Note: Descriptions are shown in the official language in which they were submitted.
CA 2959864 2017-03-02
MODULAR VEHICLE
FIELD
[0001] The present disclosure generally relates to vehicles, and more
particularly to an improved
modular vehicle and methods of assembly thereof.
BACKGROUND
[0002] Typically, multi-passenger buses and other vehicles are constructed of
a chassis onto
which a frame, often made of metal such as steel, is built. Attached onto the
frame are exterior
panels, which are often aluminum or fiberglass. Interior panels are attached
to the frame to form
the interior of the vehicle.
[0003] Multi-passenger vehicles, since they carry passengers that often do not
wear restraints
such as seatbelts, are subject to rigorous safety and crash test standards.
However, since the
frame is rigid and the panels are made of malleable, brittle materials, a
crash or rollover of the
vehicle results in the panels and frame deforming and/or breaking, causing
serious injury to
passengers. This results in a limited residual space (i.e., a survival zone
for passengers) within
the passenger compartment of the bus or vehicle.
[0004] Reinforcement measures have been implemented to increase the structural
integrity of
present frames and panels. For example, steel plates or other heavy, durable
materials are
appended to the frame and/or panels to increase their structural integrity.
[0005] Moreover, sandwich type panel constructions have also been used, such
as to build
recreational vehicles. These include a sandwich panel core material such as
polystyrene, paper,
metal honeycomb, foamed polyurethane, plywood, or fibrous boards. A sandwich
panel facing
material (such as steel, aluminum, plywood, hardboard, or fiberglass-
reinforced plastic) is then
bonded to the core materials and any reinforcing member. Another sandwich
panel facing
material may also be bonded to the core materials on the opposite side as the
sandwich panel
facing material. A support member can then be secured using a fastener to an
outside of the
sandwich panel at the reinforcing member.
[0006] However, these reinforcement techniques (i.e., steel plates and
sandwich type panels)
cause the multi-passenger vehicles to become excessively heavy, creating
issues regarding Gross
Vehicle Weight. Moreover, known sandwich type panels often insufficiently
provide structural
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support to the vehicle, thereby still resulting in deformation and breakage
upon impact during a
crash, roll-over, etc.
SUMMARY
[0007] In general, the present disclosure relates to an improved modular
vehicle, such as a
paratransit passenger bus, optimally configured to satisfy weight and strength
considerations, and
methods for assembling the modular vehicle. A passenger compartment of the
modular vehicle,
such as a bus, includes a roof panel and sandwich-type side panels coupled to
structural joiners
to form the passenger compartment. The side panels and the joiners may include
pultruded
beams for increased structural integrity. A chassis of the vehicle has
channels integrated therein
for coupling of the side panels and passenger compartment to the chassis. This
coupling to the
chassis channel may also include the use of a bonding agent.
[0008] The modular vehicle, according to the disclosure, has an increased
residual space. Gross
vehicle weight is reduced over steel frame vehicle structures, while
structural integrity is
improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of devices, systems, and methods are illustrated in the
figures of the
accompanying drawings which are meant to be exemplary and not limiting, in
which like
references are intended to refer to like or corresponding parts, and in which:
[0010] FIG. 1 A illustrates a perspective view of a modular vehicle according
to embodiments of
the disclosure;
[0011] FIG. 1B illustrates a perspective view of components of the modular
vehicle according to
embodiments of the disclosure;
[0012] FIG. 1C illustrates a perspective view of a passenger compartment of
the modular vehicle
according to embodiments of the disclosure;
[0013] FIG. 1D illustrates a cross-section view of the passenger compartment
of the modular
vehicle according to embodiments of the disclosure, taken along the line AA of
FIG. 1C;
[0014] FIG. 2A illustrates an exploded view of a chassis coupled to a side
panel according to
embodiments of the disclosure;
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[0015] FIG. 2B illustrates the chassis coupled to the side panel according to
embodiments of the
disclosure;
[0016] FIG. 2C illustrates the chassis decoupled from the side panel according
to embodiments
of the disclosure;
[0017] FIG. 2D illustrates a perspective view of an embodiment of the chassis
coupled to the
side panel according to embodiments of the disclosure;
[0018] FIG. 2E illustrates a perspective view of another embodiment of the
chassis coupled to
the side panel according to embodiments of the disclosure;
[0019] FIG. 3 illustrates an exploded view of the side panel according to
embodiments of the
disclosure;
[0020] FIG. 4 illustrates a perspective view of the side panel according to
embodiments of the
disclosure with structural pultrusions shown in phantom;
[0021] FIG. 5 illustrates a side view of the side panel incorporating cutting
lines according to
embodiments of the disclosure with structural pultrusions shown in phantom;
[0022] FIG. 6 illustrates a perspective view of the cut side panel according
to embodiments of
the disclosure with structural pultrusions shown in phantom;
[0023] FIG. 7 illustrates an enlarged view of a first portion of the cut side
panel of FIG. 6
according to embodiments of the disclosure;
[0024] FIG. 8 illustrates an enlarged view of a second portion of the cut side
panel of FIG. 6
according to embodiments of the disclosure;
[0025] FIG. 9 illustrates a cross-section view of a joiner coupled to the side
panel of FIGS. 3
through 8 and a roof panel according to embodiments of the disclosure
[0026] FIG. 10 illustrates a side view of the roof panel according to
embodiments of the
disclosure;
[0027] FIG. 11 illustrates a system for constructing a panel according to
embodiments of the
disclosure;
[0028] FIG. 12 illustrates an alternative system for constructing a panel
according to
embodiments of the disclosure;
[0029] FIG. 13 illustrates an alternative system for constructing a panel
according to
embodiments of the disclosure;
[0030] FIG. 14A illustrates orthogonal pultrusions according to embodiments of
the disclosure;
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[0031] FIG. 14B illustrates orthogonal pultrusions with one of the pultrusions
having a hole cut
therethrough according to embodiments of the disclosure;
[0032] FIG. 14C illustrates an insert for coupling orthogonal pultrusions
according to
embodiments of the disclosure;
[0033] FIG. 14D illustrates orthogonal pultrusions coupled using the insert of
FIG. 14C
according to embodiments of the disclosure;
[0034] FIG. 15A illustrates orthogonal pultrusions coupled using a bracket
according to
embodiments of the disclosure;
[0035] FIG. 15B illustrates orthogonal pultrusions coupled using the bracket
according to
embodiments of the disclosure;
[0036] FIG. 16A illustrates a tee-bracket for coupling pultrusions according
to embodiments of
the disclosure;
[0037] FIG. 16B illustrates a pultrusion having a portion removed from an end
thereof for
coupling pultrusions using the tee-bracket of FIG. 16A according to
embodiments of the
disclosure;
[0038] FIG. 16C illustrates pultrusions coupled using the tee-bracket of FIG.
16A according to
embodiments of the disclosure;
[0039] FIG. 16D illustrates pultrusions coupled using the tee-bracket of FIG.
16A according to
embodiments of the disclosure;
[0040] FIG. 16E illustrates pultrusions coupled using the tee-bracket of FIG.
16A according to
embodiments of the disclosure;
[0041] FIGS. 17A - 17M illustrate major aspects of construction of a modular
paratransit bus
according to the disclosure; and
[0042] FIG. 18 is a flow diagram illustrating steps in a method to construct a
modular vehicle
according to the disclosure.
DETAILED DESCRIPTION
[0043] Detailed embodiments of devices, systems, and methods are disclosed
herein, however, it
is to be understood that the disclosed embodiments are merely exemplary of the
devices,
systems, and methods, which may be embodied in various forms. Therefore,
specific functional
details disclosed herein are not to be interpreted as limiting, but merely as
a basis for the claims
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and as a representative basis for teaching one skilled in the art to variously
employ the present
disclosure.
[0044] In general, the present disclosure provides an improved modular vehicle
and methods for
assembling the modular vehicle. The modular vehicle is optimally configured to
satisfy weight
and strength considerations. A passenger compartment of the modular vehicle
includes a roof
panel and sandwich-type side panels coupled to joiners using a bonding agent,
such as resin.
Both side panels and the joiners include pultruded beams for increased
structural integrity. A
chassis of the vehicle has channels integrated therein for coupling of the
panels to the chassis
using a bonding agent, for example. As a result, the modular vehicle has an
increased residual
space.
[0045] Referring to FIGS. 1 A through 1D, a modular vehicle 101 having a
modular passenger
compartment 100 according to the present disclosure is described. The modular
vehicle 101
includes a driver compartment 103 coupled to the passenger compartment 100
and/or a chassis
102 using a fastener such as an adhesive, resin, epoxy, or the like. The
driver compartment 103
may be bonded to a front panel 105 of the passenger compartment 100.
[0046] The passenger compartment 100, which couples to a portion of the
chassis 102, is formed
of two sandwich-type side panels 104 that are each coupled at or proximate an
edge of the
chassis 102, joiners 106 that are each coupled to an edge of a side panel 104,
and a roof panel
108 coupled to the joiners 106. As illustrated (best illustrated in the
perspective view of FIG.
1C), each joiner 106 spans the length (front to back) of the passenger
compartment 100.
However, one skilled in the art should appreciate the joiners 106 could be
configured having
lengths not commensurate in scope with lengths of the passenger compartment
100. For
example, each joiner 106 may have a length shorter than that of the passenger
compartment 100,
thereby resulting in more than one joiner 106 being used on each side of the
passenger
compartment 100 in order to cover the length of the passenger compartment 100.
In this
alternative construction, a seal would be introduced between each section of
joiner 106.
[0047] FIGS. 1D, 2A through 2C illustrate the chassis 102 coupled to the side
panel(s) 104. The
chassis 102 includes a channel(s) 200, such as a U channel, for, example. The
channel 200 is
formed by a first side 203, a bottom portion 205, and a second side 207. The
channel 200 may or
may not have a length commensurate with the length of the chassis 102 and/or
side panel 104 but
in most implementations that may be desirable. The side panel 104 is coupled
to the channel 200
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=
of the chassis 102. Such coupling may include the use of a bonding agent, such
as resin, epoxy,
or the like. For example, the side panel 104 may be coupled to the chassis 102
(i.e., the first side
203, the bottom portion 205, and/or the second side 207) using a one (1)
component
polyurethane adhesive, such as Sikaflex 252 or 255, offered by Sika
Corporation of Lyndhurst,
New Jersey. Neither, one, or both of the sides 203, 207 may have one or more
angled edges 202
that provide structural integrity to the channel 200 and/or provide a guide
mechanism to help
guide the edges of the side panels 104 into the channel 200 during assembly of
the compartment
to the chassis 102. The angled edges 202 may also provide increased surface
area for bonding of
the side panels 104 to the channel 200. Although not shown, it should be
appreciated that edges
of the side panel may have mechanical structures such as bumps or detents to
mate with
corresponding mechanical features formed in the chassis channel in order to
provide a friction fit
and supplement a bonding agent in attaching the compartment/side panels to the
chassis.
[0048] FIG. 2D illustrates a specific embodiment for coupling the side panel
104 to the chassis
102. According to this embodiment, the channel 200 is formed by two portions
(i.e., the bottom
portion 205 and the first side 203). The first side 203 may be an interior
side of the channel 200.
That is, the first side 203 may abut a surface of the side panel 104 that
faces an interior of a fully
constructed modular vehicle as described herein. The side panel 104 may be
coupled to the
bottom portion 205 and/or the first side 203 using a bonding agent, such as
resin, epoxy, or the
like.
[0049] FIG. 2E illustrates another specific embodiment for coupling the side
panel 104 to the
chassis 102. According to this embodiment, the channel 200 is formed by two
portions (i.e., the
bottom portion 205 and the second side 207). The second side 203 may be an
exterior side of the
channel 200. That is, the second side 207 may abut a surface of the side panel
104 that forms an
outer surface of a fully constructed modular vehicle as described herein. The
side panel 104 may
be coupled to the bottom portion 205 and/or the second side 207 using a
bonding agent, such as
resin, epoxy, or the like.
[0050] Referring now to FIGS. 3 and 4, a side panel 104 according to the
present disclosure is
described. Side panels may be configured and constructed as described in
detail in commonly
owned, co-pending U.S. Patent Application Serial No. 14/739,569 filed June 15,
2015, which is
incorporated herein by reference in its entirety, filed by the same inventors
as the present
application. The panel 104 includes a first outer sheet 302, a second outer
sheet 304, one or
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more pultruded box beams or "pultrusions" 306 disposed between the first outer
sheet 302 and
the second outer sheet 304, and one or more core material portions 308
disposed between the
first outer sheet 302 and the second outer sheet 304. In an example, the panel
104 may be a
modular panel configured for use in a paratransit passenger bus. Accordingly,
the panel 104 may
be about 169 inches by about 81 inches, for example.
[0051] The first and second outer sheets 302, 304 may be monolithically formed
as single pieces,
and act as a type of skin of the panel 104. For example, the first and second
outer sheets 302,
304 may be fiber reinforced plastic or fiber reinforced polymer (FRP). The
outer sheets 302, 304
may also be coated, embossed, laminated, or otherwise provide decorative
appeal to the panel
104.
[0052] The one or more pultruded box beams 306 may be disposed in selected
locations between
the first and second outer sheets 302, 304 to provide necessary weight,
strength, and structural
aspects to the panel 104. As illustrated, the panel 104 is designed to be used
as a side panel for a
modular vehicle, such as a bus or paratransit bus, so the pultruded box beams
306 are optimally
sized for strength and structural weight considerations. For example the
pultrusions 306 could
be square or rectangular, or the like, and dimensioned to be from about 1 to 3
inches by about 1
to 3 inches formed as square or rectangular beams to provide desired strength
and weight
characteristics for the illustrative paratransit bus side panel
implementation. In an illustrative
embodiment, the pultrusions 306 may be 1.5 inch by 1.5 inch square beams. In
this example, the
one or more box beams 306 include four substantially vertical portions 310 and
two substantially
horizontal portions 312. The four substantially vertical portions 310 are
spaced apart from one
another along a horizontal length of the panel 104 at a distance in a range of
approximately 30 to
55 inches, or otherwise spaced for window placement and to maintain structural
integrity.
[0053] Similarly, the two horizontal sections 312 of the pultruded box beams
306 are optimally
sized for strength and structural weight considerations. The horizontal
pultrusions 312 are
positioned below a center line of the panel 104 at a distance between each
pultrusion in a range
of approximately 30 to 55 inches. This allows for windows and other features
of a side of the
modular vehicle to be formed utilizing the load carrying characteristics of
the integrated frame
and side panel 104 without the weight and complexity of welded metal framing.
[0054] The core material 308 may fill the space between the first and second
outer sheets 302,
304, as well as between the various pultruded box beams 306. The core material
308 may be a
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foam, or other lightweight, durable material, such as high-density and closed-
cell foam. In an
example, when the core material 308 is a solid type material, the core
material 308 may include
one or more portions disposed between the horizontal and vertically disposed
pultruded box
beams 306. In another example, when the core material 308 is a solid type
material, the core
material 308 may include recesses or channels 314 formed therein, in which
case the box beams
306 are disposed in the channels 314.
[0055] In one example, the side panel 104 may be formed by coupling the first
outer sheet 302 to
a first side of the box beams 306 and coupling the second outer sheet 304 to a
second side,
opposite the first side, of the box beams 306. The core material 308 may then
be injected
between the first and second outer sheets 302, 304 and the box beams 306. In
another example,
the panel 104 may be formed by positioning the box beams 306 in channels 314
and coupling the
box beams 306 to the core material 308. The first outer sheet 302 is then
coupled to a first side
of the box beams 306 and core material 308 and the second outer sheet 304 is
then coupled to a
second side, opposite the first side, of the box beams 306 and core material
308.
[0056] In yet another example, the panel 104 may be formed by positioning the
box beams 306
between sheets or portions of the core material 308 and coupling the box beams
306 to the core
material 308. The first outer sheet 302 is then coupled to a first side of the
box beams 306 and
core material 308 and the second outer sheet 304 is then coupled to a second
side, opposite the
first side, of the box beams 306 and core material 308, as described in
greater detail hereinafter.
[0057] The various elements (the first outer sheet 302, the second outer sheet
304, the box beams
306, and the core material 308) may be coupled together via bonding to
construct a side 104
panel with an integrated structural frame. This may include bonding using one
or more bonding
agents, such as, adhesives, resins, etc.
[0058] As mentioned above, the panel 104 is designed to be used as a
lightweight structural side
panel with an integrated frame for a modular vehicle, such as a bus or
paratransit bus. For
example, in FIG. 5, a paratransit bus side panel 104 with an integrated
structural frame is
illustrated having outlines for one or more windows 500 and a wheel well 502
to be cut out after
the modular side panel 104 is assembled as described hereinafter. The one or
more windows
500, wheel well 502, and a perimeter 504 of the side panel 104 may then be
cut, resulting in the
side panel 104 illustrated in FIG. 6 having a fully integrated structural
frame comprised of
vertical and horizontal box beam pultrusions 310, 312 as described herein
before. In this
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example, the windows 500 are located between the four vertically oriented box
beams 310 and
vertically above the horizontally positioned box beams 312. This allows the
side panel 104 of
the vehicle to be constructed as a modular panel with integrated structural
components without
compromising the structure of the vehicle. However, it should be appreciated,
that box beams
306 may be oriented in any of various directions and spacings to accommodate
other features of
a side panel 104 of a vehicle or modular application to be formed with fully
integrated structural
components comprising the box beams 310, 312.
[0059] Referring to FIGS. 7 and 8, the box beams 306 provide for increased
strength as well as a
lighter side wall of a vehicle than that of any conventional vehicle side wall
construction. As
illustrated in FIG. 8, the modular side panel 104 also allows for a greater
radius in the windows
500 than that of conventional vehicle side wall construction. This greater
radius in the window
500 provides increased strength at window connections.
[0060] Referring now to FIG. 9, the joiner 106 for connecting a roof panel and
side panels to
form a modular vehicle according to the present disclosure is described. The
joiner may be
configured and constructed as described in detail in commonly owned, co-
pending U.S. Patent
Application Serial No. 14/806,730, filed July 23, 2015, which is incorporated
herein by reference
in its entirety, filed by the same inventors as the present application. The
joiner 106 includes an
inner extrusion 900, an outer extrusion 902, and optionally one or more
pultruded box beams
306. The inner and outer extrusions 900, 902 may be coated, embossed,
laminated, or otherwise
provide decorative appeal to the joiner 106.
[0061] The inner extrusion 900 is an arcuate structure having an arcuate or
curved surface 904
that is convex with respect to an inner passenger compartment when
implemented. Furthermore,
one or more support channels 901, 903, 905, 907 are created along the curved
surface 904 by
walls 909, 911, 913, 915, 917, 919 that extend from the curved surface 904.
For example, these
walls 909, 911, 913, 915, 917, 919 may perpendicularly extend from the curved
surface 904.
Moreover, the curved surface 904 may have at least one substantially linear or
planar surface
from which the walls 909, 911, 913, 915, 917, 919 extend. One or more box beam
channels 903,
905 may be created by the walls 909, 911, 913, 915, 917, 919 proximate to ends
of the curved
surface 904. Additionally, a side panel channel 901 is created proximate to or
at an end of the
curved surface 904 and a roof panel channel 907 is created proximate or at a
different end of the
curved surface 904. One or both of the sidewall panel and roof panel channels
901, 907 may be
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CA 2959864 2017-03-02
partially created by the curved surface 904 and partially created by a wall
909, 919 of a
proximate box beam channel 903, 905.
[0062] The outer extrusion 902, like the inner extrusion 900, is also an
arcuate structure having
an arcuate or curved surface 906 that is convex with respect to an inner
passenger compartment
when implemented. As illustrated, the arcuate surface 906 of the outer
extrusion 902 does not
have a uniform curve (it contains one or more bends). However, one skilled in
the art should
appreciate that the arcuate surface 906 of the outer extrusion 902 may be
substantially or
perfectly arcuate without departing from the scope of the present disclosure.
A rigid channel 908
may be defined within or proximate to an end of the outer extrusion 902, which
allows for
cables, lines, such as refrigerant lines, and the like to be passed through
the joiner 106. Walls
923, 925, 929, 931, 933, 939 extend from the curved surface 906 and/or rigid
channel 908 to
create a side panel channel 921, roof panel channel 937, and one or more box
beam channels
927, 935. These walls 923, 925, 929, 931, 933, 939 may perpendicularly extend
from the curved
surface 906 and/or rigid channel 908, for example. Each of the one or more box
beam channels
927, 935 houses one or more box beams 306. At least one of the box beam
channels 927, 935
may be created by walls 923, 925, 929, 931, 933, 939 proximate ends of the
curved surface 906.
The side panel channel 921 is created proximate to or at an end of the curved
surface 906 and the
roof panel channel 937 is created proximate to or at a different end of the
curved surface 906.
One or both of the side panel and roof panel channels 921, 937 may be
partially created by the
curved surface 906 and/or a wall 923, 939 of a proximate box beam channel 927,
935. A portion
of the rigid channel 908 may be used to create either a portion of the side
panel channel 921 or a
portion of the roof panel channel 937, or the rigid channel 908 may not form a
portion of either
the side panel channel 921 or roof panel channel 937. Moreover, a portion of
the rigid channel
908 may be used to partially create one or more of the box beam channels 927,
935.
[0063] An illustrative method for assembling the extrusions 900, 902 into the
joiner 106 is
described as follows. An adhesive may be applied to one or more box beam(s)
306 and/or box
beam channels 903, 905 of the inner and the outer extrusions 900, 902. The box
beam(s) 306 are
placed within/coupled to the box beam channels 903, 905 of either the inner or
outer extrusion
900, 902. The box beam channels of the extrusion (either inner or outer) not
containing the box
beams(s) 306 are coupled to the box beam(s) 306. Alternatively, the box beam
channels of
CA 2959864 2017-03-02
respective inner and outer extrusions 900, 902 may be coupled to the box
beam(s) 308
simultaneously.
[0064] Furthermore, the box beams 306 within the joiner 106 may be used to
pass cables, lines,
and the like through the joiner 106. The one or more box beams 306 may be
disposed in selected
locations within the box beam channels 903, 905, 927, 935 of the inner and
outer extrusions 900,
902 to provide necessary weight, strength, and structural integrity to the
joiner 106. Thus, each
box beam 306 may have a length substantially equal to or identical to the
length of the structural
joiner 106, resulting in a single box beam 306 being implemented within each
box beam channel
903, 905, 927, 935. However, one skilled in the art should appreciate the box
beams 306 having
different lengths resulting in one or more box beams 306 being implemented
within a single box
beam channel 903, 905, 927, 935 of the joiner 106.
[0065] Unassembled, the box beam 903, 905, 927, 935, side panel 903, 905, 927,
935, and roof
panel 907, 937 channels of the inner and outer extrusions 900, 902 each only
partially house the
box beam(s) 306, side panel 104, and roof panel 108. When assembled, these
channels of the
inner extrusion 900 correspond with respective channels of the outer extrusion
902 (i.e., 901-
921, 903-927, 905-935, 907-937) to fully encapsulate or house the box beams(s)
306, portions of
the side panel 104, and portions of the roof panel 108. All or some of the
channels (that is the
box beam 903, 905, 927, 935, side panel 901, 921, roof panel 907, 937, and
rigid 908 channels)
may run parallel or substantially parallel to each other along their
respective extrusion 900, 902.
[0066] As illustrated, the joiner 106 is constructed of two separate and
distinct extrusions 900,
902. However, one skilled in the art should appreciate the joiner 106 being
constructed of a
single unitary structure that resembles the two extrusions 900, 902 coupled
together. Regardless
of the construction methodology used, a channel 910 is formed between the two
arcuate surfaces
904, 906. This channel 910 may be used to pass materials through the joiner
106, such as cables,
refrigerant lines, and the like, for example.
[0067] Coupling of the inner and outer extrusions 900, 902, when not a single
unitary structure,
may include ensuring respective channels of the extrusions 900, 902 (such as
box beam-box
beam 903, 905, 927, 935, side panel-side panel 901, 921, roof panel-roof panel
907, 937, etc.)
substantially or perfectly correspond to or line up with each other. Moreover,
coupling of the
extrusions 900, 902 may include the use of an adhesive, epoxy, resin, or like
light weight,
durable bonding material. For example, a structural adhesive, such as Sikaflex
3131s or 3121s
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CA 2959864 2017-03-02
offered by Sika Corporation of Lyndhurst, New Jersey, a methyl methacrylate
adhesive, or a two
(2) component adhesive may be used to adjoin portions of the inner and outer
extrusions 900,
902 to the roof panel 108 and the box beam(s) 306 interspersed between the
inner and outer
extrusions 900, 902 and proximate to the roof panel 108. For further example,
a structural
adhesive, such as Sikaflex 3131s or 3121s offered by Sika Corporation of
Lyndhurst, New
Jersey, a methyl methacrylate adhesive, or a two (2) component adhesive may be
used to adjoin
portions of the inner and outer extrusions 900, 902 to the side panel 104.
Moreover, a structural
adhesive, such as Sikaflex 3131s or 3121s offered by Sika Corporation of
Lyndhurst, New
Jersey, a methyl methacrylate adhesive, or a two (2) component adhesive may be
used to adjoin
the box beam(s) 306 (which are proximate to the side panel 104) to surfaces
909, 911, 913, 915,
925, 929, and 931of the inner and outer extrusions 900, 902. Yet further, a
single component
polyurethane adhesive, such as Sikaflex 252 or 255, offered by Sika
Corporation of Lyndhurst,
New Jersey, may be used to bond the box beam(s) 306 (which are proximate to
the side panel
104) to surfaces of the inner and outer extrusions 900, 902 that form part of
the channels 903,
927.
[0068] Core material may be disposed within the channels created by and within
the inner and
outer extrusions 900, 902. The core material may impart further structural
integrity to the joiner
106. For example, the core material may be disposed in the channels 903, 905,
927, 935 that
house the box beams 306 in a way that either completely fills the box beam
channels, forms a
barrier between the channel walls 909, 911, 913, 915, 917, 919, 923, 925, 929,
931, 933, 939 and
the box beam(s) 306, and/or fills the box beam(s) 306. The core material may
be a fluid, foam,
or other lightweight, durable material.
[0069] Referring now to FIG. 10, a roof panel 108 is illustrated according to
the present
disclosure. The roof panel 108 may include the first outer sheet 302, the
second outer sheet 304,
and core material 308 disposed between the first outer sheet 302 and the
second outer sheet 304.
As illustrated, the roof panel 108 may be curved. However, one skilled in the
art should
appreciate the roof panel being substantially planar without departing from
the scope of the
present disclosure.
[0070] One or more box beams 306 may also be disposed between the first outer
sheet 302 and
the second outer sheet 304 of the roof panel 108. The box beam(s) 306 may
extend from a first
end 1002 to a second end 1004 of the roof panel 108 with exemplary dimensions
as described for
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the modular side panels 104 as described above. Inclusion of the box beam(s)
306 within the
roof panel 108 may provide added strength to the roof panel 108 and may add
significant
strength and protection in the event of a rollover of the modular vehicle. It
should be appreciated
by those skilled in the art that other roof panel constructions may be
implemented for integration
with a modular side panel and joiner to construct a modular vehicle
compartment according to
the present disclosure. Inclusion of a box beam(s) 306 within the roof panel
108 may also allow
for harness and refrigerant lines, etc. to be passed through the roof panel
108. This may be
particularly beneficial when an air conditioning unit is placed atop the roof
panel 108.
[0071] Referring to FIG. 11, a system 1100 for forming the side (and possibly
roof) panels 104,
108 is disclosed. The system 1100 is configured to limit delarnination of the
elements of the
panels 104, 108. The outer sheets 302 and 304 are created by running glass
fiber, mat, or cloth
through a resin (e.g., polyester) bath 1102. In an example, each outer sheet
302, 304 may have a
thickness of about 0.05 inches to about 0.15 inches. The wet outer sheets 302,
304 containing
resin are moved to separate walls of a preformer 1104. At the preformer 1104,
the beams 310,
312 and the core material 308 are strategically placed at locations between
the outer sheets 302,
304. Veils 1106 may be applied to the outer sheets 302, 304 just before or
while the wet outer
sheets 302, 304 enter the preformer 1104. The veils 1106 are additional
materials/layers added
to the laminar structure during construction that provide additional
characteristics, such as
assisting in the protection of the outer sheets 302, 304 from wear, tear, and
other degradation.
As the outer sheets 302, 304 are moved through the preformer 1104, the
preformer 1104 applies
pressure to exterior sides of the outer sheets 302, 304 to press the sheets
302, 304 against the
beams 310, 312 and the core material 308, thereby producing a panel having a
desired cross-
section and size. The resulting pressed panel is moved to a heated steel die
1108 that maintains
the shape of the panel and cures the resin of the panel.
[0072] While the heated steel die 1108 is illustrated as being separate from
the preformer 1104,
one skilled in the art should appreciate the heated steel die 1108 being
integrated within the
preformer 1104 without departing from the scope of the present disclosure. The
cured panel is
pulled by a puller 1110 from the heated steel die 1108 and sent to a cutter
1112, where window
holes and wheel well(s) may be cut into the panel. In an example, after the
panel is cured but
prior to the panel reaching the cutter 1112, the outer surfaces of the panel
may be
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'
laminated/finished (not illustrated). That is, a decorative interior/exterior
surface material may
be applied as a finish for a fully constructed modular panel prior to cutting
of the modular panel.
[0073] FIG. 12 illustrates an alternative system 1200 for forming the panels
104, 108. An outer
sheet 302 is disposed upon a lower press 1202. A bonding agent such as resin,
epoxy, or the like
is disposed upon an upper surface of the outer sheet 302 (i.e., the surface
not contacting the
lower press 1202). Pultrusions 310, 312 and core material 308 are
strategically placed upon the
bonding agent covered surface of the outer sheet 302 in a manner that
addresses weight and
structural considerations. Bonding agent is placed upon exposed surfaces of
the pultrusions 310,
312 and core material 308. Another outer sheet 304 is disposed upon the
bonding agent covered
surfaces of the pultrusions 310, 312 and core material 308. An upper press
1204 is brought in
contact with the outer sheet 304, and pressure is applied to the outer sheets
302, 304 by the
presses 1202, 1204 until a panel according to the present disclosure is
obtained. Moreover, the
presses 1202, 1204 may introduce heat to the material interposed therebetween.
Addition of heat
allows for the curing process to be achieved more rapidly.
[0074] Referring to FIG. 13, a still further alternative system 1300 for
forming the panels 104,
108 is described. An outer sheet 302 is disposed within a vacuum bag 1302. A
bonding agent
such as resin, epoxy, or the like is disposed upon an upper surface of the
outer sheet 302 (i.e., the
surface not contacting the vacuum bag 1302). Core material 308 is placed upon
the bonding
agent covered surface of the outer sheet 302 in a manner that addresses weight
and structural
considerations. Bonding agent is placed upon an exposed surface of the core
material 308 and
another outer sheet 304 is disposed upon the bonding agent covered surface of
the core material
308. Upper and lower presses 1204, 1202 are brought in contact with the vacuum
bag 1302, and
pressure is applied to the outer sheets 302, 304 by the presses 1202, 1204 and
vacuum bag 1302
(i.e., air is removed from the vacuum bag 1302) until a panel according to the
present disclosure
is obtained. Moreover, the presses 1202, 1204 may introduce heat to the
material interposed
therebetween. Addition of heat allows for the curing process to be achieved
more rapidly. In an
example, the upper press 1204 is not utilized. According to this example, the
only forces applied
to the materials of the panel are from the vacuum bag 1302 when air is removed
from the
vacuum bag 1302.
[0075] As described with respect to FIG. 13, materials of the panel are added
into the vacuum
bag 1302 as they are layered. However, one skilled in the art should
appreciate the materials of
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CA 2959864 2017-03-02
the panel not being added to the vacuum bag 1302 until layering of the
materials is complete.
Moreover, while the illustrated panel produced by the system 1300 does not
include pultrusions
306, one skilled in the art should appreciate the panel produced by the system
1300 including
pultrusions 306 placed for weight and structural considerations.
[0076] As described with reference to FIGS. 11 through 13, the panels
according to the present
disclosure may be formed with the box beams 310, 312 being uncoupled or
unattached to each
other (i.e., they are attached by the resin to the outer sheets 302, 304).
However, in an alternative
implementation the box beams 310, 312 may be coupled prior to the box beams
310 and 312
being formed in a modular panel with the outer sheets 302, 304.
[0077] FIGS. 14A through 14D illustrate a mechanism for coupling orthogonally
disposed box
beams 306 (illustrated in FIG 14A) using an insert 1400 (illustrated in FIG.
14C). A hole 1402
(illustrated in FIG. 14B) is cut into a side surface of one of the box beams
(either the horizontal
beam or the vertical beam). A base portion 1404 of the insert 1400 is
frictionally fit within an
end of a box beam. The insert 1400 may be made of a durable material such as
steel, aluminum,
or the like. In an example, the insert 1400 may be attached within the end of
the box beam using
a resin, epoxy, adhesive, or the like. An extension portion 1406 of the insert
is mated to or
inserted through the hole 1402 cut out of the orthogonal box beam. The
extension portion 1406
of the insert 1400 inserted through the hole 1402 may be maintained in
position using friction, or
may be held in position using a bonding agent such as a resin, epoxy,
adhesive, or the like.
[0078] FIGS. 15A and 15B illustrate an alternative mechanism for coupling
orthogonal box
beams 306 using a bracket 1500. An insert portion 1502 of the bracket 1500 is
fit within an end
of a box beam. Fitting of the insert portion 1502 of the bracket 1500 within
the end of the box
beam may occur frictionally, or through the use of a bonding agent such as
epoxy, glue, and the
like. The bracket 1500 also has an abutment surface 1504 that couples to a
surface of a box
beam orthogonal to the box beam that has the insert portion 1502 of the
bracket 1500 inserted
therein. Coupling of the bracket 1500 to the surface of the box beam may occur
through the use
of a bonding agent, such as glue or the like, and/or through the use of one or
more fasteners 1506
such as rivets, machine screws, or the like, for example. Moreover, the
abutment surface 1504 of
the bracket 1500 that couples to the surface of the box beam may have one or
more edges
extending therefrom that increase the efficiency of coupling when using a
bonding agent. The
bracket 1500 may be a durable material such as aluminum, ABS, nylon, or the
like, for example.
CA 2959864 2017-03-02
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[0079] FIGS. 16A through 16E illustrate a further mechanism for coupling box
beams 306 using
a tee-bracket 1600 (illustrated in FIG. 16A). As illustrated in FIG. 16B, a
portion of a surface at
the end of a box beam 1602 is removed and a portion of the bracket 1600 is
inserted into the end
of the box beam 1602 until a surface of the bracket 1600 orthogonal to the
portion of the bracket
1600 inserted into the box beam 1602 abuts a surface of the box beam 1602.
This may result in
the box beam 1602 housing more of the bracket 1600 than the other box beams
1604, 1606
respectively. The other box beams 1604, 1606 are then coupled to portions of
the bracket 1600
not inserted into the box beam 1602. As illustrated, the box beams 1602, 1604,
1606 are coupled
to the bracket 1600 in a manner that results in the box beams 1602, 1604, 1606
abutting each
other. However, one skilled in the art should appreciate the box beams 1602,
1604, 1606 being
coupled to the bracket 1600 in a manner that does not result in the box beams
1602, 1604, 1606
abutting. The box beams 1602, 1604, 1606 may be frictionally coupled to the
bracket 1600
and/or may be coupled to the bracket 1600 using a bonding agent. Moreover, if
the box beams
1602, 1604, 1606 are installed to abut, the box beams 1602, 1604, 1606 may be
coupled to one
or more abutting box beam using a bonding agent, for example.
[0080] The outer sheets 302, 304 may be one or more of fiber reinforced
plastic or fiber
reinforced polymer (FRP), an electrically-conductive polymer, gel coatings,
resins, thermoplastic
polyolefin (TPO), carbon fiber, aluminum (e.g., stainless), acrylonitrile
butadiene styrene (ABS),
etc. The outer sheets 302, 304 may also be coated or provide decorative appeal
to the panel 104.
[0081] The box beams 306 may be formed of a pultruded combination of
fiberglass
reinforcements and thermosetting polyester or vinyl ester resin systems, such
as those sold under
the name EXTREN by Strongwell Corporation. The pultruded box beams 306 may
provide
corrosion resistance, low thermal conductance, low electrical conductance,
electromagnetic
transparency, light weight, high strength, fire resistance, and/or dimensional
stability to the
modular panel 104. The box beams 306 may also be formed of aluminum, steel,
wood,
acrylonitrile butadiene styrene (ABS), or a like durable material, for
example.
[0082] While the positions of the box beams 306 in the panel 104 are described
and illustrated in
connection with a panel of a vehicle, the box beams 306 may be positioned in
other locations to
provide strength for other types of applications. For example, in the case of
a solid wall,
vertically oriented box beams 310 may be equally spaced along a length of the
wall, and/or
horizontally oriented box beams 312 may be equally spaced along a height of
the wall. In some
16
CA 2959864 2017-03-02
'
applications, the location and position of the box beams 306 are tailored to
areas where
additional components may be connected to and supported by the panel 104 or
other structure
formed in a similar manner as the panel 104.
[0083] Further, while the pultruded box beams 306 are described and
illustrated as having a
square or rectangular cross-sectional shape, the box beams 306 may have other
cross-sectional
shapes. For example, the box beams 306 may have triangular, trapezoidal, or
other polygonal
cross-sections that have appropriate strength and surface area.
[0084] The core material 308 may be a foam, or other material. In one example,
the core
material 308 may be a light weight fill material, such as, foam sheets,
polymer sheets,
honeycomb polymer or metal, injectable foam or polymer. The core material 308
may be
polyurethane, polystyrene or other light weight polymer in any form (foam,
honeycomb, sheet,
injectable, etc.), balsa wood, and other lightweight materials. The core
material 308 may also be
selected to provide certain properties. For example, the core material 308 may
be selected to
provide additional strength, corrosion resistance, thermal insulation, etc.
[0085] Although the chassis herein is described as having a "u-shaped" channel
for receiving
edges of side panels, it should be appreciated that the u-shaped channels
could include other
geometries and features to facilitate interconnection of the side panels to
the chassis.
[0086] The above embodiments of the present disclosure are meant to be
illustrative. They were
chosen to explain the principles and application of the disclosure and are not
intended to be
exhaustive or to limit the disclosure. Many modifications and variations of
the disclosed
embodiments may be apparent to those of skill in the art. Moreover, it should
be apparent to one
skilled in the art, that the disclosure may be practiced without some or all
of the specific details
and steps disclosed herein.
[0087] FIGS. 17A - 17M illustrate major aspects of construction of a modular
paratransit bus
according to the disclosure. A cab 103 is generally received as a constructed
assembly from a
vehicle manufacturer such as _Chrysler , Ford*, General Motors , or Promaster
, and a
chassis 102 having u-shaped channels 200 is mechanically fastened to the cab
103. In this
illustrative embodiment the cab 103 is configured with beam receivers 1700 and
the chassis 102
is configured with protruding beams 1702 for insertion into the beam receivers
1700 (illustrated
in FIG. 17A). Mechanical fasteners such as nuts/bolts, welds, or the like may
be implemented to
retain the beams 1702 in the beam receivers 1700.
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CA 2959864 2017-03-02
[0088] FIGS. 17B and 17C illustrate installation of a front panel 1704 to the
cab 103 and the
chassis 102. The front panel 1704 is placed centrally along a width of the cab
103 and/or the
chassis 102. Shims may be used to properly align the front panel 1704. The
front panel 1704
may be fastened to the cab 103 and/or the chassis 102 using an adhesive 1706.
For example, a
bead of adhesive 1706 may be layered along a back surface of the cab 103, a
top surface of the
chassis 102 proximate the back surface of the cab 103, and/or surfaces of the
front panel 1704
that mate with surfaces of the cab 103 and chassis 102 once installed.
Additionally or
alternatively, other fasteners, such as nuts/bolts, screws, or the like may be
used to couple the
front panel 1704 to the cab 103 and/or chassis 102. In an example, three (3)
screws are used to
couple the front panel 1704 to a bulkhead panel of the cab 103.
[0089] FIGS. 17D through 17F illustrate installation of the roof panel 108
onto inner extrusions
900 of structural joiners 106. As illustrated in FIG. 17D, the structural
joiners may be held in a a
jig or frame so that pultrusions or box beams 306 are inserted into channels
of the inner
extrusions 900. The pultrusions 306 may be held into the channels using
clamps, such as deep
throat clamps, for example. In an example, the pultrusions 306 may be bonded
to the inner
extrusions 900 using an adhesive, such as the adhesive 1706.
[0090] FIGS. 17G through 171 illustrate coupling of the inner extrusions 900
of the structural
joiner 106 to the side panels 104. Each side panel 104 is mated to walls of
the support channel
901 of an inner extrusion 900. The side panel 104 may be coupled to a support
channel 901
using an adhesive, such as the adhesive 1706. If an adhesive is used, clamps,
such as deep throat
claims, may be used to hold the side panels 104 and inner extrusions 900
together to ensure
adequate coupling.
[0091] FIG. 17J illustrates installation of the outer extrusions 902. Each
outer extrusion 902 has
box beam channels 927, 935 that receive the box beams 306. Each outer
extrusion 902 also has
surfaces that mate with and couple to the roof panel 108 and a side panel 104
respectively.
Coupling of the outer extrusions 902 of the joining structure 106 to the box
beams 306, roof
panel 108, and side panels 104 may involve the use of an adhesive and/or
mechanical fasteners,
such as screws, nuts/bolts, welds, or the like.
[0092] FIGS. 17K and 17L illustrates installation of side and roof panels 104,
108 onto the
chassis 102. Portions of the side panels 104 are received by the u-shaped
channels 200 of the
chassis 102. Coupling of the side panels 104 to the u-shaped channels 200 may
involve the use
18
CA 2959864 2017-03-02
of an adhesive and/or mechanical fasteners, such as screws, nuts/bolts, welds,
or the like. A
downward force may be applied to the top of the roof panel 108 and an upward
force may be
applied to the bottom of the chassis 102 to ensure adequate coupling of the
side panels 104 to the
chassis 102. Moreover, shims may be used to ensure the side panels 104 are
positioned desirable
within the u-shaped channels 200.
[0093] FIG. 17M illustrates an assembled modular paratransit bus according to
the disclosure. A
back panel 1708 may be coupled to back portions of the roof panel 108 and side
panels 104.
Coupling of the back panel 1708 may involve the use of an adhesive.
[0094] There are several types of adhesives that may be used during assembly
of the modular
paratransit bus of the present disclosure. For example, a moisture cured,
single or double
component, polyurethane adhesive may be used. Such a polyurethane adhesive may
include
Sikaflex 252 FC, offered by Sika Corporation of Lyndhurst, New Jersey.
Alternatively or in
addition, a methyl methacrylate, two (2) component structural adhesive or two
(2) component
epoxy may be used. An example of a suitable two (2) component structural
adhesive is
Sikafast 3131s, offered by Sika Corporation of Lyndhurst, New Jersey.
[0095] FIG. 18 illustrates a series of steps in construction of a modular
vehicle using
components as described herein. At block 1800, the cab is coupled to the
chassis. At block
1802, the front panel is coupled to the cab and the chassis. At block 1804,
the roof panel is
coupled to the inner extrusions structural joiner. At block 1806, the side
panels are coupled to
the inner extrusions of the structural joiner. At block 1808, the outer
extrusions are coupled to
the roof panel, box beams, and side panels. At block 1810, the roof and side
panels are coupled
to the chassis and front panel. At block 1812, the back panel is coupled to
the roof and side
panels.
[0096] The concepts disclosed herein may be applied within a number of
different devices and
systems, including, for example, vehicles, watercraft, residential
construction, commercial
construction, etc. The specification and drawings are, accordingly, to be
regarded in an
illustrative rather than a restrictive sense. It should, however, be evident
that various
modifications and changes may be made thereunto without departing from the
broader spirit and
scope of the disclosure as set forth in the claims.
19
