Sealing element for a motor vehicle heat exchanger

Description

[0001] The present invention claims priority from French application 2201954 filed on March 7, 2022.

[0002] The invention relates to a sealing element for a vehicle. In particular, the invention relates to a sealing element between a heat exchanger and a bumper of a motor vehicle. The invention also provides a motor vehicle comprising such a sealing element. The invention further relates to a method for assembling a vehicle comprising such a sealing element.

[0003] The front end of a vehicle closes off the engine compartment at the front and regulates its temperature. This unit typically consists of a frame supporting a heat exchanger, such as an engine cooling radiator, a charge air cooler, or a cabin air conditioning condenser. This front end is attached to the vehicle's structure, specifically to the front right and left frame rails extending on either side of the engine. This attachment is achieved via two components called "front end supports," each with a reinforcement to which the front end is fixed.

[0004] The front end assembly also supports the vehicle's front bumper. A motor vehicle's bumper typically consists of an outer bumper skin supported by this assembly. This assembly usually features a central support that helps to hold the bumper in place and ensure its precise positioning.

[0005] In the design of modern vehicles, the bumper must also meet the requirements of a "pedestrian impact." A "pedestrian impact" is an impact in which the bumper strikes a pedestrian's leg, typically between the knee and ankle, preventing the pedestrian's leg from becoming trapped under the vehicle. Furthermore, the bumper is designed to absorb low-speed impacts without requiring repairs to the vehicle.

[0006] These constraints imply, among other things, leaving a free volume between bodywork elements such as the bumper skin, and any potential hard points inside the vehicle located behind this bodywork element.

[0007] To channel the incoming airflow through the front bumper grille, the vehicle features a sealing frame leading to the heat exchanger. This sealing frame channels the airflow through the heat exchanger, thus improving its thermal efficiency.

[0008] For integration purposes, the central support leg of the bumper frame passes through the sealing frame, which has a notch formed on its leading edge. This mounting notch is designed to fit around the central support leg via a longitudinal translational movement. In some configurations, the depth of the notch is greater than the longitudinal thickness of the central support leg. Therefore, a gap remains in the notch when the central support leg is in its mounted position. However, the persistence of this gap in the notch creates leaks that reduce the available airflow. Furthermore, these leaks create unwanted airflows that generate noises detrimental to the perceived quality of the vehicle. In addition, these airflows increase drag and therefore the vehicle's energy consumption.

[0009] Therefore, there is a need to counteract this loss of usable airflow. The simple solution of attaching an add-on to the sealing frame, at the mounting notch and against the central foot, would not be satisfactory. Indeed, it would require an additional assembly step in a difficult-to-access environment. Furthermore, it necessitates managing a new part number.

[0010] The invention aims to address at least one of the problems or drawbacks encountered in the prior art. In particular, the invention aims to provide a sealing frame that improves the channeling of airflow entering the vehicle. The invention also aims to optimize airflow management and ease of assembly of a motor vehicle sealing frame. The invention further aims to reduce vibrations of a central reinforcement bracket inserted into a mounting recess.

[0011] To this end, and according to a first aspect, the invention relates to a vehicle sealing element, said sealing element having a wall forming a frame, the wall having a sealing edge and a mounting notch in the sealing edge, said mounting notch comprising an inlet and a bottom opposite the inlet, notable in that the sealing edge comprises at least one movable shutter between an open configuration; and a through configuration in which at least one shutter passes through the mounting notch at the level of the inlet, so as to partially close the mounting notch.

[0012] Preferably, the shutter flap(s) includes at least one hinge with at least one notch.

[0013] Preferably, the shutter flap(s) includes / include retaining means capable of retaining said at least one shutter flap in the through-configuration.

[0014] Preferably, the mounting notch comprises two opposing edges extending from the inlet to the bottom; and at least one shutter flap is dimensioned to connect the two opposing edges in the through configuration and resting on one of the two edges.

[0015] Preferably, the mounting notch comprises two opposing edges extending from the inlet to the bottom; the sealing element comprises two shuttering flaps each extending from one of the opposite edges; in the through-mount configuration the shuttering flaps are dimensioned to be at least partially overlapped.

[0016] Preferably, the mounting notch comprises two opposite edges extending from the inlet to the bottom; at least one shutter flap comprising two shutter flaps each extending from one of the opposite edges; in the through configuration the shutter flaps are at least partially overlapping, in the open configuration the shutter flaps are separated from each other.

[0017] Preferably, the wall comprises a first material with a first Young's modulus, and the sealing edge comprises a second material with a second Young's modulus lower than the first Young's modulus.

[0018] Preferably, the mounting notch includes a general plane; in the through configuration at least one shutter flap is substantially parallel to the general plane, and in the open configuration at least one shutter flap is inclined with respect to said general plane.

[0019] Preferably, the sealing edge and at least one shutter flap are made of material.

[0020] Preferably, the at least one shutter flap includes at least one end bound to the notch, and at least one free end opposite the at least bound end.

[0021] According to another aspect of the invention, a motor vehicle is proposed comprising a sealing element, remarkable in that the sealing element conforms to the invention.

[0022] Preferably, the vehicle further comprises a frame with a central foot passing through the mounting notch against the bottom of said mounting notch, and in that, in the through configuration, the shutter flap(s) fit the central foot.

[0023] Preferably, the mounting notch comprises two opposing edges extending from the inlet to the bottom; at least one sealing flap comprising two sealing flaps each extending from one of the opposite edges; in the through-configuration the sealing flaps are at least partially overlapping, and the central foot comprises a rib suitable for positioning the two sealing flaps in the through-configuration.

[0024] Preferably, the vehicle also includes a bumper with locking means configured to maintain the shutter flap(s) in a through configuration.

[0025] Preferably, the vehicle features a controlled air intake module with a heat exchanger cooperating with the sealing element.

[0026] According to another aspect, the invention proposes a method for assembling a motor vehicle, said motor vehicle comprising: a heat exchanger, a bumper with a bumper skin, a frame with a central support for carrying the bumper skin and extending between the heat exchanger and the bumper skin, a sealing element capable of channeling an airflow from the bumper skin to the heat exchanger; remarkable in that the sealing element conforms to the invention, and in that the method comprises the steps of: mounting the sealing element in which the sealing flap(s) are in the open configuration; inserting the central support into the mounting notch; moving the sealing flap(s) from the open configuration into the through configuration and against the central support so as to close the mounting notch.

[0027] Preferably, during the movement step, at least one shutter flap pivots by at least 30°; preferably by at least 60°.

[0028] Preferably, during the insertion step, the central foot slides along the shutter flap(s).

[0029] Preferably, the process further includes a step of mounting the bumper skin against at least one shutter flap, the flap being compressed longitudinally between the bumper skin and the frame.

[0030] In the present invention, the characteristics generally applicable to sealing means apply to the sealing flaps.

[0031] As will be understood from the definition just given, the invention equips the sealing frame with means for closing the notch made in one of its edges, which are formed from the same material as the sealing edge. These closing means are produced by molding at the same time as the frame, which reduces production and installation costs, as well as the number of parts to be referenced, compared to a solution in which a separate closing part is added. This aspect also improves compactness and ease of assembly, and in particular the operation of closing the notch as close as possible to the central foot. Furthermore, the closing means benefit from the ability to manage the flow of material from the sealing edge.

[0032] Document EP2 332 764 A1 discloses a vehicle sealing element according to the preamble of claim 1. It should be noted that document US20210245690A1 discloses a motor vehicle comprising a bumper on which a sensor, for example a thermometer, is mounted. This sensor is attached to the bumper by means of a hinged portion of the bumper. The temperature sensor is secured in the bumper by a clip. This solution does not address the underlying problem of the invention.

[0033] The invention will be well understood and other aspects and advantages will become clear upon reading the following description given with reference to the accompanying figures, in which: [ Fig. 1 ] There figure 1 Diagram of a motor vehicle according to the invention. Fig. 2 ] There figure 2 shows a portion of a front block of a motor vehicle according to a first embodiment of the invention; [ Fig. 3 ] There figure 3 shows a mounting notch in a sealing element with closing means in an open configuration according to the first embodiment of the invention; [ Fig. 4 ] There figure 4 shows the mounting notch in the sealing element with the sealing means in a through-conversion configuration according to the first embodiment of the invention; [ Fig. 5 ] There figure 5 shows means of sealing a sealing element according to a second embodiment of the invention; [ Fig. 6 ] There figure 6 shows means of sealing a sealing element according to a third embodiment of the invention; [ Fig. 7 ] There figure 7 shows a diagram of a method for assembling a motor vehicle according to the invention.

[0034] In the following description, the term "include" is synonymous with "include" and is not restrictive in that it permits the presence of other steps in the process or other elements in the sealing system or the vehicle to which it relates. It is understood that the term "include" includes the terms "consist of." The terms "external" and "internal" will refer, respectively, to what is oriented towards the outside of the vehicle and towards the inside of the vehicle.

[0035] Similarly, the terms "lower", "higher", "top" and "bottom" shall be understood according to their usual definition, in which the terms "lower" and "bottom" indicate a greater proximity to the ground in the vertical direction than respectively the terms "higher" and "top".

[0036] In this description, the terms "longitudinal" and "transverse" are used in relation to the vehicle's frame of reference, in the mounting configuration. "Longitudinal" refers to the vehicle's principal direction of travel. "Transverse" refers to a direction perpendicular to the vehicle's principal direction of travel.

[0037] There figure 1 Figure 10 shows a motor vehicle comprising a front section 12 viewed from the outside, showing a bumper skin 14 referenced to other body elements 16 including, for example, a hood, side fenders, etc. The bumper 14 includes an air intake grille 15 surrounded by a bumper skin 17. This skin 17 forms the exterior surface of the vehicle and is flush with the hood and fenders. It defines the front end block of the vehicle 10.

[0038] There figure 2 presents a portion of the front facade block 11, a bumper device, or bumper, comprising a transverse bumper beam 30 and a rigid bumper frame 20. The frame 20 includes a body to which the bumper skin (not shown) is attached.

[0039] The front end assembly further includes a heat exchanger 32 and a sealing element 40 according to a first embodiment. The heat exchanger 32 is used to cool the vehicle's internal combustion engine. Alternatively, it can be used for air conditioning the vehicle's passenger compartment. The sealing element forms a frame surrounding the heat exchanger 32. The frame shape is generally rectangular. The sealing element 40 forms a sleeve positioned in front of the heat exchanger 32 and channels the incoming air into the front end assembly 11.

[0040] The frame 20 includes a central leg 22. This leg extends vertically to the beam 30 and serves as an attachment point for the bumper skin (not shown). The central leg 22 passes vertically through the sealing element 40. For this purpose, the sealing element 40 has a notch 43 used to insert the central leg 22. The mounting notch 43 is shown here horizontal and open towards the front; however, the invention contemplates other arrangements. It has a general plane P, which is a geometric plane along which the opening of the mounting notch 43 is formed. The general plane P is substantially perpendicular to the central leg 22.

[0041] There figure 3 represents the intersection between a central support 22 of reinforcement 20 and a notch 43 of a sealing element 40 of the vehicle. The vehicle may be similar or identical to those described in the preceding figures.

[0042] The sealing element 40 comprises several walls 41 forming the structure of this entity. The wall 41 is advantageously made of polypropylene, for example PP20A. At its leading edge, the wall 41 has a sealing edge 42. This edge is designed to contact the bumper skin (not shown) in order to channel the flows entering the front end assembly. By way of illustration, the sealing edge 42 is made of a plastic material having elastic properties, preferably an elastomer chosen from ethylene propylene diene monomer (EPDM), thermoplastic elastomer (TPE), or latex. The sealing edge may include a sealing lip, preferably with a variation in thickness, in particular a reduction in thickness.

[0043] The wall 41 comprises a first material with a first Young's modulus. The sealing edge 42 comprises a second material with a second Young's modulus that is lower than the first Young's modulus, preferably ten times lower. The Young's moduli are measured by tensile tests, according to the reference standard ISO 527-1:2019. For the wall 41, regardless of the manufacturing process chosen; A person skilled in the art would benefit from selecting a thermoplastic polymer matrix from one or more materials chosen from among polypropylene (PP), polyphthalamide (PPA), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyamide-imide (PAI), polyetherimide (PEI), polyarylamide (PAA), or polyamide (PA) such as, for example, polyamide 6 (PA 6 or polycaprolactam) or polyamide 6.6 (PA 6.6 or polyhexamethylene adipamide).

[0044] The mounting notch 43 extends longitudinally into the wall 41. It is optionally bordered by the sealing edge 42, which improves sealing and absorbs vibrations from the central leg 22. The transverse width of the mounting notch 43 can substantially correspond to that of the central leg 22. The sealing edge 42 extends transversely on both sides of the mounting notch 43.

[0045] The sealing edge 42 includes sealing means 50 adapted to close the mounting notch 43, for example at the central foot 22. The sealing means 50 comprise at least one sealing flap, preferably two sealing flaps 52 and 54. In the present figure 3 The sealing flaps 52 and 54 are in the open configuration since the mounting notch 43 is at least partially open. Access to it is free, or partially free. Its entrance is accessible and allows the central foot 22 to be inserted. In the open configuration, the flaps create a gap in the entrance. The entrance is partially unobstructed. The sealing flaps 52 and 54 are made from the same material as the sealing edge 42; for example, by molding. They thus benefit from the same advantages as the material of the sealing edge 42. Vertically at the level of the sealing flaps 52 and 54, i.e., at the level of the general plane P, the central foot 22 preferably includes a rib 23, the role of which will be explained below.

[0046] In the open configuration, the shutter flaps 52 and 54 are inclined relative to the general plane (not shown). Their angles of inclination are between 30° and 90°; optionally between 45° and 60°. The shutter flaps 52 and 54 are oriented towards the center of the sealing element 40, which reduces the dimensions of the mold used to manufacture the latter, and therefore its cost.

[0047] There figure 4 represents an enlargement of the sealing element 40 in figure 3 ; at the intersection of the mounting notch 43 and the central foot 22. The notch area of ​​the figure 3 in which the shutter flaps 52 and 54 are in a through-configuration.

[0048] The mounting notch 43 includes a base 44 opposite the inlet 45. These two longitudinal zones are connected by two opposing edges 46 of the mounting notch 43. The transversely opposed edges 46, or lateral edges, define the internal width of the mounting notch 43. They border the central leg 22 and contribute to its stability. Furthermore, the central leg 22 abuts against the base 44.

[0049] In the through-hole configuration, the sealing means 50 pass transversely through the mounting recess 43. The overall surface is covered. The sealing flaps 52 and 54 partially cover the recess 43. They run alongside the inlet 45 and block it. Access to the mounting recess 43 is physically prevented. At least one flap edge extends the sealing edge 42.

[0050] In the through-hole configuration, the shutter flaps 52 and 54 are generally parallel to each other, and in particular parallel to the wall 41. The angles of inclination of the wall 41 with respect to the shutter flaps 52 and 54 can be approximately 0°, possibly + / - 5°. In the through-hole configuration, the shutter flaps 52 and 54 are superimposed. They overlap transversely.

[0051] The shutter flaps (52; 54) include retaining means 48. Once engaged, the retaining means 48 hold the shutter flaps (52; 54) in a through-position, in contact with each other. The retaining means 48 may include a slot formed in one of the flaps and a pin formed on the other flap for insertion into the slot. Alternatively, the retaining means include adhesive at the overlapping interface of the flaps.

[0052] In through configuration, the shutter flaps (52; 54) are parallel to the positioning rib 23. The positioning rib 23 is suitable for positioning shutter flaps (52; 54) at the level of the general plane P, which allows them to be arranged in an efficient position to manage airflow.

[0053] The shutter flaps (52; 54) are movable at hinges 47 along the edges 46 of the mounting recess 43. The hinges 47 are configured to allow pivoting movements, for example, along longitudinal pivot axes. The hinges 47 may include notches 49. The notches 49 result in a reduced cross-section, increasing flexibility. Furthermore, the notches 49 on the bottom side 44 accommodate stiffeners from the central foot 22. Consequently, leakage is limited, and airflow management is optimized.

[0054] There figure 5 Figure 140 represents a portion of a sealing element according to a second embodiment of the invention. The sealing element 140 is similar to that of the first embodiment and can be installed in a vehicle as shown in the preceding figures. The present figure uses reference numbers based on those of the first embodiment, with the numbering incremented by 100.

[0055] In the second embodiment, the shuttering means 150 include a shutter flap 152, which is pivotable. The shutter flap 152 is shown as a solid line in the open configuration and as a dashed line in the through-contour configuration. In the open configuration, the shutter flap 152 is inclined relative to the general plane P. It extends from one edge 146 and remains at a distance from the opposite edge 146. Thus, the opening 145 of the mounting recess 143 remains free. It is open along its entire length, that is, across the entire width of the mounting recess 143. A central support (not shown) can be inserted by lowering the flap 152 further, via pivoting on the hinge 147.

[0056] In its through-hole configuration, the shutter 152 is substantially parallel to the general face P. It passes through the mounting notch 143 from one edge to the other. Its surface area prevents any potential airflow that might otherwise pass through the mounting notch 143. When changing configuration, the shutter 152 pivots from one face, for example the lower face, of the wall 141, to an opposite face, for example the upper face, of the wall 141. The shutter 152 extends from one of the edges 146 and touches the opposite edge 146. It rests against this edge due to its inherent rigidity. This feature makes any retaining means entirely optional. However, these means can be added to increase the retention. The change in configuration can be achieved by pivoting the shutter 152 through an angle of at least 20°, preferably at least 30°.

[0057] The use of single-flap closure devices limits the handling required to close the notch.

[0058] There figure 6 Figure 240 represents a portion of a sealing element according to a second embodiment of the invention. The sealing element 240 is similar to that of the first embodiment and can be installed in a vehicle as shown in the preceding figures. The present figure uses reference numbers based on those of the first embodiment, with the numbering incremented by 200.

[0059] In the third embodiment, the shutter means 250 include an extendable shutter flap 256. The shutter flap 256 is shown as a solid line in the open configuration and as a dashed line in the through-contour configuration. The flap 256 is configured to extend along the opening 245 of the mounting recess 243.

[0060] In its open configuration, the shutter flap 256 may have a sinusoidal or accordion profile. The wall forming the flap 256 may be corrugated. It is at the level of the general plane P. It extends over a portion of the inlet 245. Thus, the inlet 245 remains partially free. The shutter flap 256 extends from an edge 246, and the free end of the shutter flap 256 remains at a distance from the opposite edge 246. The bottom remains accessible.

[0061] In the through-hole configuration, the shutter flap 256 is substantially parallel to the general pan P. It passes through the mounting notch 243 from one edge 246 to the other. Thanks to its extent relative to its sealing surface, it prevents any airflow attempting to enter the mounting notch 243. When changing configurations, the shutter flap 256 lengthens. Retaining means 248 allow the flap to remain in position during the configuration change.

[0062] A type of shutter with a corrugated flap allows this flap to be integrated into the recess in the open configuration. In this position, the flap is easily accessible from either side.

[0063] There figure 7 represents a diagram of a vehicle assembly process including a sealing element. The latter is indiscriminately according to the first, second or third embodiment.

[0064] The process includes the following steps, carried out in the following order: mounting 300 of the sealing element in which the shutter flap or each shutter is in the open configuration; insertion 302 of the central foot into the mounting notch, for example by pushing the flap or each flap out of the mounting notch; movement 304 of at least one shutter flap from the open configuration into the through configuration and against the central foot so as to close the mounting notch; mounting 306 of the bumper skin against the sealing means.

[0065] During movement step 304, at least one or each flap pivots by at least 30°; preferably by at least 60°. At the end of movement step 304, the optional holding means are locked to block the flap(s).

[0066] During the assembly step 306 of the bumper skin, the flap is compressed longitudinally between the skin and the frame, which helps to hold it in place. This action can replace other retaining means.

[0067] The technical characteristics described in one embodiment can be used in other embodiments.

Claims

1. Sealing element (40; 140; 240) of a vehicle (10), the said sealing item having a wall (41; 141) forming a frame, the wall (41; 141) having a sealing edge (42) and an assembly line notch (43; 143; 243) in the sealing edge (42), the said assembly line notch (43; 143; 243) comprising an entry (45; 145; 245) and a bottom (44) opposite the entry (45; 145; 245), wherein the sealing rim (43; 143; 243) comprises at least one shutter (52; 54; 152; 256) movable between an open configuration; and a through configuration in which the at least one shutter (52; 54; 152; 256) passes through the assembly line notch (43; 143; 243) at the level of the entry (45; 145; 245), so as to partially plug the assembly line notch (43; 143; 243).

2. Sealing element according to Claim 1, characterised in that the closure flap or flaps (52; 54; 152; 256) comprise / comprise at least one hinge with at least one notch (49).

3. Sealing element according to one of Claims 1 to 2, characterised in that the closure flap or flaps (52; 54; 152; 256) comprise / comprise holding means (48; 248) capable of holding the said at least one closure flap (52; 54; 152; 256) in the through-configuration.

4. Sealing element according to one of Claims 1 to 3, characterised in that the assembly line notch (143; 243) comprises two opposite edges (146; 246) extending from the entry to the bottom; and at least one shutter is dimensioned to connect the two opposite edges (146; 246) in the through-configuration and to bear on one of the two edges.

5. Sealing element according to one of Claims 1 to 3, characterised in that the assembly line notch (43) comprises two opposite edges (46) extending from the entry to the bottom; the sealing item comprising two closure flaps (52; 54) each extending from one of the opposite edges; in the through configuration, the closure flaps (52; 54) are dimensioned to be at least partially superposed.

6. Sealing element according to one of Claims 1 to 5, characterised in that the wall (41; 141) comprises a first material with a first Young's modulus, and the sealing edge (42) comprises a second material with a second Young's modulus less than the first Young's modulus.

7. A motor vehicle (10) comprising a sealing item, wherein the sealing item (40; 140; 240) is in accordance with one of claims 1 to 6; and the vehicle has a controlled air entry unit with a heat exchanger (32) sealingly cooperating with the sealing item (40; 140; 240).

8. Motor vehicle (10) according to Claim 7, characterised in that the vehicle further comprises a framework (20) with a central leg (22) passing through the assembly line recess (43; 143; 243) against the bottom (44) of the said assembly line recess, and in that, in the through configuration, the closure flap or flaps (50; 150; 250) follow the central leg (22).

9. A method of assembling a motor vehicle, said motor vehicle comprising: a heat exchanger, a bumper (14) with a bumper skin, a frame (20) with a centre leg (22) intended to support the bumper skin and extending between the heat exchanger and the bumper skin, a sealing item capable of channelling an air flow from the bumper skin to the heat exchanger; wherein the sealing item (40; 140; 240) is in accordance with one of Claims 1 to 6, and in that the process comprises the steps of: ·assembly line (300) of the sealing item (40; 140; 240) in which the shutter flap(s) (50; 150; 250) are in an open configuration; ·insertion (302) of the centre foot (22) into the assembly line notch (43; 143; 243); ·moving (304) the one or more shutter flaps (50; 150; 250) from the open configuration into the through configuration and against the centre foot to close the assembly line notch.

10. Method of assembly according to Claim 9, characterised in that the method further comprises a step of assembly line (306) of the bumper skin against the at least one closure flap (52; 54; 152; 256), the closure flap being compressed longitudinally between the bumper skin and the frame.