FR3160149A1 - Modular reinforcement element for motor vehicle side member - Google Patents

Abstract

The invention relates to a modular reinforcing element (1a) designed to at least partially fill and reinforce a hollow structural part (2a) of a motor vehicle body, the reinforcing element (1a) comprising a body (5a) forming a profile extending between two ends (6, 7) along a longitudinal axis, the body (5a) having at least one first assembly interface and at least one second assembly interface, the first and second interfaces projecting from the body (5a), each first assembly interface being designed to interact with a second assembly interface of another reinforcing element (1a) to form a modular assembly (4a) of reinforcing elements (1a). The invention also relates to an assembly (4a) comprising a plurality of reinforcing elements (1a). The invention further relates to a structural part (2a) of a motor vehicle body having a hollow (3a) partially filled with an assembly (4a). (Figure 3)

Description

Modular reinforcement element for motor vehicle side member

The technical field concerns modular reinforcing elements for forming assemblies designed to fill and reinforce hollow structural parts of vehicle bodies and motor vehicles comprising at least one such reinforced structural part.

When it comes to road safety, car manufacturers must consider multiple concerns and regulations when developing new vehicles. For example, car manufacturers must ensure the safety of passengers and other road users in the event of a collision involving the vehicle. To this end, vehicles are subjected to various standardized procedures for simulating impacts against a rigid obstacle impacting the vehicle. Standardized procedures are, for example, described by the international organization Euro NCAP. Among these standardized procedures, one of them simulates the behavior of a vehicle during an impact with a pole.

In this context, car manufacturers are constantly looking for solutions to strengthen the structure of essential parts of their vehicles in order to improve their behavior in the event of impacts. Structural reinforcement is even more crucial when it comes to an electric vehicle, due to its increased mass compared to a vehicle with a thermal engine (mainly due to the mass of the battery). The growing interest among customers in electric vehicles is directly linked to the increase in their autonomy. This increase in autonomy is primarily due to the development of new technologies to offer ever more efficient batteries. But in parallel with the improvement of technologies, the increase in autonomy also emphasizes the increase in the volume dedicated to batteries in a vehicle. To this end, it is necessary to free up space in a structure. Finally, batteries suffer from a major drawback, the risk of ignition in the event of impacts, which requires a reinforced body structure capable of protecting them against impacts during an impact.

Therefore, there is a need for a solution to strengthen the body structure of a motor vehicle while limiting the increase in mass or even freeing up space.

The present invention aims to overcome the problems set out above. In this technical context, one aim of the present invention is to provide a reinforcing element capable of reinforcing a vehicle structural part by limiting the increase in mass due to the reinforcement, or making it possible to reduce its dimensions while providing adequate strength. Finally, the reinforcing element must also allow for great adaptability in order to easily adapt the reinforcement solution to the specific features of the structural part to be reinforced.

To this end, the present invention relates to a modular reinforcing element designed to at least partially fill and reinforce a hollow structural part of a motor vehicle body, the reinforcing element comprising a body forming a profile extending between two ends along a longitudinal axis, the body having at least one first assembly interface and at least one second assembly interface, the first and second interfaces projecting from the body, each first assembly interface being designed to interact with a second assembly interface of another reinforcing element to form a modular assembly of reinforcing elements.

The invention also relates to an assembly comprising a plurality of reinforcing elements according to the invention, each reinforcing element being fixed to at least one other adjacent element of the assembly by the interaction of at least one first or second interface with respectively a second or first interface of the adjacent element.

The invention also relates to a structural part of a motor vehicle body having at least one hollow at least partly filled with at least one assembly according to the invention.

The invention finally relates to a motor vehicle having a structural part according to the invention.

Thus, a reinforcing element according to the invention makes it possible to form an assembly according to the invention which can be used to reinforce a structural part having an internal hollow. The assembly according to the invention, thanks to the body, makes it possible to give the structural part increased resistance against deformation compared to a part without the assembly. Each reinforcing element is modular and makes it possible to adapt the number of elements to the hollow to be filled. Furthermore, the cylindrical shape of the body makes it possible to produce an element of standardized length and to adjust its length, subsequently, according to the structural part to be reinforced. Thanks to an assembly according to the invention, the dimensions, in particular the thicknesses of a structural part to be protected, can possibly be reduced, while having a similar or improved resistance thanks to the assembly. Where appropriate, by using a composite or plastic material to form the reinforcing element, the assembly allows a significant weight saving of the structural part according to the invention. The reinforcing element is finally modular thanks to its first and second interfaces which allow secure fixing of several reinforcing elements in a multitude of different arrangements.

According to one embodiment of the reinforcing element, the body has a plurality of faces together forming a hollow cylindrical shape with a polygonal base extending along the longitudinal axis, the first and second interfaces each projecting from one of the faces. Such a reinforcing element makes it possible to obtain an assembly having a so-called honeycomb or similar structure, which is particularly strong.

Advantageously, the body at least partially delimits a cavity, the body having at least one drain orifice passing through the body to put the cavity of the body in communication with the exterior of the element. Thus, a structural part according to the invention drains easily after cataphoresis treatment.

According to one possibility of the reinforcing element, each first interface is formed of at least one rail, each second interface forming a slide, each rail being shaped to slide in a slide to form a fixing of two elements.

According to one embodiment, the reinforcing element is formed at least in part by a material extrusion process. Such a process is simple to implement.

According to one possibility of the reinforcing element, each body has at least one fixing head, extending one of its ends, designed to allow the fixing of the element to a structural part.

According to one possibility, the assembly comprises an arrangement plate, each reinforcing element being fixed on the arrangement plate, each longitudinal axis of each reinforcing element being oriented orthogonally to the arrangement plate.

The invention will be better understood upon reading the detailed description which follows, given solely as a non-limiting example and made with reference to the appended drawings in which:

FIG. 1 there FIG. 1 represents a perspective view of a modular reinforcement element;

FIG. 2 there FIG. 2 represents a perspective view of an assembly according to the invention formed from reinforcing elements of the FIG. 1 ;

FIG. 3 there FIG. 3 represents a cutaway view of a structural part filled and reinforced by the assembly of the FIG. 2 ;

FIG. 4 there FIG. 4 represents a schematic sectional view of a structural part having an arrangement plate;

FIG. 5 there FIG. 5 represents a schematic sectional view of a structural part according to the invention having an assembly formed of reinforcing elements each having a fixing head;

FIG. 6 there FIG. 6 represents a schematic view of a structural part according to another embodiment of the invention;

In these figures, the same references are used to designate the same elements.

A reinforcing element 1a, 1b according to the invention, illustrated in Figures 1 to 6, is modular and is designed to at least partially fill and reinforce a hollow structural part 2a, 2b, illustrated in Figures 3 to 6, of a body of a motor vehicle according to the invention. The reinforcement provided by the reinforcing element 1a, 1b is such as to limit and/or prevent deformations of the structural part 2a, 2b in the event of a frontal and/or lateral impact suffered by the vehicle according to the invention. For this purpose, the structural part 2a, 2b has a hollow 3a, 3b filled at least in part with at least one assembly 4a, 4b consisting of a plurality of reinforcing elements 1a, 1b. In the example illustrated in the FIG. 6 , the hollow 3b of the structural part 2b is filled with several assemblies 4b, in this case 4 assemblies 4b. For example, the structural part 2a, 2b is a side member or a rocker cross member.

In the examples illustrated in the figures, the assemblies 4a, 4b each comprise identical reinforcing elements 1a, 1b. Alternatively, it is possible to envisage assemblies having different reinforcing elements 1a, 1b.

In order to ensure adequate reinforcement, each reinforcing element 1a, 1b is advantageously made of plastic and/or composite material. Advantageously, each reinforcing element 1a, 1b is formed at least in part by a material extrusion process.

The reinforcing element 1a, 1b comprises a body 5a, 5b forming a profile extending between two ends 6, 7 along a longitudinal axis AL. The body 5a, 5b has a plurality of faces 8 together forming a hollow cylindrical shape with a polygonal base extending along the longitudinal axis AL. In a first embodiment, illustrated in Figures 1 to 4, the body 5a has a hexagonal base shape. In a second embodiment illustrated in Figures 5 and 6, the body 5b has a pentagonal base shape. The body 5a, 5b at least partially delimits a cavity 9a, 9b. In the example illustrated in Figures 1 to 3, the cavity 9a, of hexagonal shape, is open on each end 6, 7 of the reinforcing element 1a, 1b. In order to be able to drain each cavity 9a, 9b, in particular after cataphoresis treatment of the structural part 2a, 2b, the body 5a, 5b has at least one drain orifice 10 passing through the body 5a, 5b to put the cavity 9a, 9b in communication with the exterior of the reinforcing element 1a, 1b.

The body 5a, 5b has at least one first assembly interface 11 and at least one second assembly interface 12, the first 11 and second 12 interfaces projecting from the body 5a, 5b. Each first assembly interface 11 is designed to interact with a second assembly interface 12 of another reinforcing element 1a, 1b, to form a modular assembly 4a, 4b of reinforcing elements 1a, 1b.

In the first embodiment of the reinforcing element 1a, the first 11 and second 12 assembly interfaces extend along the longitudinal axis AL. In the second embodiment, the first 11 and second 12 interfaces extend along an axis orthogonal to the longitudinal axis AL. Advantageously, each element 1a, 1b has a first 11 or a second 12 interface on each of the faces 8 of the body 5a, 5b. The first 11 and second 12 interfaces are advantageously in equal numbers on the same reinforcing element 1a, 1b.

In the examples illustrated in the figures, each first interface 11 is formed of at least one rail 13a, 13b. For example, a rail 13a, 13b with a T-shaped cross-section. Each second interface 12 forms a slide 14a, 14b, each rail 13a, 13b being shaped to slide in a slide 14a, 14b in order to form a fixing of two elements 1a, 1b. In the examples illustrated in the figures, each slide 14a, 14b is formed of two walls 15, projecting from a face 8, in the shape of an L and arranged opposite one another.

The assemblies 4a, 4b are formed from a plurality of elements 1a, 1b where each is fixed to at least one other adjacent element 1a, 1b of the assembly 4a, 4b by the interaction of at least one first 11 or a second 12 interface with respectively a second 12 or a first 11 interface of the adjacent element 1a, 1b. Thus, in an assembly 4a, 4b each element 1a, 1b can have between 1 and 6 adjacent reinforcing elements 1a, 1b.

As illustrated on the FIG. 4 , in order to assist in the positioning of each reinforcing element 1a and in the fixing of the assembly 4a in the hollow 3a of the structural part 2a, each reinforcing element 1a is, for example, fixed by a weld 16, to one 6 of the ends 6, 7 on an arrangement plate 17. The weld 16 is, for example, obtained by ultrasonic welding. On the arrangement plate 17, each element 1a is fixed so that its longitudinal axis AL is orthogonal to the arrangement plate 17. The arrangement plate 17, with its assembly 4a, is then slid into a housing 18 provided for this purpose in the structural part 2a.

Alternatively, in the second embodiment of the structural part 2b, each reinforcing element 1b has at least one fixing head 19 extending one 6 of its ends 6, 7, designed to allow the element 1b to be fixed to the structural part 2b. As illustrated in the FIG. 5 , each fixing head 19 is sized to be inserted into a groove 20 of the structural part 2b. Each groove 20 extends, for example, along a longitudinal extension of the hollow 3b. Each fixing head 19 is connected to the body 5b by a neck 21, of smaller dimension than the body 5b, in order to allow sliding in the groove 20, the body 5b extending outside the groove 20. Thus, the use of several grooves 20 makes it possible to define the position of each assembly 4b in the hollow 3b.

In order to lock the position of each assembly 4b in the hollow 3b, locking means 22, illustrated in the FIG. 6 , are designed to block the sliding of an assembly 4b in its groove 20. The locking means 22 are, for example, formed of stops 23, shown diagrammatically on the FIG. 6 .

Thus, the reinforcing element 1a, 1b makes it possible to form an assembly 4a, 4b which can be used to reinforce a structural part 2a, 2b having an internal hollow 3a, 3b. The assembly 4a, 4b, thanks to the body 5a, 5b having a cavity 9a, 9b and forming a honeycomb structure, makes it possible to give the structural part 2a, 2b resistance against deformations. Each reinforcing element 1a, 1b is modular and makes it possible to adapt the number of elements 1a, 1b to the hollow 3a, 3b to be filled thanks to its first 11 and second 12 interfaces.

The invention is not limited to the embodiment of the reinforcing element described above, only by way of example, but other embodiments can be designed by those skilled in the art without departing from the scope and scope of the present invention.

Claims (10)

Modular reinforcing element (1a, 1b) designed to at least partially fill and reinforce a hollow structural part (2a, 2b) of a motor vehicle body, the reinforcing element (1a, 1b) comprising a body (5a, 5b) forming a profile extending between two ends (6, 7) along a longitudinal axis (AL), the body (5a, 5b) having at least one first assembly interface (11) and at least one second assembly interface (12), the first (11) and second (12) interfaces projecting from the body (5a, 5b), each first assembly interface (11) being designed to interact with a second assembly interface (12) of another reinforcing element (1a, 1b) to form a modular assembly (4a, 4b) of reinforcing elements (1a, 1b). Reinforcing element (1a, 1b) according to claim 1, characterized in that the body (5a, 5b) has a plurality of faces (8) together forming a hollow cylindrical shape with a polygonal base extending along the longitudinal axis (AL), the first (11) and second (12) interfaces each projecting from one of the faces (8). Reinforcing element (1a, 1b) according to claim 2, characterized in that the body (5a, 5b) at least partially delimits a cavity (9a, 9b), the body (5a, 5b) having at least one drain orifice (10) passing through the body (5a, 5b) to put the cavity (9a, 9b) of the body (5a, 5b) in communication with the exterior of the element (1a, 1b). Reinforcing element (1a, 1b) according to one of claims 1 to 3, characterized in that each first interface (11) is formed of at least one rail (13a, 13b), each second interface (12) forming a slide (14a, 14b), each rail (13a, 13b) being shaped to slide in a slide (14a, 14b) to form a fixing of two elements (1a, 1b). Reinforcing element (1a, 1b) according to one of claims 1 to 4, characterized in that it is formed at least in part by a material extrusion process. Reinforcing element (1b) according to one of claims 1 to 5, characterized in that each body (5b) has at least one fixing head (19), extending one of its ends (6, 7), designed to allow the fixing of the element (1b) to a structural part (2b). Assembly (4a, 4b) comprising a plurality of reinforcing elements (1a, 1b) according to one of claims 1 to 6, each reinforcing element (1a, 1b) being fixed to at least one other adjacent element (1a, 1b) of the assembly (4a, 4b) by the interaction of at least one first (11) or second (12) interface with respectively a second (12) or first (11) interface of the adjacent element (1a, 1b). Assembly (4a) according to claim 7, characterized in that it comprises an arrangement plate (17), each reinforcing element (1a) being fixed to the arrangement plate (17), each longitudinal axis (AL) of each reinforcing element (1a) being oriented orthogonally to the arrangement plate (17). Structural part (2a, 2b) of a motor vehicle body having at least one hollow (3a, 3b) at least partly filled with at least one assembly (4a, 4b) according to claim 7 or 8. Motor vehicle having a structural part (2a, 2b) according to claim 9.