Method for fabricating a monocoque structure for land vehicles using a modular system

Abstract

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

Description

【Technical Field】 【0001】 This application claims the priority and benefit of U.S. Provisional Patent Application No. 62 / 957,577, filed on January 6, 2020, entitled "SYSTEMS AND METHODS FOR MANUFACTURING LAND VEHICLES". The content of this application is hereby incorporated by reference in its entirety. 【0002】 This disclosure generally relates to land vehicles and methods of manufacturing land vehicles, and more particularly to all-terrain vehicles and delivery vehicles, and methods of manufacturing all-terrain vehicles and delivery vehicles. 【Background Art】 【0003】 Current systems and methods for manufacturing all-terrain vehicles and delivery vehicles have various drawbacks and limitations. For these reasons in particular, further improvements are still needed in this technical field. 【Summary of the Invention】 【Means for Solving the Problems】 【0004】 This disclosure can include one or more of the following features and combinations thereof. 【0005】 According to one aspect of this disclosure, a land vehicle can include a monocoque structure that supports a plurality of wheels for enabling movement of the vehicle relative to a surface beneath the vehicle during use of the land vehicle. The monocoque structure can be an integral, monolithic structure not supported by an internal chassis. The monocoque structure can include a front cage that defines an operator cabin and a rear floor positioned behind the front cage. The monocoque structure can have a composite structure such that each of the front cage and the rear floor is formed from one or more composite materials. 【0006】 In some embodiments, the monocoque structure may not include metal materials, and may include a core and a shell that at least partially surrounds the core, the core may be formed from one or more lightweight, low-density materials, and the shell may be formed from resin and glass fiber. The core may include balsa wood. The core may include plastic. The monocoque structure may include a laminate that at least partially covers the shell. 【0007】 In some embodiments, the monocoque structure may include an intermediate section positioned between the front cage and the rear floor, and the vehicle may include a storage compartment having multiple side walls and a ceiling, at least partially defined by the intermediate section and the rear floor, each of which the intermediate section, multiple side walls, and ceiling may be formed from one or more composite materials, and each of which may not include metal material. The storage compartment may 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 may 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 may include a refrigeration unit configured to cool the storage compartment, at least partially housed by the storage compartment. 【0008】 In some embodiments, the vehicle may not include an internal combustion engine. The height of the rear floor above the surface below may be between 55.9 cm (22 inches) and 71.1 cm (28 inches). 【0009】 According to another aspect of the present disclosure, a modular system for forming a monocoque structure of a land vehicle may include a front cage unit, a rear floor unit, and a plurality of intermediate units. The front cage unit may include a front cage cavity having a size and shape corresponding to a front cage of a monocoque structure defining an operator's cabin. The front cage unit may have an opening at its rear end for establishing a fluid coupling between the front cage cavity and another component of the system. The rear floor unit may include a rear floor cavity having a size and shape corresponding to a rear floor of a monocoque structure positioned behind the front cage. The rear floor unit may have an opening at its front end for establishing a fluid coupling between the rear floor cavity and another component of the system. Each of the plurality of intermediate units may be sized to be positioned between the front cage unit and the rear floor unit. Each of the plurality of intermediate units may include an intermediate cavity having a size and shape corresponding to an intermediate section of a monocoque structure positioned between the front cage and the rear floor. Each of the intermediate units may have a front opening at its front end for establishing a fluid coupling between the intermediate cavity and the front cage cavity, and a rear opening at the rear end of the intermediate unit for establishing a fluid coupling between the intermediate cavity and the rear floor cavity. 【0010】 In some embodiments, the front end of each of the multiple intermediate units may be configured to connect directly to the rear end of the front cage unit. The rear end of each of the multiple intermediate units may be configured to connect directly to the front end of the rear floor unit. When any one of the intermediate units is directly connected to the front cage unit and the rear floor unit, the front cage cavity, the intermediate cavity, and the rear floor cavity can be fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structure cavity into which one or more composite materials can be introduced to form a monocoque structure as a single, integrated monolithic structure. 【0011】 In some embodiments, the rear end of the front cage unit may be configured to connect directly to the front end of the rear floor unit. When the front cage unit is directly connected to the rear floor unit, the front cage unit and the rear floor unit can be fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structure cavity, into which one or more composite materials can be introduced to form a monocoque structure as a single, integrated monolithic structure. 【0012】 In some embodiments, the intermediate units may 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 may be sized to form an intermediate section of a monocoque structure contained within a vehicle having a storage volume of 18.4 cubic meters (650 cubic feet), the second intermediate unit may be sized to form an intermediate section of a monocoque structure contained within a vehicle having a storage volume of 28.3 cubic meters (1000 cubic feet), and the third intermediate unit may be sized to form an intermediate section of a monocoque structure contained within a vehicle having a storage volume of 34 cubic meters (1200 cubic feet). 【0013】 According to yet another aspect of this disclosure, a land vehicle may include a monocoque structure supporting a plurality of wheels to allow the vehicle to move toward a surface below 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's cabin, a rear floor positioned behind 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 that at least partially surrounds 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 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 unit may include a rear floor cavity having a size and shape corresponding to the rear floor of a monocoque structure. The rear floor unit may have an opening at its front end for establishing a fluid coupling between the rear floor cavity and another component of the system. The intermediate unit may be sized to be positioned between the front cage unit and the rear floor unit. The intermediate unit may include an intermediate cavity having a size and shape corresponding to the intermediate section of a monocoque structure. The intermediate unit may have a front opening at its front end for establishing a fluid coupling between the intermediate cavity and the front cage cavity, and a rear opening at the rear end of the intermediate unit for establishing a fluid coupling between the intermediate cavity and the rear floor cavity. 【0014】 Also according to yet another aspect of the present disclosure, a method for forming a monocoque structure of a land vehicle using a modular system may include: selecting a monocoque structure configuration for a land vehicle; selecting a first mold unit of the modular system based on the selected monocoque structure configuration; coupling the selected first mold unit to the front cage mold unit of the modular system such that the front cage mold cavity of the front cage mold unit is fluidly coupled to the mold cavity of the selected first mold unit to at least partially establish a continuous monocoque structure mold cavity; introducing one or more composite materials into the continuous monocoque structure mold cavity; and curing one or more composite materials within the continuous monocoque structure mold cavity to form a monocoque structure. 【0015】 In some embodiments, introducing one or more composite materials into a continuous monocoque structural cavity may include introducing one or more composite materials into a continuous monocoque structural cavity without introducing any metallic materials into the continuous monocoque structural cavity. Additionally, in some embodiments, a front cage type unit of the modular system may correspond to a monocoque structural front cage defining the operator's cabin of the vehicle, and a selected first type unit of the modular system may correspond to a monocoque structural rear floor positioned behind the front cage. 【0016】 In some embodiments, introducing one or more composite materials into a continuous monocoque structure cavity may include placing a first material within the continuous monocoque structure cavity and placing a second material different from the first material within the continuous monocoque structure cavity. The first material may include balsa wood or plastic, and the second material may include glass fiber and resin. Curing one or more composite materials within a continuous monocoque structure cavity may include forming a core containing the first material and forming a shell containing the second material that at least partially surrounds the core. 【0017】 In some embodiments, a front cage type unit of the modular system may correspond to a front cage of a monocoque structure defining the operator's cabin of the vehicle, and a selected first type unit of the modular system may correspond to an intermediate section of a monocoque structure located behind the front cage. The method may further include selecting a second type unit of the modular system corresponding to a rear floor of a monocoque structure located behind the front cage and intermediate section, based on a selected monocoque structure configuration, and coupling the selected first type unit to the selected second type unit such that the front cage type cavity of the front cage type unit, the cavity of the selected first type unit, and the type cavity of the selected second type unit are fluidly coupled to each other to establish a continuous monocoque structure type cavity. Selecting a first type unit of a modular system may include selecting one of the following: a small intermediate section type unit of a modular system having a first length; a medium intermediate section type unit of a modular system having a second length longer than the first length; and a large intermediate section type unit of a modular system having a third length longer than the second length. 【0018】 According to another aspect of the present disclosure, a method for forming multiple monocoque structures of a land vehicle using at least one modular system is as follows: selecting a first monocoque structure configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of at least one modular system based on the selected first monocoque structure configuration; coupling the selected first mold unit to the front cage mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit is fluidly coupled to the mold cavity of the selected first mold unit to form at least partially a first continuous monocoque structure mold cavity; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or more composite materials in the first continuous monocoque structure mold cavity to form a first monocoque structure; and forming a second monocoque structure of a second land vehicle different from the first land vehicle. The present invention may include selecting a second monocoque structural configuration of a buck structure, selecting a first mold unit of at least one modular system that is different from a selected first mold unit of at least one modular system based on the selected second monocoque structural configuration, coupling a selected first mold unit of at least one modular system to a front cage mold unit of at least one modular system such that the front cage mold cavity of a front cage mold unit of at least one modular system is fluidly coupled to the mold cavity of a selected first mold unit of 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 one or more composite materials within the second continuous monocoque structural mold cavity to form the second monocoque structure. 【0019】 In some embodiments, introducing one or more composite materials into a first continuous monocoque structural cavity may include introducing one or more composite materials into the first continuous monocoque structural cavity without introducing a metallic material into the first continuous monocoque structural cavity, and introducing one or more composite materials into a second continuous monocoque structural cavity may include introducing one or more composite materials into the second continuous monocoque structural cavity without introducing a metallic material into the second continuous monocoque structural cavity. 【0020】 In some embodiments, introducing one or more composite materials into a first continuous monocoque structural cavity may include placing the first material in the first continuous monocoque structural cavity and placing a second material different from the first material in the first continuous monocoque structural cavity, and introducing one or more composite materials into a second continuous monocoque structural cavity may include placing the first material in the second continuous monocoque structural cavity and placing the second material in the second continuous monocoque structural cavity. The first material may include balsa wood or plastic, and the second material may include glass fiber and resin. Curing one or more composite materials in a first continuous monocoque structure cavity may include forming a core of a first monocoque structure containing the first material and forming a shell of a first monocoque structure containing a second material that at least partially surrounds the core of the first monocoque structure, and curing one or more composite materials in a second continuous monocoque structure cavity may include forming a core of a second monocoque structure containing the first material and forming a shell of a second monocoque structure containing the second material that at least partially surrounds the core of the second monocoque structure. 【0021】 In some embodiments, at least one front cage type unit of the modular system can correspond to a front cage of a first monocoque structure defining the operator cabin of a first land vehicle, a selected first type unit of the modular system can correspond to a rear floor of a first monocoque structure positioned behind the front cage of the first monocoque structure, a front cage type unit of the modular system can correspond to a front cage of a second monocoque structure defining the operator cabin of a second land vehicle, and a selected first type unit of the modular system can correspond to an intermediate section of a second monocoque structure positioned behind the front cage of the second monocoque structure. 【0022】 In some embodiments, the method may further include selecting a second mold unit of at least one modular system that corresponds to the front cage and rear section of the second monocoque structure, based on a selected second monocoque structure configuration, and coupling the selected first mold unit of at least one modular system to the selected second mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit of at least one modular system, the cavity of a selected first mold unit of at least one modular system, and the mold cavity of a selected second mold unit of at least one modular system are fluidly coupled to each other to establish a second continuous monocoque structure mold cavity. Selecting a first type unit of at least one modular system may include selecting one of the following: a small intermediate section type unit of at least one modular system having a first length; a medium intermediate section type unit of at least one modular system having a second length longer than the first length; and a large intermediate section type unit of at least one modular system having a third length longer than the second length. 【0023】 In some embodiments, at least one front cage type unit of a modular system can correspond to a front cage of a first monocoque structure defining the operator cabin of a first land vehicle, and a selected first type unit of at least one modular system can correspond to an intermediate section of a first monocoque structure having a first length and positioned behind the front cage of the first monocoque structure, and at least one front cage type unit of a modular system can correspond to a front cage of a second monocoque structure defining the operator cabin of a second land vehicle, and a selected first type unit of at least one modular system can correspond to an intermediate section of a second monocoque structure having a second length different from the first length and positioned behind the front cage of the second monocoque structure.The method is as follows: Selecting a second mold unit of at least one modular system corresponding to the rear floor of the first monocoque structure, positioned behind the front cage and intermediate section of the first monocoque structure, based on a selected first monocoque structure configuration; and coupling the selected first mold unit of at least one modular system to the selected second mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit of at least one modular system, the cavity of the selected first mold unit of at least one modular system, and the mold cavity of the selected second mold unit of at least one modular system are fluidly coupled to each other to establish a first continuous monocoque structure mold cavity; Based on the second monocoque structure configuration, the present invention may further include selecting a second mold unit of at least one modular system corresponding to the front cage and rear section of the second monocoque structure, and coupling the selected first mold unit of at least one modular system to the selected second mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit of at least one modular system, the cavity of the selected first mold unit of at least one modular system, and the mold cavity of the selected second mold unit of 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 this disclosure, a method for forming multiple monocoque structures of a land vehicle using at least one modular system is as follows: selecting a first monocoque structure configuration for a first monocoque structure of a first land vehicle; selecting a first mold unit of at least one modular system based on the selected first monocoque structure configuration; coupling the selected first mold unit to the front cage mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit is fluidly coupled to the mold cavity of the selected first mold unit to at least partially establish a first continuous monocoque structure mold cavity; introducing one or more composite materials into the first continuous monocoque structure mold cavity; curing one or more composite materials in the first continuous monocoque structure mold cavity to form a first monocoque structure; selecting a second monocoque structure configuration for a second monocoque structure of a second land vehicle different from the first land vehicle; and selecting the selected second mo Based on the monocoque structural configuration, the selection of a first mold unit of at least one modular system that is different from a selected first mold unit of at least one modular system; coupling a selected first mold unit of at least one modular system to a front cage mold unit of at least one modular system such that the front cage mold cavity of a front cage mold unit of at least one modular system is fluidly coupled to the mold cavity of a selected first mold unit of 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 one or more composite materials within 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 a first land vehicle and a second land vehicle; and based on the selected third monocoque structural configuration,This may include selecting a selected first mold unit of at least one modular system and a first mold unit of at least one modular system that is different from the selected first mold unit of at least one modular system; coupling the selected first mold unit of at least one modular system to the front cage mold unit of at least one modular system such that the front cage mold cavity of the front cage mold unit of at least one modular system is fluidly coupled to the mold cavity of the selected first mold unit of 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 one or more composite materials within the third continuous monocoque structural mold cavity to form the third monocoque structure. 【0025】 Furthermore, according to another aspect of the present disclosure, a method for forming a monocoque structure of a land vehicle using a modular system includes: selecting a monocoque structure configuration for a land vehicle; selecting a first mold unit of the modular system based on the selected monocoque structure configuration; coupling the selected first mold unit to the front cage mold unit of the modular system such that the front cage mold cavity of the front cage mold unit is fluidly coupled to the mold cavity of the selected first mold unit to at least partially establish a continuous monocoque structure mold cavity; introducing one or more composite materials into the continuous monocoque structure mold cavity; and curing one or more composite materials within the continuous monocoque structure mold cavity to form a monocoque structure. Introducing one or more composite materials into the continuous monocoque structure mold cavity may include introducing one or more composite materials into the continuous monocoque structure mold cavity without introducing any metallic materials into the continuous monocoque structure mold cavity. Introducing one or more composite materials into a continuous monocoque structure cavity may include placing a first material, including balsa wood or plastic, within the continuous monocoque structure cavity, and placing a second material, including glass fiber and resin, within the continuous monocoque structure cavity. 【0026】 In some embodiments, curing one or more composite materials within a continuous monocoque-structured cavity can include forming a core that includes a first material and forming a shell that includes a second material and at least partially surrounds the core. A front-cage-type unit of a modular system can correspond to a front cage of a monocoque structure that defines an operator cabin of a vehicle, and a selected first-type unit of the modular system can correspond to an intermediate section of the monocoque structure positioned behind the front cage. The method can include selecting a second-type unit of the modular system that corresponds to a rear floor of the monocoque structure positioned behind the front cage and the intermediate section, based on a selected monocoque structure configuration, and coupling the selected first-type unit to the selected second-type unit such that a front-cage-type cavity of the front-cage-type unit, a cavity of the selected first-type unit, and a type cavity of the selected second-type unit are fluidly coupled to each other to establish a continuous monocoque-structured cavity. Selecting a first-type unit of the modular system can include selecting one of a small intermediate-section-type unit of the modular system having a first length, a medium intermediate-section-type unit of the modular system having a second length longer than the first length, and a large intermediate-section-type unit of the modular system having a third length longer than the second length. 【0027】 These and other features of the present disclosure will become more apparent from the following description of the exemplary embodiments. 【0028】 The invention described herein is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. For the sake of brevity and clarity of explanation, the elements shown in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, reference numerals may be repeated in the figures to indicate corresponding or similar elements where appropriate. 【Brief Description of the Drawings】 【0029】 [Figure 1] Side views of several electric vehicles that can be included within a vehicle type of an electric vehicle, according to a particular embodiment of the present disclosure. [Figure 2] A perspective view of a monocoque structure or unibody that can be incorporated into any electric vehicle of the present disclosure. [Figure 3] A partially exploded assembly view of an electric vehicle according to at least one embodiment of the present disclosure. [Figure 4] A partial schematic rear view of a conventional delivery vehicle. [Figure 5] A partial schematic rear view of a delivery vehicle according to at least one embodiment of the present disclosure. [Figure 6] A table showing the US standard vehicle classes according to the gross vehicle weight rating (GVWR). [Figure 7] A partial schematic view of a composite structure that can be used to form a monocoque structure or unibody of any electric vehicle of the present disclosure. [Figure 8] A diagram of at least one modular type system according to a particular embodiment of the present disclosure. [Figure 9] A perspective view of a monocoque structure system formed from several type units included within at least one modular type system of FIG. 8. [Figure 10] A simplified flowchart of a method of forming a monocoque structure of an electric vehicle using one modular type system, according to one embodiment of the present disclosure. [Figure 11] A simplified flowchart of a part of another method of forming a monocoque structure of an electric vehicle using one modular type system, according to another embodiment of the present disclosure. [Figure 12] A diagram of another part of the method of FIG. 11. [Figure 13]This is a simplified flowchart of a method for forming multiple monocoque structures of an electric vehicle using at least one modular system, according to yet another embodiment of the present disclosure. [Modes for carrying out the invention] 【0030】 While the concepts of this disclosure allow for various modifications and alternative forms, specific embodiments are illustrated in the figures and described in detail herein. However, it should be understood that there is no intention to limit the concepts of this disclosure to any particular form, but rather to cover all modifications, equivalents, and alternative forms that are consistent with this disclosure and the accompanying claims. 【0031】 References in this specification to “one example,” “one embodiment,” “exemplary example,” etc., indicate that the example described may include a particular feature, structure, or characteristic, but all examples may include or not include that particular feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same example. Moreover, when a particular feature, structure, or characteristic is described in relation to one example, it is considered within the knowledge of those skilled in the art to make such feature, structure, or characteristic effective in relation to other examples, whether or not it is explicitly stated. Additionally, it should be understood that items included in the list in the form of “at least one A, B, and C” can mean (A);(B);(C), (A and B);(A and C);(B and C), or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A);(B);(C), (A and B);(A and C);(B and C), or (A, B, and C). 【0032】 In the diagrams, certain structural or method features, such as those representing devices, modules, instruction blocks, and data elements, may be shown in a specific arrangement and / or order for the sake of clarity. However, it should be understood that such a specific arrangement and / or order is not required. Rather, in some embodiments, such features may be arranged in a different way and / or order than those shown in the illustrative diagrams. Additionally, the inclusion of structural or method features within a particular diagram is intended to indicate that such features are not required in all embodiments, and may be omitted or combined with other features in some embodiments. 【0033】 In some embodiments, schematic elements used to represent blocks of a method may be implemented manually by the user. In other embodiments, the implementation of these schematic elements may be automated using any suitable form of machine-readable instruction, such as software or firmware applications, programs, functions, modules, routines, processes, procedures, plug-ins, applets, widgets, code fragments, and / or others, each of which may be implemented using any suitable programming language, library, application programming interface (API), and / or other software development tool. For example, in some embodiments, schematic elements may be implemented using Java®, C++, and / or other programming languages. Similarly, schematic elements used to represent data or information may be implemented using any suitable electronic arrangement or structure, such as 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, if in a figure connecting elements such as solid or dotted lines or arrows are used to indicate connections, relationships, or associations between or within two or more other schematic elements, the absence of such connecting elements does not mean that connections, relationships, or associations cannot exist. In other words, any connections, relationships, or associations between elements may not be shown in the figure so as not to obscure the present disclosure. In addition, for the sake of illustration, a single connecting element may be used to represent multiple connections, relationships, or associations between elements. For example, if a connecting element represents the communication of signals, data, or instructions, a person skilled in the art will understand that such an element may represent one or more signal paths (e.g., buses) if necessary to enable the communication. 【0035】 Referring next to Figure 1, the exemplary type of land vehicle 100 includes several land vehicles. In exemplary embodiments, the type of land vehicle 100 includes, but is not limited to, a two-occupant flatbed multi-purpose vehicle 110, an 18.4 cubic meter (650 cubic feet) capacity delivery vehicle 120, a 28.3 cubic meter (1000 cubic feet) capacity delivery vehicle 130, a six-occupant flatbed multi-purpose vehicle 140, and a 34 cubic meter (1200 cubic feet) capacity delivery vehicle 150. However, in some embodiments, the type of land vehicle 100 may include any vehicle having a capacity within a specific range, such as from 11.3 cubic meters (400 cubic feet) to 39.6 cubic meters (1400 cubic feet). To conform to industrial terminology, the phrase “cubic meter (cubic foot) capacity” may be abbreviated or shortened to simply “cube”. It should be understood that the term “cubic meter (cubic foot) capacity” as intended herein may refer to the storage volume or capacity of a particular land vehicle. In any case, as will become apparent from the subsequent discussion, one or more of the vehicle types 100 may be manufactured using the systems and methods described herein. 【0036】 In exemplary embodiments, each of the vehicles included within the vehicle type 100 (i.e., each of vehicles 110, 120, 130, 140, and 150) includes a monocoque structure or unibody 200 (see Figure 2) that supports wheels (e.g., wheels 112, 122, 132, 142, and 152) to allow the movement of a particular vehicle relative to a surface below during use. As described herein, the monocoque structure 200 is a one-piece monolithic structure not supported by an internal chassis. The monocoque structure 200 includes a front cage 210 defining an operator's cabin 212 and a rear floor 220 positioned behind the front cage 210. The monocoque structure 200 exemplary has a composite structure (e.g., a composite structure 700 shown in Figure 7) such that each of the front cage 210 and the rear floor 220 is formed from one or more composite materials, as will be described in more detail below. 【0037】 At least some of the exemplary vehicles of model 100 (e.g., vehicles 110, 140) may be embodied as electric all-purpose vehicles, may be included in such vehicles, or may be otherwise adapted for use in such vehicles. Furthermore, at least some of the exemplary vehicles of model 100 (e.g., vehicles 120, 130, 150) may be embodied as electric vehicles having enclosed storage compartments, may be included in such vehicles, or may be otherwise adapted for use in such vehicles. Naturally, it should be understood that in other embodiments, vehicles of model 100 may be embodied as other suitable vehicles, may be included in such vehicles, or may be otherwise adapted for use in such vehicles. 【0038】 It should be understood that each of the 100 vehicle types can be used for a variety of purposes. In some embodiments, one or more of the 100 vehicle types may be embodied, or otherwise included, as, to name a few, a fire and emergency vehicle, a garbage truck, a coach vehicle, a recreational vehicle or camper van, a local and / or public service vehicle, an agricultural vehicle, a mining vehicle, a special vehicle, an energy vehicle, a defense vehicle, a port service vehicle, a construction vehicle, and a transport and / or bus vehicle. In addition, in some embodiments, one or more of the 100 vehicle types may be equipped with, among other suitable devices, a tractor, a front-end loader, a scraper system, a cutter and It may be adapted for use with, or otherwise incorporated into, shredders, hay and fertilizer equipment, planting equipment, seeding equipment, sprayers and applicators, tilling equipment, multi-purpose vehicles, lawnmowers, dump trucks, backhoes, truck loaders, crawler loaders, bulldozers, excavators, motor graders, skid steers, tractor loaders, wheel loaders, rakes, aerators, skidders, tying machines, forwarders, harvesters, swing machines, knuckle boom loaders, diesel engines, axles, planetary gear mechanisms, pump drives, transmissions, generators, and marine engines. 【0039】 In exemplary embodiments, each of the vehicle types 100 includes one or more electric motors (not shown) capable of generating rotational forces that can be transmitted to the wheels to drive the movement of the vehicle. Thus, each of the exemplary vehicles is embodied as an electric vehicle or otherwise includes it. Details relating to the electric motors and associated powertrain and / or suspension components contained within each vehicle are described in concurrently pending U.S. Patent Application No. XX / XXX,XXX, which is incorporated herein by reference in whole. 【0040】 Each of the exemplary vehicle types 100 does not include an internal combustion engine or generator in at least some embodiments. Furthermore, each of the exemplary vehicle types 100 does not include an engine or generator housed by a front cage 210 and positioned above the lower surface 214 of the monocoque structure 200. Instead, as described in concurrently pending U.S. Patent Application No. XX / XXX, XXX, multiple electric motors or generators are detachably coupled to the lower surface 214 of the monocoque structure 200 of each of the exemplary vehicle types 100. 【0041】 It should be understood that each of the 100 exemplary vehicle models may include one or more features that enhance the experience of the driver, owner, and / or maintenance personnel. Such features may include, but are not limited to, a low floor, a modular battery system, air springs 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 easy maintenance, aerodynamic body, and advanced safety systems. Further details regarding at least some of these features are provided herein. 【0042】 Referring to Figure 2, in addition to the front cage 210 and rear floor 220, in at least some embodiments, the monocoque structure 200 includes an intermediate section 230 positioned between the front cage 210 and the rear floor 220. The intermediate section 230 can form part of a floor section positioned in front of the rear floor 220. As will be described in more detail below with reference to Figure 8, each of the front cage 210, the rear floor 220, and the intermediate section 230 can be associated with and formed using a corresponding mold unit of a modular mold system (e.g., system 800). Furthermore, as will be described in more detail below with reference to Figure 9, the mold units of the modular mold system can be joined together to form a monocoque structure mold (e.g., monocoque structure mold 900), and composite materials can be introduced into that mold to form the monocoque structure 200. 【0043】 In exemplary embodiments, the monocoque structure 200 combines what would conventionally be formed from one or more separate structures (e.g., one or more body components and one or more frame components) into a single, monolithic structure. Therefore, none of the vehicles of this disclosure incorporating the monocoque structure 200 include an internal chassis or frame structure supporting separate body components (e.g., panels, doors, etc.). By integrating the body and frame structures into a single, integrally formed structure, at least in part, the exemplary monocoque structure 200 can be associated with improved productivity and / or simplified maintenance compared to other configurations, or can be facilitated in other ways. 【0044】 Depending on the specific vehicle type and monocoque structure configuration, one or more dimensions of the intermediate section 230 of the monocoque structure 200 may be variable. In one example, the intermediate section 230 may have a first length defined by being associated with a small intermediate section type unit (e.g., type unit 832 shown in Figure 8). In this example, the first length of the intermediate section 230 can at least partially define a storage compartment for an 18.4 cubic meter (650 cubic feet) delivery vehicle (e.g., vehicle 120). In another example, the intermediate section 230 may have a second length defined by being associated with a medium intermediate section type unit (e.g., type unit 834 shown in Figure 8). In this example, the second length of the intermediate section 230 can at least partially define a storage compartment for an 28.3 cubic meter (1000 cubic feet) delivery vehicle (e.g., vehicle 130). In yet another example, the intermediate section 230 may be associated with a larger intermediate section type unit (for example, type unit 836 shown in Figure 8) and have a third length defined thereby. In this example, the third length of the intermediate section 230 can at least partially define a storage compartment for a 34 cubic meter (1200 cubic feet) delivery vehicle (for example, vehicle 150). 【0045】 Furthermore, depending on the specific vehicle type and monocoque structure configuration, the intermediate section 230 of the monocoque structure 200 may be completely omitted. In such embodiments, the front cage 210 and rear floor 220 may be integrally formed as a single monolithic structure without the intermediate section 230 interposed between them. It should be understood that the universal vehicles 110 and 140 each may, in at least some embodiments, include a monocoque structure formed without the intermediate section 230. 【0046】 Referring next to Figure 3, the vehicle 300 incorporates a monocoque structure 200 in which an intermediate section 230 is positioned between the front cage 210 and the rear floor 220. Additionally, the vehicle 300 includes a cab hood 302 positioned above the front cage 210 to enclose the operator cabin 212, and a storage compartment 310 positioned behind the front cage 210 and the cab hood 302. In an exemplary embodiment, the storage compartment 310 is at least partially defined by the intermediate section 230 and the rear floor 220 and has a roof 312 and side walls 314. The exemplary vehicle 300 may, in at least some embodiments, be similar to any one of the vehicles 120, 130, and 150 discussed above. 【0047】 Since the monocoque structure 200 has a composite structure as described above, it should be understood that any vehicle described herein (for example, any of vehicles 110, 120, 130, 140, 150, 300, or 500) that incorporates the monocoque structure 200 incorporates a composite structure (for example, structure 700 shown in Figure 7). In the case of vehicle 300, each of the intermediate section 230, roof 312, and side walls 314 is formed from a composite material and has a composite structure in at least some embodiments. In these embodiments, each of the intermediate section 230, roof 312, and side walls 314 does not contain a metallic material. 【0048】 Referring next to Figure 4, a prior art delivery vehicle 400 includes a storage compartment 410. The storage compartment 410 includes a floor 412, a pair of side walls 414, a ceiling 416, and a refrigeration unit 418, which is at least partially housed 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 leading to the floor 412 of the storage compartment 410. 【0049】 As shown in Figure 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 about 63.5 cm (25 inches), the step height 426 is about 25.4 cm (10 inches), and the floor height 422 is about 88.9 cm (35 inches). 【0050】 Referring next to Figure 5, the delivery vehicle 500 may include the monocoque structure described above with reference to Figure 2 (for example, the monocoque structure 200). Furthermore, in some embodiments, the vehicle 500 may be similar to one or more of the vehicles 120, 130, and 150 described above. In any case, the exemplary delivery vehicle 500 includes a floor 512, a pair of side walls 514, and a storage compartment 510 having a ceiling 516, and a refrigerated unit 518 housed in 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 which may substantially correspond to or be equal to the landing height 424. The floor height 522 may be less than 76.2 cm (30 inches), for example, in the range of 55.9 cm (22 inches) to 71.1 cm (28 inches). The pairs of wheel wells 530 formed within the storage compartment 510 are offset from each other by a separation distance 532. In certain embodiments, the separation distance 532 may be approximately 127 cm (50 inches). 【0051】 In some cases, the conventional delivery vehicle 400 has one or more disadvantages that are not associated with the exemplary vehicle 500. In one respect, the side walls 414 and ceiling 416 of the conventional vehicle 400 are typically made of a metallic material such as aluminum, which has poor thermal insulation properties. Therefore, the compartment 410 may have poor thermal insulation and tend to absorb ambient temperature relatively quickly. This can be particularly true in summer, when radiant heat from the sun intensifies the surrounding hot air, causing a significant temperature rise in the compartment 410. In contrast, the side walls 514 and ceiling 516 of the exemplary vehicle 500 are made of a composite material which has superior insulation properties compared to metallic materials such as aluminum. Accordingly, the compartment 510 is significantly more isolated from the surrounding environment than the compartment 410. This isolation can be particularly advantageous if the vehicle 500 is a refrigerated vehicle, such as a food delivery vehicle. It should be understood that the isolation characteristics of compartment 510 reduce the cooling load on the refrigeration unit 518, thereby increasing the performance of the refrigeration unit 518. Additionally, in certain circumstances, the increased performance of the refrigeration unit 518 may allow the vehicle 500 to be equipped with a smaller refrigeration unit 518 than that typically required by a conventional vehicle 400. 【0052】 Another drawback associated with the conventional vehicle 400 is the nature of the floor 412 being higher than the ground level 402. It should be understood that the raised floor 412 is a feature often required to accommodate the internal chassis or frame, powertrain, and related components, not merely a design choice. In other words, to accommodate the mounting of a conventional internal combustion engine and other powertrain components (e.g., transmission, transaxle, and / or differential) to the internal chassis, the floor 412 is raised above the ground level 402 by a floor height 422. As a result, the raised floor 412 reduces the storage capacity and / or storage volume of the storage compartment 410 and necessitates the provision of a step 406. Thus, a delivery person using the vehicle 400 must climb onto the landing 404 and proceed up the step 406 to access the compartment 410. 【0053】 The exemplary vehicle 500 eliminates some of the aforementioned disadvantages by eliminating the need for a raised floor 412. Partly by providing a monocoque structure 200 as a single, monolithic structure having a relatively lightweight composite structure, and partly by the absence of powertrain components that are normally located 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 raised above ground level like the floor 412. As a result, the vehicle 500 allows for increased storage capacity of the storage compartment 510 without the need to raise the ceiling 516. Furthermore, since steps 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 the delivery person can avoid the effort of climbing both the landing 404 and step 406 to access the storage compartment 510 of the vehicle 500. Notably, the rear bumper of the vehicle 500 may be slightly lower than the floor 512, and it should be understood that the delivery person can access the storage compartment 510 simply by stepping onto the rear bumper first. In some embodiments, the rear bumper may be about 50.8 cm (20 inches) above ground level, while the floor 512 may be about 63.5 cm (25 inches) above ground level. 【0054】 Referring next to Figure 6, in the United States, trucks are often classified according to their Gross Vehicle Weight (GVWR). The classifications of these trucks, the associated tariff classifications, and the corresponding GVWRs are shown in Table 600. In exemplary examples, one or more of the vehicles 110, 120, 130, 140, and 150 have a GVWR between 2.7 tons (6,000 pounds) and 9 tons (19,800 pounds) (i.e., considering the weight of the truck when empty and the load of the truck when full). In some examples, 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), thereby one or more of the vehicles 110, 120, 130, 140, and 150 are embodied as Class 3 trucks, or include them in other forms. In one particular example, in some embodiments, a 28.3 cubic meter (1,000 cubic foot) capacity vehicle 130 weighs approximately 2.9 tons (6,500 pounds) when empty and has a load capacity of 2.7 tons (6,000 pounds), thereby the vehicle 130 has a GVWR of approximately 5.7 tons (12,500 pounds). Naturally, it should be understood that in other embodiments, the vehicle type 100 may 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 relation to Grade 3 to 5 delivery vehicles. For example, using methods 1000, 1100, and 1300 described below, a monocoque structure can be formed for a delivery vehicle having a GVWR between 4.5 tons (10,001 pounds) and 8.8 tons (19,500 pounds). 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, the vehicle's storage compartment (e.g., compartment 510) may be isolated from the vehicle's operator's cabin (e.g., operator's cabin 212). 【0056】 Referring next to Figure 7, any vehicle of this disclosure includes a monocoque structure having a composite structure 700. In exemplary embodiments, the 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 structures 700 include one or more of balsa wood, plastics, glass fiber, resins, Kevlar®, honeycomb, and carbon fiber. In at least some embodiments, the composite structure 700 does not include and is not formed from metallic materials. In these embodiments, the monocoque structure incorporating the composite structure 700 (e.g., monocoque structure 200) does not include metallic materials. 【0057】 An 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 glass fiber, multidirectional glass fiber, Kevlar®, carbon fiber, plastic, honeycomb, or other suitable non-metallic composite materials. Naturally, in other embodiments, the core 702 may be formed from other suitable materials to provide the composite structure 700 with a relatively lightweight structure. The exemplary shell 704 is formed from glass fiber and resin. However, in other embodiments, the shell 704 may be formed from other suitable materials. Additionally, in the exemplary embodiment, the composite structure 700 includes a lamination 706 that at least partially covers the shell 704. 【0058】 It should be understood that the composite structure 700 used to form the monocoque structure of any vehicle in this disclosure offers several advantages over the multi-part metal structures of conventional vehicles. In one respect, a one-piece monolithic structure formed with the composite structure 700 has fewer parts than a vehicle structure that requires multiple parts, thus offering greater structural simplicity. In another respect, the structural simplicity provided by the composite structure 700 can facilitate maintenance and improve structural efficiency. Still in another respect, the absence of metal materials allows the composite structure 700 to minimize or eliminate rust and / or corrosion, thereby allowing it to have a service life exceeding that of vehicles with conventional structures. In some cases, a monocoque structure incorporating the composite structure 700, consistent with the teachings of this disclosure, can have a service life of 20 years or more. 【0059】 Referring next to Figures 8 and 9, the modular system 800 (see Figure 8) includes several exemplary mold units that can be selected and arranged to form the monocoque structure system 900 (see Figure 9). It should be understood that when arranged to form the monocoque structure system 900, selected mold units of the modular system 800 are used to form a monocoque structure, such as the monocoque structure 200 described above. Furthermore, it should be understood that similar reference numbers in the 800 and 900 ranges are used to indicate corresponding features of the modular system 800 and the monocoque structure system 900. 【0060】 An 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 intermediate section mold unit 832, a medium intermediate section mold unit 834, and a large intermediate section mold unit 836. As will be discussed below, each of the mold units 810, 820, 832, 834, and 836 has a mold cavity having a size and shape corresponding to the corresponding features of the monocoque structural system 900, so that the corresponding features of the monocoque structural system 900 are formed after the introduction of the composite material (e.g., the 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 further front cage 210) of the monocoque structural system 900. The rear floor unit 820 includes a rear floor cavity 922 having a size and shape corresponding to the rear floor 920 (and further rear floor 220) of the monocoque structural system 900. The intermediate units 832, 834, and 836 each include intermediate cavities 933, 935, and 937, each having a size and shape corresponding to the respective intermediate sections 932, 934, and 936 (and further intermediate section 230) of the monocoque structural system 900. 【0061】 As is evident from Figures 8 and 9, each of the intermediate units 832, 834, and 836 is sized to be positioned between the front cage unit 810 and the rear floor unit 820 in order to form the monocoque structural system 900. It should be understood that one of the intermediate units 832, 834, and 836 can be selected and positioned between the front cage unit 810 and the rear floor unit 820 in order to form the monocoque structural system 900. The selection of a particular unit 832, 834, or 836 is based on the configuration of the vehicle and the monocoque structure contained therein, as will be discussed further below. 【0062】 In exemplary embodiments, 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 intermediate sections 932, 934, and 936, as shown in Figure 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 arranged in conjunction with one of the corresponding intermediate mold units 832, 834, and 836, a fluid coupling may be established between the front cage cavity 912 and one of the intermediate mold cavities 933, 935, and 937. Additionally, in some embodiments, when the front cage unit 810 is arranged in conjunction with the rear floor unit 820, a fluid coupling may be established between the front cage cavity 912 and the rear floor cavity 922. 【0063】 In an 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 intermediate sections 932, 934, and 936, as shown in Figure 9) for establishing a fluid coupling between the cavity 922 and another component of the mold system 800. Each of the intermediate mold cavities 933, 935, and 937 of the intermediate mold units 832, 834, and 836 has an opening 938 at its front end (i.e., the end closest to the front cage 910, as shown in Figure 9) and an opening 940 at its rear end (i.e., the end closest to the rear floor 920, as shown in Figure 9). When one of the intermediate units 832, 834, and 836 is arranged in conjunction with the front cage unit 810, a fluid coupling is established between the corresponding intermediate cavities 933, 935, and 937 and the front cage cavity 912 via openings 914 and 938. Additionally, when one of the intermediate units 832, 834, and 836 is arranged in conjunction with the rear floor unit 820, a fluid coupling is established between the corresponding intermediate cavities 933, 935, and 937 and the rear floor cavity 922 via openings 924 and 940. 【0064】 It should be understood that the front ends of each exemplary intermediate unit 832, 834, and 836 are configured to be directly connected to and mounted to the rear end of the front cage unit 810. Furthermore, it should be understood that the rear ends of each exemplary intermediate unit 832, 834, and 836 are configured to be directly connected to and mounted to the front end of the rear floor unit 820. As a result, when any one of the intermediate units 832, 834, and 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, and 937, and the rear floor cavity 922 are fluidly coupled to each other in a continuous arrangement to establish a continuous monocoque structure cavity, into which composite material can be introduced to form a monocoque structure as a single, integrated 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 to 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 each other in a continuous arrangement to establish a continuous monocoque structure cavity into which composite material can be introduced to form a monocoque structure as a single, integrated monolithic structure. 【0066】 In exemplary embodiments, a small intermediate section unit 832 has a length L1 as proposed by Figure 9. A medium intermediate section unit 834 has a length L2 that is longer than length L1 in at least some embodiments. A large intermediate section unit 836 has a length L3 that is longer than both length L2 and length L1 in at least some embodiments. 【0067】 In some embodiments, a small intermediate section mold unit 832 can be used to form the intermediate section 932 of the monocoque structural system 900, thereby allowing the monocoque structure, at least partially produced using the mold unit 832, to be contained within a vehicle (e.g., vehicle 120) having a storage volume of 18.4 cubic meters (650 cubic feet). Additionally, in some embodiments, a medium intermediate section mold unit 834 can be used to form the intermediate section 934 of the monocoque structural system 900, thereby allowing the monocoque structure, at least partially produced using the mold unit 834, to be contained within a vehicle (e.g., vehicle 130) having a storage volume of 28.3 cubic meters (1000 cubic feet). Furthermore, in some embodiments, a large intermediate section mold unit 836 can be used to form the intermediate section 936 of the monocoque structural system 900, thereby allowing the monocoque structure, at least partially produced using the mold unit 836, to be contained within a vehicle (e.g., vehicle 150) having a storage volume of 34 cubic meters (1200 cubic feet). 【0068】 Referring now to Figure 10, an exemplary method 1000 is shown of forming a monocoque structure (e.g., monocoque structure 200) using a modular system (e.g., system 800). Method 1000 corresponds to, or is otherwise associated with, the implementation of the blocks described below in the exemplary order of Figure 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 executed 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 included as, a set of instructions implemented by an automated control system. 【0069】 Exemplary Method 1000 begins in Block 1002. In Block 1002, the operator or control system selects a land vehicle type or a monocoque structural configuration for a particular land vehicle. It should be understood that in order to carry out Block 1002, the operator or control system may select any vehicle envisioned by the Disclosure or any monocoque structural configuration associated with a particular vehicle contemplated by the Disclosure. From Block 1002, Method 1000 then proceeds to Block 1004. 【0070】 In block 1004 of exemplary method 1000, the operator or control system selects a first type unit of the modular type system based on a 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) a small intermediate section type unit 832 (i.e., in block 1008), (ii) a medium intermediate section type unit (i.e., in block 1010), or (iii) a large intermediate section type unit 836 (i.e., in block 1012). The selection of one of the intermediate type units 832, 834, and 836 as the first type unit will be described in more detail below with reference to Figure 11. In any case, from block 1004, method 1000 then proceeds to block 1014. 【0071】 In block 1014 of exemplary method 1000, an operator or control system couples a selected first mold unit to a front cage mold unit 810 of modular system 800. To implement block 1014, it should be understood that the selected first mold unit (i.e., the rear floor mold unit 820) is coupled to the front cage mold unit 810 such that the front cage mold cavity 912 is fluidly coupled to the rear floor mold cavity 922 to at least partially establish a continuous monocoque structural mold cavity. Following the implementation of block 1014, method 1000 proceeds to block 1016. 【0072】 In block 1016 of exemplary method 1000, the operator or control system introduces one or more composite materials (e.g., composite materials contained within composite structure 700) into a continuous monocoque structural cavity formed in block 1014. More specifically, in order to carry out block 1016, in at least some embodiments, the operator or control system carries out blocks 1018, 1020, and 1022. In block 1018, the operator or control system introduces one or more composite materials into the continuous monocoque structural cavity without introducing a metallic material into the cavity. However, in other embodiments, block 1018 may be omitted from method 1000. In block 1020, the operator or control system places a first material into a continuous monocoque structural cavity. In at least some embodiments, the first material may include balsa wood and / or plastic. In block 1022, the operator or control system places a second material, different from the first material, within a continuous monocoque structure cavity. In at least some embodiments, the second material may include glass fiber and resin. Following the implementation of block 1016, method 1000 proceeds to block 1024. 【0073】 In block 1024 of exemplary method 1000, an operator or control system curing one or more composite materials in a continuous monocoque structure cavity to form a monocoque structure. To carry out block 1024, the operator or control system may carry out blocks 1026, 1028, and 1030 in at least some embodiments. In block 1026, the operator or control system forms a core (e.g., core 702) comprising a first material introduced in block 1016. In block 1028, the operator or control system forms a shell (e.g., shell 704) comprising a second material introduced in block 1016 that at least partially surrounds the core. In block 1030, the operator or control system forms a lamination (e.g., layer 706) that at least partially covers the shell. 【0074】 Referring next to Figures 11 and 12, an exemplary method 1100 for 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 Figures 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 executed simultaneously or in parallel with each other. 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 included as, a set of instructions implemented by an automated control system. 【0075】 Exemplary Method 1100 begins in Block 1102. In Block 1102, the operator or control system selects a land vehicle type or a monocoque structural configuration for a particular land vehicle. It should be understood that in order to carry out Block 1102, the operator or control system may select any vehicle envisioned by the Disclosure or any monocoque structural configuration associated with a particular vehicle contemplated by the Disclosure. From Block 1102, Method 1100 then proceeds to Block 1104. 【0076】 In block 1104 of exemplary method 1100, the operator or control system selects a first type unit of the modular system based on a selected vehicle type or monocoque structural configuration. In exemplary embodiments, to implement block 1104, the operator or control system implements one of blocks 1106, 1108, and 1110. In block 1106, the operator or control system selects a small intermediate section type unit 832. In block 1108, the operator or control system selects a medium intermediate section type unit 834. In block 1110, the operator or control system selects a large intermediate section type unit 836. Following the implementation of block 1104, method 1100 proceeds to block 1112. 【0077】 In block 1112 of exemplary method 1100, the operator or control system selects a second type unit of the modular system. In exemplary embodiments, to carry out block 1112, the operator or control system carries out 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 exemplary method 1100, an operator or control system couples a selected first mold unit to a front cage mold unit 810 of modular system 800. To implement block 116, it should be understood that the selected first mold unit (i.e., one of intermediate mold units 832, 834, 836) is coupled to the front cage mold unit 810 such that the front cage mold cavity 912 is fluidly coupled to a corresponding intermediate mold unit cavity (i.e., one of cavities 933, 935, 937) to at least partially establish a continuous monocoque structural mold cavity. Following the implementation of block 1116, method 1100 proceeds to block 1118. 【0079】 In block 1118 of exemplary method 1100, an operator or control system couples a selected first mold unit (i.e., one of the intermediate mold units 832, 834, and 836) to a selected second mold unit (i.e., a rear floor mold unit 820). To implement block 1118, it should be understood that one of the intermediate mold units 832, 834, and 836 is coupled to the rear floor mold unit 820 such that the rear floor mold cavity 922 is fluidly coupled to the corresponding intermediate mold unit cavity (i.e., one of the cavities 933, 935, and 937) to at least partially establish a continuous monocoque structural mold cavity. Following the implementation of block 1118, method 1100 proceeds to block 1120. 【0080】 In block 1120 of exemplary method 1100, the operator or control system introduces one or more composite materials (e.g., composite materials contained within the composite structure 700) into a continuous monocoque structural cavity formed in block 1118. More specifically, in order to carry out block 1120, in at least some embodiments, the operator or control system carries out blocks 1122, 1124, and 1126. In block 1122, the operator or control system introduces one or more composite materials into the continuous monocoque structural cavity without introducing a metallic material into the cavity. However, in other embodiments, block 1122 may be omitted from method 1100. In block 1124, the operator or control system places a first material into a continuous monocoque structural cavity. In at least some embodiments, the first material may include balsa wood and / or plastic. In block 1126, the operator or control system places a second material, different from the first material, within a continuous monocoque structure cavity. In at least some embodiments, the second material may include glass fiber and resin. Following the implementation of block 1120, method 1000 proceeds to block 1202. 【0081】 In block 1202 of exemplary method 1100, an operator or control system curing one or more composite materials in a continuous monocoque structure cavity to form a monocoque structure. To carry out block 1202, the operator or control system may carry out blocks 1204, 1206, and 1208 in at least some embodiments. In block 1204, the operator or control system forms a core (e.g., core 702) comprising a first material introduced in block 1120. In block 1206, the operator or control system forms a shell (e.g., shell 704) comprising a second material introduced in block 1120, at least partially surrounding the core. In block 1208, the operator or control system forms a lamination (e.g., layer 706) at least partially covering the shell. 【0082】 Referring next to Figure 13, an exemplary method 1300 for forming multiple monocoque structures of 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 exemplary order of Figure 13. However, it should be understood that Method 1300 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 executed 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】 Exemplary method 1300 begins in block 1302, in which an operator or control system forms a first monocoque structure of a first land vehicle. To implement block 1302, the operator or control system forms a first monocoque structure of a first land vehicle in block 1304 using at least one modular system (e.g., system 800). In some embodiments, the first monocoque structure of a first land vehicle is formed using only the front cage unit 810 and the rear floor unit 820 of modular system 800. In these embodiments, the first monocoque structure of a first land vehicle may be formed by implementing method 1000 as described above. In other embodiments, the first monocoque structure of a 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 embodiments, the first monocoque structure of the first land vehicle may be formed by carrying out the method 1100 described above. In any case, following the implementation of block 1302, the method 1300 proceeds to block 1306. 【0084】 In block 1306 of exemplary method 1300, an operator or control system forms a second monocoque structure of a second land vehicle distinct from a first land vehicle. To implement block 1306, the operator or control system forms a second monocoque structure of a second land vehicle in block 1308 using at least one modular system (i.e., system 800). In an embodiment in which the first monocoque structure of the first land vehicle is formed in block 1302 using only the front cage unit 810 and the rear floor unit 820 of modular system 800 (i.e., according to method 1000), the second monocoque structure of 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, and 836 (i.e., according to method 1100). In an embodiment in which the first monocoque structure of the first land vehicle is formed in block 1302 using a front cage unit 810, a rear floor unit 820, and a first intermediate unit 832, 834, 836 (i.e., according to method 1100), the second monocoque structure of the second land vehicle is formed using a front cage unit 810, a rear floor unit 820, and a second intermediate unit 832, 834, 836, different from the first. In either embodiment, starting from block 1306, method 1300 then proceeds to block 1310. 【0085】 In block 1310 of exemplary method 1300, an operator or control system forms a third monocoque structure of a third land vehicle distinct from a first land vehicle and a second land vehicle. To implement block 1310, the operator or control system forms a third monocoque structure of a third land vehicle using at least one modular system (i.e., system 800) in block 1310. In an embodiment in which (i) a first monocoque structure of 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., in accordance with method 1000), and (ii) a second monocoque structure of 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, and 836 (i.e., in accordance with method 1100), a third monocoque structure of 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, and 836, which is different from the first. In an embodiment in which (i) a first monocoque structure of a first land vehicle is formed in block 1302 using a front cage unit 810, a rear floor unit 820, and a first intermediate unit 832, 834, 836 (i.e., in accordance with method 1100), and (ii) a second monocoque structure of a second land vehicle is formed in block 1306 using a front cage unit 810, a rear floor unit 820, and a second intermediate unit 832, 834, 836 different from the first, a third monocoque structure of a third land vehicle is formed using a front cage unit 810, a rear floor unit 820, and a third intermediate unit 832, 834, 836 different from the first and second. 【0086】 While this disclosure has been shown and described in detail in the aforementioned figures and descriptions, it should be understood that this disclosure is not restrictive but illustrative, and only exemplary embodiments are shown and described, and it is desirable that all changes and modifications included within the scope of this disclosure be protected.

Claims

[Claim 1] A method for forming a monocoque structure for a land vehicle using a modular system, To form a front cage type unit of the modular system corresponding to the front cage of the monocoque structure, To form a rear floor type unit of the modular system corresponding to the rear floor of the monocoque structure which is positioned rearward from the front cage in the longitudinal direction, The rear floor unit is coupled to the front cage unit such that the front cage cavity of the front cage unit is fluidly coupled to the rear floor cavity of the rear floor unit, thereby establishing a monocoque structure cavity that is at least partially continuous. A method that includes this. [Claim 2] Introducing one or more composite materials into the continuous monocoque structure cavity, The method according to claim 1, further comprising curing the one or more composite materials in the continuous monocoque structure type cavity in order to form the monocoque structure. [Claim 3] The first mold unit of the modular system is positioned behind the front cage mold unit in the longitudinal direction, The first mold unit is coupled to the front cage type unit and the rear floor type unit such that the front cage type cavity, the mold cavity of the first mold unit, and the rear floor type cavity are fluidly coupled to each other to establish the continuous monocoque structure type cavity, The method according to claim 1, further comprising the following: [Claim 4] The method according to claim 3, wherein the first type unit is selected from the group consisting of a first intermediate section type unit of the modular system having a first length, a second intermediate section type unit of the modular system having a second length longer than the first length, and a third intermediate section type unit of the modular system having a third length longer than the second length. [Claim 5] Introducing one or more composite materials into the aforementioned continuous monocoque-type cavity, To form the monocoque structure, one or more composite materials are cured within the continuous monocoque-type cavity. The method according to claim 3, further comprising the following: [Claim 6] The method according to claim 5, wherein introducing one or more composite materials into the continuous monocoque structure cavity includes introducing one or more composite materials into the continuous monocoque structure cavity without introducing a metal material into the continuous monocoque structure cavity. [Claim 7] Introducing one or more of the aforementioned composite materials into the continuous monocoque structure cavity is The first material is placed in the continuous monocoque structure cavity, The method according to claim 5, further comprising placing a second material different from the first material within the continuous monocoque structure cavity. [Claim 8] The curing of one or more of the aforementioned composite materials within the continuous monocoque structure cavity is Forming a core containing the first material, The method according to claim 5, comprising forming a shell comprising a second material different from the first material, which at least partially surrounds the core. [Claim 9] The method according to claim 1, wherein the front cage-type unit and the rear floor-type unit are structurally different from each other. [Claim 10] The method according to claim 1, wherein forming the rear floor unit includes defining a notch that penetrates the rear floor unit in a transverse direction perpendicular to the longitudinal direction such that the rear floor unit has a reduced width between the notches in the transverse direction.

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