WO2024110216A1

WO2024110216A1 - A composite component of a vehicle body

Info

Publication number: WO2024110216A1
Application number: PCT/EP2023/081408
Authority: WO
Inventors: Frederic SICARD; Tom Parker; Nicholas GUNTRIP HOOK; William Massey
Original assignee: Jaguar Land Rover Limited
Priority date: 2022-11-21
Filing date: 2023-11-10
Publication date: 2024-05-30
Also published as: GB2624460A; GB202217371D0

Abstract

A composite component (1) of a vehicle body (100). The component comprising: at least one closed recess (4) in a first side (2) of the component (1), the at least one closed recess (4) being configured to receive a locating pin (6) to locate the composite component (1) and being bounded by an inner face (7) and a side wall (8) surrounding the inner face (7); wherein the inner face (7) is configured, when in use, to be parallel to one of three orthogonal vehicle planes when the component (1) is assembled in the vehicle (200), the orthogonal vehicle planes comprising: a first plane parallel to a longitudinal axis (101) and a lateral axis (102) of the vehicle (200); a second plane parallel to the longitudinal axis (101) and a vertical axis (103) of the vehicle (200); and a third plane parallel to the lateral axis (102) and the vertical axis (103) of the vehicle (200).

Description

A COMPOSITE COMPONENT OF A VEHICLE BODY

TECHNICAL FIELD

The present disclosure relates to a composite component of a vehicle body. Aspects of the invention relate to a composite component of a vehicle body, a method of manufacturing the composite component, a locating pin for components of a vehicle body, a kit of parts comprising the composite component and the locating pin and a method for positioning composite components of a vehicle body for assembly.

BACKGROUND

Assembly of a vehicle requires precise positioning of components of the vehicle body. Conventionally, metallic components of a vehicle body are precisely located using “hole and slot” features. That is, the metallic component comprises a hole and a slot each extending through the component. The hole and slot are punched or machined into the component. To assemble the component in vehicle body, the component is positioned on a jig and locating pins on the jig extend through each of the hole and slot to constrain the location of the component. Thus, precise positioning of components during assembly is facilitated.

However, when a vehicle is assembled from composite components of a vehicle body, providing “hole and slot” features in the composite components requires costly and time consuming machining operations. Additionally, hole and slot features introduce weaknesses in a composite component due to disruption of the composite fibre structures.

It is an object of embodiments of the invention to at least mitigate one or more of the problems of the prior art. In particular, the embodiments of the invention seek to provide improved assembly features for composite components of a vehicle body.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a composite component of a vehicle body, a vehicle comprising the composite component, a locating pin for components of a vehicle body, a kit of parts comprising the composite component and the locating pin, a method for positioning composite components of a vehicle body for assembly and a method of manufacturing a composite component of a vehicle body. According to an aspect of the invention, there is provided a composite component of a vehicle body. The component comprising: at least one closed recess in a first side of the component, the at least one closed recess being configured to receive a locating pin to locate the composite component and being bounded by an inner face and a side wall surrounding the inner face; wherein the inner face is configured, when in use, to be parallel to one of three orthogonal vehicle planes when the component is assembled in the vehicle, the orthogonal vehicle planes comprising: a first plane parallel to a longitudinal axis and a lateral axis of the vehicle; a second plane parallel to the longitudinal axis and a vertical axis of the vehicle; and a third plane parallel to the lateral axis and the vertical axis of the vehicle.

The closed recess provides a positional reference which can be used on any component of a vehicle body. When assembling a vehicle body, the closed recess receives a locating pin in order to enable correct positioning of the component. Providing the inner face of the recess parallel to one of the vehicle places enables the recess to be used on all components in the vehicle body and simplifies assembly of the vehicle body. Providing the positional reference as a closed recess is advantageous for a composite component compared to the conventional use of a hole for receiving the locating pin because forming a composite component having a closed recess is less costly and time consuming than machining a hole through the component. Additionally, providing a closed recess in the component mitigates any weakness introduced into the component by the presence of a hole thereby reducing the risk of future failure of the component. This is particularly advantageous for composite structures where a hole in the component can disrupt fibres in the composite structure and cause future failure of the component.

The side wall may be inclined at an obtuse angle relative to the inner face, thus improving ease of removing the component from the locating pin. The at least one closed recess may be shaped as a frustum of a cone. Providing the closed recess as a cone improves the repeatability and reproducibility of the closed recess across different components of the vehicle body. Additionally, an obtuse angle facilitates easy removal of the cone from a mould in any direction when the composite component is formed. The angle between the side wall the inner face may be at least 91.5°. The angle between the side wall the inner face may be from 91.5° to 179° or from 91 .5° to 135°.

The at least one closed recess may have a depth of at least 5 mm. The depth of the recess is from a portion of the first side of the component adjacent to the recess to the inner face. This depth enables the closed recess to be securely located on the locating pin during assembly of the component into a vehicle to correctly position the component for assembly. The at least one closed recess may have a depth of less than 15 mm. Thus, the recesses on the component may be easily accommodated within the packaging constraints of a vehicle body.

In certain embodiments, the component may comprise a material having a uniform thickness across the at least one closed recess and a portion of the component adjacent to the least one closed recess. Thus, the closed recess does not result in a reduction of thickness of the material of the component thereby minimising any weakness in the component caused by the closed recess. The closed recess consequently results in a protrusion on a second side of the component opposing the first side.

The at least one closed recess may comprise a first closed recess in the first side of the component and a second closed recess in the first side of the component, wherein the inner face of the second closed recess is elongated relative to the inner face of the first closed recess. Providing an elongated closed recess in combination with a circular recess enables precise positioning of the component whilst reducing stresses in the component when the locating pins are positioned in the closed recesses which may arise as a result of over-constraint of the component location. The inner face of the first closed recess may be circular, and the inner face of the second closed recess may have the form of an obround.

In certain embodiments, the component may comprise a carbon-filled polymer material or glass-filled polymer material.

According to an aspect of the invention, there is provided a vehicle comprising the above described composite component. According to an aspect of the invention, there is provided a locating pin for components of a vehicle body. The locating pin comprising: a first end comprising a flat upper face configured to be received in the closed recess in the component according to the above-described aspect; a second end configured to be supported by a jig; and a chamfered edge adjoining the upper face, wherein the locating pin has a side wall extending from the second end to the chamfered edge, wherein the side wall extends in a direction that is perpendicular to the upper face.

A pin having this shape provides improved repeatability and reproducibility of the pin and of the engagement of the pin within the closed recess of a component of the vehicle body because the number of contact points between the pin and closed recess are minimal.

The locating pin may have a circular cross-section. The circular cross-section of the pin further improves the repeatability and reproducibility of the pin and of the engagement of the pin within the closed recess of a component of the vehicle body.

An angle between the chamfered edge and the upper face may be 268.5° or less. This angle may further improve the repeatability and reproducibility of the engagement of the pin within the closed recess of a component of the vehicle body by reducing the contact points between the pin and the closed recess.

The chamfered edge may have a length of at least 2 mm. The chamfered edge may have a length of from 2 to 5 mm. Thus, friction between the locating pin and recess during use is minimised and ease of removing the pin from the recess is improved.

In certain embodiments, the locating pin may comprise a spring coupled to the second end for supporting the locating pin on the jig. Having the locating pin spring loaded onto the jig avoids over constraining the component during assembly of the component into the vehicle body.

According to an aspect of the invention, there is provided a kit of parts for assembling a vehicle body, the kit comprising a composite component for a vehicle body according to the above-described aspect; and a locating pin according to the above-described aspect configured to be received within the closed recess of the component.

The upper face of the pin may have a width that is less than or equal to the width of the inner face of the component. The upper face of the pin therefore engages the inner face of the component to enable the closed recess to be securely located on the locating pin during assembly of the component into a vehicle to correctly position the component for assembly.

In certain embodiments, the sum of an angle between the chamfered edge and the upper face and the angle between the side wall the inner face may be at least 360°. This sum of angles ensures that the chamfered edge of the pin does not contact the side wall of the closed recess thereby improving the repeatability and reproducibility of the engagement of the pin within the closed recess of component of the vehicle body by reducing the contact points between the pin and the closed recess.

According to an aspect of the invention, there is provided a method for positioning composite components of a vehicle body for assembly, the method comprising: providing a jig having at least one locating pin according to the above-described aspect supported on the jig, and positioning a composite component of a vehicle body according to the abovedescribed aspect on the jig such that the at least one locating pin is received in the at least one closed recess of the component.

According to an aspect of the invention, there is provided a method of manufacturing a composite component of a vehicle body comprising: forming a composite component having at least one closed recess in a first side, the at least one closed recess being configured to receive a locating pin and being bounded by an inner face and a side wall surrounding the inner face; forming the inner face so that it is parallel to one of three orthogonal vehicle planes when the component is assembled in a vehicle, wherein the orthogonal vehicle planes comprise: a first plane parallel to a longitudinal axis and a lateral axis of the vehicle; a second plane parallel to the longitudinal axis and a vertical axis of the vehicle; and a third plane parallel to the lateral axis and the vertical axis of the vehicle.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a plan view of a composite component in accordance with an embodiment of the invention;

Figure 2 shows a cross-section of the composite component of Figure 1 ;

Figure 3 shows a section of the composite component of Figure 1 ;

Figure 4 shows a perspective view of a composite component in accordance with an embodiment of the invention;

Figure 5 shows a perspective view of a composite component in accordance with an embodiment of the invention;

Figure 6 schematically shows a locating pin in accordance with an embodiment of the invention;

Figure 7 and 8 each schematically show a locating pin and a composite component in accordance with an embodiment of the invention; Figures 9 and 10 shows a plan view and a perspective view, respectively, of a vehicle component in accordance with an embodiment of the invention;

Figure 11 shows a flow chart for a method for positioning composite components of a vehicle body for assembly in accordance with an embodiment of the invention; and

Figure 12 shows a flow chart for a method of manufacturing a composite component of a vehicle body in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

Figures 1 and 2 show a composite component 1 of a vehicle body 100 according to an embodiment of the invention. The composite component 1 may comprise a carbon- fil led polymer material, a glass-filled polymer material, a fibre reinforced plastic or any other suitable composite material.

The composite component 1 comprises a first side 2 and a second side 3 opposing the first side 2. In the first side 2, the composite component 1 comprises at least one closed recess 4. That is, the recess 4 is a depression extending into the first side 2 of the composite component 1 but there is no hole through the composite component 1 unless one or more holes are required for other purposes than assembly of the component in the vehicle. As such, the first side 2 of the composite component 1 is continuous across the recess 4.

The closed recess 4 is configured to receive a locating pin 6 (as shown in Figure 6, for example) to locate the composite component 1 during assembly of the vehicle body 100. During assembly, the locating pin 6 is supported on a jig (not shown) and the composite component 1 is positioned such that locating pin 6 is received in the recess 4 of the component 1 thereby precisely positioning the composite component 1 on the jig-

In certain embodiments, the component 1 may comprise at least two closed recesses 4. If the composite component 1 comprises two or more recesses 4, the jig may support the same number of locating pins 6 as the number of recesses 4 in the component 1 so that each recess 4 in the component 1 receives a locating pin 6. Providing two recesses 4 in the composite component 1 may improve ease of precisely locating the component 1 during assembly of the vehicle body 100. In the embodiment shown in Figures 1 and 2, the component 1 comprises six recesses. However, the invention is not limited to this number of recesses.

As shown in Figure 2, the recess 4 is bounded by an inner face 7 and a side wall 8 surrounding the inner face 7. The side wall 8 and inner face 7 may be joined by a radiused portion 9. As shown in the embodiment of Figures 1 and 2, the composite component 1 is formed from a material having a substantially uniform thickness across the closed recess 4 and a portion of the component 1 adjacent to recess 4. In a nonlimiting example, the material may have a thickness of at least 1.8 mm. Due to the uniform thickness, the composite component 1 comprises a protrusion 5 on the second side 3 corresponding to each recess 4 on the first side 2. The protrusions 5 has an outer face 9 which has substantially the same shape as the inner face 4.

The inner face 7 is configured, when in use, to be parallel to one of three orthogonal vehicle planes when the component 1 is assembled in the vehicle 200. The orthogonal vehicle planes comprise: a first plane parallel to a longitudinal axis 101 and a lateral axis 102 of the vehicle 200; a second plane parallel to the longitudinal axis 101 and a vertical axis 103 of the vehicle 200; and a third plane parallel to the lateral axis 102 and the vertical axis 103 of the vehicle 200. Thus, when the vehicle body 100 has been assembled the inner face 7 is parallel to one of three orthogonal vehicle planes.

Figures 9 and 10 show the longitudinal axis 101 , the lateral axis 102 and the vertical axis 103 of a vehicle 200. An example of a first plane would be a plane extending parallel to the ground on which the vehicle 200 stands. An example of a second plane would be a plane extending perpendicular to the ground and from the front 105 to the rear 104 of the vehicle 200. An example of a third plane would be a plane extending perpendicular to the ground and from the left hand side 106 to the right hand side 107 of the vehicle 200.

Composite components which are assembled to form a vehicle body 100 have different shapes. Some of the components may have convoluted shapes. Figure 5 shows an embodiment of a component 30 of a vehicle body 100 including two recesses and two corresponding protrusions 35 having a similar form as the recess 4 and protrusions 5 of the embodiment shown in Figure 1 and 2. However, the component 30 shown in the embodiment shown Figure 5 has a more convoluted shape than the component 1 of embodiment shown in Figures 1 and 2. Providing the inner face 7 of the recess 4 that is parallel to one of the vehicle planes enables the recess 4 to be used on all components in the vehicle body, regardless of their shape, and simplifies assembly of the vehicle body.

Figure 2 is a cross-section from a composite component 1 showing three recesses 4 in the first side 2. The component comprises a first recess 4a, a second recess 4b and a third recess 4c. As shown in Figure 2, a portion of the first side 2 of the component 1 that is adjacent each of the first recess 4a and the third recess 4c is inclined relative to the inner face 7 of each of the first 4a and the third 4c recess. That is, the portion of the first side 2 of the component 1 that is adjacent to each of the first recess 4a and the third recess 4c is not parallel to one of three orthogonal vehicle planes when the component 1 is assembled in the vehicle 200. Therefore, the length of the side wall 8 (i.e. from the inner face 7 to the portion of the first side 2 the component 1 that is adjacent to the recess 4) varies around the recess 4a, 4c to enable the inner face 7 to be parallel to one of the vehicle planes when the component 1 is assembled in the vehicle 200. Regarding the second recess 4b in the component 1 , as shown in Figure 2, the portion of the first side 2 of the component 1 that is adjacent the second recess 4b is parallel to the inner face 7. As such, the length of the side wall 8 of the second recess 4b does not vary around the second recess 4b. For any of the above described recesses 4, the length of the side wall 8 at any point around the recess may be selected such that the depth D1 of the recess may be at least 5 mm so enable the component 1 to be securely located on the locating pin 6 during assembly. The depth D1 of the recess is the distance from the portion of the first side 2 closest to and adjacent to the recess 4 to the inner face 7.

As shown in Figure 2, the inner face 7 of each of the first 4a, second 4b and third 4c recesses are parallel to each other i.e. parallel to the same vehicle plane when the component is assembled in the vehicle 200. If a composite component 1 comprises more than one recess 4, the inner face 7 of all the recesses on the component that are employed for assembly of the component may be parallel with the same vertical plane to facilitate ease of assembly the vehicle body 100 (not all recesses that are formed in a component may be so employed - some may be provided for other purposes).

The side wall 7 of each recess shown in the embodiment of Figures 1 and 2 is inclined at an obtuse angle a relative to the inner face 7. As indicated in Figure 3, the angle a is defined on the first side 2 of the component 1. The angle a between the side wall the inner face may be at least 91.5°, from 91.5° to 179° or from 91.5° to 135°. Providing this obtuse angle a facilitates easy removal of the recess 4 from a mold in any direction when the composite component 1 is formed and easy removal the component 1 from the locating pin 6 during assembly of the vehicle body 100.

As shown in Figure 1 , the recess 4 may have a circular inner face 7 (i.e. a circular cross-section in a direction planar to the inner face). Thus, the recess 4 may be shaped as a frustum of a cone. Such a shape improves the repeatability and reproducibility of the closed recess 4 across different components 1 of the vehicle body 100. However, the recess 4 is not limited to having a circular inner face 7 and may take any suitable shape.

In certain embodiments (not shown), the composite component may comprise a first recess as described above and a second closed recess in the first side, where the inner face of the second closed recess is elongated relative to the inner face of the first closed recess. Providing an elongated second closed recess in combination with a circular first closed recess enables precise positioning of the component whilst reducing stresses in the component when the locating pins are positioned in the closed recesses, which stresses may arise as a result of over-constraint of the component location. In certain embodiments, the first recess may comprise a circular inner face like the recesses 4 shown in Figures 1 and 2. Figure 4 shows an embodiment of the second recess 14. The inner face of the second recess 14 may have the form of an obround or a stadium. That is, the inner face is formed as two semi-circles 16, 17 positioned on opposing sides of a rectangle 18 where the diameters of the two semicircles are the same as each other and at least two of the sides of the rectangle. Thus, the obround inner face is elongated relative to a recess 4 with a circular inner face 7. Figure 4 shows an embodiment of a recess 14 having an obround inner face and, consequently, an obround outer face 19 on the corresponding protrusion 15. Apart from the shape of the inner face, a recess 14 having the form of an obround may be substantially the same as a recess 4 with a circular inner face 7.

In certain non-limiting embodiments, the inner face 7 may have a width of at least 28 mm. For example, when the inner face 7 is circular, the diameter of the circular inner face 7 may be at least 28 mm. When the inner face has a non-circular shape, the minimum width across any part of the inner face may be at least 28 mm. When the recess is elongated relative to a recess having a circular inner face as shown in Figure 4, the recess may be elongated by 2 mm to 6 mm relative to a recess having a circular inner face. Figures 6 to 8 show a locating pin 6 according to an embodiment of the invention. The locating pin 6 is configured to be received in a recess of a composite component.

The locating pin 6 comprises a first end 11 comprising a flat upper face 12 configured to be received in the closed recess 4. The locating pin 6 comprises a second end 13 opposing the first end 11. The second end 13 is configured to be supported by the jig. The second end 13 may be supported by the jig by any conventional means. In the embodiment shown in Figure 6, the locating pin 6 comprises a spring 20 coupled to the second end 13. When the locating pin 6 is positioned on the jig, the spring 20 is located between the second end 13 and the jig. Having the locating pin 6 spring loaded onto the jig avoids over constraining the component during assembly of the component into the vehicle body.

The locating pin 6 comprises a chamfered edge 21 adjoining the upper face 12 and a side wall 22 extending from the second end 13 to the chamfered edge 21. As shown in Figure 6, the side wall 22 extends in a direction that is perpendicular to the upper face 12. Thus, the chamfered edge 21 is inclined relative to both the upper flat face 12 and the side wall 22. As shown in Figure 6, the chamfered edge 21 is inclined relative to the upper flat face 12 so that there is an angle p between the chamfered edge 21 and the upper face 12. The angle defined on the exterior of the pin. In certain embodiments, the angle p between the chamfered edge 21 and the upper face 12 may be 268.5° or less.

The chamfered edge 21 of the locating pin 6 may be configured such that the chamfered edge 21 is parallel to the side wall 8 bounding the recess 4 when the locating pin 6 is received in the recess 6 as shown in Figures 7 and 8. Thus, the sum of the angle p between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 may be at least 360°.

The width W2 of the upper flat face 12 of the locating pin may be configured to be greater than, less than or substantially the same as the width W1 of the inner face 7 bounding the recess 4 depending on the desired contact points between the locating pin 6 and the composite component 1 during assembly of the vehicle body 100. The width of the of the inner face 7 bounding the recess 4 may be selected to enable the recess 4 to be securely located on the locating pin 6 to correctly position the component 1 during assembly. In certain non-limiting embodiments, the inner face 7 bounding the recess 4 may have a width W1 of at least 28 mm. The inner face 7 bounding the recess 4 may have a width W1 no greater than the distance W3 of the locating pin 6 between the side wall 22 which extends from the second end of the locating pin 6 to the chamfered edge 21. Due to the chamfered edge 21 of the locating pin 6 the distance W3 between the side wall 22 of the locating pin 6 is greater than the width W2 of the upper flat face 12. In certain non-limiting embodiments, the distance W3 between the side wall of the locating pin may be 36 mm or less. During assembly of the vehicle body 100, as described above, the jig is provided having at least one locating pin 6 supported on it. The composite component 1 of the vehicle body 100 is positioned on the jig such that the at least one locating pin 6 is received in the at least one closed recess 4 of the component 1. Thus, the composite component 1 is supported on and precisely positioned on the jig by the recess 4 and the locating pin 6. The points of contact between the locating pin 6 and the component 1 depend on the choice of the relative widths of the upper flat face 12 of the locating pin 6 and the inner face 7 bounding the recess 4.

Figure 7 shows a locating pin 6 positioned within a recess 4 of the component 1 . In the embodiment shown in Figure 7, the width W2 of the upper flat face 12 of the locating pin 6 is greater than the width W1 of the inner face 7 bounding the recess 4. The sum of the angle p between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 is substantially 360° so that the chamfered edge 21 is parallel with the side wall 8 bounding the recess 4. Thus, the chamfered edge 21 of the pin 6 contacts the side wall 8 bounding the recess 4, but the upper flat face 12 of the locating pin 6 does not contact the inner face 7 bounding the recess 4. As such, movement of the component 1 relative to the locating pin 6 is constrained in directions parallel to the upper flat face 12 of the locating pin 6 is and the inner face 7 bounding the recess 4. To constrain movement of the component 1 in a direction perpendicular to the upper flat face 12 of the locating pin 6 and the inner face 7 bounding the recess 4 locating pads may be used to clamp the component 1 in position. The points of contact between the locating pin 6 and the composite component 1 are minimal which enables the recess 4 and locating pin 6 to provide a more repeatable and reproducible alignment features.

The chamfered edge 21 may have a length L1 of at least 2 mm to enable sufficient contact to constrain movement of the composite component 1 relative to the locating pin 6 and enable precise positioning of the composite component 1 . The chamfered edge 21 may have a length L1 of no more than 5 mm to limit friction between the locating pin 6 and the composite component 1 and thereby facilitate easy removal of the composite component 1 from the pin 6.

Figure 8 shows a locating pin 6 positioned within a recess 4 of the component 1. However, in the embodiment shown in Figure 8, the width W2 of the upper flat face 12 of the locating pin is smaller than the width W1 of the inner face 7 bounding the recess 4. Thus, the upper flat face 12 of the locating pin 6 contacts the inner face bounding the recess 4, but the chamfered edge 21 of the pin 6 does not contact the side wall 8 bounding the recess 4. As such, movement of the component 1 relative to the pin 6 in directions parallel to the upper flat face 12 of the locating pin 6 is and the inner face 7 bounding the recess 4 is less constrained compared to the embodiment shown in Figure 7. As the upper flat face 12 of the locating pin 6 contacts the inner face 7 bounding the recess 4, the component 1 is less likely to distort when clamped to constrain movement relative to the locating pin 6 in directions perpendicular to the upper flat face 12 of the locating pin 6. In the embodiment shown in Figure 8, the sum of the angle p between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 is substantially 360° so that the chamfered edge 21 is parallel with the side wall 8 bounding the recess 4. However, to reduce possible points of contact between the composite component 1 and the locating pin 6, the sum of the angle between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 may be greater than 360° so that the chamfered edge 21 is not parallel with and does not contact the side wall 8 bounding the recess 4.

In alternative embodiments, the width W2 of the upper flat face 12 of the locating pin 6 may be substantially the same as the width W1 of the inner face 7 bounding the recess 4. Thus, the upper flat face 12 of the locating pin 6 contacts the inner face 7 bounding the recess 4 and the chamfered edge 21 of the pin 6 contacts the side wall 8 bounding the recess 4. As such, movement of the component 1 relative to the locating pin 6 is constrained in directions parallel to the upper flat face 12 of the locating pin 6 and the inner face 7 bounding the recess 4 and the component 1 is less likely to distort when clamped to constrain movement relative to the locating pin 6 in directions perpendicular to the upper flat face 12 of the locating pin 6. However, the number of contact points between the component 1 and the locating pin 6 are increased compared to the embodiments shown in Figures 7 and 8. This may result in the recess 4 and locating pin 6 providing less repeatable and reproducible alignment features compared to the embodiments shown in Figures 7 and 8. In certain embodiments, the sum of the angle p between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 may be substantially equal to or greater than 360°. To reduce possible points of contact between the composite component 1 and the locating pin 6, the sum of the angle between the chamfered edge 21 and the upper face 12 and the angle a between the side wall 8 the inner face 7 may be greater than 360° so that the chamfered edge 21 is not parallel with the side wall 8 bounding the recess 4.

As shown in the embodiment in Figures 6 to 8, the locating pin 6 may have a circular cross-section. Thus, the upper flat face 12 is circular in shape. During use, the circular pin 6 may be received by both a recess 4 having a circular inner face 7 and a recess 14 having an obround inner face. When the locating pin 6 is received by a recess 14 having an obround inner face movement of the component 1 relative to the pin 6 is less constrained than when the pin 6 is received by a recess 4 having a circular inner face 7. Providing a first recess with a circular inner face and a second recess with an elongated inner face enables precise positioning of the component 1 for assembly whilst reducing stresses in the component 1 when the locating pins 6 are positioned in closed recesses 4, 14 which may arise as a result of over-constraint of the component location.

The recess 4, 14 having an inner face 7 parallel to one of the three orthogonal vehicle planes may be used on any component 1 of the vehicle body 100 to precisely position the component for assembly into the vehicle body 100. The recess 4, 14, unlike the conventional “hole and slot” features, does not disrupt the composite fibre structures or introduce a point of weakness into the composite component 1. The locating pin 6 is receivable within the recess 4, 14 and enables repeatably precise positioning of components 1 on the jig throughout assembly of a vehicle body 100.

According to an embodiment of the invention, there is also provided a method 300 shown in Figure 11 for positioning above-described composite components 1 of a vehicle body 100 for assembly. The method 300 comprises providing 301 a jig having at least one locating pin 6 (as described above) on the jig. The method 300 comprises positioning 302 the composite component 1 of a vehicle body 100 on the jig such that the at least one locating pin 6 is received in the at least one closed recess 4 of the component 1 . The method may be repeated to assemble any number of composite components 1 into the vehicle body 100. In embodiments where the composite component 1 comprises more than one recess 4, the method 300 comprises providing a jig supporting the same number of locating pins 6 as recesses 4 in the component 1 . The composite component 1 may then positioned on the jig such that each locating pin 6 is received in a recess 4. Once the composite component 1 has been positioned on the jig, to further constrain movement of the component 1 relative to the jig the method 300 may comprise using locating pads to clamp the component 1 in position.

According to an embodiment of the invention, there is also provided a method 400 shown in Figure 12 for manufacturing the above-described composite component 1 of a vehicle body 100. The method 400 comprises forming 401 a composite component 1 having at least one closed recess 4 in a first side 2. Forming 401 the component 1 may comprise moulding 402 the component 1 from a composite material. The at least one closed recess 4 is configured to receive a locating pin 6 and is bounded by an inner face 7 and a side wall 8 surrounding the inner face 7. The method 400 comprises forming 403 the inner face 7 so that it will be parallel to one of three orthogonal vehicle planes when the component 1 is assembled in a vehicle 200. The method 400 may comprise forming 404 the side wall 8 so that it is inclined at an obtuse angle a relative to the inner face 7 to facilitate easy removal of the recess 4 from a mould in any direction.

In certain embodiments, the composite component 1 may be formed with more than one recess 4. In such embodiments, the inner faces 7 may be formed so that of all the recesses in the composite component 1 may be parallel to the same vehicle plane.

Unless the context dictates otherwise, a “recess” as described above in a component is one employed for the purpose of assembly of the component in a vehicle as described above and not for other purposes that the component may be designed to accomplish. Nevertheless, any such recess may also serve other purposes beyond assembly. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims.

Claims

1. A composite component of a vehicle body, the component comprising: at least one closed recess in a first side of the component, the at least one closed recess being configured to receive a locating pin to locate the composite component and being bounded by an inner face and a side wall surrounding the inner face; wherein the inner face is configured, when in use, to be parallel to one of three orthogonal vehicle planes when the component is assembled in the vehicle, the orthogonal vehicle planes comprising: a first plane parallel to a longitudinal axis and a lateral axis of the vehicle; a second plane parallel to the longitudinal axis and a vertical axis of the vehicle; and a third plane parallel to the lateral axis and the vertical axis of the vehicle.

2. A composite component according to claim 1, wherein the side wall is inclined at an obtuse angle relative to the inner face.

3. A composite component according to claim 2, wherein the angle between the side wall the inner face is at least 91.5°.

4. A composite component according to any one of claims 2 to 3, wherein the at least one closed recess is shaped as a frustum of a cone.

5. A composite component according to any one of the preceding claims, wherein the at least one closed recess has a depth of at least 5 mm.

6. A composite component according to any one of the preceding claims, wherein the component comprises a material having a uniform thickness across the at least one closed recess and a portion of the component adjacent to the least one closed recess.

7. A composite component according to any one of the preceding claims, wherein the at least one closed recess comprises a first closed recess in the first side of the component and a second closed recess in the first side of the component, wherein the inner face of the second closed recess is elongated relative to the inner face of the first closed optionally the inner face of the first closed recess is circular, and the inner face of the second closed recess has the form of an obround.

8. A composite component according to any one of the preceding claims, wherein the component comprises a carbon-filled polymer material or glass-filled polymer material.

9. A vehicle comprising the composite component according to any one of claims 1 to 8.

10. A locating pin for components of a vehicle body, the locating pin comprising: a first end comprising a flat upper face configured to be received in the closed recess in the component according to any one of claims 1 to 8; a second end configured to be supported by a jig; and a chamfered edge adjoining the upper face, wherein the locating pin has a side wall extending from the second end to the chamfered edge, wherein the side wall extends in a direction that is perpendicular to the upper face.

11. A locating pin according to claim 10, wherein the locating pin has a circular cross-section, optionally an angle between the chamfered edge and the upper face is 268.5° or less and optionally the chamfered edge has a length of at least 2 mm and optionally comprising a spring coupled to the second end for supporting the locating pin on the jig.

12. A kit of parts for assembling a vehicle body, the kit comprising a composite component for a vehicle body according to any one of claims 1 to 8; and a locating pin according to any one of claims 10 to 11 configured to be received within the closed recess of the component.

13. A kit of parts according to claim 12, when dependent on claim 2, wherein the sum of an angle between the chamfered edge and the upper face and an angle between the side wall the inner face is at least 360°.

14. A method for positioning composite components of a vehicle body for assembly, the method comprising: providing a jig having at least one locating pin according to any one of claims 10 to 11 supported on the jig, and positioning a composite component of a vehicle body according to any one of claims 1 to 8 on the jig such that the at least one locating pin is received in the at least one closed recess of the component.

15. A method of manufacturing a composite component of a vehicle body comprising: forming a composite component having at least one closed recess in a first side, the at least one closed recess being configured to receive a locating pin and being bounded by an inner face and a side wall surrounding the inner face ; forming the inner face so that it is parallel to one of three orthogonal vehicle planes when the component is assembled in a vehicle, wherein the orthogonal vehicle planes comprise: a first plane parallel to a longitudinal axis and a lateral axis of the vehicle ; a second plane parallel to the longitudinal axis and a vertical axis of the vehicle ; and a third plane parallel to the lateral axis and the vertical axis of the vehicle.