Vehicle and method of producing the same

A vehicle such as a railroad car is constructed by connecting together side and roof blocks, each equipped with interior components, in a manner to improve the outer appearance of the connections between the side and roof blocks. Longitudinal beams of the side blocks are in contact with the under surfaces of gutters formed by the outer plate of the roof block. The side and roof blocks, equipped with the interior components, are connected together at the gutter portions by a welding which can be conducted solely from an exterior side of the vehicle. In the interior of the vehicle, the longitudinal beams and joints secured to the side blocks are connected to lateral beams of the roof block by rivets. Thereafter, a third interior plate is provided between interior plates of the side and roof blocks. Since the connections are formed at the gutter portions, the connecting operations can easily be conducted outside the vehicle and in a manner to assure a good from an exterior of appearance.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to the body structure of a vehicle, such as a 
railroad car, a vehicle running on a guideway, an astride-type monorail 
car, a bus, or the like. 
2. Description of the Prior Art 
The body of a vehicle of this type is formed as a hexahedron, which 
consists of a floor, a roof, walls extending in the longitudinal direction 
of the vehicle (referred to as "sides"), and walls extending in the 
widthwise direction of the vehicle (referred to as "ends"). 
This type of vehicle body is generally produced in the following manner. 
First, each of the planes constituting the hexahedron is formed as a block 
which consists of a framework and a board forming an outer surface. Then, 
these six blocks are assembled and connected together by welding, by using 
bolts, or the like. The connecting operation is generally conducted both 
inside and outside the vehicle. Subsequently, various components such as 
pipes, wires and interior equipment (a floor sheet, interior plates 
forming the walls and ceiling of the body, seats, window fittings, and 
lighting equipment, etc.) are put in the vehicle body through doorways and 
window provided in the side blocks and the end blocks, and are installed 
inside the vehicle. An example of such a vehicle body is shown in Japanese 
Patent Laid-Open Publication No. 55-31694 (corresponding to U.S. Pat. No. 
4,222,335). 
In the above example, mounting various interior components is conducted in 
the interior of the vehicle, that is, in a rather small space, resulting 
in poor operational efficiency. Further, the mounting operation requires a 
lot of time. 
In view of this problem, a system has been proposed wherein six blocks are 
connected together after the various interior components have been 
attached to the inner sides of the blocks. The assembly of the blocks is 
conducted by using rivets, bolts and nuts, or the like. The connection of 
the side blocks and the roof block is substantially effected at positions 
around the roof, interior and exterior of the vehicle. The connection 
exterior the vehicle is effected by fastening outwardly protruding end 
portions of the side blocks to outwardly protruding end portions of the 
roof block by rivets or the like. These outwardly protruding end portions 
are protected by covers so as to prevent water leakage. The covers are 
made of stainless steel or the like. These outwardly protruding end 
portions also serve as gutters. The connection on the inner side of these 
portions is also effected by rivets. The construction described above is 
disclosed in Japanese Utility Model Laid-Open Publication No. 48-64910. 
It appears that a problem with the construction shown in Japanese Utility 
Model Laid-Open Publication No. 48-64910 is that no consideration is given 
to exterior appearance or waterproofing. 
SUMMARY OF THE INVENTION 
It is an object of the present invention to improve the appearance of the 
joint sections between the side blocks and the roof block of a vehicle of 
the above-described type, in which the side blocks and the roof block are 
connected together after the interior components have been attached 
thereto. 
In accordance with the present invention, the gutters in the upper sections 
of the side blocks are formed by end portions of an external plate of the 
roof block, and the above-mentioned end portions of the external plate, 
which are in or near the gutter sections, are connected to the side blocks 
by a connecting means which enables them to be connected to the side 
blocks solely by an operation conducted exteriorly of the vehicle, with an 
interior plate of the roof block and an interior plate of each side block 
being connected together through an intermediate third interior plate. 
Since the connection of the side blocks and the roof block is conducted in 
the gutter sections provided in the upper sections of the side blocks, the 
connecting operation can be carried out only from the exterior of the 
vehicle, and after the interior finish work has been completed. The 
connecting operation can be easily conducted without impairing the 
appearance of the vehicle even though it is conducted exteriorly of the 
vehicle. Further, since third interior plates are attached after effecting 
the connection of the inner portions of the joint sections between the 
roof block and the side blocks, a connection is also effected on the inner 
side of the joint sections.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
An embodiment of the present invention will now be described with reference 
to FIGS. 1 and 2. 
As shown in FIG. 2, a vehicle body constructed in accordance with the 
present invention includes a floor block 100, side blocks 200, end blocks 
300, and a roof block 400. The floor block 100, the side blocks 200 and 
the roof block 400 have the same length as a vehicle body to be 
constructed. The interior components are attached to these six blocks 
before they are connected together to form a hexahedron. 
Attached to the lower surface of the floor block 100 are air pipes, 
electric wiring tubes, various electric apparatuses and pneumatic 
apparatuses (none of which are shown). Of these components, particularly 
the heavy components are mounted after the assembly of the blocks. 
The floor block 100 is composed of right and left longitudinal beams 101 
extending in the longitudinal direction of the vehicle, a plurality of 
lateral beams 103 linking these longitudinal beams 101 to each other, a 
floor board 105 provided on the upper surfaces of these beams and 
including one a flat metal plate, a light-metal shape member, a honeycomb 
panel, or the like, a resin mat 107 provided on the upper surface of the 
floor board 105, etc. Provided under the floor are couplers (not shown) 
for connecting the vehicle to a bogie or another vehicle. The strength 
members namely, the longitudinal beams 101, lateral beams 103, floor board 
105, etc. are joined to each other by spot welding or the like except for 
the mat 107. The longitudinal and lateral beams 101 and 103 are formed of 
stainless steel. 
Each side block 200 includes a framework composed of two longitudinal beams 
201, a plurality of columns 205, a plurality of side members 207, an 
entrance frame 209, etc., an outer plate 220 attached to the outer side of 
the framework, an interior plate 230 attached to the inner side of the 
framework, window devices 235 equipped with window panes, a door device 
240, racks 250, seats 260 extending in the longitudinal direction of the 
vehicle, etc. 
An inspection cover 242 is provided for covering a drive device for driving 
the door device 240 and, since the door device 240 is provided on the side 
block 200, the inspection cover 242 is also provided on the side block 
200. The racks 250 and the seats 260 are arranged on the interior plate 
230. 
The back sections of the seats 260 are fixed to the above-mentioned 
framework. The fixation can be effected in various ways. Each seat 260 is 
composed of an L-shaped seat frame, a seat section serving as a cushion, 
and a backrest section. First, the L-shaped frame is fixed to the 
above-mentioned framework. For example, reverse-L-shaped hook members 
which are provided on the upper section of the seat frame may be engaged 
with holes provided on the framework, and then the lower section of the 
seat frame is fixed to the framework by means of bolts or the like. 
Alternatively, both the upper and lower sections of the seat frame may be 
hooked onto the framework, or else, both the upper and lower frame 
sections may be fixed to the framework by means of bolts or the like. 
Subsequently, the backrest section of the seat is attached to the frame. 
This attachment is effected by inserting upper hook members provided on 
the backrest into holes in the seat frame, and then fixing the lower 
section of the backrest section to the seat frame by bolts or the like. 
Finally, the seat section is attached to the seat frame by inserting 
protruding sections on the lower surface of the seat section into recesses 
in the seat frame. 
The members 201, 202, 205, 207, 209, etc. forming the framework of each 
side block 200 are connected to each other by spot welding. The outer 
plate 220 of each side block 200 is also connected thereto by spot 
welding. The interior plate 230 of each side block 200 is fixed to the 
framework thereof by an adhesive, screws or the like. The framework and 
the outer plate 220 are made of stainless steel. 
The interior plate 310 of each end block 300 is attached thereto after the 
exterior plate thereof has been connected to other associated blocks. 
The roof block 400 comprises a framework composed of a plurality of arcuate 
lateral beams 402 and a plurality of longitudinal beams 403 and 404 
linking the lateral beams 402, an exterior plate 410 fixed to the lateral 
beams 402, rain gutters 415, interior plates 420 and 421 joined to the 
longitudinal beams 403 and 404, illuminating equipment 430, 
air-conditioning ducts 440, etc. 
The longitudinal beams 404 also serve as air conditioning ducts, which 
communicate with an air conditioner (not shown). Air outlets for the air 
conditioner are formed in the lower surfaces of the longitudinal beams 
404. Reflectors of the illuminating equipment 430 serve as diffusers for 
the air from the air outlets. 
The connection of the lateral beams 402 and the longitudinal beams 403 and 
404 to form the framework and the attachment of the exterior plate 410 and 
the interior plates 420 and 421 to this framework are effected by the same 
connecting means as used with the side blocks. The lateral beams 402, the 
longitudinal beams 403 and 404, and the exterior plate 410 are made of 
stainless steel. 
The six blocks, constructed as described above, are connected together 
after they are equipped with interior components. That is, prior to the 
assembly, each of the side blocks 200 is equipped with the interior plate 
230, the window devices 235, the door device 240, the racks 250, the seats 
260, etc. Here, the window devices 235 are substantially incapable of 
being opened or closed. The roof block 400 is equipped with the interior 
plates 420 and 421, the illuminating equipment 430, the air conditioning 
duct 440, etc. 
When connecting the lower sections of the side blocks 200 to the floor 
block 100, assemblies of the longitudinal beams 202 and the outer plates 
220 are attached from the exterior side to the vertical surfaces of the 
longitudinal beams 101 of the floor block 100. This attachment is 
performed using a method which allows the attaching operation to be 
conducted only on the exterior side. For example, it may be performed by 
an indirect-type spot welding, plug welding, rivets, or the like. The 
indirect-type spot welding allows the attaching operation to be conducted 
only from the exterior side. Since the floor block 100, on which the 
welding is effected, is firmly built, it is possible to employ the 
above-mentioned welding method. That is, in this type of welding, one of 
the electrodes is strongly pressed from the exterior side against the 
floor block 100, so that it is necessary for the member which constitutes 
the other electrode (i.e., the floor block 100) to be strong enough. 
Regarding an attaching method using rivets, it is possible to use rivets 
500 described later. 
The connection of the end blocks 300 and the floor block 100 can be 
effected in the same manner as described above. 
FIG. 1 shows a joint section between one of the side blocks 200 and the 
roof block 400. Provided at each side edge of the width of the roof block 
400 is a gutter 415 which is formed by upwardly bending an end portion of 
the outer plate 410. A bottom section 415b of each gutter 415 is 
substantially horizontal. Each gutter 415 further includes a vertical 
section 415c, an upper end portion 415d the top end of which is bent 
inwardly. Each gutter 415 is situated at the upper end of each side block 
200, which is substantially vertical. 
The structure of the upper end portion of each side block 200 will now be 
described. The longitudinal beam 201 is bent in such a manner as to be in 
contact with the lower surfaces of the lateral beams 402, the inner 
vertical section 415a of the gutter 415, the bottom section 415b of the 
same, and the exterior plate 220. Each column 205 has a sectional 
channel-like configuration and is equipped with an end flange 205c, which 
is secured to the exterior plate 220 by spot welding. The lower end of the 
longitudinal beam 201 is placed between the flange 205c of each column 205 
and the exterior plate 220, with these three members being connected 
together by spot welding. 
The exterior plate 220, which is situated below the gutter 415, has an 
upward extension formed as an upper end section 220a which is bent in such 
a manner as to be in contact with the outer vertical section 415c of the 
gutter 415. That section of the exterior plate 220 which extends between 
the upper end section 220a, which is in contact with the vertical gutter 
section 415c, and the rest of the exterior plate 220 is formed as an 
oblique section which is not in contact with the bottom section 415b of 
the gutter 415. 
Fixed to the upper interior section of each column 205 by spot welding is a 
joint 211 for Joining the column to the roof block 400. The upper end of 
the joint 211 is fixed by spot welding to the lower side of the upper end 
section 201b of the longitudinal beam 201. The joint 211 is made of 
stainless steel. 
An elongated mounting seat 215 is provided for the interior plate 230, with 
the mounting seat 215 being attached to the columns 205 by spot welding 
and extending in the longitudinal direction of the vehicle. The interior 
plate 230 is attached to the mounting seat 215 by an adhesive, screws, or 
the like. 
The operation of connecting the side blocks 200 to the roof block 400 will 
now be described. After the side blocks 200 and the outer plates of the 
end blocks 300 have been connected to the floor block 100 and the side 
blocks 200 and the end blocks 300 have been connected together, the roof 
block 400 is lowered and placed on the side blocks 200. Then, the sections 
415a, 415b and 415c of the gutter 415 are brought into contact with the 
longitudinal beams 201c and 201d of the side blocks 200 and the outer 
plates 220. The upper end sections 220a of the outer plates 220 are 
inclined toward the gutters 415. However, since there is a rounded portion 
between the bottom section 415b and the vertical section 415c of each 
gutter 415, the upper end portions 220a of the vertical exterior plates 
220 can be diverged to allow the gutters 415 to be fitted into the side 
blocks 200. Since there is a inclined section 220e between the upper 
section 220a and the rest of each vertical exterior plate 220, the upper 
end section 220a can be inclined and then easily restored to a position in 
which the upper end section 220a is in contact with the vertical section 
415c of each gutter 415. 
The side blocks 200 and the roof block 400 are connected with each other at 
the following three positions: 
The upper end section 220a of each exterior plate 220 is connected to the 
vertical section 415c of each gutter 415 by spot welding, as indicated at 
W1. Since the width of the gutter 415 is so sized as to allow the 
insertion of one of welding electrodes used, welding can be conducted 
across the upper end section 220a of the exterior plate 220 and the 
vertical section 415c of the gutter 415. 
Further, the bottom section 415b of each gutter 415 and the flat section 
201d of each longitudinal beam 201 is welded to each other, as indicated 
at W2, by a welding method which can only be conducted from the outside. 
Examples of the welding methods which may be adopted include arc spot 
welding, series spot welding, in which two electrodes arranged in parallel 
are used, and plug welding. In any case, the electrodes are set on the 
outside. Here, arc spot welding and series spot welding are preferable. In 
particular, series spot welding is most preferable in respect of vehicle 
appearance after welding. 
The upper ends of the joints 211, the upper sections 201b of the 
longitudinal beams 201, and the lateral beams 402 are connected together 
from the inside by using rivets 500. Each rivet 500 is composed, for 
example, of a cylinder, a pin extending therethrough and a clamping 
member. The cylinder is inserted into holes provided in the two plates to 
be connected together. The clamping member is set on the side of the 
operator, and the pin is pulled using the clamping member as a guide to 
enlarge the tip end of the cylinder, thereby fixing the pin to the 
clamping member. In this manner, the two plates are firmly connected to 
each other. This rivet 500 is well known per se. 
After the connection of these components has thus been effected, an 
interior plate 510 is attached to the mounting seat 215 and the 
longitudinal beam 403. The interior plate 510 is attached by means of an 
adhesive, screws, or the like. Further, the gap between the upper end 
section 220a of each exterior plate 220 and the vertical section 415c of 
each gutter 415 is sealed with a sealing material. The upper end portion 
415d of the gutter 415 may be bent outwardly so as to cover the gap 
between the vertical section 415c and the upper end section 220a, thereby 
facilitating the sealing. 
As described above, the side blocks 200 and the roof block 400 are 
connected to each other on the side of the exterior plates 220 and 410. 
Further, the inner sides of the frameworks of the blocks are also 
connected to each other. Since the attachment is thus effected both from 
the exterior side and the interior side, a firm connection can be 
realized. 
Of the two types of connecting means used for the sections of the gutters 
415, spot welding is used in connecting the outer vertical sections 415c 
of the gutters 415 to the upper end sections 220a of the exterior plates 
220. Although the spot welding entails discoloration, there is an 
established method available which helps to eliminate such discoloration 
and which can be applied relatively easily. Therefore, although the 
sections where the exterior plates 220 and the vertical section of the 
gutters 415 are connected to each other by spot welding are visible from 
the outside, the spot does not lead to any deterioration in the outer 
appearance of the vehicle. The sections where the welding of the bottom 
sections 415b is effected are not visible from the outside, so that there 
is no deterioration in outer appearance after the welding. Accordingly, it 
is possible to produce a vehicle having a satisfactory outer appearance 
even though the welding is performed on the outside. Further, it should be 
noted that welding is more advantageous than rivets in that welding is 
less expensive and requires no waterproofing. 
Further, since spot welding is employed for connecting the outer vertical 
section 415c of each gutter 415 to the upper end section 220a of each 
exterior plate 220, the welding operation is relatively easy and can be 
conducted at short intervals along the length of the vehicle. As a result, 
a firm connection can be obtained in these sections. Accordingly, the 
welding interval for the bottom sections 415b can be made large, thus 
facilitating the welding. Therefore, a substantial reduction in the 
production cost can be attained on the whole. Where a sufficiently firm 
connection can be obtained by the spot welding W1 only, the welding of the 
bottom sections 415b can be omitted. 
As described above, in this embodiment, end portions of the exterior plate 
410 of the roof block 400 are bent so as to form gutters 415 having 
vertical sections 415c, on which the outer plates 220 of the side blocks 
are superimposed. Due to this arrangement, it is only necessary for the 
sealing material for bonding the roof block 400 to each side block 200 to 
be applied to a single position, which is not the case with the examples 
shown in FIGS. 3, 5 and 6. 
The weldings W1 and W2 are conducted outside the vehicle. By "outside" it 
is meant to say that all the instruments needed for the connecting 
operation (for example, the welding electrodes) are placed exteriorly the 
vehicle. Accordingly, the interior plates 230 and 420 are not affected by 
sputters. The connection on the inner side is effected by using the rivets 
500, which means that the interior plates 230 and 420 are not affected by 
sputters. The connection using the rivets 500 can be conducted solely 
inside the vehicle. In other words, all the instruments needed for the 
connecting operation (for example, a device for pulling pins) may be set 
in the interior of the vehicle. In this manner, each connecting operation 
can be conducted either only exteriorly of or only interiorly of the 
vehicle, so that the connection can be effected even with the window 
devices 235 and the interior plates 230 and 420 attached to the blocks 
beforehand. 
Since the longitudinal beams 201 fixed to the side blocks 200 are bent, 
there is no possibility that the side blocks 200 are bent while they are 
independently conveyed, and thus can be easily handled. Further, the 
vertical sections 415c and 220a serve as positioning members when the roof 
block 400 is lowered toward the side blocks 200. 
If the connection at only the bottom sections 415b of the gutters 415 is 
not sufficient, or if it is desired to omit the welding of the bottom 
sections 415b, the upper end of the inner vertical section 415a of each 
gutter 415 (a border section between the gutter 415 and the roof section) 
is welded to the vertical section 201c of each longitudinal beam 201 to 
form a welding W3, by the same welding method as used above. The position 
of this welding W3 is determined at a level as low as possible. This 
section is hardly visible from the outside. Moreover, in the case of a 
railroad car, an insulating paint or an insulating sheet is applied 
thereto, so that the welding does not affect the outer appearance of the 
vehicle. The welding W3 is shown in FIG. 3. 
Rivets 500 may be used as the means for connecting the bottom section 415b 
of each gutter 415 to the associated longitudinal beam 201d. In that case, 
a sufficient waterproof sealing has to be provided. 
The upper sections 220a of the exterior plates 220 in contact with the 
vertical sections 415c of the gutters 415 may be prepared as separate 
members independent of the outer plates. In that case, these separate 
members are fixed by spot welding to those sections of the exterior plates 
220 registered with the columns 205 prior to the connection of the roof 
block 400 and the side blocks 200. The vehicle body assembling operation 
described above is also applicable to vehicle bodies having no gutters. 
Other embodiments of the means for connecting the side blocks 200 to the 
roof block 400 will now be described with reference to FIGS. 3 to 6. In 
these FIGS. 3-6, for the sake of clarity, the interior members 230, 420 
and 510 are not shown. A sealing material for waterproofing is applied to 
the joint sections between the plate sections forming the gutters 415 and 
the sections around the same. However, a description of this arrangement 
will be omitted here. 
In the embodiment shown in FIG. 3, the lower end section 201e of each 
longitudinal beam 201 is situated outside the exterior plate 220. The 
lower end section 201e of each longitudinal beam 201 is connected to the 
exterior plate 220 by spot welding. The side block 200 and the roof block 
400 are welded to each other at positions indicated at W2 and W3. 
In the embodiment shown in FIG. 4, the gutter 415 is situated outside the 
columns 205. The upper end sections 220b and 220a of each exterior plate 
220 are in contact with the bottom section 415b and the vertical section 
415c of each gutter 415. The vertical section 415c and the bottom section 
415b of each gutter 415 are connected to the associated exterior plate 220 
by spot welding as indicated at W1 and W4. This arrangement helps to 
reduce the production costs. Unlike the beam 201 of the embodiment of FIG. 
3, the beam 201 in this embodiment has no section 201d. The lower end 201e 
is spot-welded to the exterior plate 220. The upper end sections 220b and 
220a may consist of a separate member spot-welded to the outer plate 220. 
In the embodiment of FIG. 5, the outer plate 410 has no vertical sections 
415c forming the gutters 415. Instead, the outer side edge portion of each 
longitudinal beam 201 is raised to form a vertical section 201g to form 
the gutter 415. The longitudinal beam 201 has a bottom section 201d and an 
inner vertical section 201c which are spot-welded to the outer plate 410 
as indicated at W5 and W6. The upper section 201b of each longitudinal 
beam 201 and the upper end portion of each joint 211 are welded to the 
lateral beams 402. The longitudinal beams 201 constitute a part of the 
outer plate of the roof block 400. This arrangement facilitates the 
connection of the side blocks 200 and the roof block 400 at the positions 
of the gutters 415. The bottom sections 415b may be omitted. 
In embodiment of FIG. 5, the lower section of each joint 211 is connected 
to the column 205 by rivets 500 after the side blocks 200 and the roof 
block 400 have been assembled together. To facilitate the lowering of the 
roof block 400, the lower end portion 211c of each joint 211 is bent 
inwardly. The connection of each side block 200 and the roof block 400 is 
effected by welding as indicated at W1 and the rivets 500. 
Further, as in the case of the embodiments of FIGS. 1 through 4, it is 
possible for the joints 211 to be secured to the side blocks 200 
beforehand and connected to the lateral beams 402 by rivets 500 after the 
assembling of the side blocks 200 and the roof block 400. 
The embodiment of FIG. 6 includes longitudinal beams 290 which are in 
contact with the inner sides of the upper end sections 220a of the 
exterior plates 220 of the side blocks 200 and with the interior sides of 
the columns 205. The section of each longitudinal beam 290 between the 
exterior plate 220 and the columns 205 is horizontal. The longitudinal 
beams 201, which have no sections 201e, are spot-welded to the roof block 
400. The side blocks 200, equipped with the longitudinal beams 290, and 
the roof block 400, equipped with the longitudinal beams 201, are 
assembled with each other. By placing an edge portion of the roof block 
400 on the horizontal section of each longitudinal beam 290, a gutter 415 
is formed. The horizontal sections of the longitudinal beams 290 and the 
edge portions of the roof block 400 are connected together by rivets 500. 
In the embodiment of FIG. 7, the lower ends 201e of the longitudinal beams 
201 are situated outside the outer plates 220, and the gutters 415 are 
situated still more outwardly. The gutters 415 are formed solely by the 
exterior plate 410. The inner vertical sections 415a of the gutters 415 
overlap the lower edge portions 201e of the longitudinal beams 201. The 
outer vertical sections 415a of the gutters 415 are connected to the 
blocks 200 from the outside by means of rivets 500. Further, this 
embodiment employs joints 211B which have the function of the joints 211 
and that of the mounting seats 215. 
In accordance with the present invention, the side blocks 200 and the roof 
block 400 are connected together at the gutter sections provided at the 
upper sections of the side blocks 200, so that the connecting operation 
can be conducted solely outside the vehicle and after the interior finish 
work has been completed. Further, the connecting operation can be easily 
conducted without impairing the outer appearance of the vehicle even 
though the connecting operation is conducted exteriorly of the vehicle.