COMPOSITE FUSELAGE FOR VEHICLES

1 . A method of assembling a vehicle, the method comprising the steps of:

providing a mandrel that approximates shape of a fuselage to be formed;

winding a fiber around the mandrel by rotating the mandrel with a driver;

heating the fiber to form the fiber into a structural, hardened shell comprising the fuselage;

removing the mandrel from the fuselage; and

mounting the fuselage onto a frame rail of the vehicle.

2 . The method of claim 1 wherein the driver has a drive shaft that is selectively attachable to the mandrel.

3 . The method of claim 1 further comprising the step of feeding fiber to the mandrel with a spindle on a fiber applicator.

4 . The method of claim 3 further comprising the step of displacing the mandrel along an axis of the driver.

5 . The method of claim 4 further comprising sliding the driver on a driver track.

6 . The method of claim 5 further comprising sliding a bearing of the driver on the driver track defined by a driver base plate.

7 . The method of claim 3 further comprising displacing the spindle generally parallel to the driver axis and with respect to the mandrel.

8 . The method of claim 3 further comprising displacing the spindle vertically with respect to the mandrel.

9 . The method of claim 1 further comprising cutting the fuselage to form openings.

10 . The method of claim 1 wherein the fuselage is formed in one continuous piece.

11 . A fiber applicator assembly for forming a structural component of a bus or automotive vehicle, comprising:

a mandrel approximating the interior shape of the structural component;

a driver selectively attached to the mandrel for rotating the mandrel about a driver axis; and

a fiber applicator having a spindle for feeding a fiber to the mandrel, the spindle being displaceable with respect to the mandrel in a direction parallel to the driver axis and in a direction vertical and transverse to the driver axis.

12 . The fiber applicator of claim 11 further comprising a driver track, wherein the driver is displaceable on the driver track in a direction parallel to the driver axis.

13 . The fiber applicator of claim 11 further comprising an applicator track, wherein the fiber applicator is displaceable on the driver track in a direction parallel to the driver axis.

14 . The fiber applicator of claim 11 further comprising a fiber bath machine that impregnates the fiber with resin, the fiber bath machine having a pulley for feeding the fiber to the fiber applicator under tension.

15 . A method of assembling a vehicle, comprising:

providing a mandrel that approximates the shape of a fuselage to be formed;

winding a fiber around the mandrel by rotating the mandrel with a driver having a drive shaft that is selectively attachable to the mandrel;

applying the fiber with a fiber applicator by feeding the fiber from a spindle mounted on the fiber applicator to the mandrel;

displacing the spindle with respect to the mandrel;

heating the fiber to form the fiber into a hardened shell comprising the fuselage;

removing the mandrel from the fuselage; and

mounting the fuselage onto a frame rail of the vehicle.

16 . The method of claim 15 wherein the mandrel further comprises:

a mounting plate having a mount structure, and the drive shaft is attached to the mounting plate with fasteners that are received by the mount structure.

17 . The method of claim 15 wherein the driver further comprises:

a bearing that engages the mandrel on a side opposite from the drive shaft.

18 . The method of claim 15 further comprising the step of:

forming at least one of a side skirt, a side rail and a luggage tube from a composite fiber material; and

attaching to the frame rail of the vehicle.

19 . The method of claim 15 wherein the spindle displaces in a direction generally parallel to a drive axis and in a direction vertical and generally transverse to the drive axis.

20 . The method of claim 15 wherein the fuselage is formed in a single, continuous piece.