Method of making monocoque of land vehicle using modular mold system

Abstract

To disclose land vehicles, modular systems for forming monocoques of land vehicles, and methods of forming monocoques of land vehicles using modular systems.SOLUTION: In certain embodiments, the land vehicles are provided as delivery vehicles and / or utility vehicles. A land vehicle includes a monocoque supporting a plurality of wheels to permit movement of the vehicle relative to an underlying surface in use of the land vehicle.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This application claims the priority and benefit of U.S. Provisional Patent Application No. 62 / 957,577, filed on January 6, 2020, entitled "SYSTEMS AND METHODS FOR MANUFACTURING LAND VEHICLES". The content of this application is hereby incorporated by reference in its entirety.

[0002] The present disclosure generally relates to land vehicles and methods of manufacturing land vehicles, and more particularly to all-terrain vehicles and delivery vehicles, and methods of manufacturing all-terrain vehicles and delivery vehicles.

Background Art

[0003] Current systems and methods for manufacturing all-terrain vehicles and delivery vehicles have various drawbacks and limitations. For these reasons in particular, further improvements are still needed in this technical field.

Summary of the Invention

Means for Solving the Problems

[0004] The present disclosure can include one or more of the following features and combinations thereof.

[0005] According to one aspect of the present disclosure, a land vehicle can include a monocoque structure that supports a plurality of wheels for enabling movement of the vehicle relative to a surface beneath the land vehicle during use of the land vehicle. The monocoque structure can be an integral, monolithic structure not supported by an internal chassis. The monocoque structure can include a front cage that defines an operator cabin and a rear floor positioned behind the front cage. The monocoque structure can have a composite structure such that each of the front cage and the rear floor is formed from one or more composite materials.

[0006] In some embodiments, the monocoque structure may not include a metallic material, and the monocoque structure can include a core and a shell that at least partially surrounds the core. The core can be formed from one or more lightweight, low-density materials, and the shell can be formed from a resin and glass fibers. The core can include balsa wood. The core can include plastic. The monocoque structure can include a laminate that at least partially covers the shell.

[0007] In some embodiments, the monocoque structure can include an intermediate section disposed between a front cage and a rear floor. The vehicle can include a storage compartment having a plurality of sidewalls and a ceiling that are at least partially defined by the intermediate section and the rear floor. Each of the intermediate section, the plurality of sidewalls, and the ceiling can be formed from one or more composite materials and each of the intermediate section, the plurality of sidewalls, and the ceiling may not include a metallic material. The storage compartment can have a volume of 18.4 cubic meters (650 cubic feet), 28.3 cubic meters (1000 cubic feet), or 34 cubic meters (1200 cubic feet). Additionally, in some embodiments, the vehicle can have a weight limit between 4.5 tons (10,001 pounds) and 6.4 tons (14,000 pounds). Further, in some embodiments, the land vehicle can include a refrigeration unit configured to cool the storage compartment that is at least partially housed by the storage compartment.

[0008] In some embodiments, the vehicle may not include an internal combustion engine. The height of the rear floor above the underlying surface can be between 55.9 cm (22 inches) and 71.1 cm (28 inches).

[0009] According to another aspect of the present disclosure, a modular system for forming a monocoque structure of a land vehicle can include a front cage-type unit, a rear floor-type unit, and a plurality of intermediate-type units. The front cage-type unit can include a front cage-type cavity having a size and shape corresponding to the front cage of the monocoque structure that defines the operator cabin. The front cage-type unit can have, at its rear end, an opening for establishing a fluid connection between the front cage-type cavity and another component of the system. The rear floor-type unit can include a rear floor-type cavity having a size and shape corresponding to the rear floor of the monocoque structure positioned behind the front cage. The rear floor-type unit can have, at its front end, an opening for establishing a fluid connection between the rear floor-type cavity and another component of the system. Each of the plurality of intermediate-type units can be sized to be positioned between the front cage-type unit and the rear floor-type unit. Each of the plurality of intermediate-type units can include an intermediate-type cavity having a size and shape corresponding to an intermediate section of the monocoque structure positioned between the front cage and the rear floor. Each of the plurality of intermediate-type units can have, at its front end, a front opening for establishing a fluid connection between the intermediate-type cavity and the front cage-type cavity, and at the rear end of the intermediate-type unit, a rear opening for establishing a fluid connection between the intermediate-type cavity and the rear floor-type cavity.

[0010] In some embodiments, the front end of each of the plurality of intermediate units can be configured to connect directly to the rear end of the front cage unit. The rear end of each of the plurality of intermediate units can be configured to connect directly to the front end of the rear floor unit. When any one of the intermediate units is directly connected to the front cage unit and the rear floor unit, the front cage cavity, the intermediate cavity, and the rear floor cavity can be fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque-structured cavity, and one or more composite materials can be introduced into this cavity to form a monocoque structure as an integral monolithic structure.

[0011] In some embodiments, the rear end of the front cage unit can be configured to connect directly to the front end of the rear floor unit. When the front cage unit is directly connected to the rear floor unit, the front cage unit and the rear floor unit can be fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque-structured cavity, and one or more composite materials can be introduced into this cavity to form a monocoque structure as an integral monolithic structure.

[0012] In some embodiments, the plurality of intermediate units can include a first intermediate unit having a first length, a second intermediate unit having a second length longer than the first length, and a third intermediate unit having a third length longer than the second length. The first intermediate unit can be sized to form an intermediate section of a monocoque structure included in a vehicle having a storage volume of 18.4 cubic meters (650 cubic feet), the second intermediate unit can be sized to form an intermediate section of a monocoque structure included in a vehicle having a storage volume of 28.3 cubic meters (1000 cubic feet), and the third intermediate unit can be sized to form an intermediate section of a monocoque structure included in a vehicle having a storage volume of 34 cubic meters (1200 cubic feet).

[0013] According to yet another aspect of the present disclosure, a land vehicle can include a monocoque structure that supports a plurality of wheels to enable movement of the vehicle relative to a surface therebelow during use of the land vehicle. The monocoque structure may be an integral, monolithic structure not supported by an internal chassis. The monocoque structure can include a front cage that defines an operator cabin, a rear floor positioned rearward of the front cage, and an intermediate section disposed between the front cage and the rear floor. The monocoque structure can include a core formed from balsa wood or plastic and a shell formed from resin and glass fibers that at least partially surrounds the core. The monocoque structure can be formed by a modular system that includes a front cage type unit, a rear floor type unit, and an intermediate type unit. The front cage type unit can include a front cage type cavity having a size and shape corresponding to the front cage of the monocoque structure. The front cage type unit can have an opening at its rear end to establish a fluid connection between the front cage type cavity and another component of the system. The rear floor type unit can include a rear floor type cavity having a size and shape corresponding to the rear floor of the monocoque structure. The rear floor type unit can have an opening at its front end to establish a fluid connection between the rear floor type cavity and another component of the system. The intermediate type unit can be sized to be positioned between the front cage type unit and the rear floor type unit. The intermediate type unit can include an intermediate type cavity having a size and shape corresponding to the intermediate section of the monocoque structure. The intermediate type unit can have a front opening at its front end to establish a fluid connection between the intermediate type cavity and the front cage type cavity and a rear opening at its rear end to establish a fluid connection between the intermediate type cavity and the rear floor type cavity.

[0014] According to yet another aspect of the present disclosure, a method of forming a monocoque structure of a land vehicle using a modular system includes: selecting a monocoque structure configuration of the land vehicle; based on the selected monocoque structure configuration, selecting a first type of unit of the modular system; coupling the selected first type of unit to a front cage type unit of the modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected first type of unit to at least partially establish a continuous monocoque structure type cavity; introducing one or more composite materials into the continuous monocoque structure type cavity; and curing the one or more composite materials within the continuous monocoque structure type cavity to form the monocoque structure.

[0015] In some embodiments, introducing one or more composite materials into the continuous monocoque structure type cavity can include introducing the one or more composite materials into the continuous monocoque structure type cavity without introducing a metallic material into the continuous monocoque structure type cavity. Additionally, in some embodiments, the front cage type unit of the modular system can correspond to a front cage of the monocoque structure that defines an operator cabin of the vehicle, and the selected first type of unit of the modular system can correspond to a rear floor of the monocoque structure positioned behind the front cage.

[0016] In some embodiments, introducing one or more composite materials into a continuous monocoque-structured cavity can include placing a first material within the continuous monocoque-structured cavity and placing a second material, different from the first material, within the continuous monocoque-structured cavity. The first material can include balsa wood or plastic, and the second material can include glass fibers and resin. Curing one or more composite materials within a continuous monocoque-structured cavity can include forming a core that includes the first material and forming a shell that includes the second material and at least partially surrounds the core.

[0017] In some embodiments, the front-cage type unit of a modular system can correspond to the front cage of a monocoque structure that defines an operator cabin of a vehicle, and a selected first type unit of the modular system can correspond to an intermediate section of the monocoque structure positioned behind the front cage. The method can further include selecting a second type unit of the modular system that corresponds to a rear floor of the monocoque structure positioned behind the front cage and the intermediate section, based on the selected monocoque structure configuration, and coupling the selected first type unit to the selected second type unit such that the front-cage type cavity of the front-cage type unit, the cavity of the selected first type unit, and the type cavity of the selected second type unit are fluidly coupled to each other to establish a continuous monocoque-structured cavity. Selecting a first type unit of the modular system can include selecting one of a small intermediate-section type unit of the modular system having a first length, a medium intermediate-section type unit of the modular system having a second length longer than the first length, and a large intermediate-section type unit of the modular system having a third length longer than the second length.

[0018] According to another aspect of the present disclosure, a method of forming a plurality of monocoque structures of a land vehicle using at least one modular system may include: selecting a first monocoque structure configuration of a first monocoque structure of a first land vehicle; selecting a first type unit of the at least one modular system based on the selected first monocoque structure configuration; coupling the selected first type unit to a front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected first type unit to at least partially form a first continuous monocoque structure type cavity; introducing one or more composite materials into the first continuous monocoque structure type cavity; curing the one or more composite materials within the first continuous monocoque structure type cavity to form the first monocoque structure; selecting a second monocoque structure configuration of a second monocoque structure of a second land vehicle different from the first land vehicle; selecting a second type unit of the at least one modular system different from the selected first type unit of the at least one modular system based on the selected second monocoque structure configuration; coupling the selected second type unit to a front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected second type unit of the at least one modular system to at least partially establish a second continuous monocoque structure type cavity; introducing one or more composite materials into the second continuous monocoque structure type cavity; and curing the one or more composite materials within the second continuous monocoque structure type cavity to form the second monocoque structure.

[0019] In some embodiments, introducing one or more composite materials into a first continuous monocoque-structured cavity can include introducing one or more composite materials into the first continuous monocoque-structured cavity without introducing a metallic material into the first continuous monocoque-structured cavity, and introducing one or more composite materials into a second continuous monocoque-structured cavity can include introducing one or more composite materials into the second continuous monocoque-structured cavity without introducing a metallic material into the second continuous monocoque-structured cavity.

[0020] In some embodiments, introducing one or more composite materials into a first continuous monocoque-structured cavity can include placing a first material within the first continuous monocoque-structured cavity and placing a second material different from the first material within the first continuous monocoque-structured cavity, and introducing one or more composite materials into a second continuous monocoque-structured cavity can include placing the first material within the second continuous monocoque-structured cavity and placing the second material within the second continuous monocoque-structured cavity. The first material can include balsa wood or plastic, and the second material can include glass fibers and resin. Curing one or more composite materials within the first continuous monocoque-structured cavity can include forming a core of a first monocoque structure that includes the first material and forming a shell of the first monocoque structure that includes the second material and at least partially surrounds the core of the first monocoque structure, and curing one or more composite materials within the second continuous monocoque-structured cavity can include forming a core of a second monocoque structure that includes the first material and forming a shell of the second monocoque structure that includes the second material and at least partially surrounds the core of the second monocoque structure.

[0021] In some embodiments, the front-cage type unit of at least one modular system can correspond to the front cage of a first monocoque structure that defines the operator cabin of a first land vehicle, the selected first type unit of at least one modular system can correspond to the rear floor of the first monocoque structure positioned behind the front cage of the first monocoque structure, the front-cage type unit of at least one modular system can correspond to the front cage of a second monocoque structure that defines the operator cabin of a second land vehicle, and the selected first type unit of at least one modular system can correspond to the intermediate section of the second monocoque structure positioned behind the front cage of the second monocoque structure.

[0022] In some embodiments, the method can further include selecting a second type unit of at least one modular system corresponding to a rear floor of a second monocoque structure positioned rearward of a front cage and an intermediate section of the second monocoque structure based on a selected second monocoque structure configuration; and coupling a selected first type unit of at least one modular system to a selected second type unit of at least one modular system such that a front cage type cavity of the front cage type unit of at least one modular system, a cavity of the selected first type unit of at least one modular system, and a type cavity of the selected second type unit of at least one modular system are fluidly coupled to each other to establish a second continuous monocoque structure type cavity. Selecting a first type unit of at least one modular system can include selecting one of a small intermediate section type unit of at least one modular system having a first length, a medium intermediate section type unit of at least one modular system having a second length longer than the first length, and a large intermediate section type unit of at least one modular system having a third length longer than the second length.

[0023] In some embodiments, the front-cage type unit of at least one modular system can correspond to the front cage of a first monocoque structure that defines the operator cabin of a first land vehicle, and the selected first type unit of at least one modular system has a first length and can correspond to an intermediate section of a first monocoque structure positioned behind the front cage of the first monocoque structure. The front-cage type unit of at least one modular system can correspond to the front cage of a second monocoque structure that defines the operator cabin of a second land vehicle, and the selected first type unit of at least one modular system has a second length different from the first length and can correspond to an intermediate section of a second monocoque structure positioned behind the front cage of the second monocoque structure.The method is as follows: selecting a second type unit of at least one modular system corresponding to the rear floor of the first monocoque structure positioned behind the front cage and the intermediate section of the first monocoque structure based on the selected first monocoque structure configuration; coupling the selected first type unit of at least one modular system to the selected second type unit of at least one modular system such that the front cage type cavity of the front cage type unit of at least one modular system, the cavity of the selected first type unit of at least one modular system, and the type cavity of the selected second type unit of at least one modular system are fluidly coupled to each other to establish a first continuous monocoque structure type cavity; selecting a second type unit of at least one modular system corresponding to the rear floor of the second monocoque structure positioned behind the front cage and the intermediate section of the second monocoque structure based on the selected second monocoque structure configuration; and coupling the selected first type unit of at least one modular system to the selected second type unit of at least one modular system such that the front cage type cavity of the front cage type unit of at least one modular system, the cavity of the selected first type unit of at least one modular system, and the type cavity of the selected second type unit of at least one modular system are fluidly coupled to each other to establish a second continuous monocoque structure type cavity, which can further be included.

[0024] According to yet another aspect of the present disclosure, a method of forming a plurality of monocoque structures of a land vehicle using at least one modular system is as follows: selecting a first monocoque structure configuration of a first monocoque structure of a first land vehicle; selecting a first type unit of the at least one modular system based on the selected first monocoque structure configuration; coupling the selected first type unit to a front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected first type unit to at least partially establish a first continuous monocoque structure type cavity; introducing one or more composite materials into the first continuous monocoque structure type cavity; curing the one or more composite materials within the first continuous monocoque structure type cavity to form the first monocoque structure; selecting a second monocoque structure configuration of a second monocoque structure of a second land vehicle different from the first land vehicle; selecting a second type unit of the at least one modular system different from the selected first type unit of the at least one modular system based on the selected second monocoque structure configuration; coupling the selected second type unit to a front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected second type unit of the at least one modular system to at least partially establish a second continuous monocoque structure type cavity; introducing one or more composite materials into the second continuous monocoque structure type cavity; curing the one or more composite materials within the second continuous monocoque structure type cavity to form the second monocoque structure; selecting a third monocoque structure configuration of a third monocoque structure of a third land vehicle different from the first land vehicle and the second land vehicle; based on the selected third monocoque structure configuration,Selecting a first type unit of at least one modular system and a first type unit of at least one modular system different from the selected first type unit of at least one modular system, coupling the selected first type unit of at least one modular system to a front cage type unit of at least one modular system such that a front cage type cavity of the front cage type unit of at least one modular system is fluidly coupled to a type cavity of the selected first type unit of at least one modular system to at least partially establish a third continuous monocoque structured cavity, introducing one or more composite materials into the third continuous monocoque structured cavity, and curing one or more composite materials within the third continuous monocoque structured cavity to form a third monocoque structure can be included.

[0025] Furthermore, according to another aspect of the present disclosure, a method of forming a monocoque structure of a land vehicle using a modular system is as follows: selecting a monocoque structure configuration of a land vehicle; based on the selected monocoque structure configuration, selecting a first type unit of the modular system; coupling the selected first type unit to a front cage type unit of the modular system such that a front cage type cavity of the front cage type unit is fluidly coupled to a type cavity of the selected first type unit to at least partially establish a continuous monocoque structure type cavity; introducing one or more composite materials into the continuous monocoque structure type cavity; and curing the one or more composite materials within the continuous monocoque structure type cavity to form the monocoque structure. Introducing one or more composite materials into the continuous monocoque structure type cavity can include introducing the one or more composite materials into the continuous monocoque structure type cavity without introducing a metal material into the continuous monocoque structure type cavity. Introducing one or more composite materials into the continuous monocoque structure type cavity can include placing a first material including balsa wood or plastic into the continuous monocoque structure type cavity and placing a second material including glass fiber and resin into the continuous monocoque structure type cavity.

[0026] In some embodiments, curing one or more composite materials within a continuous monocoque-structured cavity can include forming a core that includes a first material and forming a shell that includes a second material and at least partially surrounds the core. A front-cage type unit of a modular system can correspond to a front cage of a monocoque structure that defines an operator cabin of a vehicle, and a selected first type unit of the modular system can correspond to an intermediate section of the monocoque structure that is positioned rearward of the front cage. The method can include selecting a second type unit of the modular system that corresponds to a rear floor of the monocoque structure that is positioned rearward of the front cage and the intermediate section, based on a selected monocoque structure configuration, and coupling the selected first type unit to the selected second type unit such that a front-cage type cavity of the front-cage type unit, a cavity of the selected first type unit, and a type cavity of the selected second type unit are fluidly coupled to each other to establish a continuous monocoque-structured cavity. Selecting a first type unit of the modular system can include selecting one of a small intermediate-section type unit of the modular system having a first length, a medium intermediate-section type unit of the modular system having a second length that is longer than the first length, and a large intermediate-section type unit of the modular system having a third length that is longer than the second length.

[0027] These and other features of the present disclosure will become more apparent from the following description of the exemplary embodiments.

[0028] The invention described herein is illustrated by way of example and not limitation in the figures of the accompanying drawings. For the sake of brevity and clarity of the description, the elements shown in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, reference numerals may be repeated in the figures to indicate corresponding or analogous elements where appropriate.

Brief Description of the Drawings

[0029]

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DETAILED DESCRIPTION OF THE INVENTION

[0030] The concepts of the present disclosure allow for various modifications and alternative forms, but specific embodiments thereof are shown by way of example in the figures and will be described in detail herein. However, it is not intended to limit the concepts of the present disclosure to the specific forms disclosed, but rather the intention is to cover all modifications, equivalents, and alternative forms consistent with the present disclosure and the appended claims.

[0031] References herein to "one embodiment" or "an embodiment," "exemplary embodiment," etc. indicate that the embodiment being described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes that particular feature, structure, or characteristic. Further, such phrases do not necessarily refer to the same embodiment. Additionally, when a particular feature, structure, or characteristic is described in connection with one embodiment, it is within the knowledge of those skilled in the art to make that feature, structure, or characteristic effective in connection with other embodiments, whether or not explicitly described. Additionally, it should be understood that items included in a list in the form of "at least one of A, B, and C" can 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" can mean (A); (B); (C), (A and B); (A and C); (B and C), or (A, B, and C).

[0032] In the figures, some structural or methodological features, such as those representing devices, modules, instruction blocks, and data elements, may be shown in a particular arrangement and / or order for ease of explanation. However, it should be understood that such a particular arrangement and / or order may not be required. Instead, in some embodiments, such features may be arranged in a manner and / or order different from that shown in the exemplary figures. Additionally, including a structural or methodological feature in a particular figure is intended to show that such a feature is not required in all embodiments, may not be included in some embodiments, or may be combined with other features.

[0033] In some embodiments, the schematic elements used to represent method blocks may be manually implemented by a user. In other embodiments, the implementation of these schematic elements can be automated using any suitable form of machine-readable instructions, such as, for example, software or firmware applications, programs, functions, modules, routines, processes, procedures, plugins, applets, widgets, code fragments, and / or others, each such instruction being implementable using any suitable programming language, library, application programming interface (API), and / or other software development tools. For example, in some embodiments, the schematic elements can be implemented using Java (registered trademark), C++, and / or other programming languages. Similarly, the schematic elements used to represent data or information can be implemented using any suitable electronic arrangement or structure, such as, for example, registers, data stores, tables, records, arrays, indexes, hashes, maps, trees, lists, graphs, files (of any file type), folders, directories, databases, and / or others.

[0034] Furthermore, in the figures, when connection elements such as solid lines, dotted lines, or arrows are used to indicate a connection, relationship, or association between or among two or more other schematic elements, the absence of such a connection element does not mean that a connection, relationship, or association cannot exist. In other words, some connection, relationship, or association between elements may not be shown in the figures so as not to obscure the present disclosure. Additionally, for ease of illustration, a single connection element may be used to represent multiple connections, relationships, or associations between elements. For example, when a connection element represents the communication of signals, data, or instructions, one of ordinary skill in the art should understand that such an element can represent one or more signal paths (e.g., a bus) if needed to enable the communication.

[0035] Next, referring to FIG. 1, an exemplary vehicle type 100 of a land vehicle includes a plurality of land vehicles. In an exemplary embodiment, the vehicle type 100 of the land vehicle includes, but is not limited to only, a two - passenger platform - type all - terrain vehicle 110, an 18.4 - cubic - meter (650 - cubic - foot) capacity delivery vehicle 120, a 28.3 - cubic - meter (1000 - cubic - foot) capacity delivery vehicle 130, a six - passenger platform - type all - terrain vehicle 140, and a 34 - cubic - meter (1200 - cubic - foot) capacity delivery vehicle 150. However, in some embodiments, the vehicle type 100 of the land vehicle can include any vehicle having a capacity within a specific range, such as in the range from 11.3 cubic meters (400 cubic feet) to 39.6 cubic meters (1400 cubic feet). In accordance with industrial terms, the phrase "cubic - meter (cubic - foot) capacity" may be abbreviated or omitted simply as "cube". It should be understood that the phrase "cubic - meter (cubic - foot) capacity" contemplated herein can refer to the storage volume or storage capacity of a particular land vehicle. In any case, as will become apparent from the subsequent discussion, one or more of the vehicles of vehicle type 100 can be manufactured using the systems and methods described herein.

[0036] In an exemplary embodiment, each of the vehicles included within vehicle type 100 of the vehicle (i.e., each of vehicles 110, 120, 130, 140, 150) includes a monocoque structure or unibody 200 (see FIG. 2) that supports wheels (e.g., wheels 112, 122, 132, 142, 152) to enable movement of the particular vehicle relative to the underlying surface during its use. As described herein, the monocoque structure 200 is an integral, monolithic structure that is not supported by an internal chassis. The monocoque structure 200 includes a front cage 210 that defines an operator cabin 212 and a rear floor 220 positioned rearward of the front cage 210. The monocoque structure 200 illustratively has a composite structure (e.g., the composite structure 700 shown in FIG. 7) such that each of the front cage 210 and the rear floor 220 is formed from one or more composite materials as will be described in further detail below.

[0037] At least some of the vehicles of the exemplary vehicle type 100 (e.g., vehicles 110, 140) may be embodied as, included within, or otherwise adapted to be used with an electric all-terrain vehicle. Further, at least some of the vehicles of the exemplary vehicle type 100 (e.g., vehicles 120, 130, 150) may be embodied as, included within, or otherwise adapted to be used with an electric vehicle having an enclosed storage compartment. Of course, it is to be understood that in other embodiments, the vehicles of vehicle type 100 may be embodied as, included within, or otherwise adapted to be used with other suitable vehicles.

[0038] It is to be understood that each of the vehicles of vehicle type 100 can be used for various purposes. In some embodiments, one or more vehicles of vehicle type 100 can be embodied as, or otherwise included in, for example, fire emergency vehicles, garbage transport vehicles, coach vehicles, recreational vehicles or campers, local area and / or public service vehicles, agricultural vehicles, mining vehicles, special vehicles, energy vehicles, defense vehicles, port service vehicles, construction vehicles, and transport and / or bus vehicles. Additionally, in some embodiments, one or more vehicles of vehicle type 100 can be adapted to be used with, or otherwise incorporated in, among other suitable devices, tractors, front-end loaders, scraper systems, cutters and shredders, hay and fertilizer equipment, planting equipment, seeding equipment, sprayers and applicators, tillage implements, all-purpose vehicles, lawn mowers, dump trucks, backhoes, truck loaders, crawler loaders, bulldozers, excavators, motor graders, skid steers, tractor loaders, wheel loaders, rakes, aerators, skidders, balers, forwarders, harvesters, swing machines, knuckle boom loaders, diesel engines, axles, planetary gear mechanisms, pump drives, transmissions, generators, and marine engines.

[0039] In an exemplary embodiment, each of the vehicles of vehicle type 100 includes one or more electric motors (not shown) capable of generating a rotational force that can be transmitted to the wheels to drive the movement of the vehicle. Thus, each of the exemplary vehicles is embodied as, or otherwise includes, an electric vehicle. Details regarding the electric motors and related power trains and / or suspension components included in each vehicle are described in co-pending U.S. Patent Application No. XX / XXX, XXX, the content of which is hereby incorporated by reference in its entirety.

[0040] Each of the vehicles of the exemplary vehicle type 100 does not include an internal combustion engine or a power generation device in at least some embodiments. Further, each of the vehicles of the exemplary vehicle type 100 is housed by a front cage 210 and positioned above the lower surface 214 of the monocoque structure 200 and does not include an engine or a power generation device. Instead, as described in co-pending U.S. Patent Application No. XX / XXX, XXX, a plurality of electric motors or power generation devices are removably coupled to the lower surface 214 of the monocoque structure 200 of each vehicle of the exemplary vehicle type 100.

[0041] It should be understood that each of the vehicles of the exemplary vehicle type 100 can include one or more features that improve the experience of the driver, owner, and / or maintenance personnel. Such features can include, but are not limited to, a low floor, a modular battery system, air spring and / or air ride features, independent rear suspension, independent front suspension, thermal battery management capabilities, flexible shelf options, a desired driver's line of sight, LED lighting, telematics / driver feedback, features for facilitating maintenance, an aerodynamic body, and advanced safety systems. Further details regarding at least some of these features are provided herein.

[0042] Next, referring to FIG. 2, in addition to the front cage 210 and the rear floor 220, in at least some embodiments, the monocoque structure 200 includes an intermediate section 230 disposed between the front cage 210 and the rear floor 220. The intermediate section 230 can form a part of the floor section disposed in front of the rear floor 220. As will be described in more detail below with reference to FIG. 8, each of the front cage 210, the rear floor 220, and the intermediate section 230 can be associated with and formed using a corresponding type unit of a modular system (e.g., system 800). Further, as will be described in more detail below with reference to FIG. 9, the type units of the modular system can be joined together to form a monocoque structure type (e.g., monocoque structure type 900), and a composite material can be introduced into that type to form the monocoque structure 200.

[0043] In an exemplary embodiment, the monocoque structure 200 combines what was previously formed from one or more separate structures (e.g., one or more body components and one or more frame components) into an integral monolithic structure. Thus, any vehicle of the present disclosure incorporating the monocoque structure 200 does not include an internal chassis or frame structure that supports separate body components (e.g., panels, doors, etc.). At least in part, by integrating the body and frame structures into an integrally formed structure, the exemplary monocoque structure 200 can be associated with improved productivity and / or simplified maintenance compared to other configurations, or can facilitate it in another way.

[0044] Depending on the type of a particular vehicle and the monocoque structure configuration, one or more dimensions of the intermediate section 230 of the monocoque structure 200 may be variable. In one example, the intermediate section 230 can be associated with a small intermediate-section type unit (e.g., the type unit 832 shown in FIG. 8) and have a first length defined thereby. In this example, the first length of the intermediate section 230 can at least partially define a storage compartment of an 18.4 cubic meter (650 cubic feet) delivery vehicle (e.g., vehicle 120). In another example, the intermediate section 230 can be associated with a medium intermediate-section type unit (e.g., the type unit 834 shown in FIG. 8) and have a second length defined thereby. In this example, the second length of the intermediate section 230 can at least partially define a storage compartment of a 28.3 cubic meter (1000 cubic feet) delivery vehicle (e.g., vehicle 130). In yet another example, the intermediate section 230 can be associated with a large intermediate-section type unit (e.g., the type unit 836 shown in FIG. 8) and have a third length defined thereby. In this example, the third length of the intermediate section 230 can at least partially define a storage compartment of a 34 cubic meter (1200 cubic feet) delivery vehicle (e.g., vehicle 150).

[0045] Furthermore, depending on the type of a particular vehicle and the monocoque structure configuration, the intermediate section 230 of the monocoque structure 200 may be completely omitted. In such an embodiment, the front cage 210 and the rear floor 220 can be integrally formed as a one-piece monolithic structure without the intermediate section 230 intervening therebetween. It should be understood that the all-purpose vehicles 110 and 140 can each include a monocoque structure formed without the intermediate section 230 in at least some embodiments.

[0046] Next, referring to FIG. 3, vehicle 300 incorporates a monocoque structure 200 in which an intermediate section 230 is disposed between a front cage 210 and a rear floor 220. Additionally, vehicle 300 includes a cab hood 302 disposed above the front cage 210 to enclose an operator cabin 212, and a storage compartment 310 disposed behind the front cage 210 and the cab hood 302. In an exemplary embodiment, storage compartment 310 is at least partially defined by intermediate section 230 and rear floor 220 and has a roof 312 and sidewalls 314. Exemplary vehicle 300 may be similar to any one of vehicles 120, 130, 150 discussed above in at least some embodiments.

[0047] Since the monocoque structure 200 has a composite structure as shown above, it should be understood that any vehicle described herein that incorporates the monocoque structure 200 (e.g., any one of vehicles 110, 120, 130, 140, 150, 300, 500) incorporates a composite structure (e.g., structure 700 shown in FIG. 7). In the case of vehicle 300, each of intermediate section 230, roof 312, and sidewalls 314 is formed of a composite material and has a composite structure in at least some embodiments. In these embodiments, each of intermediate section 230, roof 312, and sidewalls 314 does not include a metallic material.

[0048] Next, referring to FIG. 4, a prior art delivery vehicle 400 includes a storage compartment 410. Storage compartment 410 includes a floor 412, a pair of sidewalls 414, a ceiling 416, and a refrigeration unit 418 that is at least partially housed by storage compartment 410 and configured to cool storage compartment 410. The rear end of vehicle 400 includes a landing 404 and a step 406 that leads to floor 412 of storage compartment 410.

[0049] As shown in FIG. 4, the landing 404 has a landing height 424 above the ground level 402, and the step 406 has a step height 426 above the landing 404. The floor 412 has a floor height 422 above the ground level 402, including both the landing height 424 and the step height 426. Typically, the landing height 424 is about 63.5 cm (25 inches), the step height 426 is about 25.4 cm (10 inches), and the floor height 422 is about 88.9 cm (35 inches).

[0050] Referring now to FIG. 5, the delivery vehicle 500 can include a monocoque structure (such as the monocoque structure 200) described above with reference to FIG. 2. Further, in some embodiments, the vehicle 500 may be similar to one or more of the vehicles 120, 130, 150 described above. In any case, the exemplary delivery vehicle 500 includes a storage compartment 510 having a floor 512, a pair of side walls 514, and a ceiling 516, and a refrigeration unit 518 housed by the storage compartment 510. However, unlike the prior art delivery vehicle 400, the vehicle 500 does not have a step corresponding to the step 406. Accordingly, the floor 512 has a floor height 522 that may substantially correspond to or be equal to the landing height 424. The floor height 522 may be less than 76.2 cm (30 inches), such as within the range of 55.9 cm (22 inches) to 71.1 cm (28 inches), for example. The pair of wheel wells 530 formed within the storage compartment 510 are offset from each other by a separation distance 532. In a particular embodiment, the separation distance 532 may be about 127 cm (50 inches).

[0051] In some cases, the prior art delivery vehicle 400 has one or more disadvantages not associated with the exemplary vehicle 500. In one aspect, the sidewalls 414 and ceiling 416 of the prior art vehicle 400 are typically formed of a metal material, such as aluminum, that has poor heat insulation properties. Thus, the compartment 410 may have low heat insulation and tend to relatively quickly take in the temperature of the surrounding environment. This can be particularly the case in summer when radiant heat from the sun enhances the surrounding hot air and exacerbates the temperature rise in the compartment 410. In contrast, the sidewalls 514 and ceiling 516 of the exemplary vehicle 500 are formed of a composite material having excellent barrier properties compared to a metal material such as aluminum. Accordingly, the compartment 510 is significantly more shielded from the surrounding environment than the compartment 410. This shielding can be particularly advantageous when the vehicle 500 is a refrigerated vehicle, such as a food delivery vehicle. It should be understood that the shielding properties of the compartment 510 reduce the cooling load on the refrigeration unit 518, thereby increasing the performance of the refrigeration unit 518. Additionally, in certain situations, the increased performance of the refrigeration unit 518 may make it possible to provide the vehicle 500 with a smaller refrigeration unit 518 than that typically required for the prior art vehicle 400.

[0052] Another drawback associated with the prior art vehicle 400 is the property that the floor 412 is high relative to the ground level 402. It should be understood that the raised floor 412 is not only a design choice but often a feature required to accommodate the inclusion of the internal chassis or frame, the powertrain, and associated components. Put another way, the floor 412 is raised above the ground level 402 by the floor height 422 in order to accommodate the mounting of a conventional internal combustion engine and other powertrain components (e.g., transmission, transaxle, and / or differential) to the internal chassis. As a result, the raised floor 412 reduces the storage capacity and / or storage volume of the storage compartment 410 and requires the provision of the step 406. Thus, a delivery person using the vehicle 400 must climb onto the landing 404 and step 406 in order to access the compartment 410.

[0053] The exemplary vehicle 500 removes some of the aforementioned disadvantages by eliminating the need for a raised floor 412. In part, by providing the monocoque structure 200 as an integral, monolithic structure having a relatively lightweight composite structure, and in part, by the absence of power train components (e.g., a central drive shaft below the lower surface 214 of the monocoque structure 200 that provides a rotational input to the differential) that are typically provided within other configurations, the floor 512 need not be raised as high above ground level as the floor 412. As a result, the vehicle 500 enables an increase in the storage capacity of the storage compartment 510 without the need to raise the ceiling 516. Further, since steps similar to step 406 can be omitted from the vehicle 500, the floor height 522 corresponds to the landing height 424 of the conventional vehicle 400, and the delivery person can avoid the effort of climbing both the landing 404 and the step 406 to access the storage compartment 510 of the vehicle 500. It should be noted that the rear bumper of the vehicle 500 may be slightly lower than the floor 512, and it should be understood that the delivery person can access the storage compartment 510 by simply stepping onto the rear bumper first. In some embodiments, the rear bumper can have a height of about 50.8 cm (20 inches) above ground level, while the floor 512 can have a height of about 63.5 cm (25 inches) above ground level.

[0054] Next, referring to FIG. 6, in the United States, trucks are often classified according to their gross vehicle weight rating (GVWR). These truck classifications, related tariff classifications, and corresponding GVWRs are shown in Table 600. In an exemplary embodiment, one or more of vehicles 110, 120, 130, 140, 150 have a GVWR between 2.7 tons (6,000 pounds) and 9 tons (19,800 pounds) (i.e., taking into account the weight of the truck when empty and the payload of the truck when full). In some embodiments, one or more of vehicles 110, 120, 130, 140, 150 have a GVWR between 4.5 tons (10,001 pounds) and 6.4 tons (14,000 pounds), whereby one or more of vehicles 110, 120, 130, 140, 150 are embodied as, or otherwise include, Class 3 trucks. In one particular example, in some embodiments, the 28.3 cubic meter (1000 cubic foot) capacity vehicle 130 weighs approximately 2.9 tons (6,500 pounds) when empty and has a payload capacity of 2.7 tons (6,000 pounds), whereby vehicle 130 has a GVWR of approximately 5.7 tons (12,500 pounds). Of course, in other embodiments, it should be understood that vehicle type 100 can include one or more Class 3 vehicles, one or more Class 4 vehicles, and / or one or more Class 5 vehicles.

[0055] In some embodiments, the systems and methods described herein can find particular utility in relation to Class 3 to 5 delivery vehicles. For example, using methods 1000, 1100, 1300 described below, a monocoque structure of a delivery vehicle having a GVWR between 4.5 tons (10,001 pounds) and 8.8 tons (19,500 pounds) can be formed. The storage capacity of such a vehicle may be between 12.7 cubic meters (450 cubic feet) and 34 cubic meters (1200 cubic feet). In a particular embodiment, a storage compartment of the vehicle (e.g., compartment 510) can be isolated from the operator's cab of the vehicle (e.g., operator's cab 212).

[0056] Next, referring to FIG. 7, any vehicle of the present disclosure includes a monocoque structure having a composite structure 700. In an exemplary embodiment, the composite structure 700 incorporates one or more relatively lightweight, low-density materials to impart a relatively lightweight structure to the vehicle. As discussed below, an exemplary composite structure 700 includes one or more of balsa wood, plastic, glass fiber, resin, Kevlar®, honeycomb, and carbon fiber. The composite structure 700 does not include and is not formed from metal materials in at least some embodiments. In these embodiments, the monocoque structure (such as monocoque structure 200) incorporating the composite structure 700 does not include metal materials.

[0057] An exemplary composite structure 700 includes a core 702 and a shell 704 that at least partially surrounds the core 702. In an exemplary embodiment, the core 702 is formed from one or more of balsa wood and / or the following non-metallic composite materials: unidirectional glass fiber, multi-directional glass fiber, Kevlar®, carbon fiber, plastic, honeycomb, or other suitable non-metallic composite materials. Of course, in other embodiments, the core 702 may be formed from other suitable materials to provide a relatively lightweight structure to the composite structure 700. An exemplary shell 704 is formed from glass fiber and resin. However, in other embodiments, the shell 704 may be formed from other suitable materials. Additionally, in an exemplary embodiment, the composite structure 700 includes a laminate 706 that at least partially covers the shell 704.

[0058] It should be understood that the composite structure 700 used to form the monocoque structure of any vehicle of the present disclosure offers several advantages over the metal structures of multiple parts of conventional vehicles. In one aspect, the one-piece monolithic structure formed by the composite structure 700 has fewer parts than a vehicle structure that requires multiple parts, providing greater structural simplicity. In another aspect, the structural simplicity provided by the composite structure 700 can facilitate maintenance and improve structural efficiency. In yet another aspect, the absence of metal materials allows the composite structure 700 to minimize or eliminate rust and / or corrosion, thereby having a service life exceeding that of a vehicle with a conventional structure. In some cases, a monocoque structure incorporating the composite structure 700 consistent with the teachings of the present disclosure can have a service life of over 20 years.

[0059] Referring now to FIGS. 8 and 9, a modular type system 800 (see FIG. 8) includes several exemplary type units that can be selected and arranged to form a monocoque structure system 900 (see FIG. 9). It should be understood that when arranged to form the monocoque structure system 900, the selected type units of the modular system 800 are utilized to form a monocoque structure, such as the monocoque structure 200 described above. Further, like reference numerals 800 and 900 are used to indicate corresponding features of the modular type system 800 and the monocoque structure system 900.

[0060] The exemplary type system 800 includes a front cage type unit 810, a rear floor type unit 820, and a plurality of intermediate type units 830 including a small intermediate section type unit 832, a medium intermediate section type unit 834, and a large intermediate section type unit 836. As discussed below, each of the type units 810, 820, 832, 834, 836 has a mold cavity having a size and shape corresponding to a corresponding feature of the monocoque structure system 900, such that, after introduction of a composite material (e.g., the material of the composite structure 700) into the mold cavity, the corresponding feature of the monocoque structure system 900 is formed. Accordingly, the front cage type unit 810 includes a front cage type cavity 912 having a size and shape corresponding to the front cage 910 (and further the front cage 210) of the monocoque structure system 900. The rear floor type unit 820 includes a rear floor type cavity 922 having a size and shape corresponding to the rear floor 920 (and further the rear floor 220) of the monocoque structure system 900. The intermediate type units 832, 834, 836 each include respective intermediate type cavities 933, 935, 937 having a size and shape corresponding to respective intermediate sections 932, 934, 936 (and further the intermediate section 230) of the monocoque structure system 900.

[0061] As is apparent from FIGS. 8 and 9, each of the intermediate type units 832, 834, 836 is sized to be positioned between the front cage type unit 810 and the rear floor type unit 820 to form the monocoque structure system 900. It is to be understood that any one of the intermediate type units 832, 834, 836 can be selected and disposed between the front cage type unit 810 and the rear floor type unit 820 to form the monocoque structure system 900. The selection of a particular type unit 832, 834, 836 is based on the configuration of the vehicle and the monocoque structure included therein, as further discussed below.

[0062] In an exemplary embodiment, the front-cage type cavity 912 of the front-cage type unit 810 has, at its rear end (i.e., the end closest to one of the intermediate sections 932, 934, 936 as shown in FIG. 9), an opening 914 for establishing a fluid connection between the cavity 912 and another component of the mold system 800. In some embodiments, when the front-cage type unit 810 is arranged continuously with one of the corresponding intermediate type units 832, 834, 836, a fluid connection can be established between the front-cage type cavity 912 and one of the intermediate type cavities 933, 935, 937. Additionally, in some embodiments, when the front-cage type unit 810 is arranged continuously with the rear-floor type unit 820, a fluid connection can be established between the front-cage type cavity 912 and the rear-floor type cavity 922.

[0063] In an exemplary embodiment, the rear-floor type cavity 922 of the rear-floor type unit 820 has, at its front end (i.e., the end closest to one of the intermediate sections 932, 934, 936 as shown in FIG. 9), an opening 924 for establishing a fluid connection between the cavity 922 and another component of the mold system 800. Each of the intermediate type cavities 933, 935, 937 of the intermediate type units 832, 834, 836 has an opening 938 at its front end (i.e., the end closest to the front cage 910 as shown in FIG. 9) and an opening 940 at its rear end (i.e., the end closest to the rear floor 920 as shown in FIG. 9). When one of the intermediate type units 832, 834, 836 is arranged continuously with the front-cage type unit 810, a fluid connection is established between the corresponding intermediate type cavities 933, 935, 937 and the front-cage type cavity 912 through the openings 914, 938. Additionally, when one of the intermediate type units 832, 834, 836 is arranged continuously with the rear-floor type unit 820, a fluid connection is established between the corresponding intermediate type cavities 933, 935, 937 and the rear-floor type cavity 922 through the openings 924, 940.

[0064] It should be understood that the front ends of the exemplary intermediate units 832, 834, 836 are each configured to be directly connected to and attached to the rear end of the front cage type unit 810. Further, it should be understood that the rear ends of the exemplary intermediate units 832, 834, 836 are each configured to be directly connected to and attached to the front end of the rear floor type unit 820. As a result, when any one of the intermediate units 832, 834, 836 is directly connected to the front cage type unit 810 and the rear floor type unit 820, the front cage type cavity 912, the corresponding intermediate cavities 933, 935, 937, and the rear floor type cavity 922 are fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structured cavity, and a composite material can be introduced into this cavity to form a monocoque structure as an integral monolithic structure.

[0065] It should also be apparent that the rear end of the exemplary front cage type unit 810 is configured to be directly connected to and attached to the front end of the rear floor type unit 820. As a result, when the front cage type unit 810 is directly connected to the rear floor type unit 820, the front cage type unit 810 and the rear floor type unit 820 are fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structured cavity, and a composite material can be introduced into this cavity to form a monocoque structure as an integral monolithic structure.

[0066] In an exemplary embodiment, the small intermediate section type unit 832 has a length L1 as proposed by FIG. 9. The medium intermediate section type unit 834 has a length L2 that is longer than the length L1 in at least some embodiments. The large intermediate section type unit 836 has a length L3 that is longer than the length L2 and the length L1 in at least some embodiments.

[0067] In some embodiments, a small intermediate-section type unit 832 can be used to form an intermediate section 932 of a monocoque structure system 900, such that the monocoque structure at least partially produced using the type unit 832 is included within a vehicle (e.g., vehicle 120) having a storage volume of 18.4 cubic meters (650 cubic feet). Additionally, in some embodiments, a medium intermediate-section type unit 834 can be used to form an intermediate section 934 of a monocoque structure system 900, such that the monocoque structure at least partially produced using the type unit 834 is included within a vehicle (e.g., vehicle 130) having a storage volume of 28.3 cubic meters (1000 cubic feet). Further, in some embodiments, a large intermediate-section type unit 836 can be used to form an intermediate section 936 of a monocoque structure system 900, such that the monocoque structure at least partially produced using the type unit 836 is included within a vehicle (e.g., vehicle 150) having a storage volume of 34 cubic meters (1200 cubic feet).

[0068] Next, referring to FIG. 10, an exemplary method 1000 for forming a monocoque structure (e.g., monocoque structure 200) using a modular type system (e.g., system 800) is shown. Method 1000 corresponds to the implementation of the blocks described below in the exemplary order of FIG. 10 or is otherwise associated therewith. However, it should be understood that method 1000 can be implemented in one or more orders different from the exemplary order. Further, it should be understood that one or more of the blocks described below can be executed simultaneously and / or in parallel with each other. In some embodiments, method 1000 may be manually performed by one or more operators. In other embodiments, method 1000 may be embodied as a set of instructions implemented by an automated control system or otherwise include the same.

[0069] Exemplary method 1000 begins at block 1002. At block 1002, the operator or control system selects a land vehicle type or a monocoque structure configuration of a particular land vehicle. To implement block 1002, it should be understood that the operator or control system can select any vehicle contemplated by this disclosure, or any monocoque structure configuration associated with a particular vehicle contemplated by this disclosure. From block 1002, method 1000 then proceeds to block 1004.

[0070] At block 1004 of exemplary method 1000, the operator or control system selects a first type of unit of a modular system based on the selected vehicle type or monocoque structure configuration. In an exemplary embodiment, to implement block 1004, the operator or control system selects the rear floor type unit 820 of modular system 800 at block 1006. However, in other embodiments, it should be understood that block 1004 can be implemented by selecting (i) a small intermediate section type unit 832 (i.e., at block 1008), (ii) a medium intermediate section type unit (i.e., at block 1010), (iii) a large intermediate section type unit 836 (i.e., at block 1012). Selecting one of the intermediate type units 832, 834, 836 as the first type of unit will be described in more detail below with reference to FIG. 11. In any case, from block 1004, method 1000 then proceeds to block 1014.

[0071] In block 1014 of exemplary method 1000, an operator or control system couples a selected first type unit to a front cage type unit 810 of modular system 800. To implement block 1014, it should be understood that a selected first type unit (i.e., rear floor type unit 820) is coupled to front cage type unit 810 such that a front cage type cavity 912 is fluidly coupled to a rear floor type cavity 922 to at least partially establish a continuous monocoque structured cavity. Following the implementation of block 1014, method 1000 proceeds to block 1016.

[0072] In block 1016 of exemplary method 1000, an operator or control system introduces one or more composite materials (e.g., composite materials included within composite structure 700) into the continuous monocoque structured cavity formed in block 1014. More specifically, to implement block 1016, in at least some embodiments, an operator or control system implements blocks 1018, 1020, and 1022. In block 1018, an operator or control system introduces one or more composite materials into the continuous monocoque structured cavity without introducing a metallic material into this cavity. However, in other embodiments, block 1018 may be omitted from method 1000. In block 1020, an operator or control system places a first material within the continuous monocoque structured cavity. The first material can include balsa wood and / or plastic in at least some embodiments. In block 1022, an operator or control system places a second material different from the first material within the continuous monocoque structured cavity. The second material can include glass fibers and resin in at least some embodiments. Following the implementation of block 1016, method 1000 proceeds to block 1024.

[0073] In block 1024 of exemplary method 1000, an operator or control system cures one or more composite materials within a continuous monocoque-structured cavity to form a monocoque structure. To implement block 1024, the operator or control system can implement blocks 1026, 1028, and 1030 in at least some embodiments. In block 1026, the operator or control system forms a core (e.g., core 702) that includes the first material introduced at block 1016. In block 1028, the operator or control system forms a shell (e.g., shell 704) that includes the second material introduced at block 1016 and that at least partially surrounds the core. In block 1030, the operator or control system forms a laminate (e.g., layer 706) that at least partially covers the shell.

[0074] Next, referring to FIGS. 11 and 12, an exemplary method 1100 for forming a monocoque structure (e.g., monocoque structure 200) using a modular-type system (e.g., system 800) is shown. Method 1100 corresponds to the implementation of blocks described below in the exemplary order of FIGS. 11 and 12 or is otherwise associated therewith. However, it should be understood that method 1100 can be implemented in one or more orders different from the exemplary order. Further, it should be understood that one or more of the blocks described below can be executed simultaneously or in parallel with each other. In some embodiments, method 1100 may be performed manually by one or more operators. In other embodiments, method 1100 may be embodied as a set of instructions performed by an automated control system or otherwise include the same.

[0075] Exemplary method 1100 begins at block 1102. At block 1102, the operator or control system selects a land vehicle type or a monocoque structure configuration of a particular land vehicle. To implement block 1102, it should be understood that the operator or control system can select any vehicle contemplated by the present disclosure, or any monocoque structure configuration associated with a particular vehicle contemplated by the present disclosure. From block 1102, method 1100 then proceeds to block 1104.

[0076] At block 1104 of exemplary method 1100, the operator or control system selects a first type unit of the modular type system based on the selected vehicle type or monocoque structure configuration. In an exemplary embodiment, to implement block 1104, the operator or control system implements one of blocks 1106, 1108, and 1110. At block 1106, the operator or control system selects the small intermediate section type unit 832. At block 1108, the operator or control system selects the medium intermediate section type unit 834. At block 1110, the operator or control system selects the large intermediate section type unit 836. Following the implementation of block 1104, method 1100 proceeds to block 1112.

[0077] At block 1112 of exemplary method 1100, the operator or control system selects a second type unit of the modular system. In an exemplary embodiment, to implement block 1112, the operator or control system implements block 1114. At block 1114, the operator or control system selects the rear floor type unit 820 of the modular system 800. From block 1112, method 1100 then proceeds to block 1116.

[0078] In block 1116 of exemplary method 1100, an operator or control system couples a selected first type unit to the front cage type unit 810 of modular system 800. To implement block 1116, it should be understood that a selected first type unit (i.e., one of intermediate type units 832, 834, 836) is coupled to the front cage type unit 810 such that a front cage type cavity 912 is fluidly coupled to a corresponding intermediate type unit cavity (i.e., one of cavities 933, 935, 937) to at least partially establish a continuous monoblock structured cavity. Following the implementation of block 1116, method 1100 proceeds to block 1118.

[0079] In block 1118 of exemplary method 1100, an operator or control system couples a selected first type unit (i.e., one of intermediate type units 832, 834, 836) to a selected second type unit (i.e., rear floor type unit 820). To implement block 1118, it should be understood that one of intermediate type units 832, 834, 836 is coupled to the rear floor type unit 820 such that a rear floor type cavity 922 is fluidly coupled to a corresponding intermediate type unit cavity (i.e., one of cavities 933, 935, 937) to at least partially establish a continuous monoblock structured cavity. Following the implementation of block 1118, method 1100 proceeds to block 1120.

[0080] In block 1120 of exemplary method 1100, an operator or control system introduces one or more composite materials (e.g., composite materials included within composite structure 700) into a continuous monocoque-structured cavity formed at block 1118. More specifically, to implement block 1120, in at least some embodiments, the operator or control system implements blocks 1122, 1124, and 1126. In block 1122, the operator or control system introduces one or more composite materials into the cavity without introducing a metallic material into the continuous monocoque-structured 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 within the continuous monocoque-structured cavity. The first material can include balsa wood and / or plastic in at least some embodiments. In block 1126, the operator or control system places a second material different from the first material within the continuous monocoque-structured cavity. The second material can include glass fibers and resin in at least some embodiments. Following the implementation of block 1120, method 1000 proceeds to block 1202.

[0081] In block 1202 of exemplary method 1100, an operator or control system cures one or more composite materials within a continuous monocoque-structured cavity to form a monocoque structure. To implement block 1202, the operator or control system can implement blocks 1204, 1206, and 1208 in at least some embodiments. In block 1204, the operator or control system forms a core (e.g., core 702) that includes the first material introduced at block 1120. In block 1206, the operator or control system forms a shell (e.g., shell 704) that includes the second material introduced at block 1120 and that at least partially surrounds the core. In block 1208, the operator or control system forms a laminate (e.g., layer 706) that at least partially covers the shell.

[0082] Next, referring to FIG. 13, an exemplary method 1300 for forming a plurality of monocoque structures of a land vehicle using at least one modular system is shown. Method 1300 corresponds to the implementation of the blocks described below in the exemplary order of FIG. 13 or is otherwise associated therewith. However, it should be understood that method 1300 may be implemented in one or more orders different from the exemplary order. Further, it should be understood that one or more of the blocks described below may be executed simultaneously or in parallel with each other. In some embodiments, method 1300 may be manually implemented by one or more operators. In other embodiments, method 1300 may be embodied as a set of instructions implemented by an automated control system or may otherwise include it.

[0083] The exemplary method 1300 begins at block 1302. At block 1302, an operator or control system forms a first monocoque structure of a first land vehicle. To implement block 1302, the operator or control system forms a first monocoque structure of the first land vehicle using at least one modular system (e.g., system 800) at block 1304. In some embodiments, the first monocoque structure of the first land vehicle is formed using only the front cage-type unit 810 and the rear floor-type unit 820 of the modular system 800. In these embodiments, the first monocoque structure of the first land vehicle may be formed by implementing method 1000 described above. In other embodiments, the first monocoque structure of the first land vehicle is formed using the front cage-type unit 810, the rear floor-type unit 820, and one of the intermediate-type units 832, 834, 836. In these embodiments, the first monocoque structure of the first land vehicle may be formed by implementing method 1100 described above. In any case, following the implementation of block 1302, method 1300 proceeds to block 1306.

[0084] In block 1306 of exemplary method 1300, an operator or control system forms a second monocoque structure of a second on-road vehicle that is different from the first on-road vehicle. To implement block 1306, the operator or control system uses at least one modular system (i.e., system 800) in block 1308 to form the second monocoque structure of the second on-road vehicle. In an example where the first monocoque structure of the first on-road vehicle is formed in block 1302 using only the front cage-type unit 810 and the rear floor-type unit 820 of the modular system 800 (i.e., in accordance with method 1000), the second monocoque structure of the second on-road vehicle is formed using the front cage-type unit 810, the rear floor-type unit 820, and one of the intermediate-type units 832, 834, 836 (i.e., in accordance with method 1100). In an example where the first monocoque structure of the first on-road vehicle is formed in block 1302 using the front cage-type unit 810, the rear floor-type unit 820, and a first one of the intermediate-type units 832, 834, 836 (i.e., in accordance with method 1100), the second monocoque structure of the second on-road vehicle is formed using the front cage-type unit 810, the rear floor-type unit 820, and a second one of the intermediate-type units 832, 834, 836 that is different from the first one. In any of the examples, from block 1306, method 1300 then proceeds to block 1310.

[0085] In block 1310 of exemplary method 1300, an operator or control system forms a third monocoque structure of a third on - road vehicle that is different from the first on - road vehicle and the second on - road vehicle. To implement block 1310, the operator or control system uses at least one modular system (i.e., system 800) in block 1310 to form the third monocoque structure of the third on - road vehicle. In an example where (i) the first monocoque structure of the first on - road vehicle is formed in block 1302 using only the front - cage - type unit 810 and the rear - floor - type unit 820 of the modular system 800 (i.e., in accordance with method 1000), and (ii) the second monocoque structure of the second on - road vehicle is formed in block 1306 using the front - cage - type unit 810, the rear - floor - type unit 820, and a first one of the intermediate - type units 832, 834, 836 (i.e., in accordance with method 1100), the third monocoque structure of the third on - road vehicle is formed using the front - cage - type unit 810, the rear - floor - type unit 820, and a second one of the intermediate - type units 832, 834, 836 that is different from the first one. In an example where (i) the first monocoque structure of the first on - road vehicle is formed in block 1302 using the front - cage - type unit 810, the rear - floor - type unit 820, and a first one of the intermediate - type units 832, 834, 836 (i.e., in accordance with method 1100), and (ii) the second monocoque structure of the second on - road vehicle is formed in block 1306 using the front - cage - type unit 810, the rear - floor - type unit 820, and a second one of the intermediate - type units 832, 834, 836 that is different from the first one, the third monocoque structure of the third on - road vehicle is formed using the front - cage - type unit 810, the rear - floor - type unit 820, and a third one of the intermediate - type units 832, 834, 836 that is different from the first and second ones.

[0086] Although the present disclosure has been shown and described in detail in the foregoing figures and description, it is to be considered as illustrative and not restrictive in nature, and only its exemplary embodiments have been shown and described, and it is to be understood that all changes and modifications within the scope of the present disclosure are desired to be protected.

Claims

1. 1. A method of forming a monocoque structure for a land vehicle using a modular system, comprising: forming a front cage type unit of said modular system corresponding to a front cage of said monocoque structure; forming a rear floor type unit of the modular system corresponding to a rear floor of the monocoque structure positioned rearward of the front cage in a longitudinal direction; coupling the rear floor-type unit to the front cage-type unit such that a front cage-type cavity of the front cage-type unit is fluidly coupled to a rear floor-type cavity of the rear floor-type unit to establish an at least partially continuous monocoque structure-type cavity; The method includes:

2. introducing one or more composite materials into said continuous monocoque cavity; The method of claim 1 , further comprising curing the one or more composite materials within the continuous monocoque mold cavity to form the monocoque structure.

3. Positioning a first type unit of the modular system longitudinally rearward of the front cage type unit; coupling the first mold unit to the front cage-type unit and the rear floor-type unit such that the front cage-type cavity, the first mold unit mold cavity, and the rear floor-type cavity are fluidly coupled to one another to establish the continuous monocoque structural mold cavity; The method of claim 1 further comprising:

4. 4. The method of claim 3, wherein the first type unit is selected from the group consisting of a first mid-section type unit of the modular system having a first length, a second mid-section type unit of the modular system having a second length longer than the first length, and a third mid-section type unit of the modular system having a third length longer than the second length.

5. introducing one or more composite materials into said continuous monocoque cavity; curing one or more composite materials within the continuous monocoque cavity to form the monocoque structure; The method of claim 3 further comprising:

6. 6. The method of claim 5, wherein introducing the one or more composite materials into the continuous monocoque cavity comprises introducing the one or more composite materials into the continuous monocoque cavity without introducing a metallic material into the continuous monocoque cavity.

7. introducing said one or more composite materials into said continuous monocoque cavity; placing a first material within the continuous monocoque mold cavity; and placing a second material within the continuous monocoque mold cavity, the second material being different from the first material.

8. curing the one or more composite materials within the continuous monocoque mold cavity; forming a core comprising the first material; and forming a shell at least partially surrounding the core, the shell comprising a second material different from the first material.

9. The method of claim 1 , wherein the front cage-type unit and the rear floor-type unit are structurally distinct from one another.

10. 2. The method of claim 1, wherein forming the rear floor type unit includes defining cutouts through the rear floor type unit in a lateral direction perpendicular to a longitudinal direction such that the rear floor type unit has a reduced width between the cutouts in the lateral direction.

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