Method for producing monocoque structures for land vehicles using modular systems

Abstract

Disclosed herein are land vehicles, modular systems for forming monocoque structures for land vehicles, and methods for forming monocoque structures for land passenger vehicles using the modular systems. In certain embodiments, the land vehicles are provided as delivery vehicles and / or utility vehicles. The land vehicles include a monocoque structure supporting a plurality of wheels to enable movement of the vehicle relative to an underlying surface during use of the land vehicle.

Description

[Technical field]

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 957,577, entitled "SYSTEMS AND METHODS FOR MANUFACTURING LAND VEHICLES," filed January 6, 2020, the contents of which are incorporated herein by reference in their entirety.

[0002] FIELD OF THE DISCLOSURE This disclosure relates generally to land vehicles and methods of making land vehicles, and more particularly to utility vehicles and delivery vehicles and methods of making utility vehicles and delivery vehicles. [Background technology]

[0003] Current systems and methods for manufacturing utility and delivery vehicles suffer from various drawbacks and limitations. For these, among other reasons, there remains a need for further improvements in the art. Summary of the Invention [Means for solving the problem]

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

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

[0006] In some examples, the monocoque structure may not include a metal material, and the monocoque structure may include a core and a shell at least partially surrounding the core, and the core may be formed from one or more lightweight, low density materials, and the shell may be formed from resin and fiberglass. The core may include balsa wood. The core may include plastic. The monocoque structure may include a laminate at least partially covering the shell.

[0007] In some embodiments, the monocoque structure can include a mid-section disposed between the front cage and the rear floor, and the vehicle can include a storage compartment having a plurality of side walls and a ceiling defined at least in part by the mid-section and the rear floor, and each of the mid-section, the plurality of side walls, and the ceiling can be formed from one or more composite materials, and each of the mid-section, the plurality of side walls, and the ceiling can be free of metal materials. 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). Furthermore, also in some embodiments, the land vehicle can include a refrigeration unit at least in part contained by the storage compartment and configured to cool 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 may be between 22 inches and 28 inches.

[0009] According to another aspect of the 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 mold units. The front cage type unit can include a front cage type cavity having a size and shape corresponding to a front cage of the monocoque structure that defines an operator cabin. The front cage type unit can have an opening at its rear end for establishing a fluid coupling 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 a rear floor of the monocoque structure positioned rearward of the front cage. The rear floor type unit can have an opening at its front end for establishing a fluid coupling between the rear floor type cavity and another component of the system. Each of the plurality of intermediate mold 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 mold units can include an intermediate mold cavity having a size and shape corresponding to a middle section of the monocoque structure positioned between the front cage and the rear floor. Each of the multiple intermediate mold units may have a front opening at its front end for establishing a fluid connection between the intermediate mold cavity and the front cage mold cavity, and a rear opening at a rear end of the intermediate mold unit for establishing a fluid connection between the intermediate mold cavity and the rear floor mold cavity.

[0010] In some embodiments, a front end of each of the plurality of intermediate units can be configured to directly connect with a rear end of the front cage unit. A rear end of each of the plurality of intermediate units can be configured to directly connect with a 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 one another in a serial arrangement to establish a continuous monocoque cavity, into which one or more composite materials can be introduced to form the monocoque structure as a one-piece monolithic structure.

[0011] In some embodiments, the rear end of the front cage unit can be configured to directly connect with 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 back-to-back arrangement to establish a continuous monocoque cavity into which one or more composite materials can be introduced to form the monocoque as a one-piece monolithic structure.

[0012] In some examples, the plurality of intermediate units can include a first intermediate unit having a first length, a second intermediate unit having a second length greater than the first length, and a third intermediate unit having a third length greater than the second length. The first intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 650 cubic feet, the second intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 1000 cubic feet, and the third intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 1200 cubic feet.

[0013] According to yet another aspect of the present disclosure, the land vehicle may include a monocoque structure supporting a plurality of wheels for enabling movement of the vehicle relative to an underlying surface during use of the land vehicle. The monocoque structure may be a one-piece monolithic structure that is not supported by an internal chassis. The monocoque structure may include a front cage defining an operator cabin, a rear floor positioned aft of the front cage, and a middle section disposed between the front cage and the rear floor. The monocoque structure may include a core formed from balsa wood or plastic, and a shell formed from resin and fiberglass at least partially surrounding the core. The monocoque structure may be formed by a modular system including a front cage type unit, a rear floor type unit, and a middle type unit. The front cage type unit may 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 may have an opening at its rear end for establishing a fluid coupling between the front cage type cavity and another component of the system. The rear floor type unit may 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 may have an opening at its front end for establishing a fluid coupling between the rear floor type cavity and another component of the system. The intermediate mold unit may be sized to be positioned between the front cage type unit and the rear floor type unit. The intermediate mold unit may include a middle mold cavity having a size and shape corresponding to the middle section of the monocoque structure. The intermediate mold unit may have a front opening at its front end for establishing a fluid coupling between the middle mold cavity and the front cage type cavity, and a rear opening at the rear end of the intermediate mold unit for establishing a fluid coupling between the middle mold cavity and the rear floor type cavity.

[0014] Also according to yet another aspect of the present disclosure, a method of forming a monocoque structure for a land vehicle using a modular system includes: selecting a monocoque structural configuration for the land vehicle; selecting a first mold unit of the modular system based on the selected monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially establish a continuous monocoque structural mold cavity; introducing one or more composite materials into the continuous monocoque structural mold cavity; and curing the one or more composite materials in the continuous monocoque structural mold cavity to form a monocoque structure.

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

[0016] In some examples, introducing one or more composite materials into the continuous monocoque mold cavity can include disposing a first material into the continuous monocoque mold cavity and disposing a second material into the continuous monocoque mold cavity, the second material being different than the first material. The first material can include balsa wood or plastic, and the second material can include fiberglass and resin. Curing the one or more composite materials in the continuous monocoque mold cavity can include forming a core including the first material and forming a shell including the second material at least partially surrounding the core.

[0017] In some embodiments, the front cage type unit of the modular system can correspond to a monocoque front cage defining an operator cabin of the vehicle, and the selected first mold unit of the modular system can correspond to a monocoque mid-section positioned aft of the front cage. The method can further include selecting a second mold unit of the modular system corresponding to a monocoque rear floor positioned aft of the front cage and the mid-section based on the selected monocoque configuration, and coupling the selected first mold unit to the selected second mold unit such that a front cage mold cavity of the front cage type unit, a cavity of the selected first mold unit, and a mold cavity of the selected second mold unit are fluidly coupled to one another to establish a continuous monocoque mold cavity. Selecting the first type unit of the modular system may include selecting one of a small mid-section type unit of the modular system having a first length, a medium mid-section type unit of the modular system having a second length longer than the first length, and a large mid-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 for a land vehicle using at least one modular system includes: selecting a first monocoque structural configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of the at least one modular system based on the selected first monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially form a first continuous monocoque structural mold cavity; introducing one or more composite materials into the first continuous monocoque structural mold cavity; curing the one or more composite materials in the first continuous monocoque structural mold cavity to form a first monocoque structure; and curing a second monocoque structure of a second land vehicle, different from the first land vehicle. selecting a second monocoque structural configuration for the at least one modular system; selecting a first mold unit of the at least one modular system different from the selected first mold unit of the at least one modular system based on the selected second monocoque structural configuration; coupling the selected first mold unit of the at least one modular system to the front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a second continuous monocoque mold cavity; introducing one or more composite materials into the second continuous monocoque mold cavity; and curing the one or more composite materials in the second continuous monocoque mold cavity to form a second monocoque structure.

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

[0020] In some examples, introducing one or more composite materials into the first continuous monocoque mold cavity can include placing a first material in the first continuous monocoque mold cavity and placing a second material in the first continuous monocoque mold cavity, different from the first material, and introducing one or more composite materials into the second continuous monocoque mold cavity can include placing a first material in the second continuous monocoque mold cavity and placing a second material in the second continuous monocoque mold cavity. The first material can include balsa wood or plastic, and the second material can include fiberglass and resin. Curing the one or more composite materials in the first continuous monocoque cavity can include forming a first monocoque core comprising the first material and forming a first monocoque shell comprising a second material at least partially surrounding the first monocoque core, and curing the one or more composite materials in the second continuous monocoque cavity can include forming a second monocoque core comprising the first material and forming a second monocoque shell comprising the second material at least partially surrounding the second monocoque core.

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

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

[0023] In some embodiments, the front cage type unit of the at least one modular system can correspond to a front cage of a first monocoque structure defining an operator cabin of the first land vehicle, and the selected first type unit of the at least one modular system can correspond to a middle section of the first monocoque structure having a first length and positioned aft of the front cage of the first monocoque structure, and the front cage type unit of the at least one modular system can correspond to a front cage of a second monocoque structure defining an operator cabin of a second land vehicle, and the selected first type unit of the at least one modular system can correspond to a middle section of the second monocoque structure having a second length different from the first length and positioned aft of the front cage of the second monocoque structure.The method includes: selecting, based on the selected first monocoque structure configuration, a second mold unit of the at least one modular system corresponding to a rear floor of the first monocoque structure positioned rearward of a front cage and a mid-section of the first monocoque structure; coupling the selected first mold unit of the at least one modular system to the selected second mold unit of the at least one modular system such that a front cage mold cavity of the front cage type unit of the at least one modular system, a cavity of the selected first mold unit of the at least one modular system, and a mold cavity of the selected second mold unit of the at least one modular system are fluidly coupled to each other to establish a first continuous monocoque structure mold cavity; The method may further include selecting a second mold unit of the at least one modular system corresponding to a rear floor of the second monocoque structure positioned rearward of a front cage and mid-section of the second monocoque structure based on the selected second monocoque structure configuration, and coupling the selected first mold unit of the at least one modular system to the selected second mold unit of the at least one modular system such that a front cage mold cavity of the front cage unit of the at least one modular system, a cavity of the selected first mold unit of the at least one modular system, and a mold cavity of the selected second mold unit of the at least one modular system are fluidly coupled to each other to establish a second continuous monocoque structure mold cavity.

[0024] Also according to a further aspect of the present disclosure, a method of forming a plurality of monocoque structures for a land vehicle using at least one modular system includes: selecting a first monocoque structural configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of the at least one modular system based on the selected first monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structural mold cavity; introducing one or more composite materials into the first continuous monocoque structural mold cavity; curing the one or more composite materials in the first continuous monocoque structural mold cavity to form a first monocoque structure; selecting a second monocoque structural configuration for a second monocoque structure of a second land vehicle different from the first land vehicle; and coupling the selected second mold 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 mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structural mold cavity. selecting a first mold unit of the at least one modular system different from the selected first mold unit of the at least one modular system based on the monocoque structural configuration; coupling the selected first mold unit of the at least one modular system to the front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a second continuous monocoque structural mold cavity; introducing one or more composite materials into the second continuous monocoque structural mold cavity; curing the one or more composite materials in the second continuous monocoque structural mold cavity to form a second monocoque structure; selecting a third monocoque structural configuration of a third monocoque structure of a third land vehicle different from the first land vehicle and the second land vehicle; and based on the selected third monocoque structural configuration,The method may include: selecting a first mold unit of the at least one modular system, the first mold unit being different from the selected first mold unit of the at least one modular system; coupling the selected first mold unit of the at least one modular system to the front cage unit of the at least one modular system such that a front cage cavity of the front cage unit of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a third continuous monocoque mold cavity; introducing one or more composite materials into the third continuous monocoque mold cavity; and curing the one or more composite materials in the third continuous monocoque mold cavity to form a third monocoque structure.

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

[0026] In some embodiments, curing one or more composite materials in a continuous monocoque mold cavity can include forming a core including a first material and forming a shell including a second material at least partially surrounding the core. The front cage type unit of the modular system can correspond to a front cage of the monocoque structure defining an operator cabin of the vehicle, and the selected first mold unit of the modular system can correspond to a mid-section of the monocoque structure positioned aft of the front cage. The method can include selecting a second mold unit of the modular system corresponding to a rear floor of the monocoque structure positioned aft of the front cage and the mid-section based on the selected monocoque configuration, and coupling the selected first mold unit to the selected second mold unit such that the front cage type cavity of the front cage type unit, the cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly coupled to each other to establish a continuous monocoque mold cavity. Selecting the first type unit of the modular system may include selecting one of a small mid-section type unit of the modular system having a first length, a medium mid-section type unit of the modular system having a second length longer than the first length, and a large mid-section type unit of the modular system having a third length longer than the second length.

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

[0028] The invention described herein is illustrated by way of example, and not by way of limitation, in the accompanying figures. For ease and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or similar elements. [Brief description of the drawings]

[0029] [Figure 1] 1A-1C are side views of several electric vehicles that may be included within a vehicle class of electric vehicles, in accordance with certain embodiments of the present disclosure. [Diagram 2] FIG. 1 is a perspective view of a monocoque structure or unibody that may be incorporated into any of the electric vehicles of the present disclosure. [Diagram 3] FIG. 1 is a partially exploded assembly diagram of an electric vehicle in accordance with at least one embodiment of the present disclosure. [Figure 4] FIG. 1 is a partial schematic rear view of a conventional delivery vehicle. [Diagram 5] FIG. 1 is a partial schematic rear view of a delivery vehicle in accordance with at least one embodiment of the present disclosure. [Figure 6] 1 is a table showing U.S. standard vehicle classifications based on gross vehicle weight rating (GVWR). [Figure 7] FIG. 1 is a partial schematic diagram of a composite structure that may be used to form the monocoque structure or unibody of any electric vehicle of the present disclosure. [Figure 8] FIG. 1 is a diagrammatic view of at least one modular system in accordance with certain embodiments of the present disclosure. [Figure 9] FIG. 9 is a perspective view of a monocoque structural system formed from several mold units contained within at least one modular mold system of FIG. [Figure 10] 1 is a simplified flowchart of a method for forming a monocoque structure for an electric vehicle using a modular system, according to one embodiment of the present disclosure. [Figure 11] 11 is a simplified flow chart of a portion of another method for forming a monocoque structure for an electric vehicle using a single modular system, according to another embodiment of the present disclosure. [Figure 12] 12 is a diagram of another portion of the method of FIG. 11. [Figure 13]1 is a simplified flowchart of a method for forming multiple monocoque structures for an electric vehicle using at least one modular system, according to yet another embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail herein, it being understood, however, that there is no intention to limit the concepts of the present disclosure to the particular forms disclosed, but the intention is to cover all modifications, equivalents, and alternatives consistent with the scope of the disclosure and the appended claims.

[0031] References herein to "one embodiment" or "one embodiment," "exemplary embodiment," and the like indicate that the described embodiment may include a particular feature, structure, or characteristic, but that all embodiments may or may not include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Moreover, when a particular feature, structure, or characteristic is described in connection with one embodiment, it is believed to be within the knowledge of one of ordinary skill in the art to enable such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described. Additionally, it should be understood that an item included in a list in the form "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, an item listed in the form "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 method 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 description. However, it should be understood that such a particular arrangement and / or order may not be required. Rather, in some embodiments, such features may be arranged in a different manner and / or order than that shown in the example figures. Additionally, the inclusion of a structural or method feature within a particular figure is intended to indicate that such feature is not required for all embodiments, and that in some embodiments, such features may not be included or may be combined with other features.

[0033] In some embodiments, the schematic elements used to represent method blocks may be implemented manually by a user. In other embodiments, the implementation of these schematic elements may be automated using any suitable form of machine-readable instructions, such as, for example, software or firmware applications, programs, functions, modules, routines, processes, procedures, plug-ins, applets, widgets, code fragments, and / or others, each such instruction may be implemented using any suitable programming language, library, application programming interface (API), and / or other software development tools. For example, in some embodiments, the schematic elements may be implemented using Java, C++, and / or other programming languages. Similarly, the schematic elements used to represent data or information may 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 a connecting element such as a solid or dotted line or an arrow is used to indicate a connection, relationship or association between or within two or more other schematic elements, the absence of such a connecting element is not meant to indicate that the connection, relationship or association cannot exist. In other words, some connections, relationships or associations between elements may not be shown in the figures so as not to obscure the present disclosure. In addition, for ease of illustration, a single connecting element may be used to represent multiple connections, relationships or associations between elements. For example, when a connecting element represents communication of signals, data or instructions, those skilled in the art should understand that such an element may represent one or more signal paths (e.g., buses) as may be required to effect the communication.

[0035] 1, an exemplary vehicle class 100 of land vehicles includes a plurality of land vehicles. In an exemplary embodiment, the vehicle class 100 of land vehicles includes, but is not limited to, a two-passenger utility vehicle 110, a 650 cubic foot capacity delivery vehicle 120, a 1000 cubic foot capacity delivery vehicle 130, a six-passenger utility vehicle 140, and a 1200 cubic foot capacity delivery vehicle 150. However, in some embodiments, the vehicle class 100 of land vehicles may include any vehicle having a capacity within a particular range, such as, for example, a range of 400 cubic feet to 1400 cubic feet. In keeping with industry terminology, the phrase "cubic meter (cubic foot) capacity" may be shortened or abbreviated to simply "cube." It should be understood that the phrase "cubic meter (cubic foot) capacity" as contemplated herein may refer to the storage volume or capacity of a particular land vehicle. In either case, as will become apparent from the ensuing discussion, one or more vehicles of vehicle make type 100 may be manufactured using the systems and methods described herein.

[0036] In an exemplary embodiment, each of the vehicles included within vehicle model 100 (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 an underlying surface during use. As described herein, monocoque structure 200 is a one-piece monolithic structure that is not supported by an internal chassis. Monocoque structure 200 includes a front cage 210 that defines an operator cabin 212, and a rear floor 220 that is positioned rearward of front cage 210. Monocoque structure 200 illustratively includes a composite structure (e.g., composite structure 700 shown in FIG. 7) in which each of front cage 210 and rear floor 220 are formed from one or more composite materials as described in more 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 in, or otherwise adapted for use with an electric all-purpose vehicle. Additionally, at least some of the vehicles of the exemplary vehicle type 100 (e.g., vehicles 120, 130, 150) may be embodied as, included in, or otherwise adapted for use with an electric vehicle having an enclosed storage compartment. Of course, it should be understood that in other embodiments, the vehicles of the vehicle type 100 may be embodied as, included in, or otherwise adapted for use with other suitable vehicles.

[0038] It should be appreciated that each of the vehicles of vehicle type 100 may be used in a variety of applications. In some embodiments, one or more of the vehicles of vehicle type 100 may be embodied as or otherwise included in a fire emergency vehicle, a refuse hauling vehicle, a coach vehicle, a recreational vehicle or camper, a local and / or public service vehicle, an agricultural vehicle, a mining vehicle, a specialty vehicle, an energy vehicle, a defense vehicle, a port service vehicle, a construction vehicle, and a transit and / or bus vehicle, to name a few. Additionally, in some embodiments, one or more of the vehicles of vehicle type 100 may be embodied as or otherwise included in a tractor, a front end loader, a scraper system, a cutter, a tractor-trailer ... The present invention may be adapted for use with, or otherwise incorporated into, machines, equipment, machinery, machinery and equipment such as trucks, shredders, hay and fertilizer equipment, planting equipment, seeding equipment, sprayers and applicators, tillage implements, utility vehicles, mowers, dump trucks, backhoes, track loaders, crawler loaders, bulldozers, excavators, motor graders, skid steers, tractor loaders, wheel loaders, rakes, aerators, skidders, binders, forwarders, harvesters, swing machines, knuckle boom loaders, diesel engines, axles, planetary gear mechanisms, pump drives, transmissions, generators, and marine engines.

[0039] In the exemplary embodiment, each of the vehicles of vehicle type 100 includes one or more electric motors (not shown) capable of generating rotational force that can be transmitted to wheels to drive 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 associated powertrain and / or suspension components included within each vehicle are described in co-pending U.S. patent application Ser. No. XX / XXX, XXX, the contents of which are incorporated herein by reference in their entirety.

[0040] Each of the vehicles of the exemplary vehicle type 100, at least in some embodiments, does not include an internal combustion engine or a power generating device. Further, each of the vehicles of the exemplary vehicle type 100 does not include an engine or a power generating device housed by the front cage 210 and positioned above the lower surface 214 of the monocoque structure 200. Instead, as described in co-pending U.S. patent application Ser. No. XX / XXX, XXX, a plurality of electric motors or power generating 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 appreciated that each of the vehicles of the exemplary vehicle make type 100 may include one or more features that enhance the driver, owner, and / or maintenance personnel experience. Such features may include, but are not limited to, a lowered 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, desired driver line of sight, LED lighting, telematics / driver feedback, features for ease of maintenance, aerodynamic body, and advanced safety systems. Further details regarding at least some of these features are provided herein.

[0042] 2, in addition to the front cage 210 and the rear floor 220, in at least some embodiments, the monocoque structure 200 includes a middle section 230 disposed between the front cage 210 and the rear floor 220. The middle section 230 may form a portion of a floor section disposed forward 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 middle section 230 may be associated with and formed with a corresponding mold unit of a modular system (e.g., system 800). Additionally, as will be described in more detail below with reference to FIG. 9, the mold units of the modular system may be joined together to form a monocoque structural mold (e.g., monocoque structural mold 900) into which composite material may be introduced to form the monocoque structure 200.

[0043] In the exemplary embodiment, the monocoque structure 200 combines what 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 one-piece, monolithic structure. Thus, any vehicle of the present disclosure incorporating the monocoque structure 200 does not include an internal chassis or frame structure supporting 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 may be associated with or otherwise facilitate increased manufacturability and / or simplified maintenance as compared to other configurations.

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

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

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

[0047] Because monocoque structure 200 comprises a composite structure as illustrated above, it should be understood that any vehicle described herein incorporating monocoque structure 200 (e.g., any of vehicles 110, 120, 130, 140, 150, 300, 500) incorporates a composite structure (e.g., structure 700 illustrated in FIG. 7 ). In the case of vehicle 300, each of mid-section 230, roof 312, and sidewalls 314, at least in some embodiments, are formed from composite materials and have a composite structure. In these embodiments, each of mid-section 230, roof 312, and sidewalls 314 does not include metallic materials.

[0048] 4, a prior art delivery vehicle 400 includes a storage compartment 410. The 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 contained by the storage compartment 410 and configured to cool the storage compartment 410. The rear end of the vehicle 400 includes a landing 404 and a step 406 that leads to the floor 412 of the storage compartment 410.

[0049] 4, the landing 404 has a landing height 424 above 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 ground level 402, including both the landing height 424 and the step height 426. Typically, the landing height 424 is approximately 25 inches, the step height 426 is approximately 10 inches, and the floor height 422 is approximately 35 inches.

[0050] 5, the delivery vehicle 500 may include a monocoque structure (e.g., monocoque structure 200) as described above with reference to FIG. 2. Additionally, 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. Thus, 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 30 inches, such as within a range of 22 inches to 28 inches, for example. The pair of wheel wells 530 formed within the storage compartment 510 are offset from one another by a separation distance 532. In certain embodiments, the separation distance 532 may be approximately 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 respect, the sidewalls 414 and the ceiling 416 of the prior art vehicle 400 are typically formed of a metal material, such as aluminum, that has poor thermal insulation. Thus, the compartment 410 may have poor insulation and tend to pick up the temperature of the surrounding environment relatively quickly. This may be especially the case in the summer, when radiant heat from the sun enhances the surrounding hot air, causing the temperature rise of the compartment 410 to become severe. In contrast, the sidewalls 514 and the ceiling 516 of the exemplary vehicle 500 are formed of a composite material that has superior insulation properties compared to a metal material, such as aluminum. Accordingly, the compartment 510 is insulated from the surrounding environment to a greater extent than the compartment 410. This insulation may be particularly advantageous when the vehicle 500 is a refrigerated vehicle, such as a food delivery vehicle. It should be appreciated that the isolation characteristics of compartment 510 reduce the cooling burden on refrigeration unit 518, thereby increasing the performance of refrigeration unit 518. Additionally, in certain circumstances, the increased performance of refrigeration unit 518 may allow vehicle 500 to be provided with a smaller refrigeration unit 518 than would typically be required by prior art vehicles 400.

[0052] Another drawback associated with the prior art vehicle 400 is the elevated nature of the floor 412 relative to the ground level 402. It should be appreciated that the elevated floor 412 is not merely a design choice, but a feature that is often required to accommodate the inclusion of an internal chassis or frame, powertrain, and related components. Stated differently, the floor 412 is elevated above the ground level 402 by a floor height 422 to accommodate the mounting of a conventional internal combustion engine and other powertrain components (e.g., a transmission, transaxle, and / or differential) to the internal chassis. As a result, the elevated floor 412 reduces the storage capacity and / or storage volume of the storage compartment 410 and necessitates the provision of the step 406. Thus, a delivery person using the vehicle 400 must ascend to the landing 404 and navigate the step 406 to access the compartment 410.

[0053] The exemplary vehicle 500 eliminates some of the aforementioned disadvantages by eliminating the need for an elevated floor 412. In part, by providing the monocoque structure 200 as a one-piece, monolithically formed structure having a relatively lightweight composite construction, and in part, due to the absence of powertrain components typically provided in other configurations (e.g., a central drive shaft below the lower surface 214 of the monocoque structure 200 that provides rotational input to the differential), the floor 512 does not need to be elevated above ground level as the floor 412 does. As a result, the vehicle 500 allows for an increase in the storage capacity of the storage compartment 510 without the need to raise the ceiling 516. Furthermore, because a step similar to the 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 a 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. Of note, it should be understood that the rear bumper of the vehicle 500 may be slightly lower than the floor 512, allowing the delivery person to access the storage compartment 510 by simply stepping first onto the rear bumper. In some embodiments, the rear bumper may have a height of approximately 20 inches above ground level, while the floor 512 may have a height of approximately 25 inches above ground level.

[0054] Referring now to FIG. 6, in the United States, trucks are often classified according to their gross vehicle weight rating (GVWR). These truck classifications, associated tariff classifications, and corresponding GVWRs are shown in Table 600. In an exemplary embodiment, one or more of the vehicles 110, 120, 130, 140, 150 have a GVWR (i.e., taking into account the weight of the truck when empty and the payload of the truck when full) between 2.7 tons (6,000 pounds) and 9 tons (19,800 pounds). In some embodiments, one or more of the vehicles 110, 120, 130, 140, 150 have a GVWR between 4.5 tons (10,001 pounds) and 6.4 tons (14,000 pounds), such that one or more of the vehicles 110, 120, 130, 140, 150 are embodied as or otherwise include a Class 3 truck. In one particular example, in some embodiments, a 1000 cubic foot capacity vehicle 130 weighs approximately 6,500 pounds when empty and has a load capacity of 6,000 pounds, such that the vehicle 130 has a GVWR of approximately 12,500 pounds. Of course, it should be understood that in other embodiments, the vehicle make 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 may find particular utility in connection with class 3 to 5 delivery vehicles. For example, the methods 1000, 1100, 1300 described below may be utilized to form a monocoque structure for a delivery vehicle having a GVWR between 4.5 tons (10,001 lbs) and 8.8 tons (19,500 lbs). 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 certain embodiments, a storage compartment (e.g., compartment 510) of the vehicle may be isolated from an operator cabin (e.g., operator cabin 212) of the vehicle.

[0056] 7, any vehicle of the present disclosure includes a monocoque structure having a composite structure 700. In exemplary embodiments, composite structure 700 incorporates one or more relatively lightweight, low density materials to provide a relatively lightweight structure to the vehicle. As discussed below, exemplary composite structure 700 includes one or more of balsa wood, plastic, fiberglass, resin, Kevlar, honeycomb, and carbon fiber. Composite structure 700, at least in some embodiments, does not include or is not formed from a metallic material. In these embodiments, a monocoque structure incorporating composite structure 700 (e.g., monocoque structure 200) does not include a metallic material.

[0057] The 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 balsa wood and / or one or more of the following non-metallic composite materials: unidirectional fiberglass, multi-directional fiberglass, 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 the composite structure 700 with a relatively lightweight construction. The exemplary shell 704 is formed from fiberglass 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 ply 706 that at least partially covers the shell 704.

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

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

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

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

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

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

[0064] It should be appreciated that the forward end of each of the exemplary intermediate units 832, 834, 836 is configured to be directly connected and attached to the rear end of the front cage unit 810. It should also be appreciated that the rear end of each of the exemplary intermediate units 832, 834, 836 is configured to be directly connected and attached to the forward end of the rear floor unit 820. As a result, when any one of the intermediate units 832, 834, 836 is directly connected to the front cage unit 810 and the rear floor unit 820, the front cage cavity 912, the corresponding intermediate cavity 933, 935, 937, and the rear floor cavity 922 are fluidly coupled to one another in a continuous arrangement to establish a continuous monocoque structure cavity into which a composite material can be introduced to form the monocoque structure as a one-piece monolithic structure.

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

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

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

[0068] 10, an exemplary method 1000 of forming a monocoque structure (e.g., monocoque structure 200) using a modular system (e.g., system 800) is shown. Method 1000 corresponds to or is otherwise associated with the performance of the blocks described below in the exemplary sequence of FIG. 10. However, it should be understood that method 1000 may be performed in one or more sequences different from the exemplary sequence. Furthermore, it should be understood that one or more of the blocks described below may be performed simultaneously and / or in parallel with one another. In some embodiments, method 1000 may be performed manually by one or more operators. In other embodiments, method 1000 may be embodied as or otherwise include a set of instructions performed by an automated control system.

[0069] The exemplary method 1000 begins at block 1002, where an operator or control system selects a monocoque structural configuration for a land vehicle type or a particular land vehicle. It should be understood that to perform block 1002, the operator or control system may select any monocoque structural configuration associated with any vehicle contemplated by the present disclosure, or a particular vehicle contemplated by the present disclosure. From block 1002, the method 1000 then proceeds to block 1004.

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

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

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

[0073] In block 1024 of the exemplary method 1000, an operator or control system cures one or more composite materials in a continuous monocoque mold cavity to form a monocoque structure. To perform block 1024, an operator or control system may perform blocks 1026, 1028, and 1030, at least in some embodiments. In block 1026, the operator or control system forms a core (e.g., core 702) including the first material introduced in block 1016. In block 1028, the operator or control system forms a shell (e.g., shell 704) including the second material introduced in block 1016 at least partially surrounding the core. In block 1030, the operator or control system forms a laminate (e.g., layer 706) at least partially covering the shell.

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

[0075] The exemplary method 1100 begins at block 1102, where an operator or control system selects a monocoque structural configuration for a land vehicle type or a particular land vehicle. It should be understood that to perform block 1102, the operator or control system may select any monocoque structural configuration associated with any vehicle contemplated by the present disclosure, or a particular vehicle contemplated by the present disclosure. From block 1102, the method 1100 then proceeds to block 1104.

[0076] In block 1104 of the example method 1100, an operator or control system selects a first type unit of the modular system based on a selected vehicle type or monocoque structural configuration. In an example 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 the small mid-section type unit 832. In block 1108, the operator or control system selects the medium mid-section type unit 834. In block 1110, the operator or control system selects the large mid-section type unit 836. Following performance of block 1104, the method 1100 proceeds to block 1112.

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

[0078] In block 1116 of the exemplary method 1100, an operator or control system couples the selected first mold unit to the front cage unit 810 of the modular system 800. It should be appreciated that to perform block 1116, the selected first mold unit (i.e., one of the middle mold units 832, 834, 836) is coupled to the front cage unit 810 such that the front cage cavity 912 is fluidly coupled to a corresponding middle mold unit cavity (i.e., one of the cavities 933, 935, 937) to at least partially establish a continuous monocoque cavity. Following performance of block 1116, the method 1100 proceeds to block 1118.

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

[0080] In block 1120 of the example method 1100, an operator or control system introduces one or more composite materials (e.g., composite materials included in composite structure 700) into the continuous monocoque mold cavity formed in block 1118. More specifically, to perform block 1120, in at least some embodiments, an operator or control system performs blocks 1122, 1124, and 1126. In block 1122, an operator or control system introduces one or more composite materials into the continuous monocoque mold cavity without introducing a metallic material into the cavity. However, in other embodiments, block 1122 may be omitted from the method 1100. In block 1124, an operator or control system places a first material into the continuous monocoque mold cavity. The first material, in at least some embodiments, may include balsa wood and / or plastic. At block 1126, an operator or a control system places a second material, different from the first material, within the continuous monocoque mold cavity. The second material, in at least some embodiments, may include fiberglass and resin. Following performance of block 1120, method 1000 proceeds to block 1202.

[0081] In block 1202 of the example method 1100, an operator or control system cures one or more composite materials in a continuous monocoque mold cavity to form a monocoque structure. To perform block 1202, an operator or control system can perform blocks 1204, 1206, and 1208, at least in some embodiments. In block 1204, the operator or control system forms a core (e.g., core 702) including the first material introduced in block 1120. In block 1206, the operator or control system forms a shell (e.g., shell 704) including the second material introduced in block 1120 at least partially surrounding the core. In block 1208, the operator or control system forms a laminate (e.g., layer 706) at least partially covering the shell.

[0082] Referring now to FIG. 13, an exemplary method 1300 of forming multiple monocoque structures for a land vehicle using at least one modular system is shown. The method 1300 corresponds to or is otherwise associated with the implementation of the blocks described below in the exemplary sequence of FIG. 13. However, it should be understood that the method 1300 may be implemented in one or more sequences different from the exemplary sequence. Furthermore, it should be understood that one or more of the blocks described below may be performed simultaneously or in parallel with one another. In some embodiments, the method 1300 may be implemented manually by one or more operators. In other embodiments, the method 1300 may be embodied as or otherwise include a set of instructions implemented by an automated control system.

[0083] The exemplary method 1300 begins at block 1302. In block 1302, an operator or control system forms a first monocoque structure for a first land vehicle. To implement block 1302, the operator or control system forms the first monocoque structure for the first land vehicle using at least one modular system (e.g., system 800) in block 1304. In some embodiments, the first monocoque structure for 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 for the first land vehicle may be formed by implementing the method 1000 described above. In other embodiments, the first monocoque structure for 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 examples, the first monocoque structure of the first land vehicle may be formed by performing method 1100 as described above. In either case, following performance of block 1302, method 1300 proceeds to block 1306.

[0084] In block 1306 of the exemplary method 1300, an operator or control system forms a second monocoque structure for a second land vehicle that is different from the first land vehicle. To implement block 1306, the operator or control system forms the second monocoque structure for the second land vehicle using at least one modular system (i.e., system 800) in block 1308. In an embodiment in which the first monocoque structure for the first land 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., according to method 1000), the second monocoque structure for the second 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 (i.e., according to method 1100). In an embodiment in which a first monocoque structure for a first land 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., according to method 1100), a second monocoque structure for a second land 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 either embodiment, from block 1306, the method 1300 then proceeds to block 1310.

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

[0086] While the present disclosure has been shown and described in detail in the foregoing drawings and description, it is to be understood that the disclosure is to be considered illustrative and not restrictive in nature, and that only illustrative embodiments thereof have been shown and described, and that all changes and modifications which come 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: selecting a monocoque structural configuration for the land vehicle; selecting a first type unit of the modular system based on the selected monocoque structural configuration; coupling the selected first mold unit to the 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 mold cavity of the selected first mold unit to at least partially establish a continuous monocoque mold cavity; introducing one or more composite materials into said continuous monocoque cavity; and curing said one or more composite materials within said continuous monocoque mold cavity to form said monocoque structure.

2. 2. The method of claim 1 , 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.

3. 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.

4. The method of claim 3 , wherein the first material comprises balsa wood or plastic and the second material comprises fiberglass and resin.

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

6. 2. The method of claim 1, wherein the front cage type unit of the modular system corresponds to a front cage of the monocoque structure that defines an operator cabin of the vehicle, and the selected first type unit of the modular system corresponds to a rear floor of the monocoque structure that is positioned rearward of the front cage.

7. 2. The method of claim 1, wherein the front cage type unit of the modular system corresponds to a front cage of the monocoque structure that defines an operator cabin of the vehicle, and the selected first type unit of the modular system corresponds to a mid-section of the monocoque structure positioned rearward of the front cage.

8. selecting a second type unit of the modular system based on the selected monocoque structure configuration, the second type unit corresponding to a rear floor of the monocoque structure positioned rearward of the front cage and the intermediate section; 8. The method of claim 7, further comprising coupling the selected first mold unit to the selected second mold unit such that the front cage mold cavity of the front cage mold unit, the mold cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly coupled to one another to establish the continuous monocoque mold cavity.

9. 9. The method of claim 8, wherein selecting the first type unit of the modular system includes selecting one of a small mid-section type unit of the modular system having a first length, a medium mid-section type unit of the modular system having a second length longer than the first length, and a large mid-section type unit of the modular system having a third length longer than the second length.

10. 1. A method for forming a multiple monocoque structure for a land vehicle using at least one modular system, comprising: selecting a first monocoque structural configuration for a first monocoque structure of a first land vehicle; selecting at least one modular system first type unit based on the selected first monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque mold cavity; introducing one or more composite materials into the first continuous monocoque cavity; curing the one or more composite materials within the first continuous monocoque mold cavity to form the first monocoque structure; selecting a second monocoque structural configuration of a second monocoque structure of a second land vehicle different from the first land vehicle; selecting a first type unit of at least one modular system based on the selected second monocoque structural configuration, wherein the selected first type unit of the at least one modular system is different from the selected first type unit of the at least one modular system; coupling the selected first mold unit of the at least one modular system 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 of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a second continuous monocoque structural mold cavity; introducing one or more composite materials into the second continuous monocoque cavity; and curing the one or more composite materials within the second continuous monocoque mold cavity to form the second monocoque structure.

11. introducing the one or more composite materials into the first continuous monocoque cavity includes introducing the one or more composite materials into the first continuous monocoque cavity without introducing a metallic material into the first continuous monocoque cavity; 11. The method of claim 10, wherein introducing the one or more composite materials into the second continuous monocoque mold cavity comprises introducing the one or more composite materials into the second continuous monocoque mold cavity without introducing a metallic material into the second continuous monocoque mold cavity.

12. introducing the one or more composite materials into the first continuous monocoque mold cavity includes placing a first material within the first continuous monocoque mold cavity and placing a second material within the first continuous monocoque mold cavity, the second material being different from the first material; 11. The method of claim 10, wherein introducing the one or more composite materials into the second continuous monocoque mold cavity comprises: placing the first material within the second continuous monocoque mold cavity; and placing the second material within the second continuous monocoque mold cavity.

13. the first material comprises balsa wood or plastic; The method of claim 12 , wherein the second material comprises fiberglass and resin.

14. curing the one or more composite materials in the first continuous monocoque mold cavity includes forming a first monocoque core including the first material and forming a first monocoque shell including the second material at least partially surrounding the first monocoque core; 14. The method of claim 13, wherein curing the one or more composite materials in the second continuous monocoque mold cavity comprises forming a second monocoque core comprising the first material, and forming a second monocoque shell comprising the second material at least partially surrounding the second monocoque core.

15. the front cage type unit of the at least one modular system corresponds to a front cage of the first monocoque structure defining an operator cabin of the first land vehicle; the selected first type unit of the at least one modular system corresponds to a rear floor of the first monocoque structure positioned rearward of the front cage of the first monocoque structure; the front cage type unit of the at least one modular system corresponds to a front cage of the second monocoque structure defining an operator cabin of the second land vehicle; 11. The method of claim 10, wherein the selected first type unit of the at least one modular system corresponds to a mid-section of the second monocoque structure positioned rearward of the front cage of the second monocoque structure.

16. selecting a second type unit of the at least one modular system based on the selected second monocoque structure configuration, the second type unit corresponding to a rear floor of the second monocoque structure positioned rearward of the front cage and the intermediate section of the second monocoque structure; 16. The method of claim 15, further comprising coupling the selected first mold unit of the at least one modular system to the selected second mold unit of the at least one modular system such that the front cage type cavity of the front cage type unit of the at least one modular system, the mold cavity of the selected first mold unit of the at least one modular system, and the mold cavity of the selected second mold unit of the at least one modular system are fluidly coupled to one another to establish the second continuous monocoque mold cavity.

17. 17. The method of claim 16, wherein selecting the first type unit of the at least one modular system comprises selecting one of a small mid-section type unit of the at least one modular system having a first length, a medium mid-section type unit of the at least one modular system having a second length longer than the first length, and a large mid-section type unit of the at least one modular system having a third length longer than the second length.

18. the front cage type unit of the at least one modular system corresponds to a front cage of the first monocoque structure defining an operator cabin of the first land vehicle; the selected first type unit of the at least one modular system has a first length and corresponds to a middle section of the first monocoque structure positioned aft of the front cage of the first monocoque structure; the front cage type unit of the at least one modular system corresponds to a front cage of the second monocoque structure defining an operator cabin of the second land vehicle; 11. The method of claim 10, wherein the selected first type unit of the at least one modular system has a second length different from the first length and corresponds to a mid-section of the second monocoque structure positioned rearward of the front cage of the second monocoque structure.

19. selecting, based on the selected first monocoque structure configuration, a second type unit of the at least one modular system corresponding to a rear floor of the first monocoque structure positioned rearward of the front cage and the intermediate section of the first monocoque structure; coupling the selected first mold unit of the at least one modular system to the selected second mold unit of the at least one modular system such that the front cage type cavity of the front cage type unit of the at least one modular system, the mold cavity of the selected first mold unit of the at least one modular system, and the mold cavity of the selected second mold unit of the at least one modular system are fluidly coupled to one another to establish the first continuous monocoque structural mold cavity; selecting a second type unit of the at least one modular system based on the selected second monocoque structure configuration, the second type unit corresponding to a rear floor of the second monocoque structure positioned rearward of the front cage and the intermediate section of the second monocoque structure; 20. The method of claim 18, further comprising coupling the selected first mold unit of the at least one modular system to the selected second mold unit of the at least one modular system such that the front cage type cavity of the front cage type unit of the at least one modular system, the mold cavity of the selected first mold unit of the at least one modular system, and the mold cavity of the selected second mold unit of the at least one modular system are fluidly coupled to one another to establish the second continuous monocoque structural mold cavity.

20. 1. A method for forming a multiple monocoque structure for a land vehicle using at least one modular system, comprising: selecting a first monocoque structural configuration for a first monocoque structure of a first land vehicle; selecting at least one modular system first type unit based on the selected first monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque mold cavity; introducing one or more composite materials into the first continuous monocoque cavity; curing the one or more composite materials within the first continuous monocoque mold cavity to form the first monocoque structure; selecting a second monocoque structural configuration of a second monocoque structure of a second land vehicle different from the first land vehicle; selecting a first type unit of at least one modular system based on the selected second monocoque structural configuration, wherein the selected first type unit of the at least one modular system is different from the selected first type unit of the at least one modular system; coupling the selected first mold unit of the at least one modular system to the front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a second continuous monocoque structural mold cavity; introducing one or more composite materials into the second continuous monocoque cavity; curing the one or more composite materials within the second continuous monocoque mold cavity to form the second monocoque structure; selecting a third monocoque structural configuration of a third monocoque structure of a third land vehicle different from the first land vehicle and the second land vehicle; selecting a first type unit of at least one modular system based on the selected third monocoque structural configuration, wherein the selected first type unit of the at least one modular system is different from the selected first type unit of the at least one modular system and the selected first type unit of the at least one modular system; coupling the selected first mold unit of the at least one modular system to the front cage type unit of the at least one modular system such that a front cage type cavity of the front cage type unit of the at least one modular system is fluidly coupled to a mold cavity of the selected first mold unit of the at least one modular system to at least partially establish a third continuous monocoque structural mold cavity; introducing one or more composite materials into the third continuous monocoque cavity; and curing the one or more composite materials within the third continuous monocoque mold cavity to form the third monocoque structure.

21. 1. A method of forming a monocoque structure for a land vehicle using a modular system, comprising: selecting a monocoque structural configuration for the land vehicle; selecting a first type unit of the modular system based on the selected monocoque structural configuration; coupling the selected first mold 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 mold cavity of the selected first mold unit to at least partially establish a continuous monocoque mold cavity; introducing one or more composite materials into the continuous monocoque mold cavity, where introducing the one or more composite materials into the continuous monocoque mold cavity includes introducing the one or more composite materials into the continuous monocoque mold cavity without introducing a metallic material into the continuous monocoque mold cavity, and introducing the one or more composite materials into the continuous monocoque mold cavity includes placing a first material into the continuous monocoque mold cavity, the first material including balsa wood or plastic, and placing a second material into the continuous monocoque mold cavity, the second material including fiberglass and resin; and curing said one or more composite materials within said continuous monocoque mold cavity to form said monocoque structure.

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

23. 23. The method of claim 22, wherein the front cage type unit of the modular system corresponds to a front cage of the monocoque structure that defines an operator cabin of the vehicle, and the selected first type unit of the modular system corresponds to a mid-section of the monocoque structure positioned rearward of the front cage.

24. selecting a second type unit of the modular system based on the selected monocoque structure configuration, the second type unit corresponding to a rear floor of the monocoque structure positioned rearward of the front cage and the intermediate section; 24. The method of claim 23, further comprising coupling the selected first mold unit to the selected second mold unit such that the front cage mold cavity of the front cage mold unit, the mold cavity of the selected first mold unit, and the mold cavity of the selected second mold unit are fluidly coupled to one another to establish the continuous monocoque mold cavity.

25. 25. The method of claim 24, wherein selecting the first type unit of the modular system includes selecting one of a small mid-section type unit of the modular system having a first length, a medium mid-section type unit of the modular system having a second length longer than the first length, and a large mid-section type unit of the modular system having a third length longer than the second length.

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