EP3081449A1 - Floor construction for a vehicle - Google Patents
Floor construction for a vehicle Download PDFInfo
- Publication number
- EP3081449A1 EP3081449A1 EP16154928.2A EP16154928A EP3081449A1 EP 3081449 A1 EP3081449 A1 EP 3081449A1 EP 16154928 A EP16154928 A EP 16154928A EP 3081449 A1 EP3081449 A1 EP 3081449A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- planks
- floor
- vehicle according
- vehicle
- rails
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000010276 construction Methods 0.000 title description 2
- 239000011162 core material Substances 0.000 claims abstract description 26
- 238000009408 flooring Methods 0.000 claims abstract description 14
- 229920005989 resin Polymers 0.000 claims abstract description 14
- 239000011347 resin Substances 0.000 claims abstract description 14
- 239000002131 composite material Substances 0.000 claims abstract description 10
- 239000000463 material Substances 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 14
- 238000005520 cutting process Methods 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 239000012783 reinforcing fiber Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 230000008878 coupling Effects 0.000 abstract description 3
- 238000010168 coupling process Methods 0.000 abstract description 3
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- 238000001802 infusion Methods 0.000 abstract description 3
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000000465 moulding Methods 0.000 description 4
- 238000005253 cladding Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 229920001296 polysiloxane Polymers 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 238000010079 rubber tapping Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
- B61D17/10—Floors
Definitions
- This invention relates to a floor construction for a vehicle particularly but not exclusively of the type which carries passengers standing or seated, such as a light rail or road transit vehicle and including other vehicles used for commercial transportation of passengers, such as a road transit vehicle, airport and hotel shuttles, converted van and truck cutaways, heavy passenger rail and light rail.
- mass transit vehicles and particularly city buses are manufactured from a welded steel frame defining a floor frame, side wall frame and roof bows which is then clad using sheet cladding material riveted, glued or otherwise fixed to the frame. Insulation material is inserted between the frame members inside the exterior cladding and outside of the interior cladding.
- the flooring is conventionally applied from individual simple rectangular panels which are arranged to span across the floor frame and fastened to the floor frame by conventional fasteners.
- the panels are arranged with butting side edges edge to edge along the vehicle.
- the floor panels are often fabricated from plywood but however composite materials are also sometimes used including flooring panels manufactured from fibre reinforced plastics material.
- One particular panel is manufactured from top and bottom sheets of a fibrous mat applied on top and bottom surfaces of a honeycomb material manufactured from phenolic resin impregnated paper with a thermosetting foam introduced into the honeycomb cores.
- the panels are formed, they are conventionally rectangular and arranged edge to edge and cut to shape and to size to complete the necessary flooring overlay.
- bus structures from fibre reinforced composite plastics material so that the side walls, roof structure and floor are each formed separately from such composite materials and are attached together to form the complete bus structure without the necessity for an additional frame supporting the structure.
- US Patent 6,375,249 (Stanton) issued April 23 2002 discloses a public transit vehicle which has a vehicle body having a roof defining an interior ceiling surface, two side walls each extending longitudinally of the vehicle including an upper side wall portion connecting to the roof and a row of windows underneath the upper portion, a central aisle and two rows of seats each on a respective side of the aisle and along the side wall at the windows.
- the roof and floor are formed from a welded frame structure over which is applied a molded panel formed in single panel structure and bonded to the frame structure.
- the panel is formed by molding a sandwich using a thermosetting resin through top and bottom fiber reinforced sheets and a honeycomb layer of resin impregnated paper and foam between the sheets.
- the floor panel is shaped so that its thickness varies and its top and bottom surfaces deviate from an otherwise planar structure to incline downwardly at a door way and to incline upwardly to clear structural elements.
- US Patent 8,006,321 (Lusk) issued November 29 2011 discloses a structural shear panel for forming a floor panel for formed by a composite of top and bottom sheets and a core with a vacuum infused resin.
- the panel is mainly planar and terminates at its side edges at a portion which lies in a common plane and portions are provided which are deformed out of the generally planar shape to form depending or elevated sections.
- the structure is formed by resin infusion into the sheets and core on a generally flat plate defining the planar panel portion with removable sections to define the depending and elevated sections. Edge pieces are attached to the plate to define the edges of the panel.
- a vehicle comprising:
- planks are formed solely by one center plank and two side planks. These are preferably in many cases of different lengths so that he center plank extends along a greater extent for example the whole length of the floor area and the side planks are typically shorter and are cut off at specific locations for example wheel arches.
- the invention is therefore also directed to the kit of parts defined by this set of planks which are pre-cut to the required lengths.
- This system allows preformed and pre-cut planks to be manufactured at relatively low cost and supplied to be assembled into the floor at the vehicle manufacturing plant. This avoids the necessity in the prior art to manufacture a whole floor in one piece which requires expensive tooling and difficult handling techniques.
- the invention thus provides a new concept for structural composite flooring for commercial vehicles.
- the flooring is lightweight, high strength, and is supplied in pultruded or vacuum-assisted resin transfer molded (VARTM) planks in long lengths up to for example a maximum length of 45 feet.
- VARTM vacuum-assisted resin transfer molded
- the key benefit is that unlike the unitized composite flooring currently manufactured in the prior art, the plank flooring is easier to handle and install. That is the flooring can be installed in relative ease by, for example a 4' x 28' x 3/4" centre plank down the length of the bus (or passenger rail car) chassis, and then installing the side planks whilst standing on the centre plank.
- planks can be trimmed to any length, facilitating the manufacture of buses and rail cars of varying lengths without additional tooling penalties. This is not true for the prior art arrangements of a single panel flooring.
- the planks interface along an optional, longitudinal seat rail profile which is mechanically attached to a longitudinal beam which makes up part of the vehicle's chassis.
- the planks are bonded to the seat rail.
- the seat rail is omitted.
- the planks are then reversed so that longitudinal flanges at the edges of the planks overlap, creating a leak-proof, structural joint.
- the center plank has a width to form a central aisle along which passengers can walk between the seats.
- the center plank has a width spanning a distance between two of said longitudinal rails.
- the floor frame is formed by two inner rails and two outer rails at the side edges and wherein the center plank spans the space between the inner rails and two side planks span the space between the inner rails and the outer rail where the center plank connects to the side planks at the inner rails.
- This can be at an overlap joint or may include a longitudinal support rail for supporting a seat frame member.
- the floor also may include at least one molded section extending across the floor at a position along the length of the floor against which an end of the planks abuts.
- the molded sections can include a front molded section and intermediate molded section for the floor of the vehicle which supplement the planks to define the full floor structure.
- the center plank of the planks can extend between the wheel arches and the two side planks terminate at the wheel arches.
- planks can be formed using different processes but typically will be arranged so that the planks are of constant thickness along their length and across their width.
- the planks are formed by pultrusion.
- the planks are formed by a vacuum infused resin process on a mold where the planks are formed simultaneously side by side on the mold.
- planks can be formed either by pultrusion or on the mold with side edges of part of reduced thickness to allow the formation of an overlap joint during assembly.
- the planks are formed as a common structure with the upper and lower sheets joined together at side edges to allow cutting through the sheets at right angles at the side edges to separate the planks to define the three (or more) separate planks for separate transport and installation for subsequent assembly in place.
- a part of the core can be formed of a material of higher density than other parts which can be used for mounting of components to be connected to the floor such as stanchions where the base of the stanchion is connected to the floor by self-tapping screws threaded directly into the high density material or through the higher density core portion to a tapping plate bonded underneath the floor plank.
- each of the side planks is formed of a material of higher density than other parts to allow cutting of the plank around side posts of the frame. This allows the plank to be cut thus penetrating the upper and lower sheets to the core whilst preventing the capillary intrusion of water into the core due to the use of the higher density non-absorbent core portion.
- the floor includes a front lower deck extending from a position adjacent a front wall to a transverse step and a rear upper deck extending from the transverse step to a rear wall with the transverse step between the decks, the front deck being formed from a first set of planks and the rear deck being formed from a second set of planks with a molded step section forming said transverse step therebetween.
- the front lower deck may include a downwardly inclined molded portion at a forward end thereof against which a front end of the planks abuts.
- the bottom frame includes two longitudinal side rails and a plurality of transverse rails and the underside of the planks is attached to the rails of the bottom frame by adhesive.
- the invention also provides a method of manufacturing a floor for a vehicle where the planks as defined above are pultruded, cut to length and installed side by side in the vehicle.
- the invention also provides a method of manufacturing a floor for a vehicle where the planks as defined above are molded side by side by a resin infusion system on a mold and are cut to length and installed side by side in the vehicle.
- the vehicle of the present invention can be of various different configurations and structures but generally includes a vehicle body 10 having a roof 11 two side walls 12, 13 typically including windows each extending longitudinally of the vehicle, seating rows 14 and 15 and a vehicle floor 16.
- the vehicle side walls and roof typically are formed from a frame including posts 17 and longitudinal rails 17A clad by suitable materials, often aluminum panels.
- the floor 16 has a bottom frame including a plurality of rails 18, 19, 20 and 21 with welded cross members 22 supporting a planar floor structure 23.
- the vehicle floor structure on top of the frame comprises three longitudinally extending flooring planks 24, 25 and 26 each extending along at least part of the length of the vehicle body.
- the planks are arranged side by side so as to collectively span between the side walls 12 and 13.
- the floor includes only the three planks defined by a center plank 24 and two side planks 25 and 26 of different lengths relative to the center plank 24.
- the floor includes a front lower deck 16A extending from a position adjacent a front wall to a transverse step 27 and a rear upper deck 16B extending from the transverse step 27 to a rear wall 29 with the transverse step 27 between the decks.
- the front deck 16A formed from a first set of planks 24, 25 and 26 and the rear deck 16B is elevated over the transmission and rear axle and is formed from a second set of planks 24A, 25A and 26A with the molded step section 27A forming the transverse floor section 27 therebetween.
- the planks of the lower deck are cut from the same profile as the planks of the upper deck allowing the flooring system to be manufactured easily with constant tooling.
- the vehicle includes a first wheel arch 36 at one side wall for covering a first wheel and a second wheel arch 37 at a second side wall for covering a second wheel and the center plank 24 extends between the wheel arches at a portion 24B while the two side planks 25 and 26 terminate at end edges 25X, 26X the wheel arches.
- the floor frame is formed by two inner rails 19 and 20 and two outer rails 18 and 21 at the side edges.
- the center plank 24 spans the space between the inner rails 19 and 20 and the side plank 26 spans the space between the inner rail 19 and the outer rail 18 and symmetrically the plank 25 spans the space between the inner rail 20 and the outer rail 21.
- the center plank 24 has a width to form a central aisle along which passengers can walk between the seats and has a width spanning a distance between two of the longitudinal rails 19 and 20.
- the center plank 24 connects to the side planks 25 and 26 at overlapping joints 31, 32 overlying the inner rails as best shown in Figure 6 .
- the center plank 24 connects to the respective side planks at a joint which includes a longitudinal support rail 33 for supporting a seat frame member 34 of the row of seats 14, 15.
- the planks include portions 35 which overlie side parts of the rail 33.
- the planks are attached to the top surface of the underlying rails by adhesive A which also connects the planks at the rail joints.
- planks are molded as shown in Figure 6 from a composite material having an upper skin 40 and a lower skin 41 of material each including reinforcing fibers and an intervening core material layer 42 all containing a cured resin material. Materials of this type are well known and can be manufactured using different processes.
- the planks including the upper and lower sheets and the core are formed by pultrusion using well known techniques of core and fiber feeding.
- the planks 24, 25 and 26 including the upper and lower sheets and the core are formed by a vacuum infused resin (VARTM) process on a mold 45.
- VARTM vacuum infused resin
- the planks 24, 25 and 26 are formed simultaneously side by side on the mold 45 with side edges 35 of part thickness to allow overlap during the assembly.
- the molding technique uses movable cores that form the "side edges". These are molded silicone trapezoids with a steel core. They are bolted to the core mold and can be moved laterally to make wider or narrower planks to fit the particular configuration of the vehicle. So for example the spacing between the longitudinal frame members on a hotel shuttle (such as a Mercedes Sprinter) may be more narrowly spaced than a full-width low floor transit bus.
- the width of the centre panel can be adjusted to the narrower width by moving the silicone inserts. Silicone is used rather than standard, rigid tooling materials so that a seal can be maintained between the core mold surface and the insert, preventing resin from flowing between the insert and the core mold surface, locking the part in the mold.
- FIG 4 shows the VARTM method of forming the planks, which may be used in the exact same manner as the pultruded planks.
- the configuration shown in Fig. 6 can be either the VARTM planks or the pultruded plank.
- the planks are formed with joined upper and lower sheets at side edges 35 to allow cutting at the side edges to separate the planks for subsequent assembly in place.
- the planks are formed with flanges 53 and 54 defined by the joined upper and lower skins 40, 41 with no intervening core.
- the core is shaped with a reduced thickness portion along the edge of the plank at 56 so that the skin 41 is recessed by the thickness of the flange 53, 54 allowing a symmetrical overlap joint where the flanges 53 and 54 sit in the recesses defined by the portion 56.
- the joining edge portion 55 is inclined at an angle of the order of 45 degrees so as to communicate loading between the planks at the overlap joint.
- the same edge shapes including the flanges 53 and 54 are used with the rail 33 which has side flanges 56 and 57 to sit in the recessed portions 55 and has shoulders 58 and 59 to receive the flanges 53, 54.
- the planks of the same configuration can be used with the joint including the rail or with the overlap joint.
- the width of the planks may be modified to accommodate the intervention of the rail in Figure 8 .
- a part of the core is formed of a material of higher density than other parts.
- an outer edge part 51 of each of the side planks is formed of a material of higher density than other parts to allow cutting of the side planks at cut-outs 52 around the side posts 17 of the frame as shown in Figure 3 whilst preventing the capillary intrusion of water.
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Mechanical Engineering (AREA)
- Body Structure For Vehicles (AREA)
Abstract
Description
- This invention relates to a floor construction for a vehicle particularly but not exclusively of the type which carries passengers standing or seated, such as a light rail or road transit vehicle and including other vehicles used for commercial transportation of passengers, such as a road transit vehicle, airport and hotel shuttles, converted van and truck cutaways, heavy passenger rail and light rail.
- Conventionally mass transit vehicles and particularly city buses are manufactured from a welded steel frame defining a floor frame, side wall frame and roof bows which is then clad using sheet cladding material riveted, glued or otherwise fixed to the frame. Insulation material is inserted between the frame members inside the exterior cladding and outside of the interior cladding.
- The flooring is conventionally applied from individual simple rectangular panels which are arranged to span across the floor frame and fastened to the floor frame by conventional fasteners. The panels are arranged with butting side edges edge to edge along the vehicle. The floor panels are often fabricated from plywood but however composite materials are also sometimes used including flooring panels manufactured from fibre reinforced plastics material. One particular panel is manufactured from top and bottom sheets of a fibrous mat applied on top and bottom surfaces of a honeycomb material manufactured from phenolic resin impregnated paper with a thermosetting foam introduced into the honeycomb cores.
- However the panels are formed, they are conventionally rectangular and arranged edge to edge and cut to shape and to size to complete the necessary flooring overlay.
- It is also proposed to manufacture bus structures from fibre reinforced composite plastics material so that the side walls, roof structure and floor are each formed separately from such composite materials and are attached together to form the complete bus structure without the necessity for an additional frame supporting the structure.
-
US Patent 6,375,249 (Stanton) issued April 23 2002 discloses a public transit vehicle which has a vehicle body having a roof defining an interior ceiling surface, two side walls each extending longitudinally of the vehicle including an upper side wall portion connecting to the roof and a row of windows underneath the upper portion, a central aisle and two rows of seats each on a respective side of the aisle and along the side wall at the windows. The roof and floor are formed from a welded frame structure over which is applied a molded panel formed in single panel structure and bonded to the frame structure. The panel is formed by molding a sandwich using a thermosetting resin through top and bottom fiber reinforced sheets and a honeycomb layer of resin impregnated paper and foam between the sheets. The floor panel is shaped so that its thickness varies and its top and bottom surfaces deviate from an otherwise planar structure to incline downwardly at a door way and to incline upwardly to clear structural elements. -
US Patent 8,006,321 (Lusk) issued November 29 2011 discloses a structural shear panel for forming a floor panel for formed by a composite of top and bottom sheets and a core with a vacuum infused resin. The panel is mainly planar and terminates at its side edges at a portion which lies in a common plane and portions are provided which are deformed out of the generally planar shape to form depending or elevated sections. The structure is formed by resin infusion into the sheets and core on a generally flat plate defining the planar panel portion with removable sections to define the depending and elevated sections. Edge pieces are attached to the plate to define the edges of the panel. - It is one object of the present invention, therefore, to provide an improved floor structure for a vehicle.
- According to the invention there is provided a vehicle comprising:
- a vehicle body having:
- a roof,
- two side walls each extending longitudinally of the vehicle,
- a vehicle floor;
- a bottom frame including a plurality of rails supporting the floor;
- two side frames each including a plurality of upstanding posts and a plurality of longitudinally extending members interconnecting the posts;
- a plurality of longitudinally extending flooring planks each extending along at least part of the length of the vehicle body;
- the planks being arranged side by side so as to collectively span between the side walls;
- the planks being molded from a composite panel having an upper skin and a lower skin each including reinforcing fibers and an intervening core material layer and containing a cured resin material.
- Preferably the planks are formed solely by one center plank and two side planks. These are preferably in many cases of different lengths so that he center plank extends along a greater extent for example the whole length of the floor area and the side planks are typically shorter and are cut off at specific locations for example wheel arches.
- The invention is therefore also directed to the kit of parts defined by this set of planks which are pre-cut to the required lengths. This system allows preformed and pre-cut planks to be manufactured at relatively low cost and supplied to be assembled into the floor at the vehicle manufacturing plant. This avoids the necessity in the prior art to manufacture a whole floor in one piece which requires expensive tooling and difficult handling techniques.
- The invention thus provides a new concept for structural composite flooring for commercial vehicles. The flooring is lightweight, high strength, and is supplied in pultruded or vacuum-assisted resin transfer molded (VARTM) planks in long lengths up to for example a maximum length of 45 feet. The key benefit is that unlike the unitized composite flooring currently manufactured in the prior art, the plank flooring is easier to handle and install. That is the flooring can be installed in relative ease by, for example a 4' x 28' x 3/4" centre plank down the length of the bus (or passenger rail car) chassis, and then installing the side planks whilst standing on the centre plank. A further and very meaningful benefit is that the planks can be trimmed to any length, facilitating the manufacture of buses and rail cars of varying lengths without additional tooling penalties. This is not true for the prior art arrangements of a single panel flooring. The planks interface along an optional, longitudinal seat rail profile which is mechanically attached to a longitudinal beam which makes up part of the vehicle's chassis. The planks are bonded to the seat rail. In cases where the passenger seats are cantilevered off the side wall of the vehicle (thus requiring no seat rail in the floor), the seat rail is omitted. The planks are then reversed so that longitudinal flanges at the edges of the planks overlap, creating a leak-proof, structural joint.
- Preferably the center plank has a width to form a central aisle along which passengers can walk between the seats.
- Preferably the center plank has a width spanning a distance between two of said longitudinal rails.
- Preferably the floor frame is formed by two inner rails and two outer rails at the side edges and wherein the center plank spans the space between the inner rails and two side planks span the space between the inner rails and the outer rail where the center plank connects to the side planks at the inner rails. This can be at an overlap joint or may include a longitudinal support rail for supporting a seat frame member.
- In many cases the floor also may include at least one molded section extending across the floor at a position along the length of the floor against which an end of the planks abuts. The molded sections can include a front molded section and intermediate molded section for the floor of the vehicle which supplement the planks to define the full floor structure.
- In the case where the floor includes a first wheel arch at one side wall for covering a first wheel and a second wheel arch at a second side wall for covering a second wheel the center plank of the planks can extend between the wheel arches and the two side planks terminate at the wheel arches.
- The planks can be formed using different processes but typically will be arranged so that the planks are of constant thickness along their length and across their width. In one process, the planks are formed by pultrusion. In another alternative process the planks are formed by a vacuum infused resin process on a mold where the planks are formed simultaneously side by side on the mold.
- In both processes the planks can be formed either by pultrusion or on the mold with side edges of part of reduced thickness to allow the formation of an overlap joint during assembly. Preferably in the molding process the planks are formed as a common structure with the upper and lower sheets joined together at side edges to allow cutting through the sheets at right angles at the side edges to separate the planks to define the three (or more) separate planks for separate transport and installation for subsequent assembly in place.
- In some cases a part of the core can be formed of a material of higher density than other parts which can be used for mounting of components to be connected to the floor such as stanchions where the base of the stanchion is connected to the floor by self-tapping screws threaded directly into the high density material or through the higher density core portion to a tapping plate bonded underneath the floor plank.
- Preferably an outer edge part of each of the side planks is formed of a material of higher density than other parts to allow cutting of the plank around side posts of the frame. This allows the plank to be cut thus penetrating the upper and lower sheets to the core whilst preventing the capillary intrusion of water into the core due to the use of the higher density non-absorbent core portion.
- In a particularly important arrangement for low floor transit vehicles, the floor includes a front lower deck extending from a position adjacent a front wall to a transverse step and a rear upper deck extending from the transverse step to a rear wall with the transverse step between the decks, the front deck being formed from a first set of planks and the rear deck being formed from a second set of planks with a molded step section forming said transverse step therebetween. In this case the front lower deck may include a downwardly inclined molded portion at a forward end thereof against which a front end of the planks abuts.
- Preferably the bottom frame includes two longitudinal side rails and a plurality of transverse rails and the underside of the planks is attached to the rails of the bottom frame by adhesive.
- The invention also provides a method of manufacturing a floor for a vehicle where the planks as defined above are pultruded, cut to length and installed side by side in the vehicle.
- The invention also provides a method of manufacturing a floor for a vehicle where the planks as defined above are molded side by side by a resin infusion system on a mold and are cut to length and installed side by side in the vehicle.
- One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
-
Figure 1 is an isometric view of a floor of a transit vehicle with the remaining structure of the vehicle omitted for convenience of illustration, the floor planks being designed for connection side by side at a coupling which supports a seat rail. -
Figure 2 is a cross-sectional view along the lines 2-2 but also showing the walls, roof and interior seating of the vehicle ofFigure 1 . -
Figure 3 is an isometric view of part of the floor and part of one wall of the vehicle ofFigure 1 . -
Figure 4 is a cross-sectional view of a mold for forming the floor planks for a vehicle of the general type shown inFigure 1 . -
Figure 5 is a cross-sectional view of the floor planks when removed from the mold ofFigure 4 . -
Figure 6 is a cross-sectional view of the floor planks when removed from the mold ofFigure 4 and assembled without the seat rail coupling into the vehicle of the type shown inFigure 1 . -
Figure 7 is a cross-sectional view along the lines 7-7 ofFigure 3 . -
Figure 8 is a cross-sectional view along the lines 8-8 ofFigure 3 . - In the drawings like characters of reference indicate corresponding parts in the different figures.
- The vehicle of the present invention can be of various different configurations and structures but generally includes a
vehicle body 10 having a roof 11 twoside walls 12, 13 typically including windows each extending longitudinally of the vehicle,seating rows vehicle floor 16. - The vehicle side walls and roof typically are formed from a frame including posts 17 and
longitudinal rails 17A clad by suitable materials, often aluminum panels. - The
floor 16 has a bottom frame including a plurality ofrails cross members 22 supporting aplanar floor structure 23. - The vehicle floor structure on top of the frame comprises three longitudinally extending
flooring planks side walls 12 and 13. In the example shown, the floor includes only the three planks defined by acenter plank 24 and twoside planks center plank 24. - In the example of the low floor transit bus shown, the floor includes a front
lower deck 16A extending from a position adjacent a front wall to atransverse step 27 and a rear upper deck 16B extending from thetransverse step 27 to arear wall 29 with thetransverse step 27 between the decks. In this arrangement thefront deck 16A formed from a first set ofplanks planks step section 27A forming thetransverse floor section 27 therebetween. The planks of the lower deck are cut from the same profile as the planks of the upper deck allowing the flooring system to be manufactured easily with constant tooling. - At the front of the lower deck is provided an inclined molded
portion 30 defining the entrance area. The vehicle includes afirst wheel arch 36 at one side wall for covering a first wheel and asecond wheel arch 37 at a second side wall for covering a second wheel and thecenter plank 24 extends between the wheel arches at aportion 24B while the twoside planks end edges - The floor frame is formed by two
inner rails outer rails center plank 24 spans the space between theinner rails side plank 26 spans the space between theinner rail 19 and theouter rail 18 and symmetrically theplank 25 spans the space between theinner rail 20 and theouter rail 21. Thus thecenter plank 24 has a width to form a central aisle along which passengers can walk between the seats and has a width spanning a distance between two of thelongitudinal rails center plank 24 connects to theside planks joints Figure 6 . - As shown in the alternative arrangement of
Figures 2 ,3 and8 , thecenter plank 24 connects to the respective side planks at a joint which includes alongitudinal support rail 33 for supporting aseat frame member 34 of the row ofseats portions 35 which overlie side parts of therail 33. The planks are attached to the top surface of the underlying rails by adhesive A which also connects the planks at the rail joints. - The planks are molded as shown in
Figure 6 from a composite material having anupper skin 40 and alower skin 41 of material each including reinforcing fibers and an interveningcore material layer 42 all containing a cured resin material. Materials of this type are well known and can be manufactured using different processes. InFigure 6 , the planks including the upper and lower sheets and the core are formed by pultrusion using well known techniques of core and fiber feeding. - In
Figures 4 and5 , theplanks mold 45. Using well known molding techniques, theplanks mold 45 withside edges 35 of part thickness to allow overlap during the assembly. The molding technique uses movable cores that form the "side edges". These are molded silicone trapezoids with a steel core. They are bolted to the core mold and can be moved laterally to make wider or narrower planks to fit the particular configuration of the vehicle. So for example the spacing between the longitudinal frame members on a hotel shuttle (such as a Mercedes Sprinter) may be more narrowly spaced than a full-width low floor transit bus. The width of the centre panel can be adjusted to the narrower width by moving the silicone inserts. Silicone is used rather than standard, rigid tooling materials so that a seal can be maintained between the core mold surface and the insert, preventing resin from flowing between the insert and the core mold surface, locking the part in the mold. -
Figure 4 shows the VARTM method of forming the planks, which may be used in the exact same manner as the pultruded planks. The configuration shown inFig. 6 can be either the VARTM planks or the pultruded plank. As shown at 46 inFigure 5 the planks are formed with joined upper and lower sheets at side edges 35 to allow cutting at the side edges to separate the planks for subsequent assembly in place. - Thus as shown best in
Figures 5 ,6 and8 , the planks are formed withflanges lower skins skin 41 is recessed by the thickness of theflange flanges portion 56. The joiningedge portion 55 is inclined at an angle of the order of 45 degrees so as to communicate loading between the planks at the overlap joint. As shown inFigure 8 the same edge shapes including theflanges rail 33 which hasside flanges portions 55 and hasshoulders 58 and 59 to receive theflanges Figure 8 . - As shown at 50 a part of the core is formed of a material of higher density than other parts. Thus for example an
outer edge part 51 of each of the side planks is formed of a material of higher density than other parts to allow cutting of the side planks at cut-outs 52 around the side posts 17 of the frame as shown inFigure 3 whilst preventing the capillary intrusion of water. - Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
Claims (15)
- A vehicle comprising:a vehicle body having:wherein the vehicle floor comprises:a roof,two side walls each extending longitudinally of the vehicle,a vehicle floor;a bottom frame including a plurality of rails supporting the floor;two side frames each including a plurality of upstanding posts and a plurality of longitudinally extending members interconnecting the posts;a plurality of longitudinally extending flooring planks each extending along at least part of the length of the vehicle body;the planks being arranged side by side so as to collectively span between the side walls;the planks being molded from a composite panel having an upper skin and a lower skin each including reinforcing fibers and an intervening core material layer and containing a cured resin material.
- The vehicle according to claim 1 wherein the planks consist of a center plank and two side planks of different lengths.
- The vehicle according to claim 1 or 2 wherein a center plank of the planks has a width to form a central aisle along which passengers can walk between the seats.
- The vehicle according to any one of claims 1 to 3 wherein a center plank of the planks has a width spanning a distance between two of said longitudinal rails.
- The vehicle according to any one of claims 1 to 4 wherein the floor frame is formed by two inner rails and two outer rails at the side edges and wherein a center plank of the planks spans the space between the inner rails and two side planks span the space between the inner rails and the outer rails, and wherein the center plank connects to the side planks at the inner rails at an overlap joint.
- The vehicle according to any one of claims 1 to 5 wherein the center plank connects to the side planks at a joint which includes a longitudinal support rail for supporting a seat frame member.
- The vehicle according to any one of claims 1 to 6 wherein the floor includes at least one molded section extending across the floor at a position along the length of the floor against which an end of the planks abut.
- The vehicle according to any one of claims 1 to 7 wherein the floor includes a first wheel arch at one side wall for covering a first wheel and a second wheel arch at a second side wall for covering a second wheel and wherein a center plank of the planks extends between the wheel arches and the two side planks of the planks terminate at the wheel arches.
- The vehicle according to any one of claims 1 to 8 wherein the planks including the upper and lower sheets and the core are formed by pultrusion.
- The vehicle according to any one of claims 1 to 8 wherein the planks including the upper and lower sheets and the core are formed by a vacuum infused resin process on a mold.
- The vehicle according to claim 10 wherein the planks are formed with joined upper and lower sheets at side edges to allow cutting at the side edges to separate the planks for subsequent assembly in place.
- The vehicle according to any one of claims 1 to 11 wherein a part of the core is formed of a material of higher density than other parts. to allow cutting around side posts of the frame whilst preventing the capillary intrusion of water.
- The vehicle according to any one of claims 1 to 12 wherein the floor includes a front lower deck extending from a position adjacent a front wall to a transverse step and a rear upper deck extending from the transverse step to a rear wall with the transverse step between the decks, the front deck being formed from a first set of planks and the rear deck being formed from a second set of planks with a molded step section forming said transverse step therebetween.
- The vehicle according to claim 13 wherein the front lower deck includes a downwardly inclined molded portion at a forward end thereof.
- The vehicle according to any one of claims 1 to 14 wherein the bottom frame includes two longitudinal side rails and a plurality of transverse rails and wherein the underside of the planks is attached to the rails of the bottom frame by adhesive.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2887720A CA2887720C (en) | 2015-04-14 | 2015-04-14 | Floor construction for a vehcle |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3081449A1 true EP3081449A1 (en) | 2016-10-19 |
EP3081449B1 EP3081449B1 (en) | 2020-04-01 |
Family
ID=55349697
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP16154928.2A Active EP3081449B1 (en) | 2015-04-14 | 2016-02-09 | Floor construction for a vehicle |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP3081449B1 (en) |
CA (1) | CA2887720C (en) |
Cited By (8)
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CN107187454A (en) * | 2017-07-19 | 2017-09-22 | 中车眉山车辆有限公司 | A kind of high temperature is heat-fed the special body frame of steel billet transportation |
CN109204524A (en) * | 2017-06-30 | 2019-01-15 | 比亚迪股份有限公司 | Body structure and vehicle |
CN111619614A (en) * | 2020-06-05 | 2020-09-04 | 上海应用技术大学 | System and method for monitoring and dredging passenger crowding in carriage |
EP3708452A1 (en) * | 2019-03-12 | 2020-09-16 | ALSTOM Transport Technologies | Interior trim of a vehicle car, in particular of a railway vehicle |
CN112078619A (en) * | 2020-09-24 | 2020-12-15 | 中车株洲电力机车有限公司 | Rail vehicle chassis structure and rail vehicle |
EP3909826A1 (en) * | 2020-05-15 | 2021-11-17 | Elbe Flugzeugwerke GmbH | Integral floor assembly for railway vehicles |
CN114179921A (en) * | 2021-12-30 | 2022-03-15 | 厦门金龙联合汽车工业有限公司 | Integrated form passenger train drive shaft skeleton with adjustable width |
CN115123322A (en) * | 2022-08-16 | 2022-09-30 | 中车唐山机车车辆有限公司 | Low-floor train, modular wheel cover and processing technology thereof |
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EP0063214A1 (en) * | 1981-04-18 | 1982-10-27 | MAN GHH Schienenverkehrstechnik GmbH | Assembly of a vehicle floor sub-assembly with fixing means |
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EP0063214A1 (en) * | 1981-04-18 | 1982-10-27 | MAN GHH Schienenverkehrstechnik GmbH | Assembly of a vehicle floor sub-assembly with fixing means |
US6375249B1 (en) | 2000-02-03 | 2002-04-23 | New Flyer Industries Limited | Body structure of a mass transit vehicle |
WO2004000633A1 (en) * | 2002-06-21 | 2003-12-31 | NABI Autóbuszipari Rt. | Platform made of fiber reinforced plastic for bus |
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CN109204524A (en) * | 2017-06-30 | 2019-01-15 | 比亚迪股份有限公司 | Body structure and vehicle |
CN107187454A (en) * | 2017-07-19 | 2017-09-22 | 中车眉山车辆有限公司 | A kind of high temperature is heat-fed the special body frame of steel billet transportation |
EP3708452A1 (en) * | 2019-03-12 | 2020-09-16 | ALSTOM Transport Technologies | Interior trim of a vehicle car, in particular of a railway vehicle |
FR3093692A1 (en) * | 2019-03-12 | 2020-09-18 | Alstom Transport Technologies | Interior trim of vehicle car, in particular of railway vehicle |
EP3909826A1 (en) * | 2020-05-15 | 2021-11-17 | Elbe Flugzeugwerke GmbH | Integral floor assembly for railway vehicles |
CN111619614A (en) * | 2020-06-05 | 2020-09-04 | 上海应用技术大学 | System and method for monitoring and dredging passenger crowding in carriage |
CN111619614B (en) * | 2020-06-05 | 2022-05-27 | 上海应用技术大学 | System and method for monitoring and dredging passenger crowding in carriage |
CN112078619A (en) * | 2020-09-24 | 2020-12-15 | 中车株洲电力机车有限公司 | Rail vehicle chassis structure and rail vehicle |
CN112078619B (en) * | 2020-09-24 | 2021-11-16 | 中车株洲电力机车有限公司 | Rail vehicle chassis structure and rail vehicle |
CN114179921A (en) * | 2021-12-30 | 2022-03-15 | 厦门金龙联合汽车工业有限公司 | Integrated form passenger train drive shaft skeleton with adjustable width |
CN115123322A (en) * | 2022-08-16 | 2022-09-30 | 中车唐山机车车辆有限公司 | Low-floor train, modular wheel cover and processing technology thereof |
Also Published As
Publication number | Publication date |
---|---|
CA2887720C (en) | 2017-02-14 |
CA2887720A1 (en) | 2016-10-14 |
EP3081449B1 (en) | 2020-04-01 |
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