Composite Monocoque Vehicle Structure Without an Internal Chassis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems for manufacturing utility and delivery vehicles face limitations, including the need for improved structural efficiency, reduced weight, and enhanced insulation capabilities, particularly in the use of composite materials and the elimination of internal chassis to increase storage capacity and reduce thermal insulation challenges.
Innovation Solution
A land vehicle with a monocoque structure formed from composite materials, including a core made from lightweight materials like balsa wood or plastic and a shell of resin and fiberglass, supported by a modular system comprising front cage, rear floor, and intermediate mold units, which eliminates the need for an internal chassis and allows for increased storage volume without elevating the floor, thereby improving structural efficiency and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an internal chassis is used to support the vehicle structure, then structural strength is improved, but weight increases and storage capacity decreases
Solution Approach 1:
The patent merges the chassis and body into a single integrated monocoque structure formed from composite materials. This eliminates the need for a separate internal chassis while maintaining structural strength, thereby reducing weight and maximizing storage capacity within the available vehicle envelope.
Solution Approach 2:
The patent employs composite materials (such as fiberglass, carbon fiber, or other fiber-reinforced polymers) to construct the monocoque structure. These materials provide high strength-to-weight ratio, enabling the vehicle to achieve structural strength without the weight penalty of traditional metal chassis systems.
2Volume of stationary object
If the floor is elevated to increase underfloor storage space, then storage capacity is improved, but accessibility worsens due to the need for a step
Solution Approach 1:
The patent utilizes three-dimensional space optimization within the monocoque structure to create storage compartments that extend laterally and vertically without requiring floor elevation. By efficiently packaging storage spaces in available gaps and contours of the vehicle structure, accessibility is maintained while storage capacity is maximized.
3Strength
If metallic materials are used in the vehicle construction, then structural strength is improved, but thermal insulation performance worsens
Solution Approach 1:
The patent replaces metallic materials with composite materials (such as fiberglass, plastic, or foam-based composites) in the monocoque construction. These non-metallic composites inherently provide better thermal insulation properties while maintaining adequate structural strength through their layered and reinforced structures.
Solution Approach 2:
The patent applies different composite materials with varying properties to different regions of the monocoque structure. Areas requiring higher strength use fiber-reinforced composites, while areas prioritizing thermal insulation use foam-based or hollow-core composites, optimizing both strength and insulation locally.
4Device complexity
If a single-piece monolithic structure is used, then structural efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the monocoque manufacturing process into modular mold units that can be independently fabricated and then assembled. This allows the final monolithic structure to be produced through staged molding operations, reducing the complexity of requiring a single巨型 mold while still achieving the structural efficiency of a one-piece construction.
Solution Approach 2:
The patent employs removable and reconfigurable mold units that can be dynamically assembled and disassembled based on production requirements. This modular molding system enables flexible manufacturing of different monocoque configurations while maintaining the structural benefits of a single-piece final product.
Data Source
AI summary
Land vehicles, modular systems for forming monocoques of land vehicles, and methods of forming monocoques of land vehicles using modular systems are disclosed. 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.