Motor vehicle structure made of composite materials, and vehicle obtained therewith

Abstract

The invention relates to a motor vehicle structure (1). According to the invention, the structure (1) consists of the assembly of: a central structural module (10) defining at least the passenger compartment of the vehicle, two front (11) and rear (12) structural high-energy shock absorption modules, and two front and rear structural medium- and low-energy shock absorption modules (13, 14), each of said structural modules (10, 11, 12, 13, 14) comprising structural and / or semi-structural elements made of composite materials.

Description

Description Title of the invention: Motor vehicle structure made of composite materials and vehicle thus obtained.

[0001] The present invention relates to a motor vehicle structure made of composite materials and to a vehicle comprising this structure.

[0002] Motor vehicles are made up of a so-called monocoque structure, whose rigidity gives the vehicle better road holding and greater resistance in the event of impacts or accidents. Such a structure is generally made of cut, stamped, and welded steel parts. To reduce weight, materials such as aluminum are also used in some vehicles.

[0003] Recommendations and regulations regarding CO2 emissions have led car manufacturers to offer lighter vehicles that consume less fossil fuel. Similarly, manufacturers now offer vehicles with electric or hybrid (electric / thermal) engines, which also require lighter vehicles.

[0004] It has therefore been proposed to replace certain vehicle elements such as the structure and bodywork with parts made from lighter materials than steel, such as aluminum, or even composite materials, thus allowing a weight saving in the vehicle.

[0005] Thus, to produce electric vehicles, it has been proposed to produce a chassis or underbody entirely composed of a molded plastic structure in the shape of a bowl onto which is then added an upper structure also molded in one piece as described in US-A-3,686,051, WO-A-2011128081 or EP-A-2,615,013.

[0006] In document FR-A-2698601, it was proposed to produce a vehicle structure comprising four molded parts comprising two half-boxes assembled together to form a central box of the vehicle constituting the chassis and forming a central beam extending axially over the entire length of the vehicle from front to rear, while two half-carcasses are assembled to the central box and to each other to form a carcass or body of the vehicle.

[0007] Although this type of structure made entirely of composite material presents a significant weight saving, it also remains a major drawback in terms of manufacturing: it is necessary to provide molds for each vehicle profile, which involves chains. specific production and therefore quite expensive manufacturing costs.

[0008] Another problem lies in the need for structural elements to have the desired characteristics of impact resistance and rigidity, allowing vehicles to meet increasingly stringent accident standards.

[0009] It was then proposed to lighten the structure or body in white, in particular by proposing to mix steel elements to maintain rigidity and impact resistance and elements made from lighter materials such as aluminum or even composite materials based on fiber-reinforced plastic resins.

[0010] Thus, it has been proposed to produce in particular vehicle floors from reinforced composite materials such as those described in US-A-3,686,051, EP 3,315,389.

[0011] However, the number of parts needed to produce a vehicle with a lightweight structure remains significant, particularly to be able to switch from one vehicle profile to another.

[0012] The present invention therefore aims to propose a structure for a motor vehicle, particularly with an electric motor, allowing a saving in terms of mass but also a structure which meets safety standards while having a limited number of parts.

[0013] To this end, the main subject of the invention is a motor vehicle structure characterized in that it is made up of the assembly: of a central structural module defining at least the passenger compartment of the vehicle, of two front and rear structural modules for absorbing high energy shocks, and two front and rear structural modules for absorbing medium and low energy shocks, each of these structural modules comprising structural and / or semi-structural elements made of composite materials.

[0014] Advantageously, the structure according to the invention thus offers the advantage of having a number of structural elements made of composite material which are presented in the form of five assemblable modules, which makes it possible to limit manufacturing costs.

[0015] The composite material constituting the structural elements of the structure such as panels is a composite material having a sandwich structure consisting of a core and two outer skins, the core preferably being made of a plastic, metallic or natural material in the form of foam, cellular or solid structure, the outer skins being made of a polymer matrix composite reinforced with continuous or discontinuous fibers and all of the structural elements are preferably made of a polymer matrix composite material reinforced with continuous or discontinuous fibers. Other structural elements of the structure are made of a polymer matrix composite material reinforced with continuous or discontinuous fibers.

[0016] By vehicle structure, we mean all the elements which in a vehicle form a central, almost non-deformable zone, namely the passenger compartment, and front and rear energy absorption zones which, by deforming, absorb a maximum of energy during frontal and rear impacts to protect the passenger compartment.

[0017] For side impacts, it is the central module that will absorb the resulting energy and prevent intrusion linked to the impact, particularly at the level of the vital parts (head, neck, thorax, abdomen) of the occupants of the passenger compartment.

[0018] According to the invention, this almost non-deformable zone of the structure is therefore formed by the central structural module which comprises a structural platform sub-module constituting the lower part of the passenger compartment, and a structural sub-module constituting the upper and lateral parts of the passenger compartment.

[0019] Preferably, the central structural module comprises a platform structural sub-module which comprises a structural floor element, a front structural bulkhead element and a rear structural bulkhead element placed respectively at each end of the structural floor element, and two front and rear structural support elements intended to respectively receive a powertrain and assembled respectively with the front structural bulkhead element and the rear structural bulkhead element.

[0020] This central structural module is advantageously sized to promote the dissipation of energy linked to a side impact in the lower part of the passenger compartment and more precisely at the level of the structural platform sub-module.

[0021] According to a secondary object of the invention, said structural platform sub-module comprises a structural floor element, a front structural bulkhead element and a rear structural bulkhead element placed respectively at each end of the structural floor element, and two structural support elements intended to respectively receive a powertrain and assembled respectively with the front bulkhead structural element and the rear structural bulkhead element.

[0022] It is thus possible to propose a structural platform sub-module for the different vehicle segments (A, B, C) by modifying only the length of the structural floor element, the front and rear structural bulkhead elements as well as the structural support elements to receive the traction means which can remain the same. The platform sub-module thus has greater modularity without requiring a large diversity of parts.

[0023] According to yet another object of the invention, the structural floor element comprises two structural panels extending apart from each other, separated by an internal frame. It also comprises two lateral structural stiffeners assembled on the lateral edges of the structural panels and, preferably, at least two so-called closing structural panels assembled on the front and rear edges of the structural panels.

[0024] Advantageously, the structural floor element which constitutes the lower part of the passenger compartment preferably has a parallelepiped shape, that is to say a closed box shape, which increases its mechanical resistance to front and rear impacts and allows it to resist deformation linked to front and rear impacts.

[0025] According to a preferred embodiment, the structural floor element further comprises a central structural stiffener, extending between the front and the rear of the structural floor element, which allows it to further increase its mechanical strength.

[0026] Furthermore, according to a preferred embodiment, a lateral structural stiffener comprises a C-shaped structural profiled element, a honeycomb structure housed in the space provided between the branches of the C-shaped profiled element, and the walls of which preferably extend orthogonally between the web of the C-shaped profiled element and a structural profiled element closing said C-shaped profiled element, a space being provided between each branch of the C-shaped profiled element and the honeycomb structure, space in which the lateral edge of a structural panel is fixed.

[0027] Advantageously, this lateral structural stiffener is resistant to bending and torsion, contributing to the dissipation of energy linked to front and rear impacts, but also lateral impacts.

[0028] Furthermore, this “box” shape of the structural floor element advantageously makes it possible to provide a structural floor element which comprises at least one receiving space intended to receive energy storage means.

[0029] Preferably, the receiving space is defined between the structural panels of the floor element, at least one cutout being provided in a structural panel of the floor element to allow the placement in the receiving space between the two structural panels of at least one assembly which encloses at least one energy storage module, the assembly being fixable at least on the edge of the cutout of the panel.

[0030] The vehicle for which the structure is intended is thus advantageously an electrically powered vehicle and, in the space delimited between the panels of the floor element, an assembly containing electric batteries is housed in the reception space.

[0031] Advantageously, the platform sub-module also comprises, positioned at the front on either side of the structural support element and against the front structural bulkhead element, two half-arch-shaped shock-absorbing elements. The same configuration is reproduced at the rear of the platform sub-module.

[0032] According to the invention, the structural sub-module constituting the upper and lateral parts of the passenger compartment comprises two lateral structural sub-module elements each comprising at least one structural roof arch, one structural door frame element, one structural door sill element, one lateral structural pillar, one structural reinforcement element of the rear window frame, one rear structural panel element with window.

[0033] In addition, the structural sub-module constituting the upper and side portions of the passenger compartment comprises a roof structural module element comprising at least one front structural roof element, at least one rear structural roof element, at least one intermediate structural roof element and at least one structural roof roof. The structural roof elements are in the form of front, rear and intermediate structural cross members extending between the two side structural sub-module elements.

[0034] Said structural roof pavilion comprises a structural panel made of composite material of the sandwich structure type consisting of a core and two external skins, said structural panel being reinforced using a core having a lattice, a honeycomb or a foam.

[0035] The upper part of the passenger compartment module is therefore also completely modular, which makes it easy to modify the geometry of the central structural module depending on the desired vehicle.

[0036] Furthermore, in order to reinforce the strength of the structure according to the invention, the lateral structural uprights and the intermediate structural roof element such as a roof cross member intermediate structural arch forms a transverse structural arch. This arch advantageously constitutes the middle legs of the structure while the front end of the roof arch associated with the front structural partition element and the rear end associated with the rear structural partition element respectively form the front leg and the rear leg of the structure.

[0037] The front or rear structural partition element comprises two structural panels made of composite materials, spaced apart from each other, preferably parallel to each other, the front or rear structural partition element thus having a double-wall structure having a base intended to be housed in structural receiving means of the floor element to allow its fixing.

[0038] The platform sub-module further comprises structural support elements, each structural support element being intended to receive a powertrain at the front or rear and comprising three structural panels of composite material assembled to present a U-shape.

[0039] At the front and rear ends of the central module, there are provided front and rear high-energy shock-absorbing modules which comprise two lateral structural elements spaced apart from each other and connected to each other by a structural frame positioned at each end of said lateral structural elements.

[0040] The front and rear high energy shock absorbing structural modules are positioned around the support members of the front and rear traction members of the platform structural sub-module and secured against the front structural bulkhead member and the rear structural bulkhead member of said platform structural sub-module.

[0041] Preferably, half-arch elements are positioned on the rear shock absorber module and half-arch elements are positioned along the rear structural support element, said arched elements being complementary to form wheel arches when placing the rear high-energy shock absorber module on the rear structural support module positioned along the side panels. These arch-forming elements participate in the high-energy absorption.

[0042] Each medium and low energy shock absorption module comprises: a cross member, a layer of shock absorbing foam fixed on the cross member, two elongated crashbox-type crush shock absorption elements, attachable respectively to a front or rear high energy shock absorption structural module and to one end of the crosspiece, and two interface elements interposed between the crosspiece and the elongated crushing shock absorption elements, also constituting a receiving box for a stack of honeycomb structures.

[0043] Advantageously, the medium and low energy shock absorption modules are of identical structure at the front or rear, helping to simplify the manufacture of the structure, avoiding a multiplicity of different parts and therefore reducing production costs.

[0044] The invention makes it possible to propose a modular type structure for a motor vehicle allowing a saving in terms of mass, the structural elements constituting said modules being made of composite materials, said structural elements being further arranged to form a structure which meets safety standards while having a limited number of parts. These structural, semi-structural elements and the formed modules are assembled by appropriate assembly and / or fixing means, such as mechanical fixing / assembly means, gluing means and / or welding means.

[0045] Furthermore, the invention proposes a vehicle structure which comprises modules whose structure comprises and / or forms, when assembled, closed “boxes” making it possible to increase the overall and local moment of inertia of the vehicle formed and therefore to be able to lighten the structure.

[0046] The invention also relates to a motor vehicle comprising a structure as defined above and in which the visible exterior part of said vehicle comprises structural and semi-structural elements of said structure which are visible and structural and / or semi-structural trim elements attached to said structure.

[0047] By proposing to leave certain elements of the structure visible as elements instead of added trim elements as in conventional vehicles, the bending and torsional rigidity of the vehicle with identical shape is increased compared to a body in white with added trim elements, and costs are also limited by reducing the number of parts required for manufacturing.

[0048] The bodywork elements of the central module also include two side panels of the floor module, and two doors.

[0049] The front body module includes a hood and the rear body module includes an underbody and a tailgate.

[0050] The invention will now be described in more detail with reference to the drawings in which are shown: [Fig. 1] an exploded top perspective view of the motor vehicle structure according to the invention; [Fig. 2] Side perspective view of the structure of Figure 1; [Fig. 3] a perspective view from above of the central module of the structure, with a partially broken away portion, of Figure 2; [Fig. 4a] a perspective view from above of the habitable platform sub-module; [Fig. 4b] a perspective view of the habitable platform sub-module of Figure 4a with wheels; [Fig. 5] a sectional view of the floor element; [Fig. 6] a sectional view of a lateral structural stiffener of the floor element; [Fig. 7] a perspective view a perspective view from above of the floor element frame; [Fig. 8] a perspective view of the underside of the floor element; [Fig. 9] a perspective view from above of a set of energy storage modules; [Fig. 10] a perspective view from above of the floor element; [Fig. 11] a front view of the front face of a front structural bulkhead element, [Fig. 12] a rear perspective view of a front structural bulkhead member, with one wall torn away; [Fig. 13] a sectional view of the element of Figure 11; [Fig. 14] a front view of the rear face of a rear structural bulkhead member; [Fig. 15] a perspective view of the rear face of a rear structural partition member, with one wall torn away; [Fig. 16] a sectional view of the element of Figure 14; [Fig. 17] a perspective view of the front support element; [Fig.18] a perspective view of the rear structural support element; [Fig. 19a] a side view of a lateral sub-module; [Fig. 19b] a side perspective view of a side sub-module; [Fig. 20] a perspective view from above of a high energy shock absorber front module; [Fig. 21] an exploded perspective view of Figure 20; [Fig. 22] a perspective view from above of a high energy rear shock absorber module; [Fig. 23] an exploded perspective view of Figure 22; [Fig. 24] a top view of a low energy front shock absorber module and a high energy front shock absorber module; [Fig. 25] a sectional view of the front low energy shock absorber module of Figure 24; [Fig. 26] a perspective view of the rear low energy shock absorber module; [Fig. 27] a view of the module according to figure 26 without absorbent foam; [Fig. 28] a side perspective view of the front end of the structure according to the invention; [Fig. 29] a side perspective view of the rear end of the structure according to the invention; [Fig. 30] an exploded perspective view of the visible structural, semi-structural and non-structural elements of the vehicle according to the invention and [Fig. 31] a side perspective view of a vehicle comprising a structure according to the invention.

[0051] As can be seen in Figure 1, the structure 1 for an electrically powered motor vehicle according to the invention comprises several assembled modules, namely a central structural module 10 defining the passenger compartment of the vehicle, two front and rear modules intended to absorb high-energy impacts 11, 12, and two front and rear medium and low-energy impact absorption modules 13, 14.

[0052] The central structural module 10 comprises a first structural platform sub-module 101 constituting the lower part of the passenger compartment, and a second sub-module forming the upper and lateral parts 102 of the passenger compartment.

[0053] As can be seen in Figures 3, 4a and 4b, this structural platform sub-module 101 comprises a structural floor element 1010, a front structural bulkhead element 1011 and a rear structural bulkhead element 1012 and two structural support elements 1013, 1014 placed respectively at the front and rear of the structural floor element 1010 and intended to receive respectively front and rear MP powertrains of the vehicle (see Fig. 4b).

[0054] The platform structural sub-module 101 further comprises half-arch-shaped elements 61 which are positioned along the rear structural support element 1014 or front 1013 and against the rear structural bulkhead element 1012 or front 1011, said elements 61 being complementary to also half-arch-shaped elements 62 carried by the rear 12 and front 11 high-energy shock-absorbing structural modules to form wheel arches 6 when the rear / front shock-absorbing module is in place. high energy impact 12 / 11 around the rear / front structural support member 1014,1013 as will be described later.

[0055] The structural floor element 1010 comprises two structural panels 1010A, 1010B extending apart from each other, separated by an internal frame 1010H, two lateral structural stiffeners 1010R assembled on the lateral edges of the structural panels 1010A, 1010B.

[0056] The composite material constituting the structural panels 1010A, 1010B has a sandwich structure comprising a core and two outer skins. The outer skins are made of a polymer matrix composite material reinforced by continuous or discontinuous fibers such as mineral fibers with a basalt base associated with a high-performance resin while the core is preferably made of a plastic, metallic or natural material in the form of foam, cellular structure or solid.

[0057] Such a composite material is thus lighter, stronger, recyclable, and with optimal energy absorption. In addition, such a material is made so that interfacial adhesion is obtained between the fibers and the matrix, in order to maintain the integrity of the structures during the aging of the composites.

[0058] The two panels 1010A and 1010B extend at a distance from each other, preferably parallel, and are carried by the frame 1010H made of a polymer matrix composite material reinforced by continuous or discontinuous fibers which comprises lateral uprights 1010K and at least one central upright 1010L, preferably two, and reinforcing crosspieces 1010T which extend between the lateral uprights 1010K and central uprights 1010L of the frame 1010H, thus defining cells.

[0059] The central uprights 1010L and central uprights 1010M extending parallel to and spaced from the central uprights 1010L form a central structural stiffener 1010E extending projecting above the main plane of the frame 1010H and forming a central channel, front and rear axle coupler made of a polymer matrix composite material reinforced by continuous or discontinuous fibers. This upper face of the structural floor element 1010 is covered by the upper panel 1010A.

[0060] The structural floor element 1010 thus has a central structural stiffener 1010E, forming a path for absorbing frontal or rear impact energy.

[0061] Each lateral structural stiffener 101 OR comprises a C-shaped structural profiled element 1010C. In the space provided between the branches of the C-shaped structural profiled element C-shaped 1010C is housed a honeycomb structure 1010D whose walls preferably extend orthogonally between the core of the C-shaped structural profiled element 1010C and a closing structural profiled element 10101 of said C-shaped structural profiled element.

[0062] Advantageously, a space is provided between each branch of the C-shaped profile 1010C and the honeycomb structure 1010D, this space allowing the housing and fixing of the lateral edge of a panel 1010A, 1010B (see figure 6).

[0063] The lateral structural stiffeners 1010R are made of a polymer matrix composite material reinforced by continuous or discontinuous fibers, in particular manufactured by pultrusion, and are resistant to bending, thus making it possible to stiffen the structural floor element 1010 with respect to front or rear impacts. They are also resistant to torsion, thus making said structural floor element 1010 stiffer with respect to lateral impacts. These lateral structural stiffeners 1010R therefore also constitute lateral impact absorbers, thus contributing to the dissipation of energy linked to lateral impacts but also to front and rear impacts.

[0064] Structural panels called closure panels 1010F are assembled on the front and rear edges of the structural panels 1010A, 1010B and on the ends of the central structural stiffener 1010E. The structural floor element 1010 thus formed has the shape of a closed box which gives it high mechanical strength allowing it to withstand front and rear impacts much better.

[0065] Between the panels 1010A and 1010B of the structural floor element 1010 is defined a space, which allows the installation of energy storage modules 31, 32 such as electric batteries.

[0066] Preferably, at least one cutout 1010G is provided in the lower panel 1010B of the structural floor element 1010, opposite a cell of the frame 1010H which forms a receiving space or housing 1010J, in which an energy storage module 31 can be placed.

[0067] The panel 1010B thus preferably has a plurality of cutouts or openings 1010G arranged opposite the cells of the frame 1010H, arranged between the crosspieces 1010T, on either side of the central structural stiffener 1010E (see figure 8).

[0068] A set of energy storage modules 3 is then provided comprising a plurality of modules 31 (see FIG. 9), each engageable through a cutout 1010G. in a corresponding receiving space 1010J, the peripheral edge 33 of the assembly 3 allowing its attachment to the lower panel 1010B.

[0069] The central structural stiffener 1010E also defines a space in which at least one energy storage module 32 can be placed as can be seen in FIG. 9. These modules 32 can be engaged by longitudinal sliding from the front and from the rear in the space delimited, between the upper panels 1010A and 1010B, at the level of the central structural stiffener 1010E.

[0070] At the front and rear ends of the structural floor element 1010 thus formed, the front 1011 and rear 1012 structural partition elements are positioned.

[0071] In Figures 11 to 13, the front structural bulkhead element 1011 of the platform structural sub-module 101 is shown. This front structural bulkhead element 1011 comprises two panels made of composite material of the type already described above, extending apart from each other, preferably parallel to each other.

[0072] Preferably, said front structural partition element 1011 comprises reinforcing elements 41, 42, 43, 44. Thus, a reinforcing element 41, 44 is housed between the two panels 1011A, 1011B, positioned along the longitudinal edge of the front structural partition element 1011 opposite the base 1011C of said front structural partition element 1011. Two lateral reinforcing elements 42 extend along the lateral edges of said front structural partition element 1011 and two reinforcing elements 43 extend respectively diagonally from one end of the reinforcing element 41 towards the central part of the front structural partition element 1011.

[0073] On the upper part of the front partition 1011 is placed a transverse structural element 1011E which serves in particular as a support for a dashboard of the vehicle and also reinforces the impact resistance of the passenger compartment. The reinforcing elements 41 and 44 thus form with the structural element 1011E, the equivalent of a front beam of the central structural module 10. Such a front structural partition element 1011 is thus suitable for increasing the resistance to frontal and lateral impacts of the central module and absorbing kinetic energy during a high-energy crash.

[0074] The front structural partition element 1011 has a base 101 IC intended to be housed in structural receiving means of the structural floor element 1010 to allow its fixing.

[0075] This structural partition element before 1011 also has in its lower part a complementary cutout of the central structural stiffener 1010E forming a housing 101 IG for the central structural stiffener 1010E.

[0076] The rear structural partition element 1012 described in Figures 14 to 16 comprises two structural panels 1012A, 1012B made of composite material, at least partly spaced from each other, preferably parallel to each other. The rear structural partition element 1012 has a base 1012C intended to be housed in structural receiving means fixed with the structural floor element 1010. This front structural partition element 1012 further has in its lower part a complementary cutout of the central structural stiffener 1010E forming a housing 1012G for the central structural stiffener 1010E.

[0077] This rear structural partition element 1012 further comprises reinforcing elements 51, 52 such as a reinforcing element 51 extending along the longitudinal edge of the rear structural partition element 1012 opposite its base 1012C fixed to the structural floor element 1010 between the two structural panels 1012A, 1012B thus forming a rear transverse beam element.

[0078] Also present are structural reinforcement elements 52 such as structural foam blocks distributed over said rear structural partition element 1012.

[0079] These front 1011 and rear 1012 structural partition elements therefore have a substantially similar structure, comprising two composite material panels made from a sandwich-type composite material such as that described above. These partition elements therefore have a “double-wall” structure.

[0080] Once the front structural partition element 1011 and the rear structural partition element 1012 are mounted at the ends of the structural floor element 1010, these two elements form respectively at their ends, the front foot or foot A, and the rear foot or foot C of the central structural module or passenger compartment 10 on which the ends of a structural roof arch 1022A are fixed. In particular, a closing element 1011F of the junction between the front structural partition element 1011 and a structural roof arch 1022A is provided (see figure 13).

[0081] As can be seen in Figures 4a, 4b and 10, the structural floor element 1010 comprises stiffening elements of the platform structural sub-module 101 which are made up of connecting and reinforcing elements 4, 4a extending between the front 1011 or rear 1012 structural bulkhead element and the structural floor element 1010. These stiffening elements 4, 4a are preferably positioned at the front and rear ends of the structural stiffener central 1010E and on the front and rear lateral ends. These connecting and reinforcing elements 4, 4a extend between said structural floor element 1010 and the front 1011 or rear 1012 structural bulkhead element and are deformable in the manner of a crash box, thus contributing to better absorption and dissipation of energy in the event of a rear or front impact. This makes it possible to increase the stiffness and resistance to torsion and bending, while reinforcing the interior panels of the bulkheads and promoting energy absorption in the event of an impact.

[0082] As seen in Figures 17 and 18, at each end of the platform structural sub-module 101, there is provided a front structural support element 1013 and a rear structural support element 1014 intended to receive elements of a front or rear MP powertrain as seen in Figure 4b.

[0083] Each front 1013, rear 1014 structural support element comprises three structural panels made of sandwich-structured composite material 1013A, 1013B, 1014A, 1014B, assembled to have a U-shape, namely two side panels 1013A, 1014A made of sandwich-structured composite material, extending parallel to each other and between which extends a third panel 1013B, 1014B having a frame shape. Each side panel 1013A, 1014A is provided with an orifice 1013C, 1014C for the passage of the traction means through which a transmission axle of a powertrain MP can extend to wheels 7.

[0084] The structural panels 1013A, 1013B, 1014A, 1014B as well as the structural floor element 1010 comprise mechanical fixing means for reduction motor housings of said MP powertrains.

[0085] The central structural stiffener 1010E which extends between the front 1011 and rear 1012 structural bulkhead elements makes it possible to directly and mechanically connect the front and rear MP powertrains, carried by the structural support elements 1013 and 1014, which in particular makes it possible to increase the stiffness of the structural platform sub-module, its resistance to torsion and bending and to reduce the mechanical stresses on the central module.

[0086] In addition, a coupling of forces, stresses, and moments during acceleration, deceleration, and cornering maneuvers is created between the central structural stiffener 1010E and the front 1013 and rear 1014 structural support elements carrying a powertrain. This promotes energy absorption in the event of a front or rear impact.

[0087] As can be seen in Figure 2 or 3, the platform structural sub-module 101 constitutes the lower part of the passenger compartment while the upper part of the passenger compartment 10 comprises a side and upper structural sub-module 102. Such a side and upper structural sub-module 102 comprises two side structural module elements 1022 and a roof structural module element 1021.

[0088] A lateral structural module element 1022 comprises - a 1022A structural roof arch, - a 1022E door structural frame element, - a 1022S door sill structural element, - a lateral structural upright 1022B, constituting the middle pillar or pillar B of the passenger compartment 10 - a rear structural panel element with window 1022C - a structural reinforcement element of the rear window frame 1022D.

[0089] The roof arch 1022A extends from the front of the passenger compartment to the rear of said passenger compartment, that is to say between the front pillar or pillar A, constituted by the lateral ends of the front structural partition element 1011 and the rear pillar or pillar C of the vehicle constituted by the lateral ends of the rear structural partition element 1012.

[0090] The roof structural module element 1021 includes at least one front structural roof element such as a front cross member 1021Tav, a rear structural roof element (rear cross member) 1021Tar, an intermediate structural roof element (intermediate cross member) 1021Ti and at least one structural roof pavilion 1021Pav extending between the front 1021Tav and rear 1021Tar structural cross members. Each structural roof element or cross member extends between the side structural module elements and is reinforced by an internal tubular member

[0091] The lateral structural uprights 1022B (center pillar) and the intermediate structural roof element 102 ITi thus form a transverse structural arch of the passenger compartment contributing to the strength of the passenger compartment 10.

[0092] Preferably, the structural roof pavilion 1021Pav comprises a structural panel made of composite material of the sandwich structure type consisting of a core and two external skins, said structural panel being reinforced using a core having a lattice, for example made of carbon fibers, a honeycomb or a foam.

[0093] Each lateral structural module element 1022 is thus connected to the other via the roof crossmember elements 1021Tav, 1021Tar and 102 ITi.

[0094] Between the intermediate structural cross member 1021Ti and the rear structural cross member 1021Tar, the rear portion of the structural roof panel 1021Pav in the example shown, comprises an opening provided with an opening structural frame element 1021Par of the roof panel 1021Pav. Similarly, the front opening of the structure defining the windshield of the vehicle receives a front windshield structural frame element 1023 Av. Similarly, the rear opening of the structure receives a rear window frame element.

[0095] Advantageously, some of the structural elements of this central structural module 10 constitute structural elements which are visible on the vehicle.

[0096] All of these structural elements are preferably made of a composite material with a polymer matrix reinforced by continuous or discontinuous fibers, such as based on thermoplastics (for example copolyamide) / mineral fibers and / or carbon fibers.

[0097] Ace central structural module 10 are joined in the front and rear part of said central structural module 10, high energy shock absorber modules front 11 and rear 12 visible in figures 20 to 23. These two modules 11, 12 of similar structure, thus comprise two lateral structural elements 110, 120, in the form of panels, extending parallel to each other and connected to each other by a front / rear structural frame 111, 112; 121,122 at each end of the side structural members 110, 120. In addition, a reinforcing member 113, 123 extends obliquely from the edge of each side panel 1013A, 1014A to a projecting portion of one of the structural frames, rear 112 for the front high energy shock absorber module 11 and front 121 for the rear high energy shock absorber module 12.

[0098] This reinforcing element 113, 123 is a structural panel in the shape of a right triangle, the sides forming the right angle of which extend for one along the edge of the side panel 1013A, 1014A and for the other along a frame 112, 121, the panel 113, 123 being positioned so as to extend outwardly relative to the side panel 1013A, 1014A.

[0099] The front 11 and rear 12 high-energy shock absorber modules are sized to be nested respectively on the front 1013 and rear 1014 support modules of the central structural module 10 and secured against the front structural bulkhead element 1011 and the rear structural bulkhead element 1012 of the central structural module 10.

[0100] Half-arch shaped shock absorbing elements 62 are positioned on the rear structural module 12 high energy shock absorber and half-arch shaped elements half-arch 61 are positioned against the rear structural bulkhead element 1012 along the rear structural support element 1014, said elements 61, 62 being complementary to form wheel arches 6 when the rear structural shock-absorbing module 12 is fitted onto the rear structural support element 1014.

[0101] The same applies to the shock absorber module 11 as can be seen in Figure 24. The half-arch shaped shock absorber elements 62 are positioned on the front structural module 11 high energy shock absorber and half-arch shaped elements 61 are positioned against the front structural bulkhead element 1011 along the front structural support element 1013, said elements 61, 62 being complementary to form wheel arches 6 when the front structural module shock absorber 11 is fitted onto the front structural support element 1013.

[0102] The rear high-energy shock-absorbing structural module 12 further comprises two shock-absorbing elements 124, each having a planar portion extending between a half-arch shock-absorbing element 62 and a side panel 120 of said rear high-energy shock-absorbing structural module 12, and a deformation shock-absorbing portion extending above the half-arch shock-absorbing element and attached to the frames 121, 122 of said rear high-energy shock-absorbing structural module 12.

[0103] These high energy shock absorber modules are joined by medium and low energy shock absorber modules 13, 14 as can be seen in Figure 24.

[0104] These medium and low energy shock absorber modules 13, 14 comprise a cross member 131, 141 of W-shaped cross section. This cross member 131, 141 is covered with a layer of shock absorbing foam such as low density memory foam 132, 142.

[0105] The cross member 131, 141 extends between two elongated crash shock absorbing elements, known by the English terminology "crashbox" 135, 145, the latter comprising shells made of composite materials assembled by gluing. These elements 135, 145 are connected respectively to the frame of the corresponding high-energy shock absorber module 11, 12 and to one end of the cross member 131, 141 using two interface elements 133 interposed between said cross member 131, 141 and the elongated crash shock absorbing elements 135, 145, also constituting a receiving box for a stack of honeycomb-type cellular structures 134.

[0106] The crosspiece 131 or 141 has edges 13 allowing it to delimit a space in which the foam 132, 142 is embedded. The crossmember 131, 141 further comprises at least two transverse grooves 136 with a W-shaped section in which a rib 137, 147 is positioned making it possible to connect the crossmember 131, 141 to the front 23 and rear 24 bumpers.

[0107] The front 13 and rear 14 high-energy shock absorbers have a structure following the same concept, however geometric adaptations and adjustments to the length of certain elements can be made.

[0108] Figures 28 and 29 show the stages of shock absorption function at the front and rear depending on the type of shock.

[0109] Thus, zones 1a) 1b) correspond to the very low energy impact structure involved for pedestrian impact protection.

[0110] Zones 2a) 2b) correspond to the structural zones involved in a low energy shock.

[0111] Zones 3a) 3b) correspond to the zones of the structure involved in a medium energy shock and zones 4a) 4b) 5a) 5b) 6a) and 6b) are those involved in a high energy shock.

[0112] The concepts of low, medium or high energy impact are given in relation to an unladen vehicle weight of approximately 1,500 kg.

[0113] Thus, a low energy impact is an impact at a speed of 4km / h (typical case ECE R42), a medium energy impact is an impact at a speed around 15km / h, which corresponds to a criterion of no damage to the structure for a high energy impact & engine block). A high energy impact is at a speed greater than 15km / h. The typical case in Europe is the ECE RI 37 reference test corresponding to an impact at 50km / h.

[0114] Figure 30 represents all the elements of the motor vehicle V called visible or external and which are for some composed of visible structural elements of the structure 1 such as the rear structural panel element with window 1022C, the structural door sill element 1022S, the structural roof arch 1022A, the structural roof pavilion 1021Pav, the structural door frame element 1022E, the transverse structural element of the front structural partition element 1011E.

[0115] These visible elements preferably also include semi-structural elements such as the door 20, the semi-structural front hood 21, the front semi-structural wings 22, the rear semi-structural wings 25, the semi-structural rear flap 26.

[0116] Other non-structural elements complete the vehicle's trim such as the front 23 and rear 24 bumpers as well as the diffuser 27.

[0117] Figure 31 represents a motor vehicle V, in particular with an electric motor, which comprises a vehicle structure 1 (shown schematically) as defined previously and the shape of which is given only as an example. This vehicle V comprises powertrains and electric batteries.

[0118] List of references: 1 motor vehicle structure 10 central structural module 101 structural platform submodule 1010 structural floor element 1010A structural panel 1010B structural panel 101 OR lateral structural stiffener 1010C C-shaped structural profiled element 1010D honeycomb structure 10101 structural profiled element closing the C-shaped structural profiled element 1010E central structural stiffener 1010F structural closure panel 1010G cutout in 1010B structural panel 101 OH frame 1010K side frame amount 1010L central upright of the frame 1010M central upright of the central structural stiffener 1010T frame reinforcement crosspiece 1010J reception area MP powertrain 1011 front structural bulkhead element 101 IA, 101 IB structural panels of the front structural bulkhead element 101 IC base of the front structural bulkhead element 1011D Side Structural Panel of the Front Structural Bulkhead Member 1011E transverse structural element of the front structural bulkhead element 101 IF closing element of the junction between the front structural partition element and the roof arch 101 IG housing for the central structural stiffener 1012 rear structural bulkhead element 1012A, 1012B structural panels of the rear structural bulkhead element 1012C base of the rear structural bulkhead element 1012G housing for the central structural stiffener 1013 U-shaped front structural support element 1013A structural panel forming a side wall of the U-shaped structural support element 1013B structural panel forming the central wall of the U-shaped structural support element 1013C hole for passage of traction means 1014 U-shaped rear structural support element 1014A structural panel forming a side wall of the U-shaped structural support element 1014B structural panel forming the central wall of the U-shaped structural support element 1014C hole for passage of traction means 102 lateral and upper structural sub-module 1021 structural roof module element 1021Tav front structural roof element 1021Tar rear structural roof element 1021 Ti intermediate structural roof element 1021Pav structural roof pavilion 1021By structural frame element of rear opening of roof pavilion 1022 lateral structural module element 1022 A structural roof arch 1022B lateral structural amount 1022C rear structural panel element with window 1022D Rear Window Frame Structural Reinforcing Element 1022E structural door frame element (exposed) 1022 S structural element of door sill (visible) 1023Av front windshield structural frame element 11 high-energy shock-absorbing front structural module 110 lateral structural element of the front structural module 111 front structural frame of the front structural module 112 rear structural frame of the front structural module 113 reinforcement element 12 high-energy shock-absorbing rear structural module 120 lateral structural element of the rear structural module 121 front structural frame of the rear structural module 122 rear structural frame of the rear structural module 123 reinforcement element 124 shock absorber elements 13 medium and low energy shock absorption front structural module 131 crosses 131a edge of the crosspiece 132 layer of shock absorbing foam 133 interface element between the cross member and a crush-deformable shock-absorbing element 134 deformable element of honeycomb structure housed in the interface element 135 crush-deformable shock-absorbing element 136 throat 137 rib 14 rear structural module for medium and low energy shock absorption 141 crosses 142 layer of shock absorbing foam 143 interface element between the cross member and a crush-deformable shock-absorbing element 145 crush-deformable shock-absorbing element 147 rib 20 doors 21 semi-structural front hood 22 front structural wing 23 front bumper 24 rear bumpers 25 rear structural wing 26 rear flap 27 diffuser 3 sets of energy storage modules 31 energy storage module 32 channel energy storage module 33 edge of the module assembly 4 connecting and reinforcing element of the platform sub-module 4a connecting and reinforcing element of the platform sub-module 41, 42, 43, 44 reinforcement elements of the front structural bulkhead element 51, 52 Reinforcing elements of the rear structural bulkhead element 61 half-arch shock absorber element carried by the central structural module partly forming the wheel arch 62 half-arch shock absorber element carried by the front or rear high-speed impact energy absorption structural module 7 wheel la, 1b of shock absorption at medium and low energies 2a, 2b medium and low energy shock absorption zone 3a, 3b medium and low energy shock absorption zone 4a, 4b high energy shock absorption zone 5a, 5b high energy shock absorption zone 6a, 6b high energy shock absorption zone V motor vehicle

Claims

Claims 1. Structure (1) of a motor vehicle characterized in that it consists of the assembly: of a central structural module (10) defining at least the passenger compartment of the vehicle, of two front (11) and rear (12) structural modules for high energy shock absorption, and two front and rear structural modules (13, 14) for medium and low energy shock absorption, each of these structural modules (10, 11, 12, 13, 14) comprising structural and / or semi-structural elements made of composite materials.

2. Structure (1) according to claim 1, characterized in that the central structural module (10) comprises a platform structural sub-module (101) which comprises a structural floor element (1010), a front structural bulkhead element (1011) and a rear structural bulkhead element (1012) placed respectively at each end of the structural floor element (1010), and two front and rear structural support elements (1013, 1014) intended to respectively receive a powertrain (MP) and assembled respectively with the front structural bulkhead element (1011) and the rear structural bulkhead element (1012).

3. Structure (1) according to claim 2, characterized in that the structural floor element (1010) comprises two structural panels (1010A, 1010B) extending apart from each other, separated by an internal frame (1010H), two lateral structural stiffeners (101 OR) assembled on the side edges of the structural panels (1010A, 1010B) and at least two so-called closing structural panels (1010F) assembled on the front and rear edges of the structural panels (1010A, 1010B).

4. Structure (1) according to one of claims 2 or 3, characterized in that the structural floor element (1010) comprises a central structural stiffener (1010E) which extends between the front (1011) and rear (1012) structural partition elements making it possible to directly and mechanically connect the front and rear powertrains (MP), carried by the structural support elements (1013) and (1014).

5. Structure (1) according to claim 3 or 4, characterized in that a lateral structural stiffener (1010R) comprises a C-shaped structural profiled element (1010C), a honeycomb structure (1010D) housed in the space provided between the branches of the C-shaped profiled element (1010C), and the walls of which preferably extend orthogonally between the web of the C-shaped profiled element (1010C) and a closing structural profiled element (10101) of said C-shaped profiled element, a space being provided between each branch of the C-shaped profiled element (1010C) and the honeycomb structure (1010D), in which space the lateral edge of a structural panel (1010A, 1010B) is fixed.

6. Structure (1) according to one of claims 3 to 5, characterized in that the structural floor element (1010) comprises at least one receiving space (1010J) intended to receive energy storage means.

7. Structure (1) according to one of claims 1 to 6, characterized in that the central structural module (10) comprises a lateral and upper structural sub-module (102) constituting the upper and lateral parts of the passenger compartment which comprises two lateral structural module elements (1022) each comprising at least one structural roof arch (1022A), a structural door frame element (1022E), a structural door sill element (1022S), a lateral structural upright (1022B), a structural reinforcement element of the rear window frame (1022D), a rear structural panel element with window (1022C).

8. Structure (1) according to claim 7, characterized in that the structural sub-module (102) constituting the upper and lateral parts of the passenger compartment comprises a structural roof module element (1021) comprising at least one front structural roof element (1021Tav), a rear structural roof element (1021Tar), an intermediate structural roof element (1021Ti) and at least one structural roof pavilion (1021Pav).

9. Structure (1) according to claim 8, characterized in that the structural roof pavilion (1021Pav) comprises a structural panel made of composite material of the sandwich structure type consisting of a core and two external skins, said structural panel being reinforced using a core having a lattice, a honeycomb or a foam.

10. Structure (1) according to one of claims 2 to 9, characterized in that the front structural partition element (1011) comprises two structural panels (101 IA, 101 IB) made of composite materials, spaced apart from each other, preferably parallel to each other, the front structural partition element (1011) having a base (101 IC) intended to be housed in structural receiving means of the floor element (1010) to allow its fixing.

11. Structure (1) according to claim 2 to 10, characterized in that the rear structural partition element (1012) consists of two structural panels (1012A, 1012B) made of composite materials, at least partly spaced from each other, preferably parallel to each other, the rear structural partition element (1012) having a base (1012C) intended to be housed in structural receiving means fixed with the floor element (1010) 12. Structure (1) according to one of claims 2 to 11, characterized in that each structural support element (1013, 1014) intended to receive a powertrain (MP) respectively at the front or at the rear comprises three structural panels made of composite materials (1013A, 1013B, 1014A, 1014B), assembled to have a U shape.

13. Structure (1) according to claim 12, characterized in that the structural panels (1013A, 1013B, 1014A, 1014B) as well as the structural floor element (1010) comprise mechanical fixing means for reduction motor casings of said powertrain units (MP).

14. Structure (1) according to one of claims 1 to 13, characterized in that the front (11) and rear (12) high-energy shock absorption modules comprise two lateral structural elements (110, 120) spaced from each other and connected to each other by a structural frame (111, 112; 121, 122) positioned at each end of said lateral structural elements (110, 120).

15. Structure (1) according to claim 14, characterized in that each front and rear high energy shock absorption module comprises a reinforcing element (113, 123), comprising a structural panel positioned so as to extend obliquely between a projecting portion of one of the frames (112, 121) which bears against the front / rear structural partition elements (1011, 1012) of the structural platform sub-module (101) and the edge of each structural panel (1013A, 1014A) of the structural support elements (1013, 1014) of said structural platform sub-module (101).

16. Structure (1) according to one of claims 14 and 15 characterized in that the front (11) and rear (12) high energy shock absorption structural modules are positioned around the front (1013) and rear (1014) structural support elements for the traction elements, of the platform structural sub-module (101) and fixed against the front structural bulkhead element (1011) and the rear structural bulkhead element (1012) of said platform structural sub-module (101).

17. Structure (1) according to one of claims 14 to 16, characterized in that: half-arch shock-absorbing elements (61) are positioned on the platform structural sub-module (101) at the front and rear thereof at the structural bulkhead elements (1011, 1012), on either side of the front and rear structural support elements (1013, 1014), half-arch shock-absorbing elements (62) are positioned along the lateral elements (110, 120) of the front (11) and rear (12) high-energy shock-absorbing structural modules, said half-arch shock-absorbing elements (61, 62) being complementary to form wheel arches when assembling the front (11) and rear (12) high-energy shock-absorbing structural modules on the platform structural sub-module (101).

18. Structure (1) according to one of claims 14 to 17, characterized in that the rear high-energy shock-absorbing structural module (12) comprises two shock-absorbing elements (124), each having a planar portion extending between a half-arch shock-absorbing element (62) and a lateral structural element (120) of said rear high-energy shock-absorbing structural module (12), and a deformation shock-absorbing portion extending above the half-arch shock-absorbing element and fixed to the frames (121, 122) of said rear high-energy shock-absorbing structural module (12).

19. Structure (1) according to one of claims 1 to 18, characterized in that each medium and low energy shock absorption module (13, 14) comprises: a cross member (131, 141), a layer of shock absorbing foam (132, 142) fixed on the cross member (131, 141), two crushing shock absorbing elements (135, 145), fixable respectively to a front (11) or rear (12) high energy shock absorbing structural module and to one end of the cross member (131, 141), and two interface elements (133) interposed between the cross member (131, 141) and the crushing shock absorbing elements (135, 145), also constituting a receiving housing for a stack of honeycomb structures (134, 144).

20. Structure (1) according to one of claims 1 to 19, characterized in that the composite material constituting the structural elements of the structure such as panels is a composite material having a sandwich structure consisting of a core and two external skins, the core preferably being made of a plastic, metallic or natural material in the form of foam, cellular or solid structure, the external skins being made of a polymer matrix composite reinforced by continuous or discontinuous fibers and all of the structural elements are preferably made of a polymer matrix composite material reinforced by continuous or discontinuous fibers.

21. Motor vehicle (V) comprising a structure (1) according to one of claims 1 to 20, characterized in that the visible external part of said vehicle (V) comprises structural and semi-structural elements of said structure (1) which are visible and structural and / or semi-structural trim elements attached to said structure (1).

22. Motor vehicle (V) according to claim 21, characterized in that the structural and semi-structural elements of the structure (1) constituting elements of the visible exterior part of the vehicle comprise: the roof panel (1021Pav), the roof arches (1022A), the structural frame elements of the vehicle openings (1023Av, 1023 Ar), the structural elements of the front and rear side wings (22, 25).

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