Extruded rail joints for sandwich panels in a vehicle

Abstract

A vehicle system for joining sandwich panels has been designed for use in vehicles. The system includes a chassis, a floor, sidewalls, a roof, and a rear panel. The walls are formed as prefabricated sandwich panels with finished surfaces. These panels are joined using single-piece aluminum extrusions in the form of roof rails and floor rails, which allow for quick assembly and strong surface-to-surface load transfer. The sandwich panels use lightweight cores and embedded stiffeners. The rails are designed to enable rotational assembly that compresses adhesive beads for robust connections. The floor is made from modular extruded panels with staggered seams and integrated tracks, and a removable closeout cover is provided for access to wiring and electronics. The design of the system supports both strong mechanical attachment and efficient manufacturing, while reducing overall vehicle weight and assembly time. The system helps maintain structural integrity under safety testing conditions.

Dependencies are inferred from the claim text.