The invention relates to a load-bearing vehicle structure of composite material, and a method for moulding such a load-bearing vehicle structure. The invention concerns the fields of fiber-reinforced thermoplastic composites, sandwich structures and compression moulding. The load-bearing vehicle structure (1) according to the invention comprises first (2) and second (3) surface materials with reinforcement fibers and one or several intermediate pieces of core material (4, 5, 6, 7) which are arranged in pattern adapted to a load-bearing material structure, and is characterized in that the surface materials and/or the core material comprise(s) thermoplastic material, and that the first surface material is attached by means of thermal bonds to first faces of the piece or pieces of core material and that the second surface material is attached by means of thermal bonds to second, opposing faces of the piece or pieces of core material. Load-bearing vehicle structures according to the invention can be utilized within the field of vehicle components with low weight and high stiffness and load-bearing ability, for example floor structures in motor vehicles.
A vehicle cell made of reinforced--reinforced thermoplastic material includes a shape-defining, long-reinforced-reinforced thermoplastic matrix (2) with integrated continuos fiber strands or strips (3). In a base structure (10), which includes a base plate (6), uninterrupted continuous fiber strands running longitudinally (3no) in an upper base area (NO) and continuous fiber strands running longitudinally (3nu) in a lower base area (NU). The upper and the lower base areas are connected with vertical walls (11). This results in an economically manufacturable, light-weight, rigid and safe vehicle cell.
A golf car (10) or utility vehicle having a composite body (58). In some aspects of the invention, the golf car or utility vehicle has a composite body assembly that includes a front clam shell assembly (62) and a rear shell-like body (64). In other aspects, the golf car or utility vehicle includes a composite body assembly having a periphery (118) and one or more decorative body panels (106, 108), the decorative body panels being recessed inwardly relative to the composite body assembly periphery to prevent impacts to the panels.
An ultrathin covered structural panel includes a panel body made from a relatively lightweight moldable material such as expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polypropylene with added strengtheners (XPP), polystyrene/polyphenylene ether (GECET.RTM.) foam, polyurethane foam, polystyrene foam, fiberglass materials, glass fiber-reinforced polypropylene (Azdel.RTM. composites), or treated reclaimed cellulose. The structural panel also includes one or more rigid high-strength structural inserts in the interior of the panel body. The structural panel further includes a covering on at least one side of the panel body. The structural panel is not more than about 20 mm thick. In a method of making the structural panel, one or more rigid high-strength structural inserts are placed into the cavity of a mold. The mold cavity has the shape of the structural panel and has a thickness of not more than about 20 mm. The mold is closed. A relatively lightweight moldable material is introduced into the mold cavity so that the moldable material surrounds the insert(s) and fills the mold cavity. The moldable material is allowed to harden to form the structural panel, and the finished structural panel is removed from the mold.
