed between the front body and the rear floor plate. The monocoque structure may include a core and a shell portion at least partially surrounding the core, the core being formed of balsa wood or plastic, and the shell portion being formed of resin and fiberglass. The monocoque structure may be formed by a modular system including a front body molding unit, a rear floor plate molding unit, and an intermediate molding unit. The front body molding unit may include a front body molding cavity whose dimensions and shape correspond to the front body of the monocoque structure. The front body molding unit may have an opening at its rear end to establish a fluid connection between the front body molding cavity and another component of the system. The rear floor plate mold unit may include a rear floor plate mold cavity, the size and shape of which correspond to the rear floor plate of the monocoque structure. The rear floor plate mold unit may have an opening at its front end to establish a fluid connection between the rear floor plate mold cavity and another component of the system. The intermediate mold unit is sized to be positioned between the front body mold unit and the rear floor plate mold unit. The intermediate mold unit may include an intermediate mold cavity, the size and shape of which correspond to the middle portion of the monocoque structure. The intermediate mold unit may have a front opening at its front end to establish a fluid connection between the intermediate mold cavity and the front body mold cavity, and a rear opening at its rear end to establish a fluid connection between the intermediate mold cavity and the rear floor plate mold cavity.

[0015] According to yet another aspect of the invention, a method for forming a monocoque structure of a land vehicle using a modular system may include the following steps: selecting a monocoque structure configuration of the land vehicle; selecting a first mold unit of the modular system based on the selected monocoque structure configuration; connecting the selected first mold unit to a front body mold unit of the modular system such that the front body mold cavity of the front body mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a continuous monocoque structure mold cavity; introducing one or more composite materials into the continuous monocoque structure mold cavity; and curing one or more composite materials in the continuous monocoque structure mold cavity to form a monocoque structure.

[0016] In some embodiments, introducing one or more composite materials into the mold cavity of a continuous single-shell structure may include introducing one or more composite materials into the mold cavity of a continuous single-shell structure without introducing metallic material. Furthermore, in some embodiments, the front body mold unit of the modular system may correspond to the front body of the cab in a defined vehicle of a single-shell structure, and a selected first mold unit of the modular system may correspond to the rear floor plate located behind the front body of the single-shell structure.

[0017] In some embodiments, introducing one or more composite materials into a continuous single-shell mold cavity may include: placing a first material in the continuous single-shell mold cavity, and placing a second material, different from the first material, in the continuous single-shell mold cavity. The first material may comprise balsa wood or plastic, and the second material may comprise glass fiber and resin. Curing one or more composite materials in the continuous single-shell mold cavity may include: forming a core comprising the first material, and forming a shell comprising the second material and at least partially surrounding the core.

[0018] In some implementations, the front body mold unit of the modular system may correspond to the front body of the cab in a defined vehicle with a single-shell structure, and a selected first mold unit of the modular system may correspond to the intermediate section of the single-shell structure located behind the front body. The method may further include: selecting a second mold unit of the modular system based on the selected single-shell structure configuration, the second mold unit corresponding to the rear floor plate of the single-shell structure located behind the front body and the intermediate section; and connecting the selected first mold unit to the selected second mold unit such that the front body mold cavity of the front body mold unit, the cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly connected to each other to establish a continuous single-shell structure mold cavity. Selecting the first mold unit of the modular system may include: selecting one of a small intermediate section mold unit of the modular system having a first length, a medium intermediate section mold unit of the modular system having a second length, and a large intermediate section mold unit of the modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

[0019] According to a further aspect of the present invention, a method for forming multiple monocoque structures of a land vehicle using at least one modular system may include the following steps: selecting a first monocoque structure configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of at least one modular system based on the selected first monocoque structure configuration; connecting the selected first mold unit to a front body mold unit of the at least one modular system selected based on the selected first monocoque structure configuration, such that the front body mold cavity of the front body mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structure mold cavity; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or more composite materials in the first continuous monocoque structure mold cavity to form the first monocoque structure; selecting a second monocoque structure configuration for a second monocoque structure of a second land vehicle different from the first land vehicle; based on the selected first monocoque structure configuration, selecting a first mold unit of at least one modular system of a first land vehicle; selecting a first mold unit of at least one modular system of a first land vehicle based on the selected first monocoque structure configuration ... The process involves selecting a second single-shell structural configuration to select a first mold unit of at least one modular system that is different from the first mold unit of at least one modular system selected based on the selected first single-shell structural configuration; connecting the selected first mold unit of at least one modular system selected based on the selected second single-shell structural configuration to the front body mold unit of at least one modular system selected based on the selected second single-shell structural configuration, such that the front body mold cavity of the front body mold unit of at least one modular system selected based on the selected second single-shell structural configuration is fluidly connected to the mold cavity of the selected first mold unit of at least one modular system selected based on the selected second single-shell structural configuration to at least partially establish a second continuous single-shell structural mold cavity; introducing one or more composite materials into the second continuous single-shell structural mold cavity; and curing one or more composite materials in the second continuous single-shell structural mold cavity to form the second single-shell structure.

[0020] In some embodiments, introducing one or more composite materials into a first continuous single-shell mold cavity may include introducing one or more composite materials into the first continuous single-shell mold cavity without introducing metal material into the first continuous single-shell mold cavity, and introducing one or more composite materials into a second continuous single-shell mold cavity may include introducing one or more composite materials into the second continuous single-shell mold cavity without introducing metal material into the second continuous single-shell mold cavity.

[0021] In some embodiments, introducing one or more composite materials into a first continuous single-shell structure mold cavity may include placing a first material into the first continuous single-shell structure mold cavity and placing a second material, different from the first material, into the first continuous single-shell structure mold cavity. Introducing one or more composite materials into a second continuous single-shell structure mold cavity may include placing a first material into the second continuous single-shell structure mold cavity and placing a second material into the second continuous single-shell structure mold cavity. The first material may comprise balsa wood or plastic, and the second material may comprise glass fiber and resin. Curing one or more composite materials in the first continuous single-shell structure mold cavity may include forming a core of the first single-shell structure containing the first material and forming a shell portion of the first single-shell structure containing the second material, the shell portion at least partially surrounding the core of the first single-shell structure. Curing one or more composite materials in the second continuous single-shell structure mold cavity may include forming a core of the second single-shell structure containing the first material and forming a shell portion of the second single-shell structure containing the second material, the shell portion at least partially surrounding the core of the second single-shell structure.

[0022] In some embodiments, the front body mold unit of at least one modular system selected based on the selected first monocoque structure configuration may correspond to the front body of the cab of the first monocoque structure in the first land vehicle, the selected first mold unit of the at least one modular system selected based on the selected first monocoque structure configuration may correspond to the rear floor plate of the first monocoque structure located behind the front body of the first monocoque structure, the front body mold unit of at least one modular system selected based on the selected second monocoque structure configuration may correspond to the front body of the second monocoque structure in the second land vehicle, and the selected first mold unit of at least one modular system selected based on the selected second monocoque structure configuration may correspond to the middle portion of the second monocoque structure located behind the front body of the second monocoque structure.

[0023] In some embodiments, the method may further include: selecting a second mold unit of at least one modular system based on a selected second monocoque structural configuration, the second mold unit corresponding to a rear floor plate located behind the front body and intermediate section of the second monocoque structure; and connecting the selected first mold unit of the at least one modular system selected based on the selected second monocoque structural configuration to the selected second mold unit of the at least one modular system selected based on the selected second monocoque structural configuration, such that the front body mold cavity of the front body mold unit of the at least one modular system selected based on the selected second monocoque structural configuration, the cavity of the selected first mold unit of the at least one modular system selected based on the selected second monocoque structural configuration, and the mold cavity of the selected second mold unit of the at least one modular system selected based on the selected second monocoque structural configuration are fluidly connected to each other to establish a second continuous monocoque structural mold cavity. Selecting the first mold unit of at least one modular system may include: selecting one of at least one small intermediate section mold unit of at least one modular system having a first length, at least one medium intermediate section mold unit of at least one modular system having a second length, and at least one large intermediate section mold unit of at least one modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

[0024] In some embodiments, the front body mold unit of at least one modular system selected based on the selected first monocoque structure configuration may correspond to the front body of the cab of the first monocoque structure in a first land vehicle. The selected first mold unit of at least one modular system selected based on the selected first monocoque structure configuration may have a first length and correspond to the middle portion of the first monocoque structure located behind the front body of the first monocoque structure. The front body mold unit of at least one modular system selected based on the selected second monocoque structure configuration may correspond to the front body of the second monocoque structure in a second land vehicle. The selected first mold unit of at least one modular system selected based on the selected second monocoque structure configuration may have a second length different from the first length and correspond to the middle portion of the second monocoque structure located behind the front body of the second monocoque structure. The method may further include the following steps: selecting at least one second mold unit of a modular system based on a selected first monohub structural configuration, the second mold unit corresponding to the rear floor plate located behind the front body and middle section of the first monohub structure; connecting the selected first mold unit of the at least one modular system selected based on the selected first monohub structural configuration to the selected second mold unit of the at least one modular system selected based on the selected first monohub structural configuration, such that the front body mold cavity of the front body mold unit of the at least one modular system selected based on the selected first monohub structural configuration, the cavity of the selected first mold unit of the at least one modular system selected based on the selected first monohub structural configuration, and the mold cavity of the selected second mold unit of the at least one modular system selected based on the selected first monohub structural configuration are fluidly connected to each other to establish a first continuous monohub structure. The structure includes a mold cavity; selecting at least one second mold unit of a modular system based on a selected second monohull structure configuration, the second mold unit corresponding to the rear bottom plate of the second monohull structure located behind the front body and middle section of the second monohull structure; and connecting the selected first mold unit of the at least one modular system selected based on the selected second monohull structure configuration to the selected second mold unit of the at least one modular system selected based on the selected second monohull structure configuration, such that the front body mold cavity of the front body mold unit of the at least one modular system selected based on the selected second monohull structure configuration, the cavity of the selected first mold unit of the at least one modular system selected based on the selected second monohull structure configuration, and the mold cavity of the selected second mold unit of the at least one modular system selected based on the selected second monohull structure configuration are fluidly connected to each other to establish a second continuous monohull structure mold cavity.

[0025] According to a further aspect of the invention, a method for forming multiple monocoque structures of a land vehicle using at least one modular system may include the following steps: selecting a first monocoque structure configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of at least one modular system based on the selected first monocoque structure configuration; connecting the selected first mold unit to a front body mold unit of at least one modular system such that the front body mold cavity of the front body mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structure mold cavity; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or more composite materials in the first continuous monocoque structure mold cavity to form the first monocoque structure; selecting a second monocoque structure configuration for a second monocoque structure of a second land vehicle different from the first land vehicle; selecting a first mold unit of at least one modular system different from the selected first mold unit of at least one modular system based on the selected second monocoque structure configuration; connecting the selected first mold unit of at least one modular system to a front body mold unit of at least one modular system such that the front body mold cavity of the front body mold unit of at least one modular system is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structure mold cavity; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or more composite materials in the first continuous monocoque structure mold cavity to form the first monocoque structure; selecting a second monocoque structure configuration for a second land vehicle different from the first land vehicle; selecting a first mold unit of at least one modular system different from the selected first mold unit of at least one modular system based on the selected second monocoque structure configuration; connecting the selected first mold unit of at least one modular system to a front body mold unit of at least one modular system such that the front body mold cavity of the front body mold unit of at least one modular system is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structure mold cavity of at least one modular system; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or The process involves: fluidly connecting a mold cavity to a selected first mold unit of at least one modular system to at least partially establish a second continuous single-shell structure mold cavity; introducing one or more composite materials into the second continuous single-shell structure mold cavity; curing one or more composite materials in the second continuous single-shell structure mold cavity to form the second single-shell structure; selecting a third single-shell structure configuration for a third land vehicle different from the first and second land vehicles; selecting a first mold unit of at least one modular system that is different from the selected first mold unit of at least one modular system and the selected first mold unit of at least one modular system based on the selected third single-shell structure configuration; connecting the selected first mold unit of at least one modular system to a front body mold unit of at least one modular system such that the front body mold cavity of the front body mold unit of at least one modular system is fluidly connected to the mold cavity of the selected first mold unit of at least one modular system to at least partially establish a third continuous single-shell structure mold cavity; introducing one or more composite materials into the third continuous single-shell structure mold cavity; and curing one or more composite materials in the third continuous single-shell structure mold cavity to form the third single-shell structure.

[0026] Furthermore, according to another aspect of the invention, a method for forming a monocoque structure of a land vehicle using a modular system may include the following steps: selecting a monocoque structure configuration of the land vehicle; selecting a first mold unit of the modular system based on the selected monocoque structure configuration; connecting the selected first mold unit to a front body mold unit of the modular system such that the front body mold cavity of the front body mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a continuous monocoque structure mold cavity; introducing one or more composite materials into the continuous monocoque structure mold cavity; and curing the one or more composite materials in the continuous monocoque structure mold cavity to form a monocoque structure. Introducing one or more composite materials into the continuous monocoque structure mold cavity may include: introducing one or more composite materials into the continuous monocoque structure mold cavity without introducing metallic materials. Introducing one or more composite materials into a continuous single-shell structure mold cavity may include: placing a first material comprising balsa wood or plastic into the continuous single-shell structure mold cavity, and placing a second material comprising glass fiber and resin into the continuous single-shell structure mold cavity.

[0027] In some embodiments, curing one or more composite materials in a continuous monocoque mold cavity may include: forming a core comprising a first material, and forming a shell comprising a second material and at least partially surrounding the core. A front body mold unit of a modular system may correspond to the front body of a cab in a defined vehicle with a monocoque structure, and a selected first mold unit of the modular system may correspond to the intermediate portion of the monocoque structure located behind the front body. The method may include: selecting a second mold unit of the modular system based on a selected monocoque configuration, the second mold unit corresponding to a rear floor plate of the monocoque structure located behind the front body and the intermediate portion, and connecting the selected first mold unit to the selected second mold unit such that the front body mold cavity of the front body mold unit, the cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly connected to each other to establish a continuous monocoque mold cavity. Selecting a first mold unit of a modular system may include: selecting one of a small intermediate mold unit of a modular system having a first length, a medium intermediate mold unit of a modular system having a second length, and a large intermediate mold unit of a modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

[0028] These and other features of the invention will become more apparent from the following description of illustrative embodiments. Attached Figure Description

[0029] The invention described herein is illustrated by way of example rather than limitation in the accompanying drawings. For the sake of simplicity and clarity, the elements shown in the figures are not necessarily drawn to scale. For example, for clarity, the dimensions of some elements may be enlarged relative to others. Furthermore, reference numerals in the figures have been repeated where deemed appropriate to indicate corresponding or similar elements.

[0030] Figure 1 A side view illustrating various electric vehicles that may be used in an electric vehicle production line, according to certain embodiments of the present invention;

[0031] Figure 2 A perspective view of a monocoque structure or unibody structure that can be incorporated into any electric vehicle of the present invention;

[0032] Figure 3 This is a partially exploded component diagram of an electric vehicle according to at least one embodiment of the present invention;

[0033] Figure 4 is a partial schematic rear view of a conventional freight vehicle;

[0034] Figure 5 A partial schematic rear-end view of a freight vehicle according to at least one embodiment of the present invention;

[0035] Figure 6 A table showing the U.S. standard vehicle class based on gross vehicular weight rating (GVWR);

[0036] Figure 7 A partial schematic depiction of a composite structure that can be used to form a monocoque structure or an integral body of any electric vehicle of the present invention;

[0037] Figure 8 A schematic depiction of at least one modular mold system according to certain embodiments of the present invention;

[0038] Figure 9 For the reason included Figure 8 A perspective view of a single-shell structure system formed by multiple mold units in at least one modular mold system;

[0039] Figure 10 A simplified flowchart of a method for forming a monocoque structure of an electric vehicle using a modular mold system according to an embodiment of the present invention;

[0040] Figure 11A simplified flowchart as part of another method for forming a monocoque structure of an electric vehicle using a modular mold system according to another embodiment of the present invention;

[0041] Figure 12 for Figure 11 A schematic diagram of another part of the method; and

[0042] Figure 13 A simplified flowchart of a method for forming various monocoque structures of an electric vehicle using at least one modular mold system according to yet another embodiment of the present invention. Detailed Implementation

[0043] While the concept of the invention is readily available for various modifications and alternatives, specific embodiments thereof have been illustrated by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that the invention is not intended to be limited to the specific forms disclosed, but rather to cover all modifications, equivalents, and alternatives consistent with the invention and the appended claims.

[0044] The terms "an embodiment," "implementation," and "illustrative embodiment" used in the specification indicate that the described embodiment may include specific features, structures, or characteristics. However, each embodiment may or may not necessarily include the specific features, structures, or characteristics. Furthermore, such terms do not necessarily refer to the same embodiment. Additionally, when a specific feature, structure, or characteristic is described in connection with an embodiment, it is assumed that a person skilled in the art would recognize that such a feature, structure, or characteristic can be implemented in conjunction with other embodiments, regardless of whether those other embodiments are explicitly described. Furthermore, it should be understood that items included in a list of items in the form of "at least one of A, B, and C" may mean (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C). Similarly, items listed in the form of "at least one of A, B, or C" may mean (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C).

[0045] In the accompanying drawings, certain structural or methodological features, such as those representing devices, modules, instruction blocks, and data elements, may be shown in a specific arrangement and / or order for ease of description. However, it should be understood that such a specific arrangement and / or order may not be necessary. Instead, in some embodiments, such features may be arranged in a manner and / or order different from that shown in the illustrative drawings. Furthermore, the inclusion of structural or methodological features in a particular figure does not imply that such features are required in all embodiments, and in some embodiments such features may be omitted or may be combined with other features.

[0046] In some implementations, the schematic elements representing the blocks used to indicate a method can be manually executed by a user. In other implementations, those schematic elements can be implemented automatically using any suitable form of machine-readable instructions, such as software or firmware applications, assemblies, functions, modules, routines, processes, code, plug-ins, applets, widgets, code segments, and / or others. Each such instruction can be implemented using any suitable programming language, library, application programming interface (API), and / or other software development tools. For example, in some implementations, the schematic elements can be implemented using Java, C++, and / or other programming languages. Similarly, the schematic elements representing data or information can be implemented using any suitable electronic arrangement or structure, such as registers, data storage, tables, records, arrays, indexes, hashes, maps, trees, lists, graphs, files (of any file type), folders, directories, databases, and / or others.

[0047] Furthermore, in the accompanying drawings, where connecting elements such as solid or dashed lines or arrows are used to show connections, relationships, or associations between two or more other schematic elements, the absence of any such connecting element does not imply that any connection, relationship, or association cannot exist. In other words, some connections, relationships, or associations between elements may not be shown in the drawings to avoid obscuring the invention. Moreover, for ease of illustration, a single connecting element may be used to represent multiple connections, relationships, or associations between elements. For example, where a connecting element represents communication of signals, data, or instructions, those skilled in the art will understand that such an element can represent one or more signal paths (e.g., a bus) as needed to enable communication.

[0048] Now for reference Figure 1The illustrative production line 100 for land vehicles includes a variety of land vehicles. In illustrative embodiments, the land vehicle production line 100 includes (but is not limited to) a two-seat flatbed multipurpose vehicle 110, a 650 cubic foot capacity cargo vehicle 120, a 1000 cubic foot capacity cargo vehicle 130, a six-seat flatbed multipurpose vehicle 140, and a 1200 cubic foot capacity cargo vehicle 150. However, in some embodiments, the land vehicle production line 100 may include any vehicle having a capacity within a specific range (e.g., a range of 400 cubic feet to 1400 cubic feet). According to industry terminology, the term "cubic foot capacity" may be abbreviated herein or simply referred to as "cubic". It should be understood that, as considered herein, "cubic foot capacity" may refer to the storage volume or storage capacity of a particular land vehicle. In any case, as will be apparent from the following discussion, one or more types of vehicles can be manufactured using the systems and methods described herein for the vehicle production line 100.

[0049] In the illustrative embodiment, each vehicle included in vehicle production line 100 (i.e., each of vehicles 110, 120, 130, 140, 150) comprises a monocoque structure or a unibody construction 200 (see [link to illustrative embodiment]). Figure 2 The monocoque structure or unibody 200 supports wheels (e.g., wheels 112, 122, 132, 142, 152) for enabling the vehicle to move relative to the ground below when in use of the vehicle. As described herein, the monocoque structure 200 is a single-piece, integral structure not supported by an internal chassis. The monocoque structure 200 includes a front body 210 defining a cab 212 and a rear floor 220 located behind the front body 210. The monocoque structure 200 illustratively has a composite construction such that each of the front body 210 and the rear floor 220 is formed of one or more composite materials (e.g., in...). Figure 7 The composite structure 700 shown is described in more detail below.

[0050] At least some of the vehicles of illustrative production line 100 (e.g., vehicles 110, 140) can be implemented as, included in, or otherwise adapted to electric multipurpose vehicles. Furthermore, at least some of the vehicles of illustrative production line 100 (e.g., vehicles 120, 130, 150) can be implemented as, included in, or otherwise adapted to electric vehicles with enclosed cargo boxes. Of course, in other embodiments, it should be understood that the vehicles of production line 100 can be implemented as, included in, or otherwise adapted to other suitable vehicles.

[0051] It should be understood that each vehicle of the illustrative production line 100 can be used in a variety of applications. In some embodiments, one or more types of vehicles of the production line 100 may be implemented as fire and emergency vehicles, garbage trucks, long-haul vehicles, recreational vehicles or motorhomes, municipal and / or service vehicles, agricultural vehicles, mining vehicles, special vehicles, energy vehicles, defense vehicles, port service vehicles, engineering vehicles, and urban rail and / or public vehicles, or otherwise included in fire and emergency vehicles, garbage trucks, long-haul vehicles, recreational vehicles or motorhomes, municipal and / or service vehicles, agricultural vehicles, mining vehicles, special vehicles, energy vehicles, defense vehicles, port service vehicles, engineering vehicles, and urban rail and / or public vehicles, to name just a few examples. Furthermore, in some implementations, one or more vehicles of production line 100 may be adapted to or otherwise incorporated into tractors, front-end loaders, scraper systems, cutters and shredders, hay and feed equipment, planting equipment, seeding equipment, sprayers and pesticide applicators, tillage equipment, multi-purpose vehicles, lawnmowers, dump trucks, backhoe excavators, loaders, tracked loaders, bulldozers, excavators, motor graders, skid steer loader, tractor-mounted loader, wheel loader, rake, aerator, timber harvester, bundler, short timber transporter, harvester, swing loader, clamp loader, diesel engine, axle, planetary gear drive, pump drive, transmission, generator and marine engine, and other suitable equipment.

[0052] In the illustrative embodiment, each vehicle of production line 100 includes one or more electric motors (not shown) capable of generating rotational power that can be transmitted to the wheels to drive the vehicle. Thus, each illustrative vehicle is implemented as an electric vehicle or otherwise includes an electric vehicle. Detailed information regarding the electric motors and associated powertrain and / or suspension components included in each vehicle is described in pending U.S. Patent Application No. XX / XXX,XXX, the entire contents of which are incorporated herein by reference.

[0053] At least in some embodiments, each vehicle of the illustrative production line 100 does not include an internal combustion engine or power unit. Furthermore, each vehicle of the illustrative production line 100 does not include an engine or power unit housed by the front body 210 and located above the lower side 214 of the monocoque structure 200. Instead, as described in pending U.S. Patent Application No. XX / XXX,XXX, multiple electric motors or power units are detachably coupled to the lower side 214 of the monocoque structure 200 of each vehicle in the illustrative production line 100.

[0054] It should be understood that the vehicles in the illustrative vehicle production line 100 may each include one or more features that improve the experience for the driver, owner, and / or maintenance personnel. Such features may include (but are not limited to) a lower floor, modular battery system, air spring and / or air suspension system features, independent rear suspension, independent front suspension, thermal battery management capabilities, flexible shelving options, ideal driver visibility, LED lighting, telematics / driver feedback, ease of maintenance features, aerodynamic body, and advanced safety systems. Further details regarding at least some of these features are provided herein.

[0055] Now for reference Figure 2 At least in some embodiments, in addition to the front body 210 and the rear floor 220, the monocoque structure 200 also includes an intermediate portion 230 disposed between the front body 210 and the rear floor 220. The intermediate portion 230 may form part of a floor portion disposed in front of the rear floor 220. See below for more details. Figure 8 Each of the front body 210, rear floor 220, and intermediate section 230 can be associated with and formed by a corresponding mold unit of a modular mold system (e.g., system 800). Furthermore, as referred to below in more detail... Figure 9 The modular mold system's mold units can be joined together to form a single-shell structure mold (e.g., single-shell structure mold 900), and composite materials can be introduced into the single-shell structure mold to form a single-shell structure 200.

[0056] In the illustrative embodiment, the monocoque structure 200 combines a structure that would traditionally be formed from one or more separate structures (e.g., one or more body components and one or more frame components) into a single, integral structure. Therefore, any vehicle of the present invention including the monocoque structure 200 does not include an internal chassis or frame structure supporting individual body components (e.g., panels, doors, etc.). At least to some extent, due to the structure that integrates the body components and frame components into a single unit, the illustrative monocoque structure 200 may provide or otherwise facilitate improved manufacturability and / or simplified maintenance compared to other configurations.

[0057] Depending on the specific vehicle type and monocoque structure configuration, one or more dimensions of the intermediate portion 230 of the monocoque structure 200 may vary. In one example, the intermediate portion 230 may have a smaller intermediate portion mold unit (e.g., in...). Figure 8The first length is associated with and defined by the mold unit 832 shown. In this example, the first length of the intermediate portion 230 may at least partially define the cargo box of a 650 cubic foot delivery vehicle (e.g., vehicle 120). In another example, the intermediate portion 230 may have a first length associated with and defined by a medium-sized intermediate portion mold unit (e.g., in...). Figure 8 The second length is associated with and defined by the mold unit 834 shown. In this example, the second length of the intermediate portion 230 may at least partially define the cargo box of a 1000 cubic foot delivery vehicle (e.g., vehicle 130). In yet another example, the intermediate portion 230 may have a second length associated with and defined by a large intermediate portion mold unit (e.g., in...). Figure 8 The mold unit 836 shown is associated with and defined by a third length. In this example, the third length of the intermediate portion 230 may at least partially define the cargo compartment of a 1200 cubic foot delivery vehicle (e.g., vehicle 150).

[0058] Furthermore, depending on the specific vehicle type and monocoque configuration, the intermediate portion 230 of the monocoque structure 200 can be completely omitted. In such an embodiment, the front body 210 and the rear floor 220 can be integrally formed as a single-piece structure without the intermediate portion 230 inserted between them. It should be understood that, at least in some embodiments, multi-purpose vehicles 110 and 140 may each include a monocoque structure formed without the intermediate portion 230.

[0059] Now for reference Figure 3 Vehicle 300 includes a monocoque structure 200 having a central portion 230 disposed between a front cargo box 210 and a rear floor 220. Furthermore, vehicle 300 includes a cab shield 302 and a cargo box 310, the cab shield 302 being disposed above the front cargo box 210 to surround the cab 212, and the cargo box 310 being disposed behind the front cargo box 210 and the cab shield 302. In an illustrative embodiment, the cargo box 310 is at least partially defined by the central portion 230 and the rear floor 220 and has a roof 312 and side walls 314. In at least some embodiments, the illustrative vehicle 300 may be similar to any of the vehicles 120, 130, and 150 discussed above.

[0060] Because the monocoque structure 200 has the composite construction described above, it should be understood that any vehicle including the monocoque structure 200 described herein (e.g., any of vehicles 110, 120, 130, 140, 150, 300, 500) includes a composite structure (e.g., in...). Figure 7The structure shown is 700. In at least some embodiments, in the case of vehicle 300, each of the intermediate section 230, the roof 312, and the side wall 314 is formed of a composite material and has a composite structure. In these embodiments, each of the intermediate section 230, the roof 312, and the side wall 314 does not include metallic materials.

[0061] Referring now to Figure 4, a prior art freight vehicle 400 includes a cargo box 410. The cargo box 410 includes a floor 412, a pair of side walls 414, a roof 416, and a refrigeration unit 418, which is at least partially housed within and configured to cool the cargo box 410. The rear end of the vehicle 400 includes a loading platform 404 and a step 406 leading to the floor 412 of the cargo box 410.

[0062] As shown in Figure 4, the boarding platform 404 has a boarding platform height 424 above the ground plane 402, and the steps 406 have a step height 426 above the boarding platform 404. The base plate 412 has a base plate height 422 above the ground plane 402, which includes the boarding platform height 424 and the step height 426. Typically, the boarding platform height 424 is about 25 inches, the step height 426 is about 10 inches, and the base plate height 422 is about 35 inches.

[0063] Now for reference Figure 5 The 500 freight vehicles can include those mentioned above. Figure 2 The aforementioned monocoque structure (e.g., monocoque structure 200). Furthermore, in some embodiments, vehicle 500 may be similar to one or more of the aforementioned vehicles 120, 130, and 150. In any case, the illustrative freight vehicle 500 includes a cargo box 510 and a refrigeration unit 518 housed within the cargo box 510, the cargo box 510 having a floor 512, a pair of side walls 514, and a roof 516. However, unlike the prior art freight vehicle 400, vehicle 500 does not have steps corresponding to steps 406. Therefore, the floor 512 has a floor height 522 that substantially corresponds to and can be equal to the boarding platform height 424. For example, the floor height 522 may be less than 30 inches, for example, in the range of 22 to 28 inches. A pair of wheel wells 530 formed within the cargo box 510 are offset from each other by a separation distance 532. In some embodiments, the separation distance 532 may be approximately 50 inches.

[0064] In some cases, the prior art freight vehicle 400 has one or more disadvantages unrelated to the illustrative freight vehicle 500. In one aspect, for example, the side walls 414 and roof 416 of the prior art vehicle 400 are typically formed of a metallic material such as aluminum, which is a poor thermal insulator. Therefore, the cargo compartment 410 is poorly insulated and tends to absorb ambient temperature relatively quickly. This is especially true in summer, when radiant heat from the sun supplies the ambient air with hot air, exacerbating the temperature rise of the cargo compartment 410. Conversely, the side walls 514 and roof 516 of the illustrative vehicle 500 are formed of a composite material, which exhibits superior thermal insulation properties compared to metallic materials such as aluminum. Therefore, the cargo compartment 510 is more insulated from the surrounding environment than the cargo compartment 410. This insulation is particularly advantageous, for example, when the vehicle 500 is a refrigerated vehicle (e.g., a food delivery vehicle). It should be understood that the improved insulation performance of the cargo compartment 510 can reduce the cooling load on the refrigeration unit 518, thereby improving the performance of the refrigeration unit 518. Furthermore, in some cases, the improved performance of the refrigeration unit 518 can enable the vehicle 500 to be equipped with a smaller refrigeration unit 518 than is typically required for a prior art vehicle 400.

[0065] Another disadvantage associated with the prior art vehicle 400 is the elevated nature of the floor 412 relative to the ground plane 402. It should be understood that the elevated floor 412 is not merely a design choice, but rather a feature generally required to accommodate the internal chassis or frame, powertrain, and related components. In other words, to accommodate the mounting of conventional internal combustion engines and other powertrain components (e.g., transmissions, drive axles, and / or differentials) to the internal chassis, the floor 412 is higher than the ground plane 402 by a floor height 422. Accordingly, the elevated floor 412 reduces the storage capacity and / or volume of the cargo compartment 410 and necessitates the installation of steps 406. Therefore, personnel using the vehicle 400 must step onto the loading platform 404 and ascend the steps 406 to access the cargo compartment 410.

[0066] The illustrative vehicle 500 avoids many of the aforementioned disadvantages by eliminating the need for an elevated floor 412. Partly due to the monocoque structure 200 being configured as a one-piece, integrally molded structure with a relatively lightweight composite construction, and partly due to the absence of powertrain components typically found in other configurations (e.g., a central drive shaft below the lower side 214 of the monocoque structure 200, which provides rotational input to the differential), the floor 512 does not need to be as high above ground level as floor 412. Therefore, the vehicle 500 can achieve an increased loading capacity of the cargo box 510 without raising the roof 516. Furthermore, since the vehicle 500 can omit steps similar to step 406, the floor height 522 corresponds to the loading platform height 424 of a conventional vehicle 400, allowing delivery personnel to avoid the effort of climbing onto the loading platform 404 and step 406 to access the cargo box 510 of the vehicle 500. Specifically, it should be understood that the rear bumper of vehicle 500 may be slightly lower than the floor 512, and delivery personnel can enter the cargo compartment 510 by first stepping on the rear bumper. In some embodiments, the rear bumper may have a height of approximately 20 inches above ground level, and the floor 512 may have a height of approximately 25 inches above ground level.

[0067] Now for reference Figure 6 In the United States, trucks are typically classified according to their Gross Vehicle Weight Rating (GVWR). These truck classifications, associated load ratings, and corresponding GVWRs are shown in Table 600. In the illustrative embodiments, one or more of vehicles 110, 120, 130, 140, and 150 have a GVWR between 6,000 lbs and 19,800 lbs (i.e., taking into account the truck's weight when unloaded and its effective load-bearing capacity when fully loaded). In some embodiments, one or more of vehicles 110, 120, 130, 140, and 150 have a GVWR between 10,001 lbs and 14,000 lbs, such that one or more of vehicles 110, 120, 130, 140, and 150 are implemented as Class 3 trucks or otherwise include Class 3 trucks. In one particular example, in some implementations, a 1000 cubic foot capacity vehicle 130 weighs approximately 6500 pounds unloaded and has a payload capacity of 6000 pounds, resulting in a GVWR of approximately 12500 pounds for vehicle 130. It should be understood, of course, that in other implementations, vehicle production line 100 may include one or more vehicles of level 3, one or more vehicles of level 4, and / or one or more vehicles of level 5.

[0068] In some implementations, the systems and methods described herein can achieve specific utilities associated with Class 3 through Class 5 freight vehicles. For example, methods 1000, 1100, and 1300 described below can be used to form a monocoque structure for freight vehicles with a GVWR between 10,001 lbs and 19,500 lbs. The loading capacity of such vehicles can be between 450 cubic feet and 1,200 cubic feet. In some implementations, the vehicle's cargo box (e.g., cargo box 510) can be separated from the vehicle's cab (e.g., cab 212).

[0069] Now for reference Figure 7 Any vehicle of the present invention includes a monocoque structure having composite structure 700. In illustrative embodiments, composite structure 700 comprises one or more relatively lightweight, low-density materials to impart a relatively lightweight construction to the vehicle. As discussed below, illustrative composite structure 700 includes one or more of the following: balsa wood, plastic, glass fiber, resin, Kevlar synthetic fiber, honeycomb material, and carbon fiber. In at least some embodiments, composite structure 700 does not include metallic materials and is not formed of metallic materials. In these embodiments, the monocoque structure including composite structure 700 (e.g., monocoque structure 200) does not include metallic materials.

[0070] The illustrative composite structure 700 includes a core 702 and a shell 704 that at least partially surrounds the core 702. In an illustrative embodiment, the core 702 is formed of balsa wood and / or one or more of the following composite nonmetallic materials: unidirectional glass fiber, multidirectional glass fiber, Kevlar synthetic fiber, carbon fiber, plastic, honeycomb material, or other suitable composite nonmetallic material. Of course, in other embodiments, the core 702 may be formed of other suitable materials to provide a relatively lightweight construction to the composite structure 700. The illustrative shell 704 is formed of glass fiber and resin. However, in other embodiments, the shell 704 may be formed of other suitable materials. Furthermore, in an illustrative embodiment, the composite structure 700 includes a laminate 706 that at least partially covers the shell 704.

[0071] It should be understood that the composite structure 700, used to form the monocoque structure of any vehicle of the present invention, offers numerous advantages over multi-piece metal constructions in conventional vehicles. In one aspect, the monocoque structure formed by the composite structure 700 has fewer parts and provides greater structural simplicity compared to vehicle constructions requiring multiple components. In another aspect, the structural simplicity provided by the composite structure 700 makes maintenance easier and improves structural efficiency. In yet another aspect, due to the absence of metal materials, the composite structure 700 can minimize or eliminate rust and / or corrosion, thereby extending its service life beyond that of vehicles with conventional constructions. In some cases, monocoque structures incorporating the composite structure 700, consistent with the teachings of the present invention, can have a service life of 20 years or longer.

[0072] Now for reference Figure 8 and Figure 9 Modular mold system 800 (see) Figure 8 This includes multiple illustrative mold units that can be selected and arranged to form a single-shell structural system 900 (see [link]). Figure 9 It should be understood that, for example, when arranged to form a single-shell structural system 900, selected mold units of the modular system 800 are used to form a single-shell structure such as the single-shell structure 200 described above. Furthermore, it should be understood that similar reference numerals in the 800 and 900 series are used to denote corresponding features of the modular mold system 800 and the single-shell structural system 900.

[0073] The illustrative mold system 800 includes a front body mold unit 810, a rear floor mold unit 820, and a plurality of intermediate mold units 830, which include a small intermediate section mold unit 832, a medium intermediate section mold unit 834, and a large intermediate section mold unit 836. As discussed below, each of the mold units 810, 820, 832, 834, and 836 has a mold cavity with dimensions and shape corresponding to a corresponding feature of the monocoque structure system 900, such that a composite material (e.g., the material of the composite structure 700) can subsequently be introduced into the mold cavity to form the corresponding feature of the monocoque structure system 900. Therefore, the front body mold unit 810 includes a front body mold cavity 912 with dimensions and shape corresponding to the front body 910 (and front body 210) of the monocoque structure system 900. The rear base plate mold unit 820 includes a rear base plate mold cavity 922, which has dimensions and shape corresponding to the rear base plate 920 (and rear base plate 220) of the single-shell structural system 900. Intermediate mold units 832, 834, and 836 include corresponding intermediate mold cavities 933, 935, and 937, each intermediate mold cavity having dimensions and shape corresponding to the corresponding intermediate portions 932, 934, and 936 (and intermediate portion 230) of the single-shell structural system 900.

[0074] from Figure 8 and Figure 9 As can be seen, each of the intermediate mold units 832, 834, and 836 has dimensions for positioning between the front body mold unit 810 and the rear floor mold unit 820 to form a monocoque structure system 900. It should be understood that any of the intermediate mold units 832, 834, and 836 can be selected and arranged between the front body mold unit 810 and the rear floor mold unit 820 to form the monocoque structure system 900. The selection of a particular mold unit 832, 834, or 836 is based on the vehicle configuration and the monocoque structure included therein, as discussed further below.

[0075] In the illustrative embodiment, the front body mold cavity 912 of the front body mold unit 810 is located at its rear end (i.e., the end closest to one of the middle portions 932, 934, 936, as in...) Figure 9(As shown) has an opening 914 to establish a fluid connection between cavity 912 and another component of mold system 800. In some embodiments, when the front body mold unit 810 is arranged adjacent to one of the corresponding intermediate mold units 832, 834, 836, a fluid connection can be established between the front body mold cavity 912 and one of the intermediate mold cavities 933, 935, 937. Furthermore, in some embodiments, when the front body mold unit 810 is arranged adjacent to the rear floor mold unit 820, a fluid connection can be established between the front body mold cavity 912 and the rear floor mold cavity 922.

[0076] In the illustrative embodiment, the rear base plate mold cavity 922 of the rear base plate mold unit 820 is located at its front end (i.e., the end closest to one of the middle portions 932, 934, 936, as shown in...) Figure 9 (As shown) has an opening 924 to establish a fluid connection between cavity 922 and another component of mold system 800. Each intermediate mold cavity 933, 935, 937 of intermediate mold units 832, 834, 836 has its front end (i.e., the end closest to the front housing 910, as shown in...) Figure 9 (as shown) has an opening 938 and at its rear end (i.e., the end closest to the rear bottom plate 920, as in Figure 9 (As shown) has an opening 940. When one of the intermediate mold units 832, 834, 836 is arranged adjacent to the front body mold unit 810, a fluid connection is established between the corresponding intermediate mold cavities 933, 935, 937 and the front body mold cavity 912 via openings 914, 938. Furthermore, when one of the intermediate mold units 832, 834, 836 is arranged adjacent to the rear floor mold unit 820, a fluid connection is established between the corresponding intermediate mold cavities 933, 935, 937 and the rear floor mold cavity 922 via openings 924, 940.

[0077] It should be understood that the front end of each of the illustrative intermediate mold units 832, 834, and 836 is configured to be directly connected to and attached to the rear end of the front body mold unit 810. Furthermore, it should be understood that the rear end of each of the illustrative intermediate mold units 832, 834, and 836 is configured to be directly connected to and attached to the front end of the rear floor mold unit 820. Therefore, when any of the intermediate mold units 832, 834, and 836 is directly connected to the front body mold unit 810 and the rear floor mold unit 820, the front body mold cavity 912, the corresponding intermediate mold cavities 933, 935, and 937, and the rear floor mold cavity 922 are fluidly connected to each other in an adjacent arrangement to establish a continuous monocoque mold cavity. Composite materials can be introduced into the continuous monocoque mold cavity to form the monocoque structure as a single-piece integral structure.

[0078] It should also be apparent that the rear end of the illustrative front body mold unit 810 is configured to be directly connected to and attached to the front end of the rear floor mold unit 820. Therefore, when the front body mold unit 810 is directly connected to the rear floor mold unit 820, the front body mold unit 810 and the rear floor mold unit 820 are fluidly connected to each other in an adjacent arrangement to establish a continuous monocoque mold cavity, into which composite material can be introduced to form the monocoque structure as a single-piece integral structure.

[0079] In the illustrative embodiment, the small intermediate mold unit 832 has as follows Figure 9 The length L1 is shown. In at least some embodiments, the length L2 of the medium-sized intermediate mold unit 834 is greater than the length L1. In at least some embodiments, the length L3 of the large intermediate mold unit 836 is greater than both length L2 and length L1.

[0080] In some embodiments, a small intermediate section mold unit 832 may be used to form the intermediate section 932 of the monocoque structure system 900, such that the monocoque structure produced using at least partially the mold unit 832 is included in a vehicle with a storage volume of 650 cubic feet (e.g., vehicle 120). Furthermore, in some embodiments, a medium-sized intermediate section mold unit 834 may be used to form the intermediate section 934 of the monocoque structure system 900, such that the monocoque structure produced using at least partially the mold unit 834 is included in a vehicle with a storage volume of 1000 cubic feet (e.g., vehicle 130). Still in some embodiments, a large intermediate section mold unit 836 may be used to form the intermediate section 936 of the monocoque structure system 900, such that the monocoque structure produced using at least partially the mold unit 836 is included in a vehicle with a storage volume of 1200 cubic feet (e.g., vehicle 150).

[0081] Now for reference Figure 10 An illustrative method 1000 is shown for forming a monocoque structure (e.g., monocoque structure 200) using a modular mold system (e.g., system 800). This method 1000 corresponds to the method described below. Figure 10The method 1000 is performed in the illustrative order described below, or otherwise associated with the execution of said blocks. However, it should be understood that the method 1000 may be performed in one or more orders different from the illustrative order. Furthermore, it should be understood that one or more blocks described below may be performed simultaneously and / or in parallel with each other. In some embodiments, the method 1000 may be performed manually by one or more operators. In other embodiments, the method 1000 may be implemented as a set of instructions executed by an automated control system or otherwise includes a set of instructions executed by an automated control system.

[0082] The illustrative method 1000 begins at block 1002. In block 1002, the operator or control system selects a land vehicle type or monocoque configuration for a particular land vehicle. It should be understood that, in order to perform block 1002, the operator or control system can select any vehicle contemplated by the present invention or any monocoque configuration associated with a particular vehicle contemplated by the present invention. Method 1000 then proceeds from block 1002 to block 1004.

[0083] In block 1004 of illustrative method 1000, the operator or control system selects a first mold unit of the modular mold system based on the selected vehicle type or monocoque configuration. In an illustrative embodiment, to perform block 1004, the operator or control system selects the rear floor mold unit 820 of the modular system 800 in block 1006. However, in other embodiments, it should be understood that block 1004 can be performed by selecting: (i) a small intermediate section mold unit 832 (i.e., in block 1008), (ii) a medium-sized intermediate section mold unit (i.e., in block 1010), or (iii) a large intermediate section mold unit 836 (i.e., in block 1012). Reference is made below. Figure 11 The selection of one of the intermediate mold units 832, 834, and 836 as the first mold unit is described in more detail. In any case, method 1000 proceeds from block 1004 to block 1014.

[0084] In block 1014 of illustrative method 1000, the operator or control system connects the selected first mold unit to the front body mold unit 810 of the modular system 800. It should be understood that, in order to perform block 1014, the selected first mold unit (i.e., the rear floor mold unit 820) is connected to the front body mold unit 810 such that the front body mold cavity 912 is fluidly connected to the rear floor mold cavity 922 to at least partially establish a continuous monocoque structure mold cavity. After performing block 1014, method 1000 proceeds to block 1016.

[0085] In block 1016 of illustrative method 1000, an operator or control system introduces one or more composite materials (e.g., composite materials included in composite structure 700) into a continuous single-shell mold cavity formed in block 1014. More specifically, to perform block 1016, in at least some embodiments, the operator or control system performs blocks 1018, 1020, and 1022. In block 1018, the operator or control system introduces one or more composite materials into the continuous single-shell mold cavity without introducing metallic material into the cavity. However, in other embodiments, block 1018 may be omitted from method 1000. In block 1020, the operator or control system places a first material into the continuous single-shell mold cavity. In at least some embodiments, the first material may include balsa wood and / or plastic. In block 1022, the operator or control system places a second material, different from the first material, into the continuous single-shell mold cavity. In at least some embodiments, the second material may include glass fiber and resin. After executing box 1016, method 1000 proceeds to box 1024.

[0086] In block 1024 of illustrative method 1000, an operator or control system cures one or more composite materials in a continuous single-shell structure mold cavity to form a single-shell structure. At least in some embodiments, to perform block 1024, the operator or control system may perform blocks 1026, 1028, and 1030. In block 1026, the operator or control system causes a core (e.g., core 702) to be formed, the core comprising the first material introduced in block 1016. In block 1028, the operator or control system causes a shell (e.g., shell 704) to be formed, at least partially surrounding the core, the shell comprising the second material introduced in block 1016. In block 1030, the operator or control system causes a laminate (e.g., layer 706) to be formed, at least partially covering the shell.

[0087] Now for reference Figure 11 and Figure 12 An illustrative method 1100 is shown for forming a monocoque structure (e.g., monocoque structure 200) using a modular mold system (e.g., system 800). This method 1100 corresponds to the method described below. Figure 11 and Figure 12The method 1100 is performed in the illustrative order described below, or otherwise associated with the execution of said blocks. However, it should be understood that the method 1100 may be performed in one or more orders different from the illustrative order. Furthermore, it should be understood that one or more blocks described below may be performed simultaneously and / or in parallel with each other. In some embodiments, the method 1100 may be performed manually by one or more operators. In other embodiments, the method 1100 may be implemented as a set of instructions executed by an automated control system or otherwise includes a set of instructions executed by an automated control system.

[0088] The illustrative method 1100 begins at block 1102. At block 1102, the operator or control system selects a land vehicle type or monocoque configuration for a particular land vehicle. It should be understood that, in order to perform block 1102, the operator or control system can select any vehicle contemplated by the present invention or any monocoque configuration associated with a particular vehicle contemplated by the present invention. Method 1100 then proceeds from block 1102 to block 1104.

[0089] In block 1104 of illustrative method 1100, the operator or control system selects a first mold unit of the modular mold system based on the selected vehicle type or monocoque configuration. In an illustrative embodiment, to perform block 1104, the operator or control system performs one of blocks 1106, 1108, and 1110. In block 1106, the operator or control system selects a small intermediate mold unit 832. In block 1108, the operator or control system selects a medium-sized intermediate mold unit 834. In block 1110, the operator or control system selects a large intermediate mold unit 836. After performing block 1104, method 1100 proceeds to block 1112.

[0090] In block 1112 of illustrative method 1100, the operator or control system selects a second mold unit of the modular system. In an illustrative embodiment, to perform block 1112, the operator or control system performs block 1114. In block 1114, the operator or control system selects the rear base plate mold unit 820 of the modular system 800. Method 1100 then proceeds from block 1112 to block 1116.

[0091] In block 1116 of illustrative method 1100, the operator or control system connects the selected first mold unit to the front body mold unit 810 of the modular system 800. It should be understood that, in order to perform block 1116, the selected first mold unit (i.e., one of the intermediate mold units 832, 834, 836) is connected to the front body mold unit 810 such that the front body mold cavity 912 is fluidly connected to the corresponding intermediate mold unit cavity (i.e., one of the cavities 933, 935, 937) to at least partially establish a continuous monocoque mold cavity structure. After performing block 1116, method 1100 proceeds to block 1118.

[0092] In block 1118 of illustrative method 1100, the operator or control system connects a selected first mold unit (i.e., one of intermediate mold units 832, 834, 836) to a selected second mold unit (i.e., the rear base plate mold unit 820). It should be understood that, in order to perform block 1118, connecting one of the intermediate mold units 832, 834, 836 to the rear base plate mold unit 820 causes the rear base plate mold cavity 922 to be fluidly connected to the corresponding intermediate mold unit cavity (i.e., one of cavities 933, 935, 937) to at least partially establish a continuous single-shell mold cavity structure. After performing block 1118, method 1100 proceeds to block 1120.

[0093] In block 1120 of illustrative method 1100, an operator or control system introduces one or more composite materials (e.g., composite materials included in composite structure 700) into a continuous single-shell mold cavity formed in block 1118. More specifically, to perform block 1120, in at least some embodiments, the operator or control system performs blocks 1122, 1124, and 1126. In block 1122, the operator or control system introduces one or more composite materials into the continuous single-shell mold cavity without introducing metallic material into the cavity. However, in other embodiments, block 1122 may be omitted from method 1100. In block 1124, the operator or control system places a first material into the continuous single-shell mold cavity. In at least some embodiments, the first material may include balsa wood and / or plastic. In block 1126, the operator or control system places a second material, different from the first material, into the continuous single-shell mold cavity. In at least some embodiments, the second material may include glass fiber and resin. After executing block 1120, method 1000 proceeds to block 1202.

[0094] In block 1202 of illustrative method 1100, an operator or control system cures one or more composite materials in a continuous single-shell structure mold cavity to form a single-shell structure. At least in some embodiments, to perform block 1202, the operator or control system may perform blocks 1204, 1206, and 1208. In block 1204, the operator or control system causes a core (e.g., core 702) to be formed, the core comprising the first material introduced in block 1120. In block 1206, the operator or control system causes a shell (e.g., shell 704) to be formed, at least partially surrounding the core, the shell comprising the second material introduced in block 1120. In block 1208, the operator or control system causes a laminate (e.g., layer 706) to be formed, at least partially covering the shell.

[0095] Now for reference Figure 13 This illustrates an illustrative method 1300 for forming various monocoque structures of land vehicles using at least one modular mold system. Method 1300 corresponds to the following... Figure 13 The method 1300 is performed in the illustrative order described below, or otherwise associated with the execution of said blocks. However, it should be understood that the method 1300 may be performed in one or more orders different from the illustrative order. Furthermore, it should be understood that one or more blocks described below may be performed simultaneously and / or in parallel with each other. In some embodiments, the method 1300 may be performed manually by one or more operators. In other embodiments, the method 1300 may be implemented as a set of instructions executed by an automated control system or otherwise includes a set of instructions executed by an automated control system.

[0096] Illustrative method 1300 begins at block 1302. At block 1302, the operator or control system causes a first monocoque structure of the first land vehicle to be formed. To perform block 1302, the operator or control system at block 1304 uses at least one modular system (e.g., system 800) to form the first monocoque structure of the first land vehicle. In some embodiments, only the front body mold unit 810 and the rear floor mold unit 820 of modular system 800 are used to form the first monocoque structure of the first land vehicle. In these embodiments, the first monocoque structure of the first land vehicle can be formed by performing method 1000 described above. In other embodiments, the first monocoque structure of the first land vehicle is formed using one of the front body mold unit 810, the rear floor mold unit 820, and intermediate mold units 832, 834, 836. In these embodiments, the first monocoque structure of the first land vehicle can be formed by performing method 1100 described above. In any case, after performing block 1302, method 1300 proceeds to block 1306.

[0097] In block 1306 of illustrative method 1300, the operator or control system causes a second monocoque structure of a second land vehicle, different from that of a first land vehicle, to be formed. To perform block 1306, the operator or control system in block 1308 uses at least one modular system (i.e., system 800) to form the second monocoque structure of the second land vehicle. In an embodiment in block 1302 where only the front body mold unit 810 and rear floor mold unit 820 of modular system 800 (i.e., according to method 1000) are used to form the first monocoque structure of the first land vehicle, the front body mold unit 810, the rear floor mold unit 820, and one of the intermediate mold units 832, 834, 836 (i.e., according to method 1100) are used to form the second monocoque structure of the second land vehicle. In an embodiment where a first monocoque structure of a first land vehicle is formed using a first intermediate mold unit (i.e., according to method 1100) among the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, and 836 at block 1302, a second monocoque structure of a second land vehicle is formed using a second intermediate mold unit (different from the first intermediate mold unit) among the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, and 836. However, method 1300 proceeds from block 1306 to block 1310.

[0098] In block 1310 of illustrative method 1300, an operator or control system causes a third monocoque structure of a third land vehicle, distinct from the first and second land vehicles, to be formed. To perform block 1310, the operator or control system in block 1310 uses at least one modular system (i.e., system 800) to form the third monocoque structure of the third land vehicle. In an embodiment where (i) a first monocoque structure of a first land vehicle is formed using only the front body mold unit 810 and the rear floor mold unit 820 of the modular system 800 in block 1302 (i.e., according to method 1000) and (ii) a second monocoque structure of a second land vehicle is formed using the front body mold unit 810, the rear floor mold unit 820, and a first intermediate mold unit of intermediate mold units 832, 834, 836 in block 1306 (i.e., according to method 1100), a third monocoque structure of a third land vehicle is formed using a second intermediate mold unit of the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, 836 that is different from the first intermediate mold unit. In an embodiment where (i) a first monocoque structure of a first land vehicle is formed using a first intermediate mold unit (i.e., according to method 1100) among the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, 836 in block 1302, and (ii) a second monocoque structure of a second land vehicle is formed using a second intermediate mold unit (different from the first intermediate mold unit) among the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, 836 in block 1306, a third monocoque structure of a third land vehicle is formed using a third intermediate mold unit (different from the first and second intermediate mold units) among the front body mold unit 810, the rear floor mold unit 820, and the intermediate mold units 832, 834, 836.

[0099] Although the invention has been illustrated in detail in the foregoing drawings and description, these drawings and descriptions should be considered exemplary rather than restrictive, and it should be understood that only illustrative embodiments of the invention have been shown and described, while all variations and modifications within the spirit of the invention are intended to be protected.

Claims

1. A method for forming a monocoque structure for a land vehicle using a modular system, the method comprising: Choose a monocoque structure configuration for land vehicles; The first mold unit of the modular system is selected based on the chosen single-shell structural configuration; The front body mold unit forming the modular system comprises: Producing a single mold unit, A base that at least partially defines the cab floor of a land vehicle and a frame that at least partially defines the top of the cab are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the land vehicle; The selected first mold unit is connected to the front box mold unit of the modular system, such that the front box mold cavity of the front box mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a continuous single-shell structure mold cavity. Introducing one or more composite materials into the cavity of a continuous single-shell mold structure; and One or more composite materials are cured in the cavity of a continuous single-shell structure mold to form a single-shell structure.

2. The method according to claim 1, wherein, Introducing one or more composite materials into a continuous single-shell structure mold cavity includes: introducing one or more composite materials into a continuous single-shell structure mold cavity without introducing metallic materials into the continuous single-shell structure mold cavity.

3. The method according to claim 1, wherein, Introducing one or more composite materials into the cavity of a continuous single-shell structure mold includes: The first material is placed in the cavity of a continuous single-shell mold structure; and A second material, different from the first material, is placed in the cavity of a continuous single-shell structure mold.

4. The method according to claim 3, wherein, The first material contains balsa wood or plastic, and the second material contains fiberglass and resin.

5. The method according to claim 4, wherein, Curing one or more composite materials in a continuous single-shell mold cavity includes: Forming a core comprising a first material; and A shell is formed that contains a second material and at least partially surrounds the core.

6. The method according to claim 1, wherein, The front body mold unit of the modular system corresponds to the front body of the cab in a single-shell structure of a defined vehicle, and the selected first mold unit of the modular system corresponds to the rear floor plate located behind the front body of the single-shell structure.

7. The method according to claim 1, wherein, The front body mold unit of the modular system corresponds to the front body of the cab in a single-shell structure of a defined vehicle, and the selected first mold unit of the modular system corresponds to the middle part of the single-shell structure located behind the front body.

8. The method of claim 7, further comprising: The second mold unit of the modular system is selected based on the chosen monocoque structure configuration, and the second mold unit corresponds to the rear floor plate of the monocoque structure located behind the front body and the middle section. as well as The selected first mold unit is connected to the selected second mold unit, such that the front mold cavity of the front body mold unit, the cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly connected to each other to establish a continuous single-shell structure mold cavity.

9. The method according to claim 8, wherein, The first mold unit of the selected modular system includes one of the following: a small intermediate mold unit of the selected modular system having a first length, a medium intermediate mold unit of the selected modular system having a second length, and a large intermediate mold unit of the selected modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

10. A method for forming multiple monocoque structures for a land vehicle, the method comprising: Select the first single-shell structure configuration for the first land vehicle; The first mold unit of the first modular system is selected based on the selected first single-shell structural configuration. The front body mold unit forming the first modular system includes: Producing a single mold unit, A base that at least partially defines the floor of the cab of the first land vehicle and a frame that at least partially defines the top of the cab of the first land vehicle are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the first land vehicle; The selected first mold unit is connected to the front box mold unit of the first modular system selected based on the selected first monohub structure configuration, such that the front box mold cavity of the front box mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish the first continuous monohub structure mold cavity. Introduce one or more composite materials into the cavity of a first continuous single-shell structure mold; One or more composite materials are cured in the cavity of a first continuous single-shell structure mold to form the first single-shell structure; Select a second monocoque structure configuration for a second land vehicle that is different from the first land vehicle; The first mold unit of the second modular system is selected based on the selected second single-shell structure configuration, wherein the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration is different from the selected first mold unit of the first modular system selected based on the selected first single-shell structure configuration. The front body mold unit forming the second modular system includes: Producing a single mold unit, A base that at least partially defines the cab floor of the second land vehicle and a frame that at least partially defines the cab top of the second land vehicle are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the second land vehicle; The selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration is connected to the front box mold unit of the second modular system selected based on the selected second single-shell structure configuration, such that the front box mold cavity of the front box mold unit of the second modular system selected based on the selected second single-shell structure configuration is fluidly connected to the mold cavity of the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration, so as to at least partially establish the second continuous single-shell structure mold cavity; Introducing one or more composite materials into the cavity of a second continuous single-shell structure mold; and One or more composite materials are cured in the cavity of a second continuous single-shell structure mold to form the second single-shell structure.

11. The method of claim 10, wherein: Introducing one or more composite materials into the cavity of a first continuous single-shell mold structure includes: introducing one or more composite materials into the cavity of the first continuous single-shell mold structure without introducing metallic material into the cavity; and Introducing one or more composite materials into the cavity of a second continuous single-shell structure mold includes: introducing one or more composite materials into the cavity of a second continuous single-shell structure mold without introducing metallic materials into the cavity of the second continuous single-shell structure mold.

12. The method according to claim 10, wherein: Introducing one or more composite materials into a first continuous single-shell mold cavity includes: placing a first material into the first continuous single-shell mold cavity, and placing a second material different from the first material into the first continuous single-shell mold cavity; and Introducing one or more composite materials into the cavity of a second continuous single-shell structure mold includes: placing a first material in the cavity of the second continuous single-shell structure mold, and placing a second material in the cavity of the second continuous single-shell structure mold.

13. The method according to claim 12, wherein: The first material comprises balsa wood or plastic; and The second material comprises glass fiber and resin.

14. The method of claim 13, wherein: Curing one or more composite materials in the cavity of a first continuous single-shell structure mold includes: forming a core of the first single-shell structure comprising a first material, and forming a shell of the first single-shell structure comprising a second material, the shell at least partially surrounding the core of the first single-shell structure; and Curing one or more composite materials in the cavity of a second continuous single-shell structure mold includes: forming a core containing a first material of the second single-shell structure, and forming a shell containing a second material of the second single-shell structure, the shell at least partially surrounding the core of the second single-shell structure.

15. The method of claim 10, wherein: The front box mold unit of the first modular system selected based on the selected first monocoque structure configuration corresponds to the front box of the cab in the first land vehicle defined by the first monocoque structure. The selected first mold unit of the first modular system, selected based on the selected first monocoque structure configuration, corresponds to the rear floor plate located behind the front body of the first monocoque structure. The front compartment mold unit of the second modular system selected based on the chosen second monocoque structure configuration corresponds to the front compartment of the cab in the second land vehicle defined by the second monocoque structure. as well as The selected first mold unit of the second modular system, selected based on the selected second monocoque structure configuration, corresponds to the middle part of the second monocoque structure located behind the front body of the second monocoque structure.

16. The method of claim 15, further comprising: The second mold unit of the second modular system is selected based on the selected second monocoque structure configuration. The second mold unit corresponds to the rear floor plate located behind the front body and middle section of the second monocoque structure. as well as The selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration is connected to the selected second mold unit of the second modular system selected based on the selected second single-shell structure configuration, such that the front mold cavity of the front box mold unit of the second modular system selected based on the selected second single-shell structure configuration, the cavity of the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration, and the mold cavity of the selected second mold unit of the second modular system selected based on the selected second single-shell structure configuration are fluidly connected to each other to establish a second continuous single-shell structure mold cavity.

17. The method according to claim 16, wherein, The first mold unit of the second modular system includes: selecting one of a small intermediate mold unit of the second modular system having a first length, a medium intermediate mold unit of the second modular system having a second length, and a large intermediate mold unit of the second modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

18. The method of claim 10, wherein: The front box mold unit of the first modular system selected based on the selected first monocoque structure configuration corresponds to the front box of the cab in the first land vehicle defined by the first monocoque structure. The selected first mold unit of the first modular system, selected based on the selected first monocoque structure configuration, has a first length and corresponds to the middle portion of the first monocoque structure located behind the front body of the first monocoque structure. The front compartment mold unit of the second modular system selected based on the chosen second monocoque structure configuration corresponds to the front compartment of the cab in the second land vehicle defined by the second monocoque structure. as well as The selected first mold unit of the second modular system, selected based on the selected second monocoque structure configuration, has a second length different from the first length and corresponds to the middle part of the second monocoque structure located behind the front body of the second monocoque structure.

19. The method of claim 18, further comprising: The second mold unit of the first modular system is selected based on the selected first monocoque structure configuration. The second mold unit corresponds to the rear floor plate of the first monocoque structure located behind the front body and the middle part of the first monocoque structure. The selected first mold unit of the first modular system selected based on the selected first single-shell structure configuration is connected to the selected second mold unit of the first modular system selected based on the selected first single-shell structure configuration, such that the front mold cavity of the front box mold unit of the first modular system selected based on the selected first single-shell structure configuration, the cavity of the selected first mold unit of the first modular system selected based on the selected first single-shell structure configuration, and the mold cavity of the selected second mold unit of the first modular system selected based on the selected first single-shell structure configuration are fluidly connected to each other to establish a first continuous single-shell structure mold cavity; The second mold unit of the second modular system is selected based on the selected second monocoque structure configuration. The second mold unit corresponds to the rear floor plate located behind the front body and middle section of the second monocoque structure. as well as The selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration is connected to the selected second mold unit of the second modular system selected based on the selected second single-shell structure configuration, such that the front mold cavity of the front box mold unit of the second modular system selected based on the selected second single-shell structure configuration, the cavity of the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration, and the mold cavity of the selected second mold unit of the second modular system selected based on the selected second single-shell structure configuration are fluidly connected to each other to establish a second continuous single-shell structure mold cavity.

20. A method for forming multiple monocoque structures for a land vehicle, the method comprising: Select the first single-shell structure configuration for the first land vehicle; The first mold unit of the first modular system is selected based on the selected first single-shell structural configuration. The front body mold unit forming the first modular system includes: Producing a single mold unit, A base that at least partially defines the floor of the cab of the first land vehicle and a frame that at least partially defines the top of the cab of the first land vehicle are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the first land vehicle; The selected first mold unit is connected to the front box mold unit of the first modular system selected based on the selected first monohub structure configuration, such that the front box mold cavity of the front box mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish the first continuous monohub structure mold cavity. Introduce one or more composite materials into the cavity of a first continuous single-shell structure mold; One or more composite materials are cured in the cavity of a first continuous single-shell structure mold to form the first single-shell structure; Select a second monocoque structure configuration for a second land vehicle that is different from the first land vehicle; The first mold unit of the second modular system is selected based on the selected second single-shell structure configuration, wherein the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration is different from the selected first mold unit of the first modular system selected based on the selected first single-shell structure configuration. The front body mold unit forming the second modular system includes: Producing a single mold unit, A base that at least partially defines the cab floor of the second land vehicle and a frame that at least partially defines the cab top of the second land vehicle are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the second land vehicle; The selected first mold unit of the second modular system selected based on the selected second monohub structure configuration is connected to the front box mold unit of the second modular system, such that the front box mold cavity of the front box mold unit of the second modular system selected based on the selected second monohub structure configuration is fluidly connected to the mold cavity of the selected first mold unit of the second modular system selected based on the selected second monohub structure configuration, so as to at least partially establish the second continuous monohub structure mold cavity. Introduce one or more composite materials into the cavity of a second continuous single-shell structure mold; One or more composite materials in the mold cavity of the second continuous single-shell structure are cured to form the second single-shell structure; Select a third monocoque structure configuration for a third land vehicle that is different from the first and second land vehicles. The first mold unit of the third modular system is selected based on the selected third single-shell structure configuration, wherein the selected first mold unit of the third modular system selected based on the selected third single-shell structure configuration is different from the selected first mold unit of the second modular system selected based on the selected second single-shell structure configuration and the selected first mold unit of the first modular system selected based on the selected first single-shell structure configuration. The front body mold unit forming the third modular system comprises: Producing a single mold unit, A base that at least partially defines the driver's cab floor of the third land vehicle and a frame that at least partially defines the top of the driver's cab of the third land vehicle are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the third land vehicle; The selected first mold unit of the third modular system selected based on the selected third single-shell structure configuration is connected to the front body mold unit of the third modular system selected based on the selected third single-shell structure configuration, such that the front body mold cavity of the front body mold unit of the third modular system selected based on the selected third single-shell structure configuration is fluidly connected to the mold cavity of the selected first mold unit of the third modular system selected based on the selected third single-shell structure configuration, so as to at least partially establish the third continuous single-shell structure mold cavity. Introducing one or more composite materials into the cavity of a third continuous single-shell structure mold; and One or more composite materials are cured in the cavity of a third continuous single-shell structure mold to form the third single-shell structure.

21. A method for forming a monocoque structure for a land vehicle using a modular system, the method comprising: Choose a monocoque structure configuration for land vehicles; The first mold unit of the modular system is selected based on the chosen single-shell structural configuration; The front body mold unit forming the modular system comprises: Producing a single mold unit, A base that at least partially defines the cab floor of a land vehicle and a frame that at least partially defines the top of the cab are interconnected, such that the frame extends vertically above the base, and Define i) a first portion of the base covered by the frame and ii) a second portion of the base, the second portion of the base extending longitudinally in front of the first portion outside the frame, such that the second portion is not covered by the frame at the front end of the land vehicle; The selected first mold unit is connected to the front box mold unit of the modular system, such that the front box mold cavity of the front box mold unit is fluidly connected to the mold cavity of the selected first mold unit to at least partially establish a continuous single-shell structure mold cavity. Introducing one or more composite materials into a continuous single-shell mold cavity, wherein introducing one or more composite materials into the continuous single-shell mold cavity includes introducing one or more composite materials into the continuous single-shell mold cavity without introducing a metal material into the continuous single-shell mold cavity, and introducing one or more composite materials into the continuous single-shell mold cavity includes placing a first material comprising balsa wood or plastic into the continuous single-shell mold cavity and placing a second material comprising glass fiber and resin into the continuous single-shell mold cavity; and One or more composite materials are cured in the cavity of a continuous single-shell structure mold to form a single-shell structure.

22. The method according to claim 21, wherein, Curing one or more composite materials in a continuous single-shell mold cavity includes: Forming a core comprising a first material; and A shell is formed that contains a second material and at least partially surrounds the core.

23. The method according to claim 22, wherein, The front body mold unit of the modular system corresponds to the front body of the cab in a single-shell structure of a defined vehicle, and the selected first mold unit of the modular system corresponds to the middle part of the single-shell structure located behind the front body.

24. The method of claim 23, further comprising: The second mold unit of the modular system is selected based on the chosen monocoque structure configuration, and the second mold unit corresponds to the rear floor plate of the monocoque structure located behind the front body and the middle section. as well as The selected first mold unit is connected to the selected second mold unit, such that the front mold cavity of the front body mold unit, the cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly connected to each other to establish a continuous single-shell structure mold cavity.

25. The method according to claim 24, wherein, The first mold unit of the selected modular system includes one of the following: a small intermediate mold unit of the selected modular system having a first length, a medium intermediate mold unit of the selected modular system having a second length, and a large intermediate mold unit of the selected modular system having a third length, wherein the second length is greater than the first length, and the third length is greater than the second length.

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