Method for implementing functional interfaces on automotive vehicle parts using 3D printing

Abstract

The invention relates to a method for implanting a functional interface (2) onto a support part (1), characterized in that the functional interface is attached and fixed to the support part, and then a retaining element (3) for said interface is produced by 3D printing on the support part. (Fig. 1)

Description

Title of the invention: Method for implanting functional interfaces onto automotive vehicle parts by 3D printing

[0001] The invention relates to the field of integration of functional elements on motor vehicles and is more particularly concerned with the implantation of specific parts and the addition of dedicated technical interfaces on these parts.

[0002] The diversity of technical interfaces that must be implemented on the numerous parts present in motor vehicles requires industrial facilities that are specifically adapted to manage this diversity reliably and qualitatively.

[0003] Generally, parts used in the automotive sector are structured and dimensioned to meet predetermined and well-defined mechanical constraints. A need for additional functions generally requires a new design, at least partial, of these parts, which can affect the overall cost of manufacturing vehicles.

[0004] Today there are various mechanical, thermal, or chemical methods for implanting and / or assembling, a posteriori, functional interfaces on parts or structural elements previously manufactured and shaped (by stamping, bending, etc.).

[0005] However, traditional methods of adding a metal part to an existing structure or part require both a large space to accommodate the part, the manufacture of additional elements which generates significant costs and then the assembly of these elements onto the structure or part.

[0006] The 3D printing technique consists of locally associating metallic functional interfaces with support parts by a process comprising 3D printing of metal.

[0007] This latter method, also known as additive manufacturing, makes it possible in particular to optimize the mass of material added to the parts as part of an overall search for the lightening of mechanical parts.

[0008] However, the processes currently implemented using this technique to graft these interfaces are not flexible and do not, moreover, allow for optimizing agility on the production line because they require the use of tools specific to each part and each function that one wishes to implement.

[0009] It turns out that existing processes generally only apply to a single type of part or equipment. Thus, patent application US20190270395A1, for example, describes the production of a clip by 3D printing on a vehicle seat.

[0010] In addition, the known methods only allow for the realization of one type of interface, for example, an interface with an anti-rotation function, as described in patent application US20150328803A1.

[0011] In this context, the invention sought a solution which, in its most general aspect, would allow for a simple and efficient resolution of the technical problems posed by previously implemented methods. Thus, the invention proposes a 3D printing implantation method, applicable to different types of support parts, enabling the creation of adaptable and reconfigurable interfaces, suitable and intended to perform a wide variety of functions.

[0012] This goal is achieved, according to the invention, by means of a method of implanting a functional interface on a support piece, characterized in that the functional interface is attached and fixed on the support piece and then a retaining element for said interface is produced by 3D printing on the support piece.

[0013] According to a first embodiment of the process of the invention, the interface is fixed to the support piece by means of an adhesive which is polymerized during a subsequent phase.

[0014] According to another embodiment of the method of the invention, the functional interface is fixed to the support part by means of a connecting element also produced by 3D printing.

[0015] According to an advantageous feature of the method of the invention, the profile and dimensions of the interface are determined in order to ensure at least one of the functions taken from the group consisting of anti-rotation, assembly of parts together, indexing of parts, reinforcement of the support part, error correction.

[0016] According to another feature of the process of the invention, 3D printing is carried out with a homogeneous metallic material.

[0017] Another object of the invention is a mechanical part provided with a functional interface and an element for retaining said interface, said part being made using the process of the invention.

[0018] Yet another object of the invention is a motor vehicle provided with at least one mechanical part locally provided with a functional interface and a retaining element made using the method as defined above.

[0019] Thus, in principle, the invention proposes an improvement of traditional methods of implementing functional interfaces which makes it possible to obtain, through 3D printing, an adaptable, reconfigurable and efficient solution to the technical problem posed by previous methods.

[0020] The interest of the invention lies in its application to a wide variety of mechanical parts by offering the possibility of implementing numerous and diverse functional interfaces while retaining the initial functionality of the support part.

[0021] Furthermore, the method of the invention can be implemented with traditional tools on the existing production line and allows for the creation of several functional interfaces on the same part while ensuring optimal agility. This method also makes it possible to add supplementary functions to an existing mechanical part, such as pre-holding, snap-fitting, positive fastening, anti-rotation, reinforcement, indexing, sealing, etc., and is compatible with all parts generally found on motor vehicles.

[0022] The method of the invention can also make it possible to improve the sound insulation function or even the vibration damping function, where appropriate, on the same support piece by adapting the interface attached to the thickness and shape of the piece.

[0023] The invention also makes it possible to limit the reaction time in case of urgent and occasional need and thus increase responsiveness while reducing the number of tools needed to intervene on the production line, which offers a significant economic gain.

[0024] From a logistical point of view, the invention eliminates the need to purchase parts from external suppliers by creating multi-functional parts directly on the assembly site.

[0025] Furthermore, the invention reduces the environmental impact associated with transport logistics. The use of homogeneous materials (e.g., steel-steel) facilitates the recycling of parts. Thanks to the 3D printing process, only the necessary amount of material is used, unlike standardized solutions which are not necessarily tailored to the specific need.

[0026] In addition, the invention avoids the diversity of parts at the line as well as storage constraints and makes it possible to reduce the number of operators.

[0027] Finally, this process allows the implementation of temporary interfaces pending the subsequent grafting of permanent functional solutions and its application is not restricted to particular areas of the support part on which a new interface is integrated.

[0028] Other features and advantages of the invention will become apparent from the following description, with reference to the accompanying figures, for which:

[0029] [Fig. 1] is a schematic side view of a first embodiment of the implantation method according to the invention.

[0030] [Fig.2] is a top view of a second embodiment of the process of the invention applied to the fixing of an electrical cable on the body of a vehicle.

[0031] [Fig.3] is a schematic side view of the implementation of the process of [Fig.2].

[0032] [Fig.4] are schematic views of a third embodiment of the method of the invention applied to the fixing of an electronic box on the body of a vehicle and in which the top views are side views and the bottom views are top views, respectively, on the left before the implementation of the method and, on the right during and after its implementation.

[0033] For clarity, identical or similar elements are indicated by identical reference signs in the description that follows and in the figure.

[0034] Naturally, the embodiments of the invention schematically illustrated in the figure above and described below are given only by way of non-limiting examples. It is explicitly provided for in the scope of the invention that different embodiments may be proposed and combined to create others.

[0035] The invention relates to the field of embedding one or more functional interfaces on a mechanical support part, the assembly being intended to be mounted on a motor vehicle. The method of the invention consists of an improvement on existing embedding methods.

[0036] A first embodiment of the method of the invention is schematically represented in [Fig. 1] and illustrates an example of the installation of a structural reinforcement element in a vehicle, particularly depending on the battery mass, in the side members or on the doors. Such reinforcement is sometimes required by the legislation of certain countries in terms of impact resistance.

[0037] The method of the invention comprises, the fixing on the support piece 1 of a functional interface 2 in the form of an added element (in [Fig.1], a reinforcing element) then the production on this support piece, by 3D printing, of a retaining element 3 (or pre-retaining element) of the interface 2. In [Fig.1], the retaining element is here in the shape of an L.

[0038] The 3D printing technique consists of depositing material on the support part 1 in a possibly sequential manner, in the form of points, cords or ribs, to create complementary functions. Several addressable interfaces can thus be provided to meet multiple needs.

[0039] According to a first embodiment of the process of the invention, the interface 2 is fixed to the support part 1 by means of an adhesive (in particular if the environment does not allow the production of EPS) which is polymerized during a later phase of the implantation process (for example, in an oven during the painting operation).

[0040] According to a second embodiment of the method of the invention, the functional interface 2 is fixed to the support part 1 by means of a connecting element 4 also produced by 3D printing, as illustrated by [Fig.1].

[0041] Figures 2 and 3 illustrate an embodiment of the method of the invention for fixing an interface 2, here consisting of the end 2a of an electrical cable, to the steel support body 1 of a motor vehicle. The retaining element 3, produced in situ by 3D printing, is positioned to correctly orient the cable 2 before it is fixed to the body 1 with screws.

[0042] Figure 4 illustrates another embodiment of the invention for attaching an interface 2, here consisting of an electronic housing, to the body of a motor vehicle. The U-shaped element 3 secures the housing 2 before it is attached to the body support 1 by means of an independent screw 2b (once the housing 2 is immobilized).

[0043] The 3D printing process for producing the support or pre-support element 3 according to the invention is implemented using equipment 5 (one of which is schematically represented in [Fig. 1]). Such equipment operates, in a known manner, either using DED (Direct Energy Deposition) technology or WAAM (Wire Arc Additive Manufacturing) technology. These two technologies use a heat source, respectively a laser beam or an electric arc, to melt a metal powder or a metal wire. In both cases, the 3D printing equipment thus ensures the melting of the filler material that will be used to produce the support element 3 in situ and also, where applicable, the connection 4 between the support part 1 and the functional interface 2.

[0044] The profile and dimensions of interface 2 are determined to ensure at least one of the functions within the group consisting of anti-rotation, assembly of parts together, indexing of parts, reinforcement of the support part, and error correction. However, the invention is not limited to the functions defined above and can incorporate all types of interfaces that are compatible with a metal 3D printing process.

[0045] The retaining element 3 or pre-retaining element is produced by 3D printing, giving it all geometric shapes (cylindrical, "L"-shaped, "U"-shaped, etc.) adapted to the profiles and geometries of the functional interfaces 2 and / or the support part 1 on which these interfaces are intended to be fixed, temporarily or permanently.

[0046] In the case of pre-holding, element 3 allows the support part 1 to be immobilized while awaiting its functionalization by an interface made by any other means (gluing, screwing, reinforcement, ...).

[0047] In the case of an application of the process of the invention to the industrial manufacturing of mechanical parts in series, the addition or modification of functionalities and interfaces can be carried out quickly and is reconfigurable. The invention thus offers an ergonomic and flexible solution that promotes adaptability and makes it possible to respond agilely and quickly adapts to potential crisis situations. Manual operations for installing or removing parts are no longer necessary.

[0048] In the case of an application of the invention to the manufacture of prototypes or with a low rate, the process makes it possible to provide flexible solutions that meet an immediate need while gaining in ergonomics, for example, in terms of the placement and removal of parts (in particular for bolts and nuts).

Claims

Demands

1. Method of implanting a functional interface (2) on a support part (1) of a motor vehicle, characterized in that the functional interface is attached and fixed on the support part in the form of an added element and then a retaining element (3) for said interface is produced by 3D printing on the support part.

2. A method according to claim 1, characterized in that the interface is fixed to the support part (1) by means of an adhesive which is polymerized during a subsequent phase.

3. Method according to claim 1, characterized in that the functional interface (2) is fixed on the support part (1) by means of a connecting element (4) also produced by 3D printing.

4. A method according to any one of the preceding claims, characterized in that the profile and dimensions of the interface (2) are determined in order to ensure at least one of the functions taken from the group consisting of anti-rotation, assembly of parts together, indexing of parts, reinforcement of the support part, and error correction.

5. A method according to any one of the preceding claims, characterized in that 3D printing is carried out with a homogeneous metallic material.

6. Motor vehicle having at least one mechanical part having locally a functional interface (2) and a retaining element (3) for said interface made using the method according to one of the preceding claims.

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