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WO2008067583A1 - Composants moulés de carrosserie de remorque ou de caravane - Google Patents

Composants moulés de carrosserie de remorque ou de caravane Download PDF

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Publication number
WO2008067583A1
WO2008067583A1 PCT/AU2006/001858 AU2006001858W WO2008067583A1 WO 2008067583 A1 WO2008067583 A1 WO 2008067583A1 AU 2006001858 W AU2006001858 W AU 2006001858W WO 2008067583 A1 WO2008067583 A1 WO 2008067583A1
Authority
WO
WIPO (PCT)
Prior art keywords
trailer
mould
component
body component
base component
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.)
Ceased
Application number
PCT/AU2006/001858
Other languages
English (en)
Inventor
Wayne Douglas Barrett
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RV IP Pty Ltd
Original Assignee
RV IP Pty Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by RV IP Pty Ltd filed Critical RV IP Pty Ltd
Priority to PCT/AU2006/001858 priority Critical patent/WO2008067583A1/fr
Publication of WO2008067583A1 publication Critical patent/WO2008067583A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/046—Combined superstructure and frame, i.e. monocoque constructions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof

Definitions

  • This invention relates to the manufacture of trailers, including caravans, and relates to the manufactured trailers. Background of the invention
  • references to manufacture of trailers is to be understood to encompass manufacture of caravans in particular and, unless the specific meaning is clearly intended, references to manufacture of caravans is to be understood to apply more generally to other vehicle bodies such as mobile home bodies and other trailers.
  • a method of manufacturing a trailer body component comprising a base component which extends substantially the entire length of the trailer and which has a floor section extending the entire length and the entire width of the trailer, and has wall sections which extend upwardly from peripheral areas of the floor section, the floor section and the wall sections being of a unitary integral construction, the method including the steps of: providing a mould having a mould cavity defining the conformations of the floor and wall sections of the base component; locating fibre reinforcing materials within the mould cavity and using a resin transfer moulding (RTM) process to fill the mould cavity to form a fibre reinforced, resin matrix body shape; curing of the fibre reinforced resin matrix within the mould cavity; and subsequently opening and removing of the moulded base component of the trailer from the mould.
  • RTM resin transfer moulding
  • the entire trailer body may be capable of being assembled and fitted out for less cost than assembly from numerous separately manufactured components performing the same function.
  • the use of resin transfer moulding technology (or RTM) can enable sufficient structural rigidity to be provided in the manufactured base component without the need for separate trailer framework components.
  • RTM resin transfer moulding technology
  • the materials used for the reinforcing fibres and the resin matrix can be selected accordingly, and the required thicknesses and conformation of the various areas of the base component can be determined and then provided in the design and construction of the mould.
  • the floor and wall sections of the base component may be composed, either wholly or in selected areas thereof, of layers of different materials, at least one of which is a layer of the resin matrix.
  • areas of the base component to have a sandwich construction, the desired structural and other physical properties (such as shape and weight) of the various areas of the base component can be predetermined and achieved.
  • areas can be provided having a sandwich construction with outer layers of resin matrix and a core layer of a foam material, such as a polyurethane, urethane, PVC or other plasties material core.
  • the core can have a honeycomb construction.
  • core materials or inserts can include metal elements such as metal mesh, ribs, grids.
  • the use of a sandwich construction can enable the base component to have sufficient structural strength and rigidity to avoid the need for internal components of the caravan fit out to contribute to structural strength.
  • the sandwich construction using RTM technology can enable the provision of radiused sections e.g. between the floor section and the wall sections, which provide substantial structural strength to the base component and to the completed trailer.
  • the process includes providing in the mould cavity predetermined conformations to define chassis sections of the moulded base component.
  • the chassis sections can comprise longitudinal chassis members extending substantially the entire length of the floor section of the base component. These longitudinal members may comprise continuous linear beams extending lengthwise of the floor section whereby the RTM process creates fibre reinforced resin matrix beams providing longitudinal structural strength to the base component. This enables elimination of prior known separate longitudinal chassis structural beams.
  • chassis sections of the moulded base component may include transverse members providing lateral structural strength and rigidity to the base component enabling elimination of such separate lateral chassis elements used in the past.- ' . ' • . ' ⁇
  • the longitudinal members and lateral members together form the chassis sections of the base component and are integrally formed simultaneously with the remainder of the floor section and wall sections of the base component.
  • the base component includes moulded integrally therewith a forwardly projecting towing section by means of which the finished trailer will be towed by a prime mover vehicle.
  • the integral fo ⁇ ned towing section may comprise for example towing members projecting forwardly of the floor section of the base component beyond a front wall section extending upwardly from a front edge area of the floor section, the towing members reaching a forward most towing point where, in use, attachment of the final assembled trailer to the prime mover vehicle will be made.
  • the forwardly projecting towing members may define for example a generally conventional looking A-frame in top plan view, although these forwardly projecting towing members are fo ⁇ ned integrally with and at the same time as the remainder of the base component.
  • the forwardly projecting towing members may comprise integral forwardly extending continuations of the longitudinal members of the chassis sections of the base component.
  • a conventional wheel bogie assembly can be mounted to the chassis sections beneath the base component.
  • the longitudinal members of the chassis sections may project downwardly below the general plane of the floor section enabling attachment of the wheel bogie, e.g. in conventional fashion analogous to prior arrangements for attachment of a wheel bogie to a separately manufactured structural chassis of a trailer.
  • the base component may be manufactured as a unitary integral component for a caravan including floor and four walls with a particular conformation at their top edges, and an upper body component of the trailer body can then be fitted thereon.
  • the upper peripheral edges of the wall sections of the base component may have for example a moulded rebate formed integrally by an appropriate conformation of the mould cavity so as to' closely fit with the complementary lower edge of the upper body component.
  • the upper body component may be manufactured according to a method substantially the same as the base component of the present invention.
  • the present invention in a second aspect may therefore provide a method of manufacturing a trailer body component, the component comprising an upper body component which extends substantially the entire length of the trailer and which has a roof section extending the entire length and the entire width of the trailer, and has wall sections which extend downwardly from peripheral areas of the roof section, the roof section and the wall sections being of a unitaiy integral construction, the method including the steps of providing a mould having a mould cavity defining the conformations of the roof and wall sections of the upper body component; using a resin transfer moulding process to fill the mould cavity to form a fibre reinforced, resin matrix body shape; curing of the fibre reinforced resin matrix within the mould cavity; and subsequently opening and removing of the moulded upper body component of the trailer from the mould.
  • the process of manufacturing trailer components according to the two aspects of the present invention includes the provision of a mould having a mould cavity of the required conformation.
  • the ' manufacture of the mould, in particular the male and female parts of the mould which define between them the mould cavity preferably comprises automatic machining of mould bodies from which the male and female mould parts are made.
  • the mould bodies having the required male and female conformations can be manufactured by a CNC routing operation.
  • the detailed design of the trailer body shapes, and hence design of the base component and upper body component can be performed using a suitable CAD program. This design in turn can then be used to control the operation of a CNC router.
  • the mould bodies may be made of medium density fibre board ("MDF").
  • MDF medium density fibre board
  • the mould bodies can be made of a laminate of many ' sheets of MDF, e.g. MDF panels 16mm thick, with the panels being adhered together to form a body of sufficient size to define the required mould part.
  • the MDF body is then machined by the CNC router to create the respective male or female mould profile according to the design criteria established using the CAD program.
  • the machined ' surfaces of the MDF body can be coated to provide a more durable surface for repeated use of die mould part in the RTM operations and/or to achieve a desired surface finish of the moulded component.
  • a fibre glass reinforced resin coating may be applied to the machined MDF surfaces.
  • the references in the specification to the resin transfer moulding or RTM process are to be understood to include variations of that process including, for example, the "Light Resin Transfer Moulding" or LRTM process.
  • the RTM process in general comprises the placement in the mould cavity of a reinforcing material, usually in the nature of a fibre material preform having the general shape of the mould cavity, followed by closing the mould, followed by injecting the resin matrix into the cavity through multiple inlet sprues until the cavity, including interstices between the reinforcing material, is completely filled and resin matrix is seen emerging from exit sprues.
  • Injection is then stopped and the resin matrix is allowed to fully cui'e in the mould cavity, or at least cure sufficiently to allow the mould to be opened and the moulded component safely removed without damage or deformation or distortion of the component.
  • the injection of the resin matrix into the mould cavity in the RTM process is carried out at relatively low pressure and/or a vacuum can be applied to the outlet sprues to achieve or facilitate filling of the mould cavity.
  • the resin matrix injected is mixed with a curing agent or hardener or initiator shortly before injection.
  • the curing can be effected by operation of the curing agent or can be accelerated for example by application of heat (or by UV radiation if one of the mould components is translucent to UV).
  • the fibre reinforcing material located in the mould cavity can be of any suitable material (glass or other ceramic fibres, polymer fibres, aramid fibres, carbon fibres, etc.) and can comprise continuous strands or filaments, or reinforcing material in the form of fabrics or cloth or roving or mats, or reinforcing material in the form of individual long fibres or short strands. Choices amongst these known alternatives depend on the structural requirements, physical and chemical properties, as is known in relation to RTM technology. Likewise, suitable resins for the matrix can be chosen for chemical and physical properties desired, cost and availability, etc. Resins known to be useable in RTM processes include polyester, epoxy, phenolic, and acrylic resins. As is also known in the moulding technology field, other fillers can be incorporated to meet chemical, physical, aesthetic, cost criteria.
  • the processes of the present invention may also include forming at least parts of the base and/or upper body components to have a sandwich construction.
  • the core materials of such sandwich construction areas can be foam or honeycomb or grid or mesh elements located in the desired positions within, the mould cavity before injection of the matrix so that the matrix encloses the core materials.
  • areas of the final manufactured body components may have a foam material core sandwiched between inner and outer layers of fibre glass.
  • a trailer particularly a caravan, which is manufactured according to a method according to either the first or second aspect of the present invention so as to have a base component and/or an upper body component of a unitary integral construction including respectively a floor or roof section and wall sections extending integrally therefrom.
  • Fig. 1 is a side view of a caravan according to an aspect of the present invention
  • Figs. 2 and 3 show side views of base and upper components of a caravan similar to Fig. 1,
  • Fig. 4 is a transverse section through the base component of Fig. 2 along the line IV-IV,
  • Fig. 5 is a perspective view of a base component manufactured according to an aspect of the present invention using the illustrated mould parts
  • Fig 6 is a plan view of a base component of a caravan
  • Fig. 7 is a transverse section along the line VII-VII in Fig.6
  • Fig. 8 is a part of the towing section with steel support member
  • Fig. 9 is a section at line FX-IX in Fig. 8
  • Fig. 10 is a plan view of the part of a towing section of Fig. 8
  • Fig. 11 is a section along line XI-XI in Fig. 10
  • Fig 12 is a section through a join line of upper and lower trailer sections
  • Fig. 13 is a section through the upper component at a window site as moulded
  • Fig. 14 is a section like Fig 13 through the upper component with a window installed
  • Figs. 15 and 16 show a door mounting in one of the trailer components.
  • the illustrated trailer body has a base component 11 which extends substantially the entire length of the trailer and which has a floor section 18 extending the entire length and the entire width of the trailer, and has wall sections 17 which extend upwardly from peripheral areas of the floor section, the floor section and the wall sections being of a unitary integral construction.
  • the manufacturing method includes the steps of: providing male and female mould parts 10a, 10b which when assembled form therebetween a mould cavity defining the conformations of the floor and wall sections of the base component; locating fibre reinforcing materials within the mould cavity and using a resin transfer moulding (RTM) process to fill the mould cavity to form a fibre reinforced, resin matrix body shape; curing of the fibre reinforced resin matrix within the mould cavity; and subsequently opening and removing of the moulded base component of the trailer from the mould.
  • the male and female mould parts 10a, 10b may be made of medium density fibre board ("MDF").
  • the mould bodies can be made of a laminate of many sheets 99 of MDF, e.g. MDF panels 16mm thick, with the panels being adhered together to form a body of sufficient size to define the required mould part.
  • the MDF body is then machined by the CNC router to create the male and female mould profiles according to the design criteria established using the CAD program.
  • the entire trailer body may be capable of being assembled and fitted out for less cost than assembly from numerous separately manufactured components performing the same function.
  • the use of resin transfer moulding technology (or RTM) can enable sufficient structural rigidity to be provided in the manufactured base component without the need for separate trailer framework components.
  • RTM resin transfer moulding technology
  • the materials used for the reinforcing fibres and the resin matrix can be selected accordingly, and the required thicknesses and conformation of the various areas of the base component can be determined and then provided in the design and construction of the mould.
  • the floor and wall sections of the base component may be composed, either wholly or in selected areas thereof, of layers of different materials, at least one of which is - a layer of the resin matrix.
  • areas can be provided having a sandwich construction with outer layers of resin matrix and a core layer of a foam material, such as a polyurethane, urethane, PVC or other plastics material core.
  • the core can have a honeycomb construction.
  • core materials or inserts can include metal elements such as metal mesh, ribs, grids.
  • the sandwich construction using RTM technology can enable the provision of radiused sections e.g. between the floor section and the wall sections, which provide substantial structural strength to the base component and to the completed trailer.
  • the. process includes providing in the mould cavity predetermined conformations 91 to define chassis sections 41 of the moulded base component.
  • the chassis sections can comprise longitudinal chassis members 42 and 42a extending substantially the entire length of the floor section 18 of the base component.
  • These longitudinal members may comprise continuous linear beams extending lengthwise of the floor section whereby the RTM process creates fibre reinforced resin matrix beams providing longitudinal structural strength to the base component. This enables elimination of prior known separate longitudinal chassis structural beams.
  • chassis sections of the moulded base component may include transverse members 43, 43a providing lateral structural strength and rigidity to the base component enabling elimination of such separate lateral chassis elements used in the past.
  • the longitudinal members 42 and lateral members 43 together form the chassis sections 41 of the base component 11 and are integrally formed simultaneously with the remainder of the floor section 18 and wall sections 17 of the base component.
  • the base component includes moulded integrally therewith a forwardly projecting towing section 31 by means of which the finished-trailer will be towed by a prime mover vehicle.
  • the integral formed towing section may comprise for example towing members 45 projecting forwardly of the floor section of the base component beyond a front wall section 19 extending upwardly from a front edge area 1 - of- the floor section 18, the towing members reaching a forwardmost towing point 55 -where, in use, attachment of the final assembled trailer to the prime mover vehicle will be made.
  • the forwardly projecting towing members may define for example a generally conventional looking A-frame in top plan view, although these . forwardly projecting towing members are formed integrally with and at the same time as the remainder of the base component. If desired, the forwardly projecting towing members 45 may comprise integral forwardly extending continuations of the longitudinal members 42 of the chassis sections of the base component.
  • a conventional wheel bogie assembly 13 can be mounted to the chassis sections beneath the base component.
  • the longitudinal members of the chassis sections may project downwardly below the general plane of the floor section enabling attachment of the wheel bogie, e.g. in conventional fashion analogous to prior arrangements for attachment of a wheel bogie to a separately manufactured structural chassis of a trailer.
  • the base component may be manufactured as a unitary integral component for a caravan including floor and four walls with a particular conformation at their top edges, and an upper body component of the trailer body can then be fitted thereon.
  • the upper peripheral edges of the wall sections of the base component may have for example a moulded rebate 16 formed integrally by an appropriate conformation of the mould cavity between mould parts 10a, 10b so as to closely fit with the complementary lower edge 20 of the upper body component.
  • the upper body component 21 may be manufactured according to a method substantially the same as the base component of the present invention.
  • the present invention in a second aspect may therefore provide a method of manufacturing a trailer body component, the component comprising an upper body component 21 which extends substantially the .
  • the method including the steps of providing a mould (composed of parts analogous to lower body part mould parts 10a, 1 Ob) having a mould cavity defining the conformations of the roof and wall sections of the upper body component; using a resin transfer moulding process to fill the mould cavity to form a fibre reinforced, resin matrix body shape; curing of the fibre reinforced resin 'matrix within the mould cavity; and subsequently opening and removing of the moulded upper body component of the trailer from the mould.
  • the wheel arches 13a for receiving therein the ground engaging wheels of the trailer bogie are formed in the same moulding process.
  • the wheel arches are integrally formed of fibre reinforced resin matrix material so as to form part of the unitaiy construction of the base component.
  • the recessed step 14 formed at the caravan doorway is part of the same integral unitary construction.
  • many other areas or profiles or sections of the base component and/or upper body component can be likewise formed in the moulding operation, e.g. the recess 12 in the back wall for receiving a spare wheel for the caravan.
  • the windows shown in the upper body component can be separately manufactured and can be fitted into the appropriately shaped holes cut in the desired positions to suit the aesthetic and functional criteria depending for example on the fit out arrangement within the caravan as described later in relation to Figs. 13 and 14.
  • the floor section 18 of the base component can have longitudinal structural members 42 formed by integrally formed ribs projecting downwardly from the plane of the main area of the floor section.
  • These longitudinal members can constitute longitudinal structural members contributing rigidity to the floor section, thereby defining integral chassis sections. Suitable means may be used for mounting of the wheel bogie thereto.
  • the integral longitudinal members 42 (and lateral members 43 as seen in Fig. 5) forming chassis sections enable elimination from the caravan construction of a separate manufactured chassis assembly.
  • the longitudinal members and/or lateral members can be solid reinforced beams moulded integrally (e.g. with reinforcing fibre preforms or reinforcing rods or bars laid in the relevant elongated mould cavity channels 91) and extending below the plane of the floor section.
  • the forwardly projecting towing section 31 can be seen. This is formed integrally with the base component, e.g. by extending the longitudinal members 42 below the floor section beyond the front wall 19 so as to extend to the forwardmost point where a conventional coupling for connecting the caravan to a vehicle can be provided.
  • a workable design of base component and its integrally formed chassis sections comprising longitudinal beams 42, 42a and transverse beams 43, 43a.
  • the overall length of the base component may be about 7 metres.
  • the stouter chassis beams 42 may be formed integrally with the floor section 18 by locating within linear channels 91 of the female mould part 10b which define the beam chassis (i) fibre reinforcing webs, mats, strands, or the like 92 and (ii) a formed core 93 whereby the resin matrix permeates through the fibre reinforcing 92 in the RTM process and encapsulates the core 93.
  • DB mats double bias fibreglass mats
  • CSM chopped strand fibreglass mats
  • the core 93 may comprise for example PVC foam (e.g. "H80" PVC foam of 80kg per cubic metre density).
  • the smaller dimensioned longitudinal and transverse beams 42a, 43 a may be of similar constitution but have less layers of reinforcing mats 92 as well as a smaller foam core 93.
  • the floor section may be formed (integrally with the beams in the RTM process) of a laminate comprising surface or skin reinforcing mats formed of layers of CSM, BE, and DB mats, a H80 core, and further DB and BE mats at the opposite surface so that the resin matrix penetrates through the fibre reinforcing and forms an integral laminate of glass fibre reinforced outer layers or skins and PVC core.
  • the two main longitudinal beams 42 project beyond the front wall 19 of the base section at 45 and taper towards each other to join at a point in the general vicinity 55 where the coupling to a prime mover will be provided together with a jockey wheel mounting 56, thus forming the towing section.
  • the core 93 and fibre reinforcing materials 92 of the main longitudinal beams 42 continue beyond the front wall up to and including the front coupling point 55 so that the towing section at the front is an extension structurally of the chassis.
  • each longitudinal chassis beam 45 has on the outside and inside of the front wall 19 additional thickness formed by wedge shaped inserts 46, 47.
  • inserts 46, 47 can be located within the female "A" mould 10b or the male “B” mould 10a, or a combination of both, so that these inserts are incorporated into the integral construction.
  • inserts can be formed of H80 foam core material and can also have reinforcing fibre materials layered along the surfaces so as to be incorporated in the resin matrix forming surface layers or skin forming surface layers or skin.
  • the resulting thickened areas provide additional strength in this area where the towing frame meets and continues integrally with the chassis beneath the floor, e.g. so that the front wall is braced externally and internally in these areas.
  • the thickened areas also are more aesthetically satisfactory.
  • Figs. 8 to 11 show a further possible configuration of and integral towing frame and with a coupling for the prime mover and jockey wheel mounting 56.
  • a generally V-shaped steel reinforcing member 50 fixed to the undersurface of the integral projecting beams 45 forming the towing frame.
  • the steel plate may nevertheless be necessary to comply with some obligatory standards for trailers, in particular some regulations which require safety chains used when coupling a trailer to a vehicle to be welded to a steel plate of the trailer's towing frame.
  • each of the two main towing frame beams 45 there may be moulded in each of the two main towing frame beams 45 a longitudinal metal bar 52, as shown in cross-section in Figs. 9 and 11.
  • These steel bars can be incorporated by locating them in the female "A" mould 10b so that they became encased in the reinforced resin matrix 53 beneath the foam core 54 in the moulding operation.
  • the fixing bolts 51 can then be attached by passing upwardly through the V-shaped reinforcing member 50 through the bottom surfaces of the moulded towing beams 45 into the steel bars 52 extending longitudinally within the beams.
  • Fig. 12 shows a detail of the laminate or layered composition of the lower body component 11 and the upper body component 21.
  • a core 93 described earlier is sandwiched between fibre or other reinforcing 92 embedded in the resin matrix in the RTM operation to form inner and outer shells or skins 65.
  • Fig. 12 also shows a possible joining system for the joining of the base component 11 of the trailer to the complementary upper body component 21 which is different to the rebate configuration shown in Figs. 2 to 5.
  • the base component has an upwardly tapering profile 60 in cross-section formed around the peripheral edges of the walls 17.
  • the upwardly tapering edge is shown to have a complementary shape to a lower peripheral edge 61 of the walls of the upper body component 21 which has a downwardly concave shape in cross-section.
  • the illustrated configuration with a V-shaped concavity or notch 61 is preferred in the lower edge of the walls of the upper body component 21, and the inverted V-shaped tapered edge 60 in the edge of the walls of lower body component 11 because these complementary shapes can be moulded effectively, because the complementary shapes will facilitate alignment and, during securing of the components together, maintenance of alignment of the upper and lower body components, and, because, although believed unnecessary, the shape will promote fluid drainage or inhibit moisture penetration.
  • a suitable bonding adhesive will be placed between the complementary profiles, such as an adhesive known as "Plexus" (trade mark).
  • FIG. 13 shows a cross-section through a portion of a wall of the upper body component where a window is to be located.
  • the inner and outer skins 72, 71 of the moulded body wall 21 sandwiching the foam core 93 meet and are joined together at the termination 94 of the core so as to pass around a removable plug 70 which is provided within the mould (on the surface of the male or "B" part 1 Oa of the mould) at the location where the window is to be provided.
  • the plug 70 is removed and the panel 73 formed within the boundary of the plug will be cut and separated from the main wall leaving the edge profile 75 shown in Fig. 14
  • the removed plug 70 can be reusable and preferably is therefore precisely constructed and finished, e.g. being made of laminated ply, glass coated, painted and polished.
  • Fig. 14 shows a window mounted at the concavity formed by the removable plug, the window comprising a glass panel 76 and a nylon piano hinge 77 fixed to the edge of the glass panel and to the inside surface of the concavity 74 formed around the removable plug 70 in the moulding process.
  • a seal 79 is provided for excluding rain, insects, etc.
  • Figs. 15 and 16 show a section of wall of the trailer body (either upper or lower body component 11, 21) having a contoured profile 80 surrounding a door opening, the profile being formed by inner and outer skins 65 of the wall meeting at an end edge of the core 93 and forming an inwardly stepped profile for receiving the door 81.
  • the door 81 is shown as having a complementary profile to form, together with seal members 82, a sealing engagement with the door opening.
  • the door is shown as having several components (but not all these are necessary), these components comprising inside and outside skins 83, 84, a glass panel 85, a security panel or mesh 86 making forced entrance difficult, and a sliding or rolling blind 87.
  • the door is mounted to the wall by hinge pins 93 extending through the integrally moulded lugs 91 formed on the outside skin 83 of the door and complementary lugs 92 formed on the outside skin 65 of the wall.
  • These lugs can be formed in the process of moulding the upper or lower body component with reinforcing material, such as the glass fibres within the inside and outside skins, being shaped before the RTM process to continuously extend outwardly from the skin 65 into the hinge lugs 91, 92.
  • This kind of door mounting can enable strong and aesthetically pleasing hinged door mounting to the trailer.
  • the methods of the present invention enable the construction of a trailer, particularly a caravan, from a greatly reduced number of components compared to conventional trailer manufacturing processes using separate structural frameworks, chassis, floor, wall and roof components and panels.
  • the trailer construction can have its structural strength provided by the body component(s).
  • the processes also can enable a great variety of aesthetic, aerodynamic, and other shape related functional effects or features to be provided. It may be possible to achieve substantial manufacturing, and particularly assembly cost savings compared to ' conventional caravan manufacturing processes leading to enhanced profitability for manufacturers and/or cost reductions for customers.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne un composant de base (11), ou un composant de carrosserie supérieure complémentaire, d'une remorque ou d'une caravane fabriqué par une opération de moulage par injection de résine (MIR). Des matériaux de renforcement à fibres, des constructions en sandwich comprenant des couches centrales en mousse, des renforcements métalliques dans la région de la barre de remorquage, autre autres, sont situés à l'intérieur de la cavité du moule définie entre les coquilles de moulage mâle et femelle (10a, 10b) avant d'injecter de la matrice résineuse et de vulcaniser celle-ci. Les pièces moulées peuvent être usinées par une mortaiseuse à commande numérique par calculateur pour la réalisation de profilés (91) qui deviendront des organes de renforcement, et peuvent être réalisées à partir de feuilles empilées de panneaux de fibres à densité moyenne (MDF, voir 99).
PCT/AU2006/001858 2006-12-08 2006-12-08 Composants moulés de carrosserie de remorque ou de caravane Ceased WO2008067583A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/AU2006/001858 WO2008067583A1 (fr) 2006-12-08 2006-12-08 Composants moulés de carrosserie de remorque ou de caravane

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2143622A4 (fr) * 2008-01-31 2011-04-27 Hankuk Fiber Glass Co Ltd Carrosserie de véhicule en matériau composite pour véhicule de transport et procédé de production correspondant
JP2012056356A (ja) * 2010-09-06 2012-03-22 Toray Ind Inc 乗用車車室用構造体およびその製造方法
JP2012056355A (ja) * 2010-09-06 2012-03-22 Toray Ind Inc 車両車室用補助構造体
ITMI20110212A1 (it) * 2011-02-11 2012-08-12 Automobili Lamborghini Spa Monoscocca per autoveicoli e processo per la sua fabbricazione
GB2554870A (en) * 2016-10-06 2018-04-18 Forward Composites Fabricating a composite article
US20210053626A1 (en) * 2020-10-26 2021-02-25 Paul Spivak Heat-reflective recreational vehicle body
EP4095020A1 (fr) * 2021-05-28 2022-11-30 Paul Spivak Carrosserie de véhicule de loisirs moulée intégralement

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GB1598603A (en) * 1978-05-23 1981-09-23 Cabby Caravan Ab Trailer tents
US4781392A (en) * 1987-07-13 1988-11-01 Cooper Gary J Molded boat trailer
US4917435A (en) * 1989-05-23 1990-04-17 Ford Motor Company Truck cab construction
WO1996000667A1 (fr) * 1994-06-29 1996-01-11 Cleall Christopher C Systeme de remorque modulaire pour les voyages, le travail ou des activites sportives
WO2000069678A1 (fr) * 1999-05-13 2000-11-23 Camp-O-Matic Products Australia Pty Ltd Realisation de cellule habitable amovible
WO2003057455A1 (fr) * 2002-01-10 2003-07-17 Joost Boxoen Procede de fabrication d'un chassis de kart en materiau composite et chassis de kart en materiau composite fabrique par ce procede

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1598603A (en) * 1978-05-23 1981-09-23 Cabby Caravan Ab Trailer tents
US4781392A (en) * 1987-07-13 1988-11-01 Cooper Gary J Molded boat trailer
US4917435A (en) * 1989-05-23 1990-04-17 Ford Motor Company Truck cab construction
WO1996000667A1 (fr) * 1994-06-29 1996-01-11 Cleall Christopher C Systeme de remorque modulaire pour les voyages, le travail ou des activites sportives
WO2000069678A1 (fr) * 1999-05-13 2000-11-23 Camp-O-Matic Products Australia Pty Ltd Realisation de cellule habitable amovible
WO2003057455A1 (fr) * 2002-01-10 2003-07-17 Joost Boxoen Procede de fabrication d'un chassis de kart en materiau composite et chassis de kart en materiau composite fabrique par ce procede

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2143622A4 (fr) * 2008-01-31 2011-04-27 Hankuk Fiber Glass Co Ltd Carrosserie de véhicule en matériau composite pour véhicule de transport et procédé de production correspondant
JP2012056356A (ja) * 2010-09-06 2012-03-22 Toray Ind Inc 乗用車車室用構造体およびその製造方法
JP2012056355A (ja) * 2010-09-06 2012-03-22 Toray Ind Inc 車両車室用補助構造体
ITMI20110212A1 (it) * 2011-02-11 2012-08-12 Automobili Lamborghini Spa Monoscocca per autoveicoli e processo per la sua fabbricazione
GB2554870A (en) * 2016-10-06 2018-04-18 Forward Composites Fabricating a composite article
US20210053626A1 (en) * 2020-10-26 2021-02-25 Paul Spivak Heat-reflective recreational vehicle body
EP4095020A1 (fr) * 2021-05-28 2022-11-30 Paul Spivak Carrosserie de véhicule de loisirs moulée intégralement
US12139060B2 (en) 2021-05-28 2024-11-12 Paul Spivak Integrally molded recreational vehicle body

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