Integrated Composite-Material Vehicle Body for a Transportation Vehicle, and a Production Method Therefor

An integrated composite-material vehicle body for a transportation vehicle obtained by integral forming in the shape of the vehicle body and using a sandwich panel, comprising:

• a core material;
• an inner skin material which is made using a prepreg of reinforcing fibres impregnated with a synthetic resin and semi-cured, and which is adhered to one side of the core material;
• an outer skin material which is made using a prepreg of reinforcing fibres impregnated with synthetic resin and semi-cured, and which is adhered to the other side of the core material;
• and a sheet metal material which is inserted between the core material and the outer skin material.

An integrated composite-material vehicle body for a transportation vehicle obtained by integral forming in the shape of the vehicle body and using a sandwich panel, comprising:

• a core material;
• an inner skin material which is made using a prepreg of reinforcing fibres impregnated with a synthetic resin and semi-cured, and which is adhered to one side of the core material;
• an outer skin material which is made using a plurality of prepregs of reinforcing fibres impregnated with synthetic resin and semi-cured, and which is adhered to the other side of the core material;
• and a sheet metal material which is inserted between the plural prepregs constituting the outer skin material.

A method of producing an integrated composite-material vehicle body for a transportation vehicle, comprising:

• producing a mold in the same form and size as the vehicle body in such a way that a front head part, a rear head part, a ceiling, and side parts of the vehicle body can be produced integrally;
• laminating an outer skin material, which is made using a prepreg of reinforcing fibres impregnated with synthetic resin and semi-cured, in the inside surface of the mold;
• laminating a sheet metal material or a porous sheet metal material on the inside surface of the outer skin material;
• laminating a core material on the inside surface of the sheet metal material;
• laminating an inner skin material, which is made using a prepreg of reinforcing fibres impregnated with synthetic resin and semi-cured, on the inside surface of the core material;
• and
• molding the above laminated materials in an autoclave.

A method of producing an integrated composite-material vehicle body for a transportation vehicle, comprising:

• producing a mold in the same form and size as the vehicle body in such a way that a front head part, a rear head part, a ceiling, and side parts of the vehicle body can be produced integrally;
• laminating a first outer skin material, which is made using a prepreg of reinforcing fibres impregnated with matrix materials and semi-cured, on the inside surface of the mold;
• laminating a sheet metal material or a porous sheet metal material on the inside surface of the first outer skin material;
• laminating a second outer skin material, which is made using a prepreg of reinforcing fibres impregnated with synthetic resin and semi-cured, on the inside surface of the mold;
• laminating a core material on the inside surface of the second outer skin material;
• laminating an inner skin material, which is made using a prepreg of reinforcing fibres impregnated with synthetic resin and semi-cured, on the inside surface of the core material;
• and
• molding the above laminated materials in an autoclave.