Motor vehicle grille frame

Abstract

A motor vehicle grid frame (T) is described herein, comprising a plurality of structural nodes (N1, N2), each of which has a central body (1) and at least one hollow arm (2, 3, 4, 30) protruding from the central body (1). The grid frame (T) also comprises a plurality of beam elements (5, 6, 11, 27) which are interconnected by the protruding hollow arms (2, 3, 4, 30). The structural nodes (N1, N2) are made by additive manufacturing technology, and at least one arm (2, 3, 4, 30) of one of the nodes (N1, N2) has an end portion opposite to the central body (1) having a channel shape (C) with open cavities at the front end (12) of the arm (2, 3, 4, 30) and along a side (13) of the arm (2, 3, 4, 30).

Description

Technical Field

[0001] The present invention relates generally to automotive frames, and more particularly to an automotive lattice frame comprising:

[0002] - a plurality of structural nodes, each having a central body and at least one hollow arm protruding from the central body, and

[0003] - Multiple beam elements connected to each other by protruding arms. Background Art

[0004] Document US Pat. No. 4,355,844 A describes a motor vehicle frame having the features indicated above.

[0005] The present invention aims to provide a motor vehicle grid frame which has a rapid and cost-effective method of manufacturing and assembling without thereby being less efficient in performing the function for which it is designed.

[0006] An additional object of the invention is to provide a motor vehicle grid frame consisting of components suitable for producing different frame geometries. Summary of the invention

[0007] In order to achieve one or more of the above-mentioned purposes, the present invention relates to a motor vehicle grid frame of the type indicated at the beginning of this specification, and is also characterized in that the structural node is made by additive manufacturing technology and at least one arm of one of the nodes has an end portion with a channel structure opposite to the central body, which end portion has an open cavity at the front end of the arm and along one side of the arm.

[0008] Preferably, the end portion having a channel-shaped configuration comprises two side flanges each extending along a side of an arm at a respective side of the open cavity, so that the at least one arm has an Ω-shaped cross section at the end portion.

[0009] The beam element connected to the at least one arm with omega-shaped cross section may comprise two end flanges arranged against the side flanges defining a free space between the inner surface of the hollow arm and the beam element inserted into the channel-shaped end portion.

[0010] According to another preferred feature, the beam element is connected to the at least one arm with the channel-shaped end portion only by means of an adhesive layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Further characteristics and advantages of the invention will become apparent from the following description made with reference to the accompanying drawings, provided purely as non-limiting examples, in which:

[0012] Figure 1 is a schematic diagram of a motor vehicle grille frame according to the present invention,

[0013] Figure 2 is a perspective view showing several components of a motor vehicle grid frame according to a first embodiment,

[0014] Figures 3 to 5 It shows Figure 2 A perspective view of several details shown in

[0015] Figure 6 is a schematic cross-sectional view of several parts of a frame according to a variant relative to that shown in the previous figures,

[0016] Figure 7 shows an exploded perspective view of several components of a frame according to another variant relative to that shown in the previous figures,

[0017] Figures 8 to 9 In assembled state Figure 7 A cross-sectional view of the detail shown in

[0018] Fig.10 and Fig.11 A perspective view and a perspective cross-sectional view respectively show a portion of a motor vehicle grid frame according to the invention,

[0019] Fig.12 A perspective view showing a portion of a motor vehicle grid frame according to the invention, and

[0020] FIG. 13A to FIG. 13E Several detailed assembly steps of a motor vehicle grid frame according to the invention are shown. DETAILED DESCRIPTION

[0021] In order to thoroughly understand the embodiment, various specific details are shown in the following description. The embodiment may be implemented without one or more of the specific details, or using other methods, components, materials, etc. In other cases, known structures, materials or operations are not shown or described in detail to avoid confusing the various aspects of the embodiment. The reference to "an embodiment" in the context of this specification indicates that the specific configuration, structure or feature described about the embodiment is included in at least one embodiment. Therefore, phrases such as "in an embodiment" that may appear in different places in this specification do not necessarily refer to the same embodiment. In addition, specific constructions, structures or features can be combined in an appropriate manner in one or more embodiments, and / or be associated with the embodiment in a manner different from that shown here, for example, the features described here with respect to the accompanying drawings can be applied to one or more embodiments described in different drawings.

[0022] The references shown herein are for convenience only and therefore do not limit the field of protection or the scope of the embodiments.

[0023] In this specification and the claims that follow, the term "additive manufacturing" refers to a method known in the art in which an energy source such as a laser or plasma beam is used to selectively melt metal layers or plastic powders or wires of various sizes to form metal or plastic parts (layer by layer).

[0024] For example, a device for manufacturing a component using additive manufacturing is known from document EP 3148784 A1. Of course, the technology shown in this document is only an example, since different additive manufacturing technologies can be applied to manufacture the motor vehicle grille frame according to the invention.

[0025] The figures show a preferred embodiment of a motor vehicle grid frame T according to the invention. The invention may relate to any type of motor vehicle frame, such as a frame of a motor vehicle structure or a frame for supporting components mounted on a motor vehicle.

[0026] As especially in Figure 1 As shown in the schematic diagram of FIG, a motor vehicle grid frame T comprises a plurality of structural nodes N1, N2, each of which has a central body 1 from which at least two hollow arms 2, 3, 4, 30 protrude. The grid frame T also comprises a plurality of beam elements 5, 6, 11, 27, which are connected to each other via the protruding arms 2, 3, 4, 30. The beam elements connected to the respective arms of the node may have cross-sections with different shapes, such as square or circular.

[0027] In the following description, various embodiments of the structural nodes N1 , N2 will be described in detail to provide a grid frame T of a motor vehicle according to the present invention.

[0028] According to an essential feature of the invention, the structural nodes N1, N2 of the lattice frame T are obtained using the construction technique of "additive manufacturing". By producing the structural nodes by means of the additive manufacturing technique, numerous advantages can be obtained with respect to conventional production methods, including the preparation of components with complex geometries without incurring a loss in terms of time or cost with respect to the production of components with simpler geometries. In the case of the invention, the structural nodes can be made of metal or plastic material, while the beam elements interconnected by the structural nodes can be made of, for example, an aluminum alloy.

[0029] Figure 2A perspective view of a first embodiment of a structural node N1 of a motor vehicle is shown. As indicated above, each structural node (which together with the beam elements is combined into a lattice frame T) comprises a central body 1 and a plurality of hollow arms 2, 3, 4, 30 protruding from the central body 1. The hollow arms can be arranged around the central body according to a variety of configurations to achieve the desired geometry of the frame.

[0030] According to an important feature of the frame T according to the invention, at least one arm 2 of one of the nodes has an end portion opposite the central body 1 comprising a C-shaped channel shape with an open cavity at the front end 12 of the arm 2 and along the sides 13 of the arm 2 ( Figures 2 to 4 ).

[0031] The C-shaped channel construction with an open cavity is arranged to accommodate therein a respective beam element 6 which is intended to be connected at one of its opposite ends to other structural nodes.

[0032] The beam element 6 is connected to the arm 2 only by means of an adhesive layer. Figures 2 to 4 In order to establish the connection between the arm 2 and the beam element 6, the C-channel-shaped end portion comprises two opposite side walls 14 on which at least one opening 7 is made to allow the passage of the adhesive layer. Of course, the configuration of the opening 7 for introducing the adhesive may be significantly modified with respect to that shown in the drawings, without thereby departing from the scope of the invention.

[0033] Due to the feature that at least one arm of the structural node is provided with an end portion having the aforementioned C-channel configuration, various geometries of the frame can be manufactured, including a frame with two beam elements constrained to each other by an angle of 45° and intended to be connected together with a single structural node at the ends defining the aforementioned angle.

[0034] According to a preferred feature of the present invention (in Figure 6 As shown in the cross-sectional view of the C-shaped channel, the aforementioned end portion of the C-shaped channel includes two side flanges 10, each of which is spaced apart at the corresponding side of the open cavity of the C-shaped channel structure along one side of the arm 2, so that the arm protruding from the central body 1 has an Ω-shaped cross-section at the aforementioned end portion.

[0035] Still refer to Figure 6 In a cross-sectional view of the embodiment of the present invention, the beam element 6 connected to the arm with an Ω-shaped cross section also comprises two end flanges 33 arranged against the side flanges 10 of the arm protruding from the central body 1 of the node, thereby defining a free space between the inner surface of the hollow arm and the beam element inserted in the end portion with the C-shaped channel configuration. It should therefore be understood that, in an embodiment, the adhesive layer inserted in the opening 7 spreads in the aforementioned free space formed between the inner surface of the hollow arm and the beam element inserted in the end portion with the C-shaped channel configuration.

[0036] According to another preferred feature of the present invention (in Figure 5 ), the arm 2 including the C-channel configuration may include a rigid cover element 8 connected to the end portion of the arm 2 with the C-channel configuration. The rigid cover element 8 is spaced along at least one side of the arm above the aforementioned open cavity and above the beam element arranged in the cavity. Preferably, after one end of the beam element 6 has completed positioning in the aforementioned cavity, the cover element 8 is slidably mounted on the corresponding guide portion 24. The cover element 8 is configured to slide on the (e.g. conical) guide portion and be held on the guide portion 24 and locked on the beam element 6 with an interference fit. In this way, the beam element 6 is locked in position until the adhesive is injected.

[0037] In the following description, various additional embodiments of structural nodes will be described to provide a grid frame T of a motor vehicle according to the present invention.

[0038] As especially in Figures 2 to 4 As shown, one arm 3 of one of the nodes may have an end portion 14, which is arranged in the cavity of the hollow arm 3 and protrudes in the opposite direction relative to the central body 1 of the structural node. The end portion 14 is configured to be mounted with a corresponding hollow beam element 5, so that one end of the beam element 5 connected to the structural node is inserted between the walls of the hollow arm 3, and the end portion 14 protrudes in the opposite direction to the central body 1.

[0039] The hollow beam element 5 may define several cavities 15 arranged side by side and separated from each other by at least one intermediate wall 16. In this case, the aforementioned end portions 14 arranged in the cavities of the hollow arms 3 define respective projecting sections separated by free spaces 25 arranged to accommodate the intermediate walls 16 of the beam element 6 mounted with an interference fit with the arms 3 of the structural node.

[0040] The figures show another embodiment of a structural node included in a lattice frame according to the invention, in which at least one arm 4 can be connected to a corresponding beam element 11 by means of an adhesive, so that the wall of the arm 4 is arranged in the corresponding end portion of the beam element 11. The arm 4 may comprise one or more inlet openings 19 for injecting the adhesive, an axial supply channel 20 for the adhesive extending inside the arm 4 and a plurality of outlet openings 21 for the adhesive ( Figure 5 , Figures 7 to 9 , Fig.12 ).

[0041] The access opening 19 may be arranged near the central body of the node and may be made in the form of a pin that protrudes from the wall defining the arm 4. Figure 7As shown in the example of , there may be two access openings 19 which protrude from two opposite sides of the arm 4 .

[0042] As in Figure 8 , Fig. 9 As shown in FIG. 1 , the supply channel 20 has an entry end coinciding with the entry opening 19 and a total extension corresponding to the length of the arm 4 . Figure 8 , Fig. 9 In the case shown in FIG. 2 , inside the arm 4 , the channel 20 surrounds an inner portion 26 of the arm 4 , so that it extends between the outer wall of the arm 4 and this inner portion 26 .

[0043] The outlet openings 21 for the adhesive may consist of holes formed through the wall of the arm 4, distributed along its extension and extending radially between the axial supply channel 20 for adhesive and the outer wall of the arm 4. Thanks to this feature, the bonding of the arm 4 in the corresponding beam element 11 becomes extremely effective and durable, since a uniform distribution of the adhesive is obtained along the entire extension of the arm 4.

[0044] According to another preferred feature shown in the drawings, the arm 4 of one of the nodes is connected to the corresponding hollow beam element 11 not only by means of an adhesive but also by a preliminary mechanical connection. The preliminary mechanical connection is achieved by a connecting member, which may include a resilient arm 17 arranged on one side of the arm 4 and an opening 18 formed on one side of the beam element, so that in the assembled state the resilient arm 17 is connected to the opening 18, thus establishing a mechanical connection between the arm 4 and the beam element 11.

[0045] Preferably, at least one of the aforementioned arms 4, which are provided with the supply channel 20 and the hole constituting the discharge opening 21, is formed by a pair of arms 4, which are arranged side by side and are configured to be mounted in a single beam element 11 ( Figure 5 , Fig.12 ).

[0046] Preferably, at least one of the structural nodes N2 of the grid frame T according to the invention comprises a plurality of the aforementioned arms 4 provided with supply channels 20 and holes constituting discharge openings 21 ( Fig.10 ). In this case, the node N2 may comprise a single access opening 19 for the adhesive, communicating with a central chamber 23 in the central body 1 of the node N2, from which the supply channels 20 of the respective arms 4 extend. Of course, the number of arms and their configuration may vary with respect to the number of arms in FIG. Fig.10 and Fig.11 For example, in addition to the obvious changes shown in Fig.10 and Fig.11 In addition to the three arms 4 with supply channels 20 shown in the drawing, it is also possible to add an arm 2 with a C-shaped channel shape, which also protrudes from the same central body 1 from which the three arms 4 protrude.

[0047] FIG. 13A to FIG. 13E Several components constituting another embodiment of a lattice frame according to the invention are shown, in which an arm 30 of a node is arranged in a beam element 27. The arm 30 is provided with a plurality of spacer elements 22 arranged along its extension, which are configured to define a free space between the inner surface of the beam element 27 and the outer surface of the arm 30 in the assembled state. The beam element 27 may be provided with one or more access openings (in FIG. 13A to FIG. 13E ), in which an adhesive can be introduced to flow in the aforementioned free space and bond between the beam element 27 and the arm 30. Preferably, the spacer element 22 is conically shaped to allow the adhesive layer to reach into the free space along the entire extension of the hollow arm 27.

[0048] Similar to that described above, the beam element 27 may have an opening 28 formed on one of its sides configured to receive a resilient arm 29 disposed on one side of the arm 30 , thereby establishing a mechanical connection between the arm 30 and the beam element 27 .

[0049] It should therefore be observed that the motor vehicle grid frame according to the present invention has a fast and cost-effective manufacturing and assembly process without thereby being less efficient in performing the function for which it is designed.

[0050] Fabricating nodes according to additive manufacturing construction techniques means that a number of advantages over conventional manufacturing methods can be achieved, including the ability to prepare parts with complex geometries without incurring a penalty in time or cost relative to fabricating parts with simpler geometries.

[0051] Due to the feature that at least one arm of the structural node is provided with an end portion having the aforementioned C-channel configuration, various frame geometries can be manufactured, including a frame with two beam elements constrained to each other by an angle of 45° and intended to be connected together with a single structural node at their ends defining the aforementioned angle.

[0052] Due to the feature that at least one arm of the structural node is provided with a discharge opening constituted by holes formed through the wall of the arm, which are distributed along the extension of the arm and extend radially between the axial channel for supplying adhesive and the outer wall of the arm, the bonding of the arm in the corresponding hollow beam element becomes extremely effective and durable, since a uniform distribution of the adhesive along the entire length of the arm is ensured.

[0053] Of course, without prejudice to the principle of the invention, the details of construction and of the embodiments may vary significantly with respect to those described and illustrated purely by way of example, without departing from the scope of the present invention.

Claims

1. A motor vehicle grille frame (T), comprising: - a plurality of structural nodes (N1, N2), each having a central body (1) and at least one hollow arm (2, 3, 4, 30) protruding from said central body (1), and - a plurality of beam elements (5, 6, 11, 27) which are interconnected by hollow protruding arms (2, 3, 4, 30), The motor vehicle grid frame (T) is characterized in that the structural nodes (N1, N2) are made by additive manufacturing technology, and at least one arm (2, 3, 4, 30) of one of the nodes (N1, N2) has an end portion opposite the central body (1), the end portion having a channel shape (C) with an open cavity at the front end (12) of the arm (2, 3, 4, 30) and along a side (13) of the arm (2, 3, 4, 30), and The at least one arm (2, 3, 4, 30) comprises a rigid covering element (8) which is slidably mounted on the end portion (C) and is arranged along at least one side of the arm (2, 3, 4, 30) above the open cavity and above the beam element (5, 6, 11, 27) arranged in the cavity to lock the beam element (5, 6, 11, 27).

2. The motor vehicle grid frame (T) according to claim 1, characterized in that The end portion having a channel-shaped configuration (C) comprises two side flanges (10), each extending along a side surface of the arm (2, 3, 4, 30) at the corresponding side surface of the open cavity (C), so that at least one arm (2, 3, 4, 30) has an Ω-shaped cross section at the end portion.

3. The motor vehicle grid frame (T) according to claim 2, characterized in that At least one beam element (5, 6, 11, 27) connected to the at least one arm (2, 3, 4, 30) with an Ω-shaped cross section comprises two end flanges (33) arranged against the side flanges (10) so as to define a free space between the inner surface of the hollow arm (2, 3, 4, 30) and the beam element (5, 6, 11, 27) inserted into the end portion (C).

4. The motor vehicle grid frame (T) according to claim 3, characterized in that The beam element (5, 6, 11, 27) is connected to the at least one arm (2, 3, 4, 30) with the channel-shaped end portion (C) only by means of an adhesive layer.

5. The motor vehicle grid frame (T) according to claim 4, characterized in that The end portion (C) comprises two opposite side walls (14) on which at least one opening (7) is formed for passing the adhesive layer.

6. The motor vehicle grid frame (T) according to claim 5, characterized in that The adhesive layer spreads in the free space between the inner surface of the hollow arm (2, 3, 4, 30) and the beam element (5, 6, 11, 27) inserted in the end portion (C).

7. The motor vehicle grid frame (T) according to claim 1, characterized in that At least one arm (2, 3, 4, 30) of one of the structural nodes (N1, N2) is connected to the corresponding hollow beam element (5, 6, 11, 27) by means of a preliminary mechanical connection and by means of an adhesive, and the at least one arm (2, 3, 4, 30) is arranged in the corresponding hollow beam element (5, 6, 11, 27).

8. The motor vehicle grid frame (T) according to claim 7, characterized in that The preliminary mechanical connection is achieved by a connecting member comprising an elastic arm (17) arranged on the side of the at least one arm (2, 3, 4, 30) and an opening (18) obtained on a side surface of the beam element (5, 6, 11, 27), so that in the assembled state the at least one arm (2, 3, 4, 30) has a wall adjacent to the wall of the beam element (5, 6, 11, 27) provided with the opening (18).

9. The motor vehicle grid frame (T) according to claim 7, characterized in that The at least one arm (2, 3, 4, 30) comprises at least one inlet opening (19) for injecting the adhesive, an axial channel (20) extending inside the arm (2, 3, 4, 30) for supplying the adhesive and a plurality of outlet openings (21) consisting of holes formed through the wall of the arm (2, 3, 4, 30), the holes being distributed along the entire extension of the arm and extending radially between the axial channel (20) for supplying the adhesive and the outer surface of the at least one arm (2, 3, 4, 30).

10. The motor vehicle grid frame (T) according to claim 1, characterized in that At least one hollow arm (2, 3, 4, 30) is arranged in the end portion of the beam element (5, 6, 11, 27) and is provided with a plurality of spacer elements (22) arranged along its extension, the plurality of spacer elements (22) being configured to define a free space between the inner surface of the hollow arm (2, 3, 4, 30) and the outer surface of the beam element (5, 6, 11, 27) in the installed state.

11. The motor vehicle grid frame (T) according to claim 8, characterized in that At least one hollow arm (2, 3, 4, 30) is arranged in the end portion of the beam element (5, 6, 11, 27) and is provided with a plurality of spacer elements (22) arranged along its extension, the plurality of spacer elements (22) being configured to define a free space between the inner surface of the hollow arm (2, 3, 4, 30) and the outer surface of the beam element (5, 6, 11, 27) in the installed state, and the at least one arm (2, 3, 4, 30) is formed by a pair of arms, which are arranged side by side and are configured to be installed in a single beam element (5, 6, 11, 27).

12. A motor vehicle comprising at least one lattice frame (T) according to any one of the preceding claims.

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