Land vehicles incorporating monocoque structures and modular systems for fabricating monocoque structures - Patents.com

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 The present 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 this field. 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 present disclosure, a land vehicle may 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. The monocoque structure may be a one-piece monolithic structure not supported by an internal chassis. The monocoque structure may include a front cage defining an operator cabin and a rear floor positioned rearward of the front cage. The monocoque structure may have a composite structure, with each of the front cage and the rear floor formed from one or more composite materials.

[0006] In some embodiments, 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, where 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 one or more of fiberglass, Kevlar, carbon fiber, or 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 at least partially defined by the mid-section and the rear floor, the storage compartment having a plurality of side walls and a ceiling, wherein 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). Further, also in some embodiments, the land vehicle can include a refrigeration unit at least partially 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 present disclosure, a modular system for forming a monocoque structure for a land vehicle may include a front cage-type unit, a rear floor-type unit, and a plurality of intermediate units. The front cage-type unit may include a front cage-type cavity having a size and shape corresponding to a front cage of the monocoque structure defining an operator cabin. 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 a rear floor of the monocoque structure positioned rearward of the front cage. 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. Each of the plurality of intermediate units may be sized to be positioned between the front cage-type unit and the rear floor-type unit. Each of the plurality of intermediate units may include an intermediate cavity having a size and shape corresponding to a mid-section of the monocoque structure positioned between the front cage and the rear floor. Each of the plurality of 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 the 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 mid-mold units can be configured to connect directly with a rear end of the front cage unit. A rear end of each of the plurality of mid-mold units can be configured to connect directly with a front end of the rear floor unit. When any one of the mid-mold units is directly connected to the front cage unit and the rear floor unit, the front cage cavity, the mid-mold cavity, and the rear floor cavity can be fluidly coupled to each other in a serial arrangement to establish a continuous monocoque cavity, and one or more composite materials can be introduced into the cavity to form the monocoque 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 continuous arrangement to establish a continuous monocoque cavity, and one or more composite materials can be introduced into this cavity to form the monocoque structure 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 longer than the first length, and a third intermediate unit having a third length longer than the second length. The first intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 18.4 cubic meters (650 cubic feet), the second intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 28.3 cubic meters (1000 cubic feet), and the third intermediate unit can be sized to form a mid-section of a monocoque structure to be included in a vehicle having a storage volume of 34 cubic meters (1200 cubic feet).

[0013] According to yet another aspect of the present disclosure, a land vehicle may 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. The monocoque structure may be a one-piece, monolithic structure not supported by an internal chassis. The monocoque structure may include a front cage defining an operator cabin, a rear floor positioned rearward of the front cage, and an intermediate section disposed between the front cage and the rear floor. The monocoque structure 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 an intermediate 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 connection 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 mid-type unit may be sized to be positioned between the front cage-type unit and the rear floor-type unit. The mid-type unit may include a mid-type cavity having a size and shape corresponding to the mid-section of the monocoque structure. The mid-type unit may have a front opening at its front end for establishing a fluid coupling between the mid-type cavity and the front cage-type cavity and a rear opening at its rear end for establishing a fluid coupling between the mid-type 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 mold unit of the modular system such that a front cage mold cavity of the front cage mold 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 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 rear floor positioned rearward of the front cage.

[0016] In some embodiments, introducing one or more composite materials into the continuous monocoque mold cavity can include depositing a first material within the continuous monocoque mold cavity and depositing a second material within the continuous monocoque mold cavity, the second material being different from 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 within 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 rearward 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 rearward of the front cage and 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-type 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 for forming a plurality of monocoque structures for land vehicles 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 mold unit of the at least one modular system such that a front cage mold cavity of the front cage mold 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 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 second continuous monocoque structural mold cavity; introducing one or more composite materials into the second continuous monocoque structural mold cavity; and curing the one or more composite materials in the second continuous monocoque structural mold cavity to form the second monocoque structure.

[0019] In some examples, introducing one or more composite materials into the first continuous monocoque cavity can include introducing one or more composite materials into the first continuous monocoque cavity without introducing a metallic material into the first continuous monocoque cavity, and introducing one or more composite materials into the second continuous monocoque cavity can include introducing 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 a second material different from the first material in the first continuous monocoque mold cavity, 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 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 that at least partially surrounds 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 that at least partially surrounds 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 a 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, based on the selected second monocoque structural configuration, a second mold unit of the at least one modular system corresponding to a rear floor of the second monocoque structure positioned rearward of the front cage and mid-section of the second monocoque structure, 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 mold 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 structural 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 a first land vehicle, the selected first type unit of the at least one modular system can correspond to a mid-section of the first monocoque structure having a first length and 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 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 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 mold 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, based on the selected second monocoque structure configuration, a second mold unit of the at least one modular system corresponding to a rear floor of the second monocoque structure positioned rearward of the front cage and mid-section of the second monocoque structure, 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 land vehicles 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 mold unit of the at least one modular system such that a front cage mold cavity of the front cage mold 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; 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 the 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 for 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 includes: selecting a selected first mold unit of the at least one modular system and 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; 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 the 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 structural mold cavity; and curing the one or more composite materials in the third continuous monocoque structural mold cavity to form a third monocoque structure.

[0025] Furthermore, according to another aspect of the present disclosure, a land vehicle may 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. 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 and a rear floor positioned rearward of the front cage. The monocoque structure may have a composite structure, with the front cage and the rear floor each formed from one or more composite materials. The monocoque structure may not include metal materials.

[0026] In some embodiments, the monocoque structure can include a core and a shell at least partially surrounding the core, where the core can be formed from balsa wood and plastic, and the shell can be formed from resin and fiberglass. The monocoque structure can include a mid-section disposed between a front cage and a rear floor, and the vehicle can include a storage compartment at least partially defined by the mid-section and the rear floor, the storage compartment having a plurality of side walls and a ceiling, where 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 vehicle can be free of an internal combustion engine. The height of the rear floor above an underlying surface can be between 22 inches (55.9 cm) and 28 inches (71.1 cm).

[0027] These and other aspects of the present disclosure will become more apparent from the following description of exemplary 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 explanation 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, according to certain embodiments of the present disclosure. [Figure 2] FIG. 1 is a perspective view of a monocoque structure or unibody that may be incorporated into any electric vehicle of the present disclosure. [Figure 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]1 is a partial schematic rear view of a conventional delivery vehicle. [Figure 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 by 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] 1 is a diagrammatic view of at least one modular system in accordance with certain embodiments of the present disclosure. [Figure 9] 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. 8. 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] 10 is a simplified flowchart 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] FIG. 12 is a diagrammatic view of another portion of the method of FIG. [Figure 13] 10 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 INVENTION

[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," "one embodiment," "exemplary embodiment," or the like indicate that the described embodiment may include a particular feature, structure, or characteristic, but that all embodiments may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, 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 items included in lists 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, items 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 illustrative 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 feature 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, a software or firmware application, program, function, module, routine, process, procedure, plug-in, applet, widget, code fragment, and / or the like, and each such instruction may be implemented using any suitable programming language, library, application programming interface (API), and / or other software development tool. 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, a register, data store, table, record, array, index, hash, map, tree, list, graph, file (of any file type), folder, directory, database, and / or the like.

[0034] Furthermore, in the figures, when a connecting element, such as a solid or dotted line or 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. Additionally, 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 will understand that such element may represent one or more signal paths (e.g., buses) as may be needed to effectuate 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 includes, but is not limited to, a two-passenger utility vehicle 110, a 650 cubic foot (18.4 cubic meter) capacity delivery vehicle 120, a 1000 cubic foot (28.3 cubic meter) capacity delivery vehicle 130, a six-passenger utility vehicle 140, and a 1200 cubic foot (34 cubic meter) 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 (11.3 cubic meters) to 1400 cubic feet (39.6 cubic meters). To align 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 can 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, and 150) includes a monocoque structure or unibody 200 (see FIG. 2 ) that supports wheels (e.g., wheels 112, 122, 132, 142, and 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 positioned rearward of front cage 210. Monocoque structure 200 illustratively comprises a composite structure (e.g., composite structure 700 shown in FIG. 7 ) in which front cage 210 and rear floor 220 are each formed from one or more composite materials, as described in further detail below.

[0037] At least some of the vehicles of exemplary vehicle type 100 (e.g., vehicles 110, 140) may be embodied as, included in, or otherwise adapted for use with, an electric utility vehicle. Additionally, at least some of the vehicles of 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 vehicle type 100 may be embodied as, included in, or otherwise adapted for use with, any other suitable vehicle.

[0038] It should be understood that each of the vehicles of vehicle type 100 may be used in a variety of applications. In some embodiments, one or more vehicles of vehicle type 100 may be embodied as or otherwise included in a fire and emergency vehicle, a garbage hauling vehicle, a coach vehicle, a recreational vehicle or camper, a local government 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 vehicles of vehicle type 100 may be embodied as a tractor, a front end loader, a scraper system, a cutter, and a tractor-mounted vehicle, among other suitable equipment. The present invention may be adapted for use with, or otherwise incorporated into, machines and 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. Accordingly, 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 exemplary vehicle type 100, at least in some embodiments, does not include an internal combustion engine or a power generating unit. Further, each of the vehicles of exemplary vehicle type 100 does not include an engine or power generating unit housed by front cage 210 and positioned above lower surface 214 of 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 units are removably coupled to lower surface 214 of monocoque structure 200 of each vehicle of exemplary vehicle type 100.

[0041] It should be understood that each vehicle of exemplary vehicle make 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 low floor, a modular battery system, air spring and / or air ride features, an independent rear suspension, an 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, an 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 mid-section 230 disposed between the front cage 210 and the rear floor 220. The mid-section 230 may form part of a floor section disposed forward of the rear floor 220. As described in more detail below with reference to FIG. 8 , each of the front cage 210, the rear floor 220, and the mid-section 230 may be associated with and formed using a corresponding mold unit of a modular mold system (e.g., system 800). Furthermore, as described in more detail below with reference to FIG. 9 , the mold units of the modular mold 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, 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. Accordingly, any vehicle of the present disclosure incorporating 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, exemplary monocoque structure 200 may be associated with or otherwise facilitate increased manufacturability and / or simplified maintenance 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 the storage compartment of a 650 cubic foot (18.4 cubic meter) 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 the storage compartment of a 1000 cubic foot (28.3 cubic meter) 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 an embodiment, the front cage 210 and the rear floor 220 may be integrally formed as a one-piece monolithic structure without the intervening mid-section 230. It should be understood that the utility vehicles 110 and 140 may each, in at least some embodiments, include a monocoque structure formed without the mid-section 230.

[0046] 3 , vehicle 300 incorporates monocoque structure 200 with mid-section 230 disposed between front cage 210 and rear floor 220. Additionally, vehicle 300 includes a cab hood 302 disposed above front cage 210 to enclose operator cabin 212, and a storage compartment 310 disposed rearward of front cage 210 and cab hood 302. In exemplary embodiments, storage compartment 310 is defined at least in part by mid-section 230 and rear floor 220 and includes a roof 312 and sidewalls 314. Exemplary vehicle 300, at least in some embodiments, may be similar to any one of 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 shown in FIG. 7 ). In the case of vehicle 300, mid-section 230, roof 312, and sidewalls 314 are each, at least in some embodiments, formed from composite materials and have a composite structure. In these embodiments, mid-section 230, roof 312, and sidewalls 314 are each free of 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, landing 404 has a landing height 424 above ground level 402, and step 406 has a step height 426 above landing 404. Floor 412 has a floor height 422 above ground level 402, including both landing height 424 and step height 426. Typically, landing height 424 is approximately 25 inches, step height 426 is approximately 10 inches, and floor height 422 is approximately 35 inches.

[0050] Referring now to FIG. 5, 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, vehicle 500 may be similar to one or more of vehicles 120, 130, 150 described above. In either case, exemplary delivery vehicle 500 includes a storage compartment 510 having a floor 512, a pair of sidewalls 514, and a ceiling 516, as well as a refrigeration unit 518 housed by storage compartment 510. However, unlike prior art delivery vehicle 400, vehicle 500 does not have a step corresponding to step 406. Accordingly, floor 512 has a floor height 522 that may substantially correspond to or be equal to landing height 424. Floor height 522 may be less than 30 inches, such as within a range of 22 inches to 28 inches. 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 127 cm (50 inches).

[0051] In some cases, prior art delivery vehicles 400 suffer from one or more disadvantages not associated with exemplary vehicle 500. In one respect, the sidewalls 414 and ceiling 416 of prior art vehicles 400 are typically formed of a metal material, such as aluminum, that provides poor thermal insulation. Consequently, compartment 410 may have poor thermal insulation and tend to absorb the temperature of the surrounding environment relatively quickly. This may be particularly the case in the summer, when radiant heat from the sun enhances the surrounding hot air, exacerbating the temperature rise in compartment 410. In contrast, the sidewalls 514 and ceiling 516 of exemplary vehicle 500 are formed of a composite material that has superior insulation properties compared to metal materials, such as aluminum. Accordingly, compartment 410 is insulated from the surrounding environment to a greater extent than compartment 410. This insulation may be particularly advantageous when vehicle 500 is a refrigerated vehicle, such as a food delivery vehicle. It will be appreciated that the insulating properties 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 prior art vehicle 400 is the elevated nature of floor 412 relative to ground level 402. It should be appreciated that elevated floor 412 is not simply a design choice, but is often a required feature to accommodate the inclusion of an internal chassis or frame, powertrain, and related components. Stated differently, 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, floor 412 is elevated above ground level 402 by floor height 422. As a result, elevated floor 412 reduces the storage capacity and / or volume of storage compartment 410 and necessitates the provision of step 406. Thus, a delivery person using vehicle 400 must ascend to landing 404 and navigate step 406 to access 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 found 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 does the floor 412. As a result, the vehicle 500 allows for an increased storage capacity of the storage compartment 510 without having 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, allowing delivery personnel to avoid the effort of climbing both the landing 404 and the step 406 to access the storage compartment 510 of the vehicle 500. Notably, it should be understood that the rear bumper of vehicle 500 may be slightly lower than floor 512, allowing a delivery person to access 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 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, and 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, and 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, and 150 are embodied as or otherwise comprise a Class 3 truck. In one particular example, in some embodiments, a 1000 cubic foot (28.3 cubic meter) capacity vehicle 130 weighs approximately 6,500 pounds when empty and has a payload capacity of 6,000 pounds, thereby giving the vehicle 130 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, methods 1000, 1100, and 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] Referring now to FIG. 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 the vehicle with a relatively lightweight structure. 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 (e.g., monocoque structure 200) incorporating composite structure 700 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 the exemplary embodiment, the core 702 is formed from balsa wood and / or one or more of the following non-metallic composite materials: unidirectional fiberglass, multidirectional 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 the exemplary embodiment, the composite structure 700 includes a ply layer 706 that at least partially covers the shell 704.

[0058] It should be appreciated that the composite structure 700 used to form any vehicle monocoque structure 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 offers greater structural simplicity than vehicle structures requiring multiple parts. In another respect, the structural simplicity afforded by the composite structure 700 can facilitate maintenance and improve structural efficiency. In yet another respect, the absence of metal 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 with 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 can 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. Furthermore, it should be understood that like reference numerals in the 800 and 900 series are used to indicate corresponding features of modular system 800 and monocoque structural system 900.

[0060] Exemplary mold system 800 includes a front cage mold unit 810, a rear floor mold unit 820, and a plurality of mid-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 mold units 810, 820, 832, 834, 836 has a mold cavity having a size and shape corresponding to a corresponding feature of monocoque structural system 900, such that the corresponding feature of monocoque structural system 900 is formed after introduction of composite material (e.g., material of composite structure 700) into the mold cavity. Accordingly, front cage unit 810 includes a front cage mold cavity 912 having a size and shape corresponding to front cage 910 (and also front cage 210) of monocoque structural system 900. Rear floor mold unit 820 includes a rear floor mold cavity 922 having a size and shape corresponding to rear floor 920 (and also rear floor 220) of monocoque structural system 900. Intermediate mold units 832, 834, 836 include respective intermediate mold cavities 933, 935, 937, each having a size and shape corresponding to respective intermediate sections 932, 934, 936 (and also intermediate section 230) of 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 positioned contiguously with one of the corresponding middle mold units 832, 834, 836, a fluid coupling can 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 positioned contiguously with the rear floor-type unit 820, a fluid coupling can be established between the front cage cavity 912 and the rear floor-type cavity 922.

[0063] In the exemplary embodiment, rear floor mold cavity 922 of rear floor mold unit 820 has an opening 924 at its front end (i.e., the end closest to one of mid-sections 932, 934, 936 as shown in FIG. 9 ) for establishing a fluid coupling between cavity 922 and another component of mold system 800. Each of mid mold cavities 933, 935, 937 of mid mold units 832, 834, 836 has an opening 938 at its front end (i.e., the end closest to front cage 910 as shown in FIG. 9 ) and an opening 940 at its rear end (i.e., the end closest to rear floor 920 as shown in FIG. 9 ). When one of the intermediate mold units 832, 834, 836 is disposed contiguously 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 contiguously 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 to 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 to and attached to the front 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 cavities 933, 935, 937, and the rear floor cavity 922 are fluidly coupled to one another in a continuous arrangement to establish a continuous monocoque cavity into which 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 structural cavity into which composite material can be introduced to form the monocoque structure as a one-piece monolithic structure.

[0066] In exemplary embodiments, small mid-section unit 832 has a length L1 as suggested by Figure 9. Medium mid-section unit 834, in at least some embodiments, has a length L2 that is longer than length L1. Large mid-section unit 836, in at least some embodiments, has a length L3 that 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 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 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 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] Referring now to FIG. 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 implementation of the blocks described below in the exemplary order of FIG. 10 . However, it should be understood that method 1000 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 and / or in parallel with one another. In some embodiments, method 1000 may be implemented manually by one or more operators. In other embodiments, method 1000 may be embodied as or otherwise include a set of instructions implemented 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 the operator or control system may select any vehicle contemplated by the present disclosure or any monocoque structural configuration associated with a particular vehicle contemplated by the present disclosure to perform block 1002. From block 1002, the method 1000 then proceeds to block 1004.

[0070] In block 1004 of the exemplary method 1000, an 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 rear floor type unit 820 of modular system 800 in block 1006. However, it should be understood that in other embodiments, block 1004 may be implemented by selecting (i) small mid-section type unit 832 (i.e., in block 1008), (ii) medium mid-section type unit (i.e., in block 1010), or (iii) large mid-section type unit 836 (i.e., in block 1012). The selection of one of mid-section types 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 a selected first mold unit to the front cage unit 810 of the modular system 800. It should be understood that to perform block 1014, the selected first mold unit (i.e., the rear floor unit 820) is coupled to the front cage unit 810 such that the front cage cavity 912 is fluidly coupled to the rear floor cavity 922 to at least partially establish a continuous monocoque cavity. Following performance of block 1014, the method 1000 proceeds to block 1016.

[0072] At block 1016 of example method 1000, an operator or control system introduces one or more composite materials (e.g., the composite materials included in composite structure 700) into the continuous monocoque mold cavity formed at block 1014. More particularly, to perform block 1016, at least in some embodiments, the operator or control system performs blocks 1018, 1020, and 1022. At block 1018, the 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 method 1000. At block 1020, the operator or control system places a first material into the continuous monocoque mold cavity. The first material, at least in some embodiments, may include balsa wood and / or plastic. At block 1022, an operator or 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, method 1000 proceeds to block 1024.

[0073] At block 1024 of the exemplary method 1000, an operator or control system cures one or more composite materials within a continuous monocoque mold cavity to form a monocoque structure. To perform block 1024, the operator or control system, in at least some embodiments, can perform blocks 1026, 1028, and 1030. At block 1026, the operator or control system forms a core (e.g., core 702) including the first material introduced at block 1016. At block 1028, the operator or control system forms a shell (e.g., shell 704) including the second material introduced at block 1016, at least partially surrounding the core. At block 1030, the operator or control system forms a laminate (e.g., layer 706) that at least partially covers 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 associated with 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] 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 vehicle contemplated by the present disclosure or any monocoque structural configuration associated with a particular vehicle contemplated by the present disclosure. From block 1102, method 1100 then proceeds to block 1104.

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

[0077] In block 1112 of 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, method 1100 then proceeds to block 1116.

[0078] In block 1116 of the exemplary method 1100, an operator or control system couples a selected first mold unit to the front cage unit 810 of the modular system 800. It should be understood that to perform block 1116, the selected first mold unit (i.e., one of the intermediate 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 intermediate mold unit cavity (i.e., one of the cavities 933, 935, 937) to at least partially establish a continuous monocoque structural 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 mid-mold units 832, 834, 836) to a selected second mold unit (i.e., rear-floor mold unit 820). It should be understood that to perform block 1118, one of mid-mold units 832, 834, 836 is coupled to rear-floor mold unit 820 such that rear-floor mold cavity 922 is fluidly coupled to a corresponding mid-mold unit cavity (i.e., one of cavities 933, 935, 937) to at least partially establish a continuous monocoque structural mold cavity. Following performance of block 1118, the method 1100 proceeds to block 1120.

[0080] At block 1120 of example method 1100, an operator or control system introduces one or more composite materials (e.g., the composite materials included in composite structure 700) into the continuous monocoque mold cavity formed at block 1118. More specifically, to perform block 1120, at least some embodiments, the operator or control system performs blocks 1122, 1124, and 1126. At block 1122, the 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 method 1100. At block 1124, the operator or control system places a first material into the continuous monocoque mold cavity. The first material, at least some embodiments, may include balsa wood and / or plastic. At block 1126, an operator or 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 example method 1100, an operator or control system cures one or more composite materials within a continuous monocoque mold cavity to form a monocoque structure. To perform block 1202, the operator or control system, in at least some embodiments, can perform blocks 1204, 1206, and 1208. 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) that at least partially covers the shell.

[0082] Referring now to FIG. 13 , an example method 1300 for forming multiple monocoque structures for a land vehicle using at least one modular system is shown. Method 1300 corresponds to or is otherwise associated with the implementation of the blocks described below in the example order of FIG. 13 . However, it should be understood that method 1300 may be implemented in one or more orders different from the example 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 1300 may be implemented manually by one or more operators. In other embodiments, 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 unit 810 and the rear floor unit 820 of the modular system 800. In these embodiments, the first monocoque structure for the first land vehicle may be formed by implementing method 1000 described above. In other embodiments, the first monocoque structure for the first land vehicle is formed using the front cage unit 810, the rear floor unit 820, and one of the intermediate units 832, 834, and 836. In these examples, the first monocoque structure of the first land vehicle may be formed by performing the above-described method 1100. In either case, following performance of block 1302, method 1300 proceeds to block 1306.

[0084] In block 1306 of exemplary method 1300, an operator or control system forms a second monocoque structure 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 unit 810 and the rear floor 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 unit 810, the rear floor unit 820, and one of the intermediate units 832, 834, 836 (i.e., according to method 1100). In embodiments in which 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 one of intermediate units 832, 834, 836 (i.e., according to method 1100), a second monocoque structure for a second land vehicle is formed using a front cage-type unit 810, a rear floor-type unit 820, and a second one of intermediate units 832, 834, 836 that is different from the first one. In either embodiment, from block 1306, method 1300 then proceeds to block 1310.

[0085] In block 1310 of example method 1300, an operator or control system forms a third monocoque structure for a third land vehicle that is 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 for a first land vehicle is formed in block 1302 using only the front cage unit 810 and the rear floor unit 820 of the modular system 800 (i.e., according to method 1000), and (ii) a second monocoque structure for a second land vehicle is formed in block 1306 using the front cage unit 810, the rear floor unit 820, and a first of the intermediate units 832, 834, 836 (i.e., according to method 1100), a third monocoque structure for a third land vehicle is formed using the front cage unit 810, the rear floor unit 820, and a second of the intermediate units 832, 834, 836 that is different from the first. 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 one of intermediate 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 one of intermediate units 832, 834, 836 that is different from the first, a third monocoque structure for a third land vehicle is formed using a front cage-type unit 810, a rear floor-type unit 820, and a third one of intermediate 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 exemplary embodiments thereof have been shown and described, and that all changes and modifications that come within the scope of the disclosure are desired to be protected.

Claims

1. A land vehicle, a monocoque structure supporting a plurality of wheels for enabling movement of the land vehicle relative to an underlying surface during use of the vehicle, the monocoque structure being a one-piece monolithic structure not supported by an internal chassis, the monocoque structure including a front cage defining an operator's cabin and a rear floor positioned rearward of the front cage, the monocoque structure having a composite structure such that each of the front cage and the rear floor is formed from one or more composite materials; The monocoque structure is formed by a modular system, the modular system comprising: a front cage-type unit including a front cage-type cavity having a size and shape corresponding to the front cage of the monocoque structure, the front cage-type unit having an opening at a rear end thereof for establishing a fluid connection between the front cage-type cavity and another component of the system; a rear floor type unit including a rear floor type cavity having a size and shape corresponding to the rear floor of the monocoque structure, the rear floor type unit having an opening at a front end thereof for establishing a fluid connection between the rear floor type cavity and another component of the system; and at least one of a plurality of intermediate mold units, each of which is sized to be positioned between the front cage-type unit and the rear floor-type unit and includes an intermediate mold cavity having a size and shape corresponding to an intermediate section of the monocoque structure positioned between the front cage and the rear floor, the intermediate mold unit having a front opening at a front end thereof for establishing a fluid connection between the intermediate mold cavity and the front cage-type cavity, and a rear opening at a rear end thereof for establishing a fluid connection between the intermediate mold cavity and the rear floor-type cavity.

2. 10. The land vehicle of claim 1, wherein the monocoque structure does not include metal materials, the monocoque structure including a core and a shell at least partially surrounding the core, the core being formed from one or more lightweight, low-density materials, and the shell being formed from resin and fiberglass.

3. The land vehicle of claim 2 , wherein the core comprises balsa wood.

4. The land vehicle of claim 3 , wherein the core comprises one or more of fiberglass, Kevlar, carbon fiber, or plastic.

5. The land vehicle of claim 4 , wherein the monocoque structure includes a laminate at least partially encasing the shell.

6. 2. The land vehicle of claim 1, wherein the monocoque structure includes the mid-section disposed between the front cage and the rear floor, the vehicle includes a storage compartment defined at least in part by the mid-section and the rear floor, the storage compartment having a plurality of side walls and a ceiling, the mid-section, the plurality of side walls, and the ceiling each being formed from one or more composite materials, and the mid-section, the plurality of side walls, and the ceiling each being free of metal materials.

7. 7. The land vehicle of claim 6, wherein the storage compartment has a volume of 650 cubic feet, 1000 cubic feet, or 1200 cubic feet.

8. 7. The land vehicle of claim 6, wherein the vehicle has a weight limit of between 4.5 tons (10,001 lbs) and 6.4 tons (14,000 lbs).

9. The land vehicle of claim 6 , further comprising a refrigeration unit at least partially contained by said storage compartment configured to cool said storage compartment.

10. The land vehicle of claim 1 , wherein the vehicle does not include an internal combustion engine.

11. 11. The land vehicle of claim 10, wherein the height of the rear floor above the underlying surface is between 22 inches and 28 inches.

12. 1. A modular system for forming a monocoque structure for a land vehicle, comprising: a front cage-type unit including 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 having an opening at a rear end thereof for establishing a fluid connection between the front cage-type cavity and another component of the system; a rear floor type unit including a rear floor type cavity having a size and shape corresponding to the rear floor of the monocoque structure positioned behind the front cage, the rear floor type unit having an opening at a front end thereof for establishing a fluid connection between the rear floor type cavity and another component of the system; A modular system comprising: a plurality of intermediate mold units, each sized to be positioned between the front cage-type unit and the rear floor-type unit, and each including an intermediate mold cavity having a size and shape corresponding to an intermediate section of the monocoque structure positioned between the front cage and the rear floor, the intermediate mold units having a front opening at a front end for establishing a fluid connection between the intermediate mold cavity and the front cage-type cavity, and a rear opening at a rear end for establishing a fluid connection between the intermediate mold cavity and the rear floor-type cavity.

13. The system of claim 12 , wherein the front end of each of the plurality of mid-type units is configured to connect directly with the rear end of the front cage type unit.

14. 14. The system of claim 13, wherein the rear end of each of the plurality of mid-type units is configured to connect directly with the front end of the rear floor-type unit.

15. 15. The system of claim 14, wherein 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 are fluidly coupled to one another in a continuous arrangement to establish a continuous monocoque structure cavity, and one or more composite materials can be introduced into the cavity to form the monocoque structure as a one-piece monolithic structure.

16. The system of claim 12 , wherein the rear end of the front cage-type unit is configured to connect directly with the front end of the rear floor-type unit.

17. 17. The system of claim 16, wherein when the front cage-type unit is directly connected to the rear floor-type unit, the front cage-type unit and the rear floor-type unit are fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structure-type cavity, and one or more composite materials can be introduced into the cavity to form the monocoque structure as a one-piece monolithic structure.

18. 13. The system of claim 12, wherein the plurality of intermediate units includes a first intermediate unit having a first length, a second intermediate unit having a second length longer than the first length, and a third intermediate unit having a third length longer than the second length.

19. 19. The system of claim 18, wherein the first intermediate unit is sized to form a mid-section of the monocoque structure to be included in a vehicle having a storage volume of 18.4 cubic meters (650 cubic feet), the second intermediate unit is sized to form a mid-section of the monocoque structure to be included in a vehicle having a storage volume of 28.3 cubic meters (1000 cubic feet), and the third intermediate unit is sized to form a mid-section of the monocoque structure to be included in a vehicle having a storage volume of 34 cubic meters (1200 cubic feet).

20. A land vehicle, a monocoque structure supporting a plurality of wheels for enabling movement of the land vehicle relative to an underlying surface during use of the vehicle, the monocoque structure being a one-piece monolithic structure not supported by an internal chassis, the monocoque structure including a front cage defining an operator cabin, a rear floor positioned rearward of the front cage, and a mid-section disposed between the front cage and the rear floor, the monocoque structure including a core formed from balsa wood or plastic, and a shell formed from resin and glass fiber at least partially surrounding the core; The monocoque structure is formed by a modular system, the modular system comprising: a front cage-type unit including a front cage-type cavity having a size and shape corresponding to the front cage of the monocoque structure, the front cage-type unit having an opening at a rear end thereof for establishing a fluid connection between the front cage-type cavity and another component of the system; a rear floor type unit including a rear floor type cavity having a size and shape corresponding to the rear floor of the monocoque structure, the rear floor type unit having an opening at a front end thereof for establishing a fluid connection between the rear floor type cavity and another component of the system; a mid-type unit including an intermediate mold cavity sized to be positioned between the front cage-type unit and the rear floor-type unit and having a size and shape corresponding to the intermediate section of the monocoque structure, the intermediate mold unit having a front opening at a front end of the intermediate mold unit for establishing a fluid coupling between the intermediate mold cavity and the front cage-type cavity, and a rear opening at a rear end of the intermediate mold unit for establishing a fluid coupling between the intermediate mold cavity and the rear floor-type cavity.

21. A land vehicle, a monocoque structure supporting a plurality of wheels for enabling movement of the land vehicle relative to an underlying surface during use of the vehicle, the monocoque structure being a one-piece monolithic structure not supported by an internal chassis, the monocoque structure including a front cage defining an operator's cabin and a rear floor positioned rearward of the front cage, the monocoque structure having a composite structure such that each of the front cage and the rear floor is formed from one or more composite materials, the monocoque structure not including any metal material; The monocoque structure is formed by a modular system, the modular system comprising: a front cage-type unit including a front cage-type cavity having a size and shape corresponding to the front cage of the monocoque structure, the front cage-type unit having an opening at a rear end thereof for establishing a fluid connection between the front cage-type cavity and another component of the system; a rear floor type unit including a rear floor type cavity having a size and shape corresponding to the rear floor of the monocoque structure, the rear floor type unit having an opening at a front end thereof for establishing a fluid connection between the rear floor type cavity and another component of the system; and at least one of a plurality of intermediate mold units, each of which is sized to be positioned between the front cage-type unit and the rear floor-type unit and includes an intermediate mold cavity having a size and shape corresponding to an intermediate section of the monocoque structure positioned between the front cage and the rear floor, the intermediate mold unit having a front opening at a front end thereof for establishing a fluid connection between the intermediate mold cavity and the front cage-type cavity, and a rear opening at a rear end thereof for establishing a fluid connection between the intermediate mold cavity and the rear floor-type cavity.

22. 22. The land vehicle of claim 21, wherein the monocoque structure includes a core and a shell at least partially surrounding the core, the core being formed from balsa wood and plastic, and the shell being formed from resin and fiberglass.

23. 23. The land vehicle of claim 22, wherein the monocoque structure includes the mid-section disposed between the front cage and the rear floor, and the vehicle includes a storage compartment defined at least in part by the mid-section and the rear floor, the storage compartment having a plurality of side walls and a ceiling, wherein each of the mid-section, the plurality of side walls, and the ceiling are formed from one or more composite materials, and wherein each of the mid-section, the plurality of side walls, and the ceiling is free of metal materials.

24. 24. The land vehicle of claim 23, wherein the vehicle does not include an internal combustion engine.

25. 25. The land vehicle of claim 24, wherein the height of the rear floor above the underlying surface is between 22 inches and 28 inches.

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