System, apparatus and method for forming an insulated cavity within a vehicle chamber

Abstract

The invention relates to a compartment for use in the chamber of a vehicle to form an insulated cavity therein, said compartment including panels forming side walls, a base and a roof to define the cavity. The compartment can be at least partially assembled prior to being introduced into and located in the chamber of the vehicle thereby increasing efficiency and accuracy of assembly and assisting in the secure location of the compartment with the chamber of the said vehicle.

Description

[0001] System, Apparatus and Method for forming an insulated cavity within a vehicle chamber

[0002] The invention to which this application relates is a means of forming an insulated cavity within a chamber of a vehicle body and, in particular, although not necessarily exclusively, a vehicle in the form of a van which includes a body mounted on a chassis. The invention also relates to a means of manufacture of the panels which can be used to form the said walls of a compartment which defines the cavity therein.

[0003] A vehicle body for the transport of goods is typically split into two sections, a cab section in which the drivers and any passengers are located and a rear chamber section in which goods can be stored and transported. Furthermore, in many instances and an instance to which the invention is particularly relevant, the chamber is provided in communication with a refrigeration unit mounted on the vehicle and which allows the temperature of the chamber to be controlled, most typically to be suitable for the storage and transport of chilled or frozen goods in the cavity, at a temperature within a predetermined temperature range so as to allow the storage and transport of goods, such as, for example, foodstuffs, which may be required to be stored in a chilled or frozen condition.

[0004] Conventionally, the chamber is lined with an insulating material retained between an inner surface of the wall of the vehicle body and plywood sheeting which, when in position, forms the walls of the chamber and hence defines the size and shape of the cavity. However, the use of plywood, which is typically bonded to conventional insulating material is not environmentally friendly as the materials, at the end of use of the vehicle, cannot be separated easily and so mots typically are not recycled and so form waste material. Furthermore the use of plywood significantly increase the weight of the vehicle and so increases fuel consumption.

[0005] It is also now known to provide panels made of plastics material which form both the insulation and interior walls of the compartment which define the cavity and which can be recycled and therefore represent a significant improvement in comparison to the conventional structures. However, it is found that the complexity of the number of panels and the different shapes of the cavities provided in different types of vehicles can mean that the panels often become dislodged from each other or require significant amounts of potentially non- recyclable adhesives and / or bonding materials to be used to maintain the engagement of the panels with each other. This can often mean that the panels become dislodged over time, and this can be exacerbated by movement and flexing of the vehicle body and result in the temperature control of the cavity being difficult to maintain due to leakage of chilled air between the panel interfaces and, as a result, causes the refrigeration unit to operate more frequently which, in turn, represents an increase in energy usage, expense, and is not environmentally friendly.

[0006] The interior walls floor and / or roof of the vehicle chamber can be provided with to receive the panels thereon to provide an insulating effect, and the panel walls define the compartment and the interior walls of the same define said cavity.

[0007] Access is required to the cavity via one or more doors of the vehicle which can be moved between open and closed positions and which are located at the rear of the vehicle and / or at the side of the vehicle. As the doors are required to be movable with respect to the vehicle to allow access to the cavity, it is found that due to the need for the doors to be free to move and to be able to accommodate handles, window opening mechanisms, hinge and guide mechanisms, it is more difficult to provide satisfactory and effective insulation at these locations. Furthermore, the requirement to move the doors means that the additional weight provided by the addition of conventional insulation to the same results in the doors not being easily movable and / or the support and hinge mechanisms need to be reinforced. This can be especially problematic with respect to doors which are mounted on the side wall of the vehicle and which are required to be slid along guide tracks between open and closed positions.

[0008] Furthermore, it is found that the configuration, shape and operation of the doors can vary from vehicle type to vehicle type.

[0009] Also typically provided in the chamber of the vehicle are first and second arch sections formed as part of the body of the vehicle and these receive, externally the rear wheels of the vehicle which protrude into the arch section and, in turn the arch sections protrude into the chamber which means that these arches are conventionally either not enclosed by the insulated compartment or are not enclosed in a sealed manner which can mean that the same act as a source of increased heat entering the cavity and so an increase in the work required to be performed by the refrigeration unit or units to retain the required temperature range within the cavity.

[0010] An aim of the present invention is therefore to provide a compartment which can be formed within the chamber of the vehicle and which has greater integrity and resistance to movement during use of the vehicle and loading and unloading of goods into and from the cavity therein.

[0011] A further aim of the present invention is to provide a compartment with portions for the enclosure of the vehicle body wheel arches and to provide the same in a form which allows the same to be provided as an integral part of the insulated walls of the compartment and so improve the insulating effect.

[0012] A further aim of the invention is therefore to provide an improved insulation effect within a compartment formed in the vehicle chamber and in particular improve the insulation effect at, and adjacent to the doors of the vehicle which are provided to allow access to the insulated cavity of the vehicle. A further aim is to provide the improvements in a form which can be used particularly to provide an effective insulation system for doors which are most commonly mounted on the side wall of the vehicle and which are substantially linearly moved between open and closed positions by a sliding action along the vehicle body.

[0013] In a first aspect of the invention, there is provided a compartment for fitment into and use in the chamber of a vehicle to form an insulated cavity therein, said compartment including interconnected panels formed of plastics material to form side walls, a base and a roof and engagement means allow the panels to be interconnected and wherein at least part of the compartment is assembled and engagement means engaged externally of the vehicle and then placed into position in said chamber.

[0014] In one embodiment the panels forming the side walls of the compartment are provided so as to be resiliently movable such as to allow the same to flex as the compartment is located within the chamber of the said vehicle and then move to engage with the chamber walls directly and / or via brace members to position the compartment in the chamber.

[0015] In one embodiment, the side walls are dimensioned with respect to the dimensions of the side walls of the chamber of the vehicle so as to allow flexing and compression of the side walls of the compartment between the roof and base panels of the compartment. Typically the side walls of the compartment, when the compartment is compressed, move outwardly so as to come into contact with the side walls of the chamber of the vehicle.

[0016] Typically, the side walls of the compartment include one or more brace members which contact with the side walls of the chamber when the compartment is compressed so as to locate and / or retain the compartment side walls in position with respect to the side walls of the chamber so that, in conjunction with the base of the compartment contacting the floor of the chamber and the roof of the compartment contacting with the roof of the chamber the compartment is located in position in the chamber.

[0017] In one embodiment, the external surface of panels which are used to form at least the side walls of the compartment include lines of weakening formed along the same to allow flexing of the panels at the lines of weakening

[0018] Typically, each of the side walls includes at least two lines of weakening which allow controlled flexing movement of the side walls outwardly so as to brace with the side walls of the chamber when the compartment is compressed and located in the chamber. This in turn, allows the locating members of the side walls to lock in position with typically indented sections of the wall of the chamber and hence locate and brace the compartment in position.

[0019] Typically, the lines of weakening form hinged movement means for the side walls and the particular position and spacing of lines of weakening is dependent upon the particular shape of the side walls or the chamber into which the compartment is to be fitted and located and / or the extent of outward movement which is to be allowed.

[0020] In one embodiment, the compartment is formed by a series of plastic material panels and at the interfaces between said panels mechanical engagement means are provided so as to provide a mechanical location of the respective panels with each other at said interfaces. In one embodiment the mechanical engagement means include, in one embodiment, location protrusions and slots so that said protrusions of one of the first or second panels are provided and located so as to be received within slots or indents in the other of the first or second panels. Typically, when engaged, the said first and second panels are retained in an angularly offset configuration.

[0021] In one embodiment, the engagement means in both the first and second panels are of a castellated form, with the castellations in the first panel linearly offset to the castellations in the second panel so as to allow the panels to be aligned when the engagement formations are engaged.

[0022] Typically, the engagement formations are formed such that when the same are engaged, a friction fit is achieved, thereby avoiding, or minimising, the need to use adhesives or other mechanical fixing means.

[0023] In one embodiment, the engagement formations are cut directly into the insulating material from which the panels are formed and thereby avoid the need for any additional components to be included as part of the panels or compartment.

[0024] In one embodiment some or all of the panels of the compartment include at least one set of the engagement formations formed therein. In one embodiment one or more of the panels include a plurality of sets of engagement formations formed therein at spaced apparat locations.

[0025] Typically, when the said panels are mechanically located, the said compartment which is formed, is freestanding.

[0026] Typically, once the compartment is located in the chamber the compartment cannot be removed from the chamber without first separating at least two of the panels or breaking at least one of the panels of the compartment.

[0027] In one embodiment, the interior surfaces of the respective panels are substantially planer whilst the opposing external surfaces of the compartments are typically contoured so as to engage with the contoured surfaces or location formations provided in the vehicle chamber walls, floor and / or roof, which are typically formed as part of the vehicle body.

[0028] Preferably, the external surfaces of the panels of the compartment are formed so that when the compartments is in position in the chamber the majority of the external surfaces of the panels of the compartment contact with the surfaces of the chamber with no, or a minimal, airgap there between. Thus, when in position, the compartment is effectively braced in position with respect to and by the walls of the chamber and / / or frames of doors into, and / or wheel arches of the chamber.

[0029] In one embodiment the panels which form the side walls of the compartment are provided with one or more lines of weakening which enhance the ability of the side panels to flex during the installation of the compartment in the chamber.

[0030] In one embodiment the lines of weakening are grooves formed in a core of the side panel and enable limited movement of portions of the side panels with respect to each other.

[0031] Typically the lines of weakening have a longitudinal axis substantially parallel with the longitudinal axis of the said side panel

[0032] In one embodiment, the compartment includes a front wall which is located at the end of the chamber closest to the cab for passengers and drivers of the vehicle and the particular formation of the front wall is selected dependent upon the particular design of chamber and vehicle into which the compartment is to be fitted.

[0033] Typically, the compartment includes a port therein for the supply of air from a temperature control unit mounted on the vehicle into the cavity within the compartment.

[0034] In one embodiment the vehicle chamber includes at least one door opening and the compartment includes a frame which locates around the door opening and is sealed to the side walls, floor, and / or roof panels of the compartment and / or the respective walls of the chamber adjacent to the door opening.

[0035] In one embodiment the compartment includes an insulation assembly for a door of a chamber of a vehicle, said door including a frame and having an external face, and an internal face and the external and internal faces are connected and spaced apart by one or more frame members so as to define one or more spaces within the door, wherein the door further includes one or more contoured portions of insulating material received in said one or more cavities to substantially fill the same, and a panel in engagement with the frame to retain the said one or more portions of insulating material in position and define a substantially uniform internal face of the door. Typically, the panels which are used to form the respective walls of the compartment are formed of a core of foamed plastics material and an external layer on at least one side of the panel, which is formed of a plastics sheet material. Typically, the external layer is of greater rigidity than the core and / or has greater resistance to impact. Typically, the external layer is provided such that when the panels of the compartment are placed in position within the cavity, said external layer faces internally into the cavity.

[0036] In one embodiment the said one or more portions are located on, or formed as part of, a base of insulating material so that the one or more contoured portions are supported by the base and are selectively positioned across the said base so that when the base is placed in position onto the frame the said contoured portions are located so as to pass into the respective cavities.

[0037] Typically, when in use and fitted to the vehicle, the frame, insulating material and panel form an integral door unit.

[0038] In one embodiment, the door is provided to close and seal an opening between the compartment and the chamber in the vehicle and the external environment and, when closed, the door forms part of the compartment for the chamber and so as to aid keeping the cavity within the said predetermined temperature range.

[0039] In one embodiment, at the interface between the door when in the closed position and the compartment wall around the periphery of the opening, there is provided a housing against which the said panel on the door interfaces so as to provide a substantially uniform seal between the panel and the said frame.

[0040] Typically, the housing is also made of a plastics material.

[0041] Typically the panel is removable from the door frame so as to allow access to be gained to the interior space of the door frame so as to allow, for example, said insulation portions to be removed and replaced or temporarily removed to allow access to be gained to components within, or on, the door such as guide means for the movement of the door between open and closed positions and / or handles which allow the movement of the door manually and / or locking systems to allow the door to be retained in the locked, closed position. Typically, a range of said portions of insulating material and / or panels are available to be selected and used to suit the particular model of vehicle for which the door is provided and therefore ensure best fit and optimise the insulating effect.

[0042] In one embodiment, the roof and / or front wall of the compartment includes apertures to allow lighting means to be provided to provide illumination of the compartment.

[0043] In one embodiment, the compartment is formed in sequence by the selective interconnection of panels from a kit of panels.

[0044] In one embodiment, the panels in the kit are initially provided in a substantially planer form for transport to a location in a flat pack form and at which the compartment is constructed.

[0045] Typically, the panels are formed of the core layer formed of a first form of recycled plastics material and one or both of the opposing external surfaces of the core layer are formed by a further layer of recycled material which, in one embodiment, is formed of a plurality of engaged fibres.

[0046] Typically the said panel is formed of a plastics material. In one embodiment, the one or more layers are formed of recycled and / or recyclable plastics material.

[0047] In one embodiment the one or more further layers is bonded to the core by the use of a layer of adhesive located between the said core and further layer.

[0048] In an alternative embodiment the said at least one further layer is joined to the core by using a thermoforming process in which the core is formed and then utilised as a mould for the thermoforming process and a further layer of plastics material which typically is that used to form the external layer of the panel, is applied onto and over at least the surface or surfaces of the core which are to form an internal wall of the cavity of the compartment and / or include engagement formations to allow engagement of the panel with other panels and / or components when the compartment is formed. Typically the said plastics material is heated by the application of heat during the thermoforming process such that at least the core material at least partially melts at the external surface thereof, and / or the said further layer of plastics material melts such that when the said respective core and layer are in contact the melting and subsequent hardening of the same creates an integral bond between the core and layer of plastics sheet material and hence form the panel without the need for a layer of adhesive to be provided between the core and the further layer of plastics material.

[0049] In one embodiment, as an alternative to using an adhesive to bond the said further layer to the core surface, the further layer is connected to the core surface by using a thermoforming techniques in which the core is utilised as the mould and the plastics material which is to form the external layer is applied onto and over at least the surface or surfaces of the core which are to be exposed and / or used to engage respective panels together to form the compartment.

[0050] When using thermoforming apparatus, the said further plastics material is heated by the application of heat in the thermoforming apparatus such that the core material at least partially melts at the external surface thereof, and / or the said further sheet material melts such that when the said respective materials are brought together, melting, and subsequently hardening of the same creates an integral bond between the two types of plastic sheet material and hence form the panel without the need for a layer of adhesive to be provided between the core and the further material.

[0051] Thus, in accordance with this aspect of the invention, the panel can be formed and retained in a formation in which there is provided the core and the external surface layer without the need for adhesive to be applied which reduces the cost, improves the durability of the bond between the respective layers and also aids the subsequent recycling of the materials as there is no need to remove the adhesive from the plastics material during the recycling process.

[0052] Typically, the particular type of plastic sheet material used to form the external layer and / or the colour of the same can be selected to suit particular purposes. In one embodiment, the plastics material is a thermoplastic polymer and in one embodiment, may be ABS (acrylonitrile butadiene styrene) and the process used is thermoforming with the temperature typically in the range of 180-190°C to cause the melting of the core plastics material and to form the ABS into a sufficiently pliable condition so as to be applied to the core and take up substantially the shape of the core.

[0053] In one embodiment, the said layer of further material is provided with engagement formations such that when respective panels are brought together an edge of a first panel is received within an engagement or location formation of the second panel and so provide for the location of the respective panels in the required configuration to form the compartment and hence retain the compartment in the required configuration.

[0054] In one embodiment, the compartment includes one or more treadplates which are formed of a sheet material. In one embodiment the sheet material includes at least one line of weakening which allows the same to be hingedly moved to an in-use position and engaged with, typically, the floor panel of the compartment and most typically located at the one or more door openings, so as to form a protective treadplate used by persons when they enter and leave the cavity.

[0055] In one embodiment, all of the components of the compartment are formed of plastics material which can be recycled.

[0056] There is therefore provided in accordance with one embodiment of the invention, an insulated compartment which is formed of panels which are interconnected by the engagement of respective engagement formations formed therein, so as to form a cavity therein.

[0057] In one embodiment the compartment includes first and second sets of panel portions, each set of panel portions provided to form an enclosure to receive at least part of one of said wheel arches of the chamber therein and said panel portions in the set are hingedly connected to at least one other panel portion in the set so as to be relatively moveable to a position in which the said enclosure is formed and located with adjacent panels of the compartment structure.

[0058] Typically, when located with the side wall and floor of the compartment, the wheel boxes form part of the bracing means for the self-standing compartment and location of the same in the vehicle chamber.

[0059] In one embodiment, the said panel portions are formed by one or more layers of plastics material and the hinged connections are formed by lines of weakening formed in said plastics material which are typically of a thinner depth than the remainer of the panel portions, thereby allowing the hinged movement of the said portions with respect to each other. Typically the lines of weakening are mitred, thereby further enabling the hinged movement.

[0060] Typically the said lines of weakening define the interface between respective portions of the set of panel portions. Typically, when the enclosure is moved to the formed condition, the enclosure comprises a front portion, first and second side wall portions and a top portion and the first and second side wall portions and top portion are angularly offset from the front portion, typically at a 90 degrees offset.

[0061] In one embodiment, engagement means are provided in the said enclosure and the floor and / or side walls of the compartment so as to aid the location of the enclosure in position. In one embodiment edges of at least some of the panel portions are provided with male location means so as to allow the same to be located in female engagement means formed in the adjacent panels of the compartment.

[0062] In one embodiment, when engaged, the enclosure is retained in the formed condition.

[0063] In one embodiment, a bonding agent is applied and / or plastic welding is performed to retain the said portions in the formed condition.

[0064] In one embodiment a sealing agent is used to seal the interfaces between the respective panel portions and adjacent panels.

[0065] In one embodiment, the location portions formed on the respective edges of the portions are castellated and the protruding parts of the same are located within female grooves or slots formed in the adjacent panels.

[0066] Typically the said adjacent panels are the panels which form the floor and a sidewall of the compartment.

[0067] In one embodiment, the said enclosure is formed of a panel material comprising an insulating material layer and an exterior layer which is bonded to the insulation layer and the exterior layer forms the external faces of the said enclosure and the hinged connections between the panel portions.

[0068] In a further embodiment, the external face of the panel may be provided with a surface pattern at all or a portion of the panel and / or different panels may be used with different surface panels such as, for example, if one of the panels is to be used as a floor panel, a surface pattern may be provided on the same which reduces the risk of slippage of personnel when walking across the panel. In addition to making this safer, this also reduces the number of additional compartments such as metal checker plates or the like, which are required to be fitted during the assembly of the compartment.

[0069] In a further aspect of the invention there is provided a kit of panels for use in the formation of an insulated compartment to be located in a vehicle chamber as herein defined.

[0070] In a further aspect of the invention, there is provided a vehicle including a compartment structure as herein defined.

[0071] In further aspect of the invention there is provided a panel for use in forming part of a compartment for a chamber of vehicle, said panel formed of at least a core of an insulating plastics material and wherein at least one set of engagement formations is formed on at least one surface of the panel.

[0072] In one embodiment at least part of the engagement formations in a set pass through the said core from said at least one surface to an opposing surface.

[0073] In a further aspect of the invention there is provided a method of forming an insulated compartment including side walls, afront wall, roof and base for fitment into a vehicle chamber to form an insulating cavity therein, said method comprising the steps of; identifying the vehicle type into which the compartment is to be fitted, forming a set of panels of a core of insulating plastics material with at least one further layer of plastics material engaged therewith, forming engagement means in said panels, moving the set of panels to the vehicle location and wherein at least part of the compartment is assembled and engagement means of respective panels engaged externally of the vehicle and then placed into position in said chamber.

[0074] In one embodiment at least the side walls, roof and base are assembled together prior to the compartment being moved into the chamber.

[0075] In one embodiment a compressive force is applied to the at least partially formed compartment to move the roof of the compartment towards the base as the same is moved into the chamber of the vehicle and the compressive force is at least partially released once the compartment is located within the chamber. In one embodiment at least one line of weakening is formed in at least the panels provided to form the side walls of the compartment.

[0076] Furthermore, the integrity of the compartment, when formed is increased with regard to conventional structures of this type and thereby ensures that the compartment is more resistant to damage from impact of goods thereon and movement of the vehicle body during movement of the vehicle, whilst ensuring that the engagement formations maintain the compartment and hence reduce the loss of cooled air from the interior of the compartment during use.

[0077] Specific embodiments of the invention are now described with reference to the accompanying drawings, wherein;

[0078] Figure 1 illustrates an example of a vehicle type with which the invention may be utilised.

[0079] Figures 2a - c illustrate a compartment with a cavity formed in accordance with one embodiment of the invention;

[0080] Figure 3a and b illustrate the engagement of the engagement formations for a wheel arch enclosure in accordance with one embodiment of the invention in greater detail;

[0081] Figures 4a and b illustrate a further embodiment of use of the engagement formations on panels for the compartment in accordance with one embodiment of the invention.

[0082] Figure 5 illustrates a door of the vehicle of Figure 1 in accordance with one embodiment of the invention,

[0083] Figure 6 illustrates a side wall of the vehicle of the type of Figures 1 and 5 with the door frame of Figure 5 removed and showing an insulating base and portions in position in accordance with one embodiment of the invention;

[0084] Figure 7 illustrates an elevation of a door in accordance with Figures 5-6 showing the interior face of the same as formed in accordance with one embodiment of the invention;

[0085] Figure 8 illustrates a further embodiment of the insulation of an alternative form of door for a vehicle in accordance with one embodiment of the invention; Figure 9 illustrates a vehicle body from the rear which includes wheel arches protruding into the goods storage chamber of the same;

[0086] Figure 10 illustrates part of the said chamber of Figure 9 including a wheel arch and in which the floor and side panels of the compartment have been installed;

[0087] Figures lla-c illustrate the formation of a wheel arch enclosure for use with the compartment shown in Figure 10 in accordance with a further embodiment of the invention;

[0088] Figure 12 illustrates the view of Figure 9 with the compartment and wheel arch enclosures installed in accordance with the invention;

[0089] Figures 13a and b illustrates a further embodiment of the invention wherein the compartment includes a tread plate for use with the compartment in accordance with one embodiment of the invention;

[0090] Figures 14a and b illustrate the provision of locating bracing members for the compartment in accordance with one embodiment of the invention;

[0091] Figures 15a and b illustrate the provision of an at least partially preformed compartment in accordance with one embodiment of the invention; and

[0092] Figures 16a-d illustrate panels formed in accordance with one embodiment of the invention.

[0093] Referring firstly to Figure 1, there is illustrated a vehicle in the form of a van 2 in one embodiment in accordance with which the invention may be utilised.

[0094] The van comprises a body 4 which is mounted on a chassis (not shown) in which there is provided an engine or motor to provide drive to at least two of a number of wheels 6 so as to propel the vehicle along the surface such as a road 8. Within the body, there is provided a cab 10 in which the driver and / or passengers sit at the front, and to the rear, a chamber 12 which includes a cavity therein which is connected to a refrigeration unit 14 which is mounted externally on the vehicle so as to draw in and expel air through the refrigeration apparatus and so aim to maintain the temperature within the cavity of the chamber 12 within a predetermined temperature range. The access to the chamber can in this embodiment be via rear doors which are typically pivotably moved about hinges between open and closed positions, and / or a side door 18 which is provided to be slid between a closed position as shown, and an open position in which the door lies offset to the opening into the chamber and outside of, but substantially parallel with, the rear part 20 of the side wall of the vehicle. The sliding movement of the door 18, is guided by the door being provided with guide wheels 22 and retaining assemblies 24 and one or more tracks 26 provided on the rear part 20 of the side wall.

[0095] As shown in Figure 2c which is a view of the compartment 16 from the rear of the vehicle, with the rear doors removed for ease of reference, the compartment structure 16 is fitted within the van chamber 12 and is formed from a series of interconnected panels and insulation assemblies for the doors. The external shape of the compartment is provided to match, as much as possible the interior face 28 of the chamber 12 of the vehicle and to include contoured portions which fit into any cavities between the interior face 28 and external wall 36 of the chamber so as to provide the desired insulating effect whilst, at the same time, maximising the available volume 30 within the cavity for the storage and transport of goods therein.

[0096] As shown in the Figures 2a-c and Figures 15a and b the compartment structure 16 includes a roof panel 32, floor panel 34, separate side panels 38,39,40 to form side wall 42 and side panels 38’, 40’ to form side wall 42’ as shown in Figures 2a- or alternatively the side walls may be formed of one panel 42, 42’ with lines of weakening 43 formed therein, and a front panel 44. (side wall 42 is removed in Figure 15b and the rear wall is removed from Figures 15a and b for ease of illustration). Two sets of wheel arch panels 46,48,50,52 and 46’, 48’, 50’, 52’ are engaged with each other, floor panel 34 and side panels 40,40’ as appropriate for form wheel arch enclosures 220. A door access opening 41 may be provided on the side wall 42 if required.

[0097] When the side walls 42,42’ of the compartment are formed from one panel each with lines of weakening 43 as shown in the side wall 42’ of Figures 15a and b, this proves to be particularly beneficial in allowing the compartment structure to be at least partially preformed prior to the compartment structure then being moved into position into the chamber of the vehicle. This means that the compartment 16 can be formed from a kit of panels which are preformed to a shape suitable for the vehicle chamber into which the compartment is to be located and the kit can be factory formed and then delivered to the site of assembly and installation. The compartment can then be assembled into the condition shown in Figure 15a, with possibly the front face 44 panel already positioned in the chamber of the vehicle so as to receive the remainder of the compartment. This means that the vehicle does not have to be present whilst the compartment is preassembled, therefore reducing the time which the vehicle spends off the road and allowing improved fitting techniques to be performed in the greater space outside, rather than inside the vehicle chamber as would conventionally be required. The engagement formations at the interfaces between the respective panels, examples of which will be detailed subsequently, are also engaged at this assembly before installation stage and this this therefore allows the preformed compartment structure to be retained as it is subsequently moved into and installed in position in the chamber of the vehicle.

[0098] The provision of the lines of weakening 43 are such as to allow the compartment structure to be resiliently compressed as indicated by arrows 47 to lower the height of the compartment and allow the same to be passed through the rear opening of the vehicle chamber and into position in the chamber. At the same time as the reduction in height, the lines of weakening 42 take up at least part of this compressive effect and so the sidewalls 42,42’ do not bow out excessively. When the compartment is within the structure the compressive force is released and so the height of the compartment resiliently increases to contact with the internal face of the roof of the chamber 12 of the vehicle or brace members provided on the roof or the external face of the roof panel 32 contact so as to aid in anchoring the compartment in position in the chamber. It should be noted that the height of the compartment may not be permitted to wholly return to the height when it was outside of the chamber and this therefore retains some compressive force thereon which, in turn, aids the retention of the compartment in position with the walls of the chamber. Bracing members 49 are typically also provided so as to brace the side walls 42, 42’ with the walls of the vehicle chamber when the compartment 16 is in position therein with full bracing being achieved between the compartment and the side walls of the chamber as the compartment at least partially regains its original shape once fully introduced into position within the chamber. Examples of the brace members 49 are illustrated in Figure 14a, in which the same are provided attached to the external face of the side wall 42’, and will also be attached to the external face of the side wall 42, and in Figure 14b in which the brace members 49 are attached to the external faces of the sidewall 51, and will also be attached to the opposing sidewall, of the vehicle chamber 12. In either embodiment the brace members 49 are shaped so as to allow engagement with location formations formed on the external faces of the sidewalls 42, 42’ of the compartment and the chamber walls so as to aid the retention of the compartment in the chamber 12.

[0099] When the compressive force is released this therefore acts to press the side walls to contact with the vehicle frame and the roof and floor panels into location with the roof and floor of the vehicle chamber respectively and so secure the compartment in a relatively fixed position within the chamber of the vehicle.

[0100] Each of the panels which are shown, are preferably made of the same form with a plastics material (such as PET) insulation core with a further layer of plastics material on one, or both opposing surfaces of the core to form one or both outer layers of the core.

[0101] In accordance with the invention, the panels include mechanical engagement formations so as to allow the same to be mechanically engaged with each other and retained in the engaged position with no, or minimal, adhesive or bonding required.

[0102] The walls of the respective engagement formations for each of the panels may also be formed with respective angles so as to allow adjacent panels, when interconnected together to also be retained at a selected angle with respect to each other. For example, the offset angle 74 of the panels 46 and 60 is 90 degrees whereas the offset angle 76 of panels 38 and 39 may be, for example, 160 degrees.

[0103] This allows the adjacent panels to be engaged and retained with an angular offset which best matches the shape of the inner walls 28 of the chamber 12 and forms a substantially airtight seal between the said panels without the need for any adhesive or other sealant materials to be used.

[0104] Similar engagement formations 80 can be provided on the other panels of the compartment as illustrated to allow the respective panels to be interconnected mechanically as illustrated in Figures 4a-b which show engagement formations for interconnecting the front panel 44 and roof panel 32.

[0105] The access to the chamber can in this embodiment be via rear doors 116, shown in Figure 8, which are typically pivotably moved about hinges between open and closed positions and a side door 118, shown in Figures 5-7, which is provided to be slid between a closed position as shown, and an open position in which the door lies offset to the opening into the chamber and outside of but substantially parallel with the rear part 120 of the side wall of the vehicle. The sliding movement of the door 118, is guided by the door being provided with guide wheels 122 and retaining assemblies 124 and one or more tracks 126 provided on the rear part 120 of the side wall.

[0106] The door frame 128 is illustrated in greater detail in Figure 5 and which shows the internal face 130 of the frame. To open the door the handle 131 is operated to release the door and the door is initially moved outwardly to be offset from the exterior of the vehicle side wall and then slid as indicated by arrow 134 along the track 126 to reach an open position. To close the door, the door is moved in the opposite direction with regard to the vehicle.

[0107] The door frame is typically formed with an external face 136 which is substantially solid although it may in certain embodiments include one or more windows, and the internal face 130 is provided which is spaced apart from the external wall by frame members 135 so as to define cavities 138. As the door represents a significant part of the overall area of the chamber, it will be appreciated that if there is no insulation provided in the door, then this can represent a significant impact on the ability of the refrigeration apparatus 114 to be able to maintain the required temperature range within the chamber during use of the vehicle and this, in turn, means that the refrigeration unit is required to be operated to a greater extent in order to maintain the required temperature range within the chamber which, in turn, requires greater energy usage and expense. Furthermore, in extreme circumstances, the lack of insulation in the door or doors may mean that the target temperature range cannot be met especially when, for example, the external environment is relatively hot.

[0108] In accordance with the invention, there is provided insulation material in the form, in this embodiment of a base 142 and a plurality of contoured insulating portions 144 and an example of which is shown in Figure 6. The insulating material portions 144 are contoured so as to have a 3-dimensional shape which substantially matches as much as possible the shape of the respective cavities 138 in the door frame into which the same are to be subsequently positioned and therefore substantially fill the said cavities. The reason for the contouring is to ensure that the base and portions of insulating material has the required depth at specific locations so as to fit into the cavities 138 defined within the door frame and fill the same with the insulating material of the base as much as is possible.

[0109] It will also be appreciated that the shape of the door frames varies between different vehicle designs and therefore, there is a need for the base and portions of insulating material to be shaped to match the doors of specific vehicles so that for example, when providing the insulation and forming the same, a range of different base and portion shapes are typically available for selective use or can be selectively formed to order using suitable machining apparatus.

[0110] Typically, once the insulating material is in position the same may be provided with securing means or alternatively, and most typically, will simply be placed in position and then enclosed therein by the provision of a panel 146 as shown in figure 7. The panel 146 is engaged with the periphery of the internal face 130 of the door frame so as to effectively trap the insulating material between the panel 146 and the external face of the door. The panel is shaped so as to provide a substantially uniform internal face whilst, at the same time, allowing access, by removal of the same, to the components located within the door frame the door such as for example, handles, hinges and location means so as to allow repair and / or maintenance.

[0111] A further embodiment of the invention is described with regard to Figure 8 where there is illustrated a rear door of the vehicle and again the same can include a base and suitably contoured portions of insulating material so as to fill cavities in the door frame and provided an effective insulation of the doors which allow access to the chamber.

[0112] In one embodiment, the apparatus further includes a housing 148, an example of which is illustrated in Figure 8 which is mounted around the periphery of the opening in which the door or doors are located and against which frame the interior face panels 146 engage so as to provide a sealed interface between the panel of the door and the housing and hence further increase the ability to maintain the required temperature range within the chamber of the vehicle.

[0113] The compartment also includes wheel arch enclosures 60,60’; 220 to receive and enclose one of the wheel arches and one embodiment of this is illustrated in greater detail in Figures 3a and b. In Figure 3a there is illustrated one embodiment of the wheel arch enclosure or structure and which shows the floor panel 34 and side panel 40 located adjacent the position of the wheel arch 54 in the vehicle body frame and which protrudes into the chamber. The panels 34 and 40 are shown as including respective sets of engagement formations respectively in the form of female recesses or slots 56, 58 located adjacent to the edges of the panels. The panels 34, 40 will themselves typically already be engaged to each other using similar forms of engagement formations.

[0114] Figures 3b illustrates the wheel arch enclosure 60 which is formed with the wheel arch panels 46,48,50 in position and the further panel 52 also engaged to enclose the wheel arch 54.

[0115] The edges 62 of the panels 46,48 are each provided with sets 64,66 of engagement formations in a castellated format and the male protrusions are located and formed so as to fit into the recesses 58 of the side wall 40 and recesses 56 of the floor 34 respectively.

[0116] As illustrated, in the wheel arch enclosure castellated engagement formations 68 are also formed on the edges 70 of panel 48, edges 78 of panel 60, edges 72 of panel 46 and, although not shown, the edges of panel 52 so as to allow the respective panels to be interconnected. The enclosure and interconnection of panels is also performed with regard to wheel arch structure 60’.

[0117] Referring now to Figure 9-11c there is illustrated a further embodiment of the formation of a wheel arch enclosure 220. Figure 9 shows the rear view of the vehicle 2 in the form of a van which includes the front cab section 10 shown in broken lines in which the driver and passengers of the vehicle are located, and the rear goods storage chamber 12 in which goods can be located and stored during transit. The vehicle includes four wheels and the rear wheels 210 are located in the wheel arches 212 which protrude inwardly into the chamber 12 as shown.

[0118] The compartment structure adjacent the wheelarch 212 is formed from a plurality of panels 216, parts of which are shown in Figure 10 and in particular part of the floor panel 216’ and part of the side wall panel adjacent one of the wheel arches 212 are shown and it will be seen that the wheel arch is a relatively complex structure which, if not enclosed, creates a heat source which can adversely affect the temperature integrity of the cavity within the compartment.

[0119] Also shown in Figure 10 are a series of female location means 218 formed on the floor and side wall panels 216’ and 216”. These are provided to be located with the wheel arch enclosure 220 as provided in accordance with the invention and a second embodiment of which is shown in more detail in Figures lla-c. The enclosure 220 is again formed from a plastics material which may be of a single or multilayered configuration, which typically has good insulating properties and defines panel portions as shown in Figures Ila and b which show the portions in an initial substantially flat condition. The portions comprise a front portion 222, side wall portions 224, 226 and a top portion 228. The portions are defined by their respective edges and lines of weakening 230 forming a hinge connection between each of the portions to another portion.

[0120] The lines of weakening 230 are typically of a reduced depth compared to the depth of the remainder of the panel portion and the side walls of the lines of weakening may also be mitred or chamfered as illustrated in Figures Ila and b so as to aid the hinged movement of the panel portions.

[0121] To form the enclosure 220, the side wall portions 224,226 are hingedly moved to be 90 degrees offset to the front portion 222 and the top portion 228 is hingedly moved to be 90 degrees offset to the front portion 228 so that an enclosure of the form shown in Figure 11c is created. Once formed, the side wall portion edges 232 can be plastic welded to the edges 234 of the front portion so as to assist in the retention of the formed enclosure 220.

[0122] It is also shown that the free edges of the side wall portions 224,226 and top portion are provided with male location means 238 which, when the enclosure is formed as shown in Figure 11c, are positioned so as to be received in the female location means 218 on the floor and side wall panels 216’, 216”. Once received therein a sealing means may be applied along the interface between the edge 236 of the enclosure and the adjacent floor or side wall panel 216’, 216”.

[0123] An enclosure 220 is provided for each of the wheel arches 212 such that the enclosure 220 can provide an insulating effect utilising material which is recyclable and as an integral part of the compartment structure which is formed as illustrated in Figure 12.

[0124] Figures 13a and b illustrate the interior of the compartment fitted in the chamber of the van in accordance with one embodiment. In this embodiment the floor panel 216’ of the compartment 214 in the chamber 12 has an interface with a rear opening 243 with rear doors, one of which, 242, is shown in a closed position in Figure 13a and a side door opening 244. Typically, each of the doors are provided with insulated panels on the inner face thereof such that when the doors are moved to the closed position, the door mounted panels form integral parts of the compartment 214. It is also shown how the wheel arch enclosures 220 are located as part of the compartment 214.

[0125] In addition, in this embodiment, facing or tread plates 246 are provided at the interface between the floor panel 216’ and the respective door openings which serves to mask the edge wall of the panel 216’ and also provide an external contact surface with gripping formations 248 thereon which aid the positioning of a person’s feet as they enter and leave the compartment 214 through the door openings 243, 244. The tread plates are in this embodiment formed of a single sheet of one or more layers of plastics material which is formed into two parts, a first part 250 which is substantially parallel with the floor panel 216’, and a second part 252 which is angularly offset by 90 degrees to the first part with the parts being defined by a fold line 254 which is typically formed by a line of weakening along the facing plate 246. The facing plate therefore provides a strong and durable surface which s resistant to impact and wear at the locations where there is most contact with personnel and goods as they enter and leave the cavity of the compartment.

[0126] In whichever embodiment, the insulation material which is used is substantially rigid and formed of one or more layers of plastics material which preferably is recyclable and preferably has previously been recycled. In one embodiment, the said panel and / or housing are also provided of a plastics material such that, should it be necessary to dismantle the doors and / or the chamber of the vehicle, the insulation material core panels and frame are entirely recyclable and therefore significantly reduce waste.

[0127] In one embodiment, the panels which are used to form the compartment and hence to form the cavity within the same are, as previously described, formed with a core of a first form of material which acts as an insulating layer and / or at least one of the surfaces of said core there is provided a layer which acts as a protective layer and forms the external surface of the panel which faces inwardly of the cavity.

[0128] In one embodiment, as an alternative to using an adhesive to bond the said further layer to the core surface, the further layer is connected to the core surface by using a thermoforming technique in which the core is utilised as the mould and the plastics material which is to form the further layer is applied onto and over at least the surface or surfaces of the core and engaged therewith. When using thermoforming apparatus, the said further plastics material and / or core is heated by the application of heat, typically at the melting point of the core of plastics material (typically in the range of 150-200 degrees Celsius) in the thermoforming apparatus such that the core material at least partially melts at the external surface thereof, and / or the said further sheet material melts such that when the said respective materials are brought together, melting, and subsequently hardening of the same creates an integral bond between the two types of plastic sheet material and hence form the panel without the need for a layer of adhesive to be provided between the core and the further material. Thus a panel 400 of the type shown in cross section in Figure 16a can be created with the core layer 402 engaged and typically integral with, the further layer 404 to form the panel for use in the construction of the compartment. This also prevents the occurrence of any crushing of the core material and hence prevents any reduction in the insulating effect of the core plastics due to the forming process.

[0129] Thus, in accordance with this aspect of the invention, the panel can be formed and retained in a formation in which there is provided the core and the external surface layer without the need for adhesive to be applied which reduces the cost, improves the durability of the bond between the respective layers and also aids the subsequent recycling of the materials as there is no need to remove the adhesive from the plastics material during the recycling process.

[0130] In one embodiment the said further layer of plastics material 404 is, in addition to being bonded with the core 402, provided with engagement formations 406 as shown in Figure 16b and 16d. In this embodiment there is shown a sample of the panel 400 in Figure 16d with the further layer 404 having an engagement lip 406 such that when respective panels are brought together, at the interface 408 formed at the edges of the respective panels 400,410, a protruding lip formation 406 of the first panel 400 is received within an engagement or location slot 412 formation of the second panel 410 and so provides for the location of the respective panels in the required configuration to form the compartment and hence retain the compartment in the required configuration. In Figure 16c there is shown another embodiment in which the panels 400 have a engagement formation 414 formed by the core 402 and further layers 404, in combination, form an engagement protrusion 414 which are received in respective rebated formations 416 in the second panel 410.

[0131] In a further embodiment, the external face of the panels may be provided with a surface pattern and, in one embodiment, panels with different surface patterns may be used such as, for example, if one of the panels is to be used as a floor panel, a surface pattern may be provided with protrusions 418 on the same as illustrated in Figure 16a which reduces the risk of slippage of personnel when walking across the panel. In addition to make the use safer, this also reduces the number of additional compartments such as metal checker plates or the like, which may subsequently be required to be fitted during the assembly of the compartment.

[0132] Typically, the particular type of plastic sheet material used to form the external layer and / or the colour of the same can be selected to suit particular purposes. In one embodiment, the plastics material is a thermoplastic polymer and in one embodiment, may be ABS (acrylonitrile butadiene styrene) with the heating during the forming process being sufficient to form the ABS into a sufficiently pliable condition so as to be applied to the core and take up substantially the shape of the core.

Claims

CLAIMS1. A compartment for fitment into and use in the chamber of a vehicle to form an insulated cavity therein, said compartment including interconnected panels formed of plastics material to form side walls, a base and a roof and engagement means allow the panels to be interconnected and wherein at least part of the compartment is assembled and engagement means engaged externally of the vehicle and then placed into position in said chamber.

2. A compartment according to claim 1 wherein the panels forming the side walls of the compartment are provided so as to be resiliently movable such as to allow the same to flex as the compartment is located within the chamber of the said vehicle and then move to engage with the chamber walls directly and / or via brace members to position the compartment in the chamber.

3. A compartment according to claim 2 wherein the side walls are dimensioned with respect to the dimensions of the side walls of the chamber of the vehicle so as to allow flexing and compression of the side walls of the compartment between the roof and base panels of the compartment as the compartment is moved into position.

4. A compartment according to any of the preceding claims wherein when in position in the chamber the walls, floor and / or roof of the chamber prevent the compartment from fully returning to the expanded condition thereby creating a locating force of the panels of the compartment against the walls, floor and / or roof of the chamber.

5. A compartment according to claim 2 wherein the side walls of the compartment include and / or contact with said one or more brace members which contact with the side walls of the chamber when the compartment is in the chamber so as in conjunction with the base of the compartment contacting the floor of the chamber and the roof of the compartment contacting with the roof of the chamber the compartment is retained in position in the chamber.

6. A compartment according to any of the preceding claims wherein the engagement means include location protrusions and the said protrusions of one of the first and second panels are provided and located so as to be received within slots or indents of an adjacent panel so as to provide mechanical location of the respective panels.

7. A compartment according to any of the preceding claims wherein the compartment at least partially formed externally of the vehicle is substantially free standing.

8. A compartment according to any of the preceding claims wherein, once located in the chamber, the compartment cannot be removed from the chamber without separating at least some of the respective panels of the compartment.

9. A compartment according to any of the preceding claims wherein interior surfaces of the respective panels of the compartment are substantially planer whilst the opposing external surfaces of the panels are contoured so as to match or follow the contour surfaces or docking formations of the walls, floor and roof of the chamber of the vehicle.

10. A compartment according to any of the preceding claims wherein the panels which form the side walls of the compartment are provided with one or more lines of weakening which enhance the ability of the side panels to flex during the installation of the compartment in the chamber.

11. A compartment according to claim 10 wherein the lines of weakening are grooves formed in a core of the side panel and enable limited movement of portions of the side panels with respect to each other.

12. A compartment according to claims 10 and 11 wherein the lines of weakening have a longitudinal axis substantially parallel with the longitudinal axis of the said side panel.

13. A compartment according to any of the preceding claims wherein the said chamber is formed by the walls, floor and roof of a goods storage of the vehicle in the form of a van.

14. A compartment according to any of the preceding claims wherein the compartment includes a front wall located at the end of the chamber closest to the seating area for passengers and drivers of the vehicle.

15. A compartment according to any of the preceding claims wherein the chamber includes at least one door opening and the compartment includes a frame which locates around the door opening and is sealed to side walls, floor and / or roof of the compartment and to the respective walls of the chamber surrounding the said door opening.

16. A compartment according to claim 15 wherein the door further includes one or more contoured portions of insulating material received in one said one or more cavities to substantially fill the same, and a panel in engagement with the frame retains the said one or more portions of insulating material in position and define a substantially uniform internal face of the door.

17. A compartment according to claim 16 wherein the said one or more portions are located on, or formed as part of, a panel core of insulating material so that the one or more contoured portions are supported by the core and are selectively positioned across the said core so that when the core is placed into position into the frame, said contoured positions are located so as to pass into the respective cavities in the door.

18. Apparatus according to any of the preceding claims wherein the said panels are formed of a core of plastics material which has insulating characteristics and at least one further layer of plastics material which forms at least one external layer of the panel so as to form at least part of a wall of the cavity formed in the compartment.

19. A compartment according to claim 18 wherein the core and said at least one further layer are engaged using a thermoforming process.

20. A compartment according to any of the preceding claims wherein the compartment includes first and second sets of panel portions, each set of panel portions provided to form an enclosure to receive at least part of one of said wheel arches of the vehicles therein.

21. A compartment according to claim 20 wherein said panel portions in the set are hingedly connected to at least one other panel portion in the set so as to be relatively movable from a relatively in line position to an erected position in which the said enclosure is formed and the enclosure is located with adjacent panels of the compartment structure so as to retain the enclosure in the erected position.

22. A compartment according to claim 22 wherein the said panel portions are formed by one or more layers of plastics material and the hinge connections are formed by lines of weakening formed in the said plastics material which are a weaker and thinner depth than the remainder of the panel portions to allow hinged movement of the said portions with respect to each other.

23. A compartment according to any of the preceding claims wherein the compartment includes one or more tread plates which are formed of a sheet material which includes first and second portions, angularly offset to each other.

24. A kit of panels provided to allow the formation of a compartment as defined herein for a chamber of a vehicle, said panels formed of a core and a further layer of plastics material and including respective engagement means to allow the respective panels to be brought into engagement and retained in an engaged position after being moved to the location of formation of the compartment in a substantially flatpack form.

25. A panel for use in forming part of a compartment as defined herein for the chamber of a vehicle, said panel formed of at least one layer of plastics material to form an insulating core and a further layer to form an externalsurface of the said panel and at least one set of engagement formations is formed on at least one face of the panel.

26. A method of forming an insulated compartment including side walls, afront wall, roof and base for fitment into a vehicle chamber to form an insulating cavity therein, said method comprising the steps of; identifying the vehicle type into which the compartment is to be fitted, forming a set of panels of a core of insulating plastics material with at least one further layer of plastics material engaged therewith, forming engagement means in said panels, moving the set of panels to the vehicle location and wherein at least part of the compartment is assembled and engagement means of respective panels engaged externally of the vehicle and then placed into position in said chamber.

27. A method according to claim 26 wherein at least the side walls, roof and base are assembled together prior to the compartment being moved into the chamber.

28. A method according to claim 27 wherein a compressive force is applied to the at least partially formed compartment to move the roof of the compartment towards the base as the same is moved into the chamber of the vehicle and the compressive force is at least partially released once the compartment is located within the chamber.

29. A method according to any of claims 26 to 28 wherein at least one line of weakening is formed in at least the panels provided to form the side walls of the compartment.

30. A vehicle including a compartment as herein defined in any of claims 1-23.

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