Patent Application
20140054916
This invention generally relates to commercial vehicles, and more particularly to class 3 commercial vehicle bodies for walk-in commercial vans.
Commercial vehicles, such as walk-in vans, parcel delivery vans, as well as truck bodies and specialty upfit vehicles for the parcel delivery, baking and snack food, textile, utilities, emergency response, mobile sales and maintenance industries must have a long life and low cost of ownership. Indeed, such commercial vehicles must be designed for hundreds of stops per day, be rugged and repairable to increase actual service life, and provide a safe and productive work environment for the driver and handling personnel.
Unlike other commercial vehicles, walk-in vans provide a low step-in height at the cab doors and rear door, as well as wide cab doors, to provide optimum entry and exit capacity. Full stand-up height in cab and cargo areas in such walk-in vans offers a superior vehicle for an ergonomical work space. When equipped with a traditional bulkhead and door, walk-in vans provide instant access from the cab to the cargo area, allowing for safer cargo delivery versus a cube van. Further, the lightweight aluminum construction of such walk-in vans provides a durable, rust-free body with lighter overall weight for increased payload capacity.
While such traditional walk-in vans provide significant advantages over other commercial vehicles for the markets they serve, the continued rise in fuel cost, service, maintenance, and repair costs, have increased the cost of ownership. Indeed, while the use of lightweight aluminum for the body of the walk-in vans provided significant improvement in terms of repair and replacement costs due to rust compared to prior constructions, the changing composition of ice melting chemicals used on city streets and highways on which such walk-in vans drive has resulted in pitting and corrosion on the aluminum body construction. This further increases the repair costs of such vans, and may require that application of new corrosion coatings or shielding of the aluminum, at a substantial cost, to protect against such pitting and corrosion.
Additionally, the use of aluminum panels to construct the sidewalls of the walk-in vans requires that such individual panels be riveted to steel vertical interior studs with buck rivets to form the sidewall. The rub rails, meant to protect the sidewalls from damage due to scraping against other objects, must also be riveted onto the sidewall structure. Such construction and riveting not only increases the initial construction cost, but also increases the repair cost of such sidewalls once damaged. The buck rivets also provide a potential leak path from the exterior to the interior of the walk-in van since they traverse the wet-to-dry barrier of the sidewall into the cargo compartment.
In view of the above, there is a need for a commercial walk-in van body that reduces the total cost of operation by reducing fuel consumption and carbon footprint, that provides a rugged commercial work truck, and that focuses on operator safety and productivity. Embodiments of the invention provide such a walk-in van body. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
In view of the above, embodiments of the present invention provide new and improved commercial vehicle bodies that overcome one or more of the problems existing in the art. More particularly, embodiments of the present invention provide new and improved commercial walk-in van bodies that overcome one or more of the problems existing in the art. Still more particularly, embodiments of the present invention provide a new and improved walk-in van body that has a reduced total cost of operation due to the reduced fuel consumption and carbon footprint of a walk-in van constructed with such a body, its rugged commercial body, and its operator safety and productivity gains enabled by its ergonomics, functionality, and design flexibility.
A lightweight commercial walk-in van body with an aerodynamic design (13% more aerodynamic in one embodiment) constructed in accordance with one embodiment of the present invention aids in the delivery of 35% better fuel-efficiency, providing a new definition of safety, performance and cost-effectiveness. Improved cab ergonomics of one embodiment of the present invention delivers faster entry/egress for the walk-in van operator, providing a 1.5 hours per day productivity gain.
Corrosion-resistant, long-life composite materials utilized in one embodiment saves 600 lbs per vehicle. Body on frame construction of one embodiment provides less costly accident repairs compared to automotive unibody designs used in prior walk-in vans. In one embodiment, the lower body panels are designed for quick removal and replacement to further reduce repair and maintenance time and expense.
To improve operator safety, an embodiment of the present invention may include integrated entry hand rails, a backup camera system, high visibility steps with slip-resistant carbide tread, and 13″ more aisle width than a cargo van (50% wider). Embodiments also provide the best-in-class visibility for improved low-speed maneuverability.
Embodiments of the present invention also include best-in-class sustainability by aiding in a reduced carbon footprint (carbon dioxide emissions) of up to 11 tons per year per vehicle, by providing numerous body components made from recycled material, and by providing a composite construction to minimizes underbody corrosion.
The wider and taller modular cargo area of three embodiments of the present invention provides 450, 540 or 630 cubic feet of storage and offers a choice of vocational packages specifically designed for functionality. With three embodiment of vehicles ranging from 10 to 14 feet in length and a payload capacity of up to 4,800 pounds, productivity in delivery or work truck applications is greatly increased.
Preferred embodiments of the present invention are commercial vehicles with flat, vertical sidewalls, sliding cab doors, have several rear door options, and are designed for walk-in van duty cycles. Such embodiments, unlike current walk-in vans, also provide improved exterior appearance, improved cab interior fit & finish, molded, impact resistant lower and rear body panels, composite floor and sidewall panels, and a large curved windshield. The material used in embodiments of the present invention are chosen based on at least one of durability/impact resistance, safety & functionality, corrosion resistance, cost and weight, manufacturability and paintability, appearance, reparability/replaceability, recycleability, and thermal and sound insulation properties.
One of the benefits provided by embodiments of the present invention is a miles per gallon (MPG) improvement from the enhanced aerodynamics of such embodiments. Specifically, MPG improvement is roughly equal to one half of the percentage reduction in drag coefficient. In certain embodiments the coefficient of drag (Cd) has been reduced from 0.61 for typical walk-in vans to 0.53. This 13% improvement, could result in a 6.5% MPG increase for commercial walk-in vans constructed using such a body.
Another of the MPG improvements provided by embodiments of the present invention is from weight reduction. In stop-and-go applications such as with walk-in vans, MPG improvement is roughly equal to one half of the percentage of weight reduction. Because embodiments of the present invention utilize lightweight composite panels for the floor and sidewalls, the body is much lighter than prior walk-in van bodies.
Body durability of embodiments of the present invention also reduces the cost of ownership. Unlike cargo vans that are made of thin-gauge welded steel bodies mounted on light-weight frames, embodiments of the present invention utilize a body that is designed for a commercial truck application. Such embodiments utilize impact resistance urethane rear and lower exterior panels, rear spring bumper and energy absorbing side bumpers, one-piece molded roof to eliminate leaks, LED interior and exterior lights (all except headlights), and doors and hardware designed for the application.
With regard to service and repair, embodiments of the present invention utilize a body designed as a true commercial vehicle, allowing quick and easy body repairs to put the vehicle back in original condition. Part of this is the vehicle repair procedures. In embodiments of the present invention, the body panels are designed for quick removal and replacement. Indeed, the replacement panels are supplied in final color to further reduce the time and expense of such repair. With regard to the maintenance aspects of these embodiments, under-hood maintenance points are organized and accessible. Indeed, the hood of the vehicle extends the entire width of the front end for maximum access. Further, the hood is designed for quick removal. The instrument panel allows quick access to under-dash components as well. Wire routing and connections are highly accessible, which also reduces the cost of maintenance.
Embodiments of the present invention also provide enhanced ergonomics and functionality. In a fleet delivery walk-in van application, such operator ergonomics when the vehicle is stopped is just as important as when it is moving. Driver safety and ergonomics are enhanced in embodiments of the present invention by improving driver movement in and around the van, driver visibility, the placement and design of driver controls, improved interior styling and fit and finish, reduced interior sound level, and simplified instruments and controls. Indeed, embodiments of the present invention approach the design of the cab as an office. The driver can walk in and out of the cab in an upright position, and has access to cargo area from driver seat. Preferred embodiments also approach the cargo compartment as a work area. Such embodiments provide stand-up height in the cargo area, a wider and taller cargo area, has multiple rear door options, and sliding doors in the cab, which eliminates the need for a side door in the cargo compartment. The design flexibility of embodiments of the present invention is also enhanced through multiple rear door options, including roll-up doors, 270° twin-swing doors, twin side-sliding doors, etc.
Design Flexibility is also enhanced by inclusion of logistic tracks integrated into body design which enable installation of custom cargo interior packages, such as shelves, wire racks, etc. Such logistic tracks allow other package delivery cargo modules, such as printer stands, spare tire mounts, hazardous goods restraints, winter driving ballast, etc.
In certain embodiments, a composite commercial walk-in van body is provided. The composite commercial walk-in van body includes a cab and a cargo area adjoining the cab which is accessible therethrough. The cargo area includes a composite cargo floor. A lower composite sidewall is coupled to the composite cargo floor. An upper composite sidewall is coupled to the lower composite sidewall by a rubrail structure. A one-piece molded roof is coupled to the upper composite sidewall.
In certain embodiments, the composite cargo floor and a lower composite sidewall are coupled to one another via a lower bracket structure. The lower bracket structure may be formed as a multi-piece assembly comprising a floor bracket, a sidewall exterior bracket coupled to the floor bracket, and a sidewall interior bracket coupled to the sidewall exterior bracket. A portion of the composite cargo floor is received in a channel of the floor bracket. The portion of the composite cargo floor is fixed within the channel with an adhesive that acts as a sealant.
In certain embodiments, the sidewall interior bracket and the sidewall exterior bracket are coupled to one another to form a channel. A portion of the lower composite sidewall is received within the channel. The portion of the lower composite sidewall is fixed within the channel using an adhesive that acts as a sealant.
In certain embodiments, the floor bracket includes an inner and an outer upstanding wall arranged in a posed space relation to form a pocket therebetween. A portion of the sidewall exterior bracket and a portion of the sidewall interior bracket cover an opening of the pocket to isolate the pocket from an exterior environment of the van body. The sidewall exterior bracket is mounted to the outer upstanding wall using at least one outer rivet. The sidewall interior bracket is mounted to the inner upstanding wall using at least one inner rivet. Each of the at least one outer and inner rivets extend into the pocket formed between the inner and outer upstanding walls.
In certain embodiments, the rubrail structure is a multi-piece structure comprising an interior bracket and a rubrail. The interior bracket and rubrail are coupled to one another to form upper and lower channels. The lower composite sidewall is received within the lower channel. The upper composite sidewall is received within the upper channel. The lower composite sidewall is fixed within the lower channel with an adhesive that acts as a sealant. The upper composite sidewall is fixed within the upper channel with an adhesive that acts as a sealant.
In certain embodiments, the rubrail includes at least one pocket which is isolated from an exterior of the van body. The interior bracket is joined to the rubrail using at least one rivet. The at least one rivet extends into the at least one pocket of the rubrail.
In certain embodiments, the one-piece molded roof is coupled to the upper sidewall via an upper bracket structure that is a multi-piece component comprising a corner bracket, a roof/sidewall interior bracket coupled to the corner bracket, and a roof/sidewall exterior bracket coupled to the roof/sidewall interior bracket. The corner bracket includes a channel for receiving at least one support beam positioned underneath the one-piece molded roof. The roof/sidewall interior bracket and roof/sidewall exterior bracket are coupled to one another to form a channel for receiving the upper sidewall. The upper sidewall is fixed within the channel with an adhesive that acts as a sealant. The one-piece molded roof is sealed to the upper bracket structure using a vutyl rope.
In certain embodiments, the composite cargo floor is formed from a corrosive resistant material and has an upper and a lower surface. The upper surface faces the cargo area. The lower surface is exposed to an exterior of the van body on an underside thereof. The composite cargo floor is a resin infused foam-core construction having fiberglass crossbeams. The upper surface of the composite cargo floor is textured for slip resistance.
In certain embodiments, the upper and lower sidewalls comprise a honeycomb core that is resin infused.
In certain embodiments, a composite commercial walk-in van body is provided. A composite commercial van body according to this embodiment includes a cab having an interior operator space. A cargo area is adjoined to the cab and is accessible therethrough via a bulkhead doorway. A bulkhead door is mounted within said doorway and slideable relative thereto. At least one vehicle fluid reservoir port is accessible from within the cab.
In certain embodiments, the interior operator space has an overall height of about five (5) feet to about seven (7) feet. The bulkhead door is mechanically coupled to an actuation mechanism. The actuation mechanism is in electronic communication with the receiver. The receiver is configured to receive an actuate signal to actuate the actuation mechanism and selectively and automatically open and close the bulkhead door.
In certain embodiments, a composite commercial walk-in van body is provided. A composite commercial walk-in van body according to this aspect includes a cab. A cargo area adjoins the cab and is accessible therethrough. The cargo area includes a cargo floor. A lower sidewall is coupled to the cargo floor by a lower bracket structure. A upper sidewall is coupled to the lower sidewall by a rubrail structure. A roof is coupled to the upper sidewall by an upper bracket structure. At least one of the lower bracket structure, rubrail structure, and upper bracket structure comprising integral logistic track formed therein.
In certain embodiments, the integral logistic track comprises a raceway and a fastener slideable within the raceway. The fastener is configured for adjustable fixed positioning within the raceway.
In certain embodiments, a method for assembling a composite commercial walk-in van body cargo area is provided. The method according to this embodiment includes mounting a composite cargo floor to a lower bracket structure using an adhesive. The method also includes mounting a lower composite sidewall to the lower bracket structure using an adhesive at a first end of the lower composite sidewall. The method also includes mounting a rubrail structure to the lower composite sidewall at a second end opposite the first end of the lower composite sidewall using an adhesive. The method also includes mounting a first end of an upper composite sidewall to the rubrail structure using an adhesive. The method also includes mounting a second end of the upper composite sidewall to an upper bracket structure using an adhesive. The method also includes sealingly installing a one-piece molded roof to the upper bracket structure.
In certain embodiments, the method additionally includes assembling the lower bracket structure by forming a rivet connection between an interior sidewall bracket to a floor bracket and by forming a rivet connection between an exterior sidewall bracket to the floor bracket. Each of the rivet connections is isolated from an exterior of the cargo area.
In certain embodiments, the method also includes assembling the rubrail structure by forming a rivet connection between an interior bracket and a rubrail. The rivet connection is isolated from an exterior of the cargo area.
In certain embodiments, the method also includes assembling the upper bracket structure by forming a rivet connection between a corner bracket and an interior roof/sidewall bracket and by forming a rivet connection between the interior roof/sidewall bracket and an exterior roof/sidewall bracket. Each of the rivet connections is isolated from an exterior of the cargo area.
Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
Turning now to the drawings, there is illustrated in
As may be seen from the embodiment illustrated in
As may be seen in
An alternate embodiment of the composite commercial walk-in van body 100 is illustrated in
As will be apparent to those of ordinary skill in the commercial vehicle art, each of the embodiments illustrated in
Further, and as will be discussed in detail below, in stop-and-go applications typical for a commercial walk-in van, an MPG improvement is also roughly equal to one-half of the percentage of weight reduction. As such, lightweight materials are used in the construction of embodiments of the walk-in van body 100 of the present invention. These lightweight materials include composite panels used for the construction of the sidewalls 102 and flooring of the cargo compartment of the walk-in van body 100, as well as usage of sheet mold composite (SMC) for structural parts in the hood, tow kicks in the cab, interior wheel wells, etc. The result of the usage of such lightweight materials and composite panels result in a body that is much lighter than prior commercial walk-in van bodies, which provide a significant weight reduction and therefore MPG improvement. As another advantage, these sidewalls 102 and the lower and rear body panels 108, as well as the other composite body components can be molded and subsequently assembled in their final color. As one example, the sidewalls 102 can incorporate a gel coat outer surface which those skilled in the art will recognize is thicker and more durable than conventional paint.
As shown in
Indeed, while not illustrated in
As introduced briefly above, embodiments of the present invention utilize molded, impact resistant lower and rear body panels 108 in order to increase the durability, reparability, replaceability, and reduce the weight of the commercial walk-in van body 100. These various lower and rear body panels 108 may be seen in the exploded isometric illustration of
In addition to the sealing nature of the adhesive affixing the cargo floor composite structure 130 and the sidewall composite structure 128 in their respective brackets, the configuration of these brackets 132-136 ensure that none of the rivets 146 traverse a wet-to-dry barrier. In other words, the rivets 146 that connect the floor bracket 132 to the sidewall exterior bracket 134 traverse from the exterior of the vehicle into a pocket that is isolated from the actual cargo compartment of the walk-in van body. Additionally, rivets 146 that connect the sidewall interior bracket 136 to the floor bracket 132 traverse from the interior of the cargo compartment into the pocket formed between the floor bracket 132 and the sidewall exterior bracket 134. In this way, leak paths from the wet exterior to the dry interior are minimized if not eliminated.
Also as illustrated in these
The sidewall interior bracket 134 is configured to form an integral logistic track 138 that runs along the entire length of the cargo compartment of the walk-in van. This logistic track 138 receives a logistic track fastener 140 that is secured in place by a logistic track fastener bolt 142. As will be recognized by those skilled in the art, the logistic track fastener 140 may be repositioned anywhere within the logistic track 138, and secured thereat by tightening the logistic track fastener bolt 142. To aid in holding the logistic track fastener in place during repositioning, a spring may also be included that spring loads the logistic track fastener 140 towards its engaged position so that it does not turn or otherwise fall out while being repositioned.
This rub rail interior bracket 150 is coupled to the rub rail 120 by rivets 146 that traverse from the dry cargo compartment into a pocket formed as part of the rub rail 120. As may be seen best from
As may also be seen in
As with the floor composite structure and the sidewall composite structures discussed above, the upper edge of the sidewall composite structure 128 is held in the slot formed between the roof/sidewall interior bracket 158 and the roof/sidewall exterior bracket 160 by an adhesive that also serves as a sealant. The single piece molded roof 118 is sealed via the use of a butyl rope that also forms a seal (not shown).
As may also be seen from
While previous embodiments discussed above included a roll-up rear door (see also
As discussed above, the inclusion of the integral logistic track within the cargo area allow for design flexibility within the cargo area. Such tracks enable the use of custom cargo interior packages or other package delivery cargo modules such as printer stands, spare tire mounts, hazardous good restraints, winter driving ballasts, etc. Indeed,
All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This patent application is a continuation of pending PCT Application No. PCT/US2012/028085, filed Mar. 7, 2012, which claims the benefit of U.S. Provisional Application No. 61/450,018, filed Mar. 7, 2011, the entire teachings and disclosure of which are incorporated herein by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| 61450018 | Mar 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2012/028085 | Mar 2012 | US |
| Child | 14020362 | US |
