Automotive vehicle body panel

Abstract

The invention relates to a motor vehicle body panel (2), comprising at least one coating (4) with a thickness between 0.1 and 1 millimeter, preferably between 0.3 and 0.7 millimeters, forming a main body of the body panel (2), the coating being fixed to at least one plastic support (10) forming at least part of a frame of the body panel (2). Figure 5 (for the abstract)

Description

Title of the invention: Motor vehicle body panel

[0001] The invention relates to motor vehicle body panels made of plastic.

[0002] Plastic body panels, for example a bumper skin or an exterior tailgate panel, are commonly made by injection molding, for example using polypropylene or polycarbonate (many other plastics can be used for this molding).

[0003] Mass saving has become a central issue for current and future developments in automotive equipment, including body panels. For example, it is known to mold body panels by reducing, locally at the level of the body panel or over the entire body panel, the thickness of plastic material or by reducing the density of the plastic material used. For example, and for a bumper skin, it is possible to reduce the thickness of the panel to 2.7 millimeters or even 2.5 millimeters (it is also possible to consider lowering the thickness locally to 1.9 millimeters, or even to 1.6 millimeters). In the same way, it is possible to reduce the density of the plastic material used, for example between 0.9 and 1.20 for polypropylene (in particular depending on the filler rate, typically talc).

[0004] However, excessive reduction in the thickness of the body panels as well as in the density of the plastic material used can lead to appearance defects, degraded mechanical performance of the body panel, or difficulties in industrial production in injection molding, these consequences not being acceptable for their use on exterior body panels and visible on a motor vehicle. Consequently, reductions in the thickness or density of a body panel are thus limited by these constraints of appearance, strength and production. Thus, depending on the choices made in thickness, in material density, and depending on the redesigns made necessary by these changes while remaining at equivalent performance, it is possible to obtain weight savings limited to approximately 5% to 15% only.

[0005] Another possibility is to make recesses by molding. Indeed, it is possible in injection to reduce the mass of a panel by making lightening recesses during molding, but this creates appearance defects (in particular bonding lines) which are not acceptable in quality if the part is visible from the outside, or to hide behind another solid part.

[0006] The object of the invention is to provide an exterior bodywork panel formed by elements making it possible to reduce its weight compared to the bodywork panels of the prior art while avoiding the drawbacks mentioned above and known from the prior art.

[0007] To this end, the invention relates to a motor vehicle body panel, comprising at least one covering with a thickness of between 0.1 and 1 millimeter, preferably between 0.3 and 0.7 millimeter, forming a main body of the body panel, the covering being fixed to at least one plastic support forming at least in part a frame of the body panel.

[0008] Thus, and as a replacement for a body panel injected with plastic, a coating of much less thickness is produced. It is not necessary to reduce the density of the plastic used. The weight saving is achieved thanks to a much greater reduction in thickness permitted due to the manufacture of the coating. In addition, the support is itself made of plastic, which also helps to lighten the body panel. Therefore, the panel obtained can have half the weight of a body panel obtained by injection molding and for an identical covered surface.

[0009] According to additional characteristics of the body panel taken alone or in combination: - the covering is chosen from a plastic film, an openwork plastic covering, preferably a woven plastic covering, or a woven covering made of natural fibers; - the coating is configured so as to allow elastic deformation in tension in an extension plane of the coating of between 1% and 50%, preferably between 3% and 10%; - at least part of the coating comprises openings whose size is between 1 millimeter and 50 millimeters, preferably between 10 millimeters and 40 millimeters; - at least one part of the covering comprises at least one decorative pattern; - the decorative pattern is formed by a material forming the coating when the covering is made of woven plastic or woven natural fibers; - the coating is made from at least one plastic material chosen from polypropylene, polyamide, polyurethane, polyvinyl chloride, polyester or elastane; - the covering is fixed irremovably to the support, for example by welding, gluing, riveting or overmoulding the covering onto the support; - the covering is removably attached to the support, for example by pinching the covering by the support; - the support includes means for fixing the body panel to a structure of a motor vehicle; - the body panel comprises several supports on which at least one covering is fixed; - the support is made from at least one plastic material chosen from polypropylene, polyamide, polyvinyl chloride, polyester, polybutylene terephthalate, or from a composite material; - the covering is stretched over the support; - the support comprises at least one bar for supporting the covering; - at least one support bar extends over an external face of the covering; and - at least one support bar locally deforms the coating.

[0010] The invention also relates to a motor vehicle comprising at least one bodywork panel according to the invention.

[0011] The invention also relates to a method of manufacturing a motor vehicle body panel according to the invention, in which:

[0012] - at least one support is made of plastic material,

[0013] - at least one coating is produced, and

[0014] - the covering is fixed to the support.

[0015] Preferably, several supports are made of plastic material, at least one covering is fixed to the supports, and the body panel is folded back on itself. Brief description of the figures

[0016] The invention will be better understood on reading the following description given solely by way of example and with reference to the appended drawings in which:

[0017] [Fig-1] is a perspective view of a part of a body panel according to the invention,

[0018] [Fig.2] is a perspective view of a portion of a body panel according to the invention, comprising a decorative pattern,

[0019] [Fig.3] is a perspective view of a part of a body panel according to a first variant of the invention,

[0020] [Fig.4] is a perspective view of a part of a body panel according to a second variant of the invention, and

[0021] [Fig.5] is a perspective view of a part of a body panel according to a third variant of the invention. Detailed description

[0022] In what follows, we understand by: - “opening”: any through opening made in the covering, allowing to obtain an openwork covering (i.e. which includes openings), - “meshes”: loops of material, regular or not, whose interlacing forms a woven covering, and - “perforation”: hole made mechanically in the initial coating full.

[0023] Reference is now made to [Fig. 1] illustrating a part of a body panel 2. This body panel 2 may be a front or rear bumper, an exterior panel of a tailgate, a door panel, etc.

[0024] This is a panel visible from the outside of the motor vehicle when it is mounted on said motor vehicle. This body panel is fixed. This means that it does not include a movable part relative to the rest of the body panel 2, and that it does not undergo deformation during normal deployment in order to move.

[0025] The bodywork panel 2 comprises at least one coating 4 with a thickness of between 0.1 and 1 millimeter, preferably between 0.3 and 0.7 millimeter, forming a main body of the bodywork panel 2. Therefore, and as explained above, it is a much thinner coating than those of the bodywork panels according to the prior art.

[0026] Advantageously, the covering 4 is chosen from a solid film of plastic material (one or more plastic materials), an openwork covering of plastic material, preferably a woven covering of plastic material, or a woven covering based on natural fibers.

[0027] As regards the possibility of producing a solid plastic film, it may for example be a film obtained by extrusion. This film could for example be subsequently cut to the dimensions of the bodywork panel.

[0028] As regards the possibility of producing an openwork plastic coating, it may be a plastic film in which perforations are made after manufacture of the film on at least part of the film. Alternatively, it may be a fabric produced by weaving plastic or natural fibers, potentially coated with another material.

[0029] As regards a woven covering made from natural fibers, we can cite for example a covering made from cotton fibers or even linen fibers. Here again, it would be possible to coat this fabric with plastic material.

[0030] In the case in which the covering 4 is at least partially openwork (by making perforations or by the presence of open meshes), it may comprise openings 6 (shown in the figures for illustrative purposes without respecting actual dimensions) whose size may be between 1 millimeter and 50 millimeters, preferably between 10 millimeters and 40 millimeters. The presence of openings 6 makes it possible in particular to let air pass in the case where the bodywork panel 2 is an element opposing an air flow, in particular when the vehicle is in motion, which makes it possible to reduce the aerodynamic pressure experienced when the motor vehicle is moving (in fact, for example and in the case of a front bumper, the maximum pressure that can be exerted can reach 250N / m2 at 70 km / h, 550N / m2 at 110 km / h, and 1200N / m2 at 160 km / h), or to allow minimal ventilation of the parts of the motor vehicle placed behind the body panel 2.

[0031] Advantageously, the covering 4 is configured so as to allow an elastic deformation of between 1% and 50%, preferably between 3% and 10%. This deformation is measured in tension, on the complete covering 4 and extending in a single plane. Thus, the bodywork panel 2 can deform in the event of pressure exerted on the latter. This is to avoid deterioration of the bodywork panel 2, either by irreversible deformation, or by rupture of the covering 4. This possibility of an elastic deformation can be obtained thanks to: - the intrinsic elasticity of the material forming the fibers of the covering 4, for example elastane, - the relative density of the fibers and / or the meshes forming the covering 4, and / or - to the weaving technique. This means the possibility given to the fibers and / or the meshes to move within the coating 4.

[0032] The coating 4 may for example comprise at least one plastic material chosen from polypropylene, polyamide, polyurethane, polyvinyl chloride, polyester or elastane. The choice of material may, among other things, be made by taking into account the deformation permitted by the material forming the coating 4. This choice may also depend on the design technique of the coating 4, the robustness of the material, its aesthetics, etc.

[0033] Advantageously, and as illustrated in [Fig.2], at least a portion of the covering 4 may comprise at least one decorative pattern 8. It may therefore be a single decorative pattern 8 or several decorative patterns 8, located in an area of ​​the covering 4 or present over the entire covering 4.

[0034] Advantageously, and when the covering 4 is made by weaving (of synthetic or natural fibers), the decorative pattern is formed by the material forming the covering 4. It is possible, for example, to provide a modification of the weaving at the level of the decorative pattern(s) 8 or even the presence of colored fibers and / or of a different appearance at the level of the decorative pattern(s) 8. Alternatively, the decorative pattern 8 can be added to the covering 4, for example by printing, painting, etc.

[0035] The covering 4 is fixed on at least one support 10 made of plastic material forming all or part of a frame of the bodywork panel 2. In other words, the bodywork panel 2 is therefore formed by at least one covering 4 attached to at least one support 10.

[0036] The covering 4 can advantageously be stretched over the support 10. This makes it possible, among other things, to obtain an optimal aesthetic result. The support can, for example, comprise one or more support bars 12 (see Figures 3 and 4) which can participate in the tensioning of the covering 4, as can be seen in [Fig. 3] illustrating a first variant of the bodywork panel 2 according to the invention.

[0037] These support bars can cover an external face 14 of the covering 4 (i.e. a face visible from the outside of the vehicle on which the bodywork panel 2 is mounted), for aesthetic purposes and / or to protect the covering 4. This is visible in [Fig.4] illustrating a second variant of the bodywork panel 2 according to the invention.

[0038] Advantageously, the covering 4 is fixed irremovably to the support 10, for example by welding, by gluing, by riveting or by overmolding the covering 4 on the support 10. This makes it possible to ensure robust anchoring of the covering 4 on the support 10.

[0039] Alternatively, the covering 4 can be fixed in different ways to the support 10, for example by pinching the covering 4 by the support 10. Such a removable fixing makes it possible to envisage a simplified replacement of the covering 4 in the event of damage to the latter during the life of the motor vehicle, or even a simplified separation of the covering 4 and the support 10 during reprocessing of the bodywork panel 2 for recycling.

[0040] Advantageously, the support 10 comprises means for fixing the bodywork panel 2 to a structure of a motor vehicle 16. This is visible in [Fig.5]. A compact solution is therefore obtained for connecting the bodywork panel 2 to the structure of the motor vehicle, for example by clipping.

[0041] It is possible to provide several supports 10 on which the coating 4 is attached or several coatings 4 are attached, as can be seen in [Fig. 5]. It is for example possible to envisage several supports 10 with edges that are joined together or not, of different colors and / or appearances, made from different materials, for example between two adjacent supports 10.

[0042] For example, it is possible to envisage producing a bodywork panel 2 comprising several supports 10, a covering 4 being fixed to each support 10, all of the supports 10 being joined together so as to form the frame of the bodywork panel 2.

[0043] The support 10 may be made from at least one plastic material chosen from polypropylene, polyamide, polyvinyl chloride, polyester, polybutylene terephthalate, or from a composite material.

[0044] The use of several supports 10 on which one or more coverings 4 are fixed makes it possible to envisage delivery of a bodywork panel 2 assembled in a folded manner.

[0045] As regards the method of manufacturing the body panel 2, the latter comprises the following steps: - Production of at least one support 10 in plastic material. Depending on the material chosen, it can be designed by injection molding, compression molding, three-dimensional printing, etc. - Production of at least one covering 4. The latter can be designed by extrusion, weaving, etc., depending in particular on the choice of material forming the covering or the desired final appearance. The decorative pattern(s) 8 can be produced during the production of the covering 4, or once the latter has been produced, as described above. - Fixing the covering 4 on the support, as described above. Detailed description

[0046] 2: body panel

[0047] 4: coating

[0048] 6: open stitches

[0049] 8: decorative motif

[0050] 10: support

[0051] 12: support bar

[0052] 14: external face

[0053] 16: motor vehicle structure

Claims

Claims

1. Body panel (2) of a motor vehicle, comprising at least one external and fixed covering (4) with a thickness of between 0.1 and 1 millimeter, preferably between 0.3 and 0.7 millimeter, forming a main body of the body panel (2), the covering being fixed on at least one support (10) made of plastic material forming at least in part a frame of the body panel (2).

2. Body panel (2) according to claim 1, wherein the covering (4) is chosen from a solid plastic film, an openwork plastic covering, preferably a woven plastic covering (4), or a woven natural fiber covering.

3. Body panel (2) according to any one of the preceding claims, in which the coating (4) is configured so as to allow elastic deformation in tension in a plane of extension of the coating of between 1% and 50%, preferably of between 3% and 10%.

4. Body panel (2) according to any one of the preceding claims, wherein at least a portion of the covering (4) comprises openings (6) whose size is between 1 millimeter and 50 millimeters, preferably between 10 millimeters and 40 millimeters.

5. A body panel (2) according to any preceding claim, wherein at least a portion of the covering (4) comprises at least one decorative pattern (8).

6. Body panel (2) according to the preceding claim, in which the decorative pattern (8) is formed by a material forming the covering (4) when the covering (4) is made of woven plastic or woven natural fibers.

7. Body panel (2) according to any one of the preceding claims, in which the covering (4) is made from at least one plastic material chosen from polypropylene, polyamide, polyurethane, polyvinyl chloride, polyester or elastane.

8. Body panel (2) according to any one of the preceding claims, in which the covering (4) is fixed irremovably to the support (10), for example by welding, by gluing, by riveting or by overmolding the covering (4) on the support (10).

9. Body panel (2) according to any one of the claims previous, wherein the covering (4) is removably attached to the support (10), for example by pinching the covering (4) by the support (10).

10. Body panel (2) according to any one of the preceding claims, wherein the support (10) comprises means for fixing the body panel (2) to a structure (16) of a motor vehicle.

11. Body panel (2) according to any one of the preceding claims, comprising several supports (10) on which at least one covering (4) is fixed.

12. Body panel (2) according to any one of the preceding claims, in which the support (10) is made from at least one plastic material chosen from polypropylene, polyamide, polyvinyl chloride, polyester, polybutylene terephthalate, or from a composite material.

13. Body panel (2) according to any one of the preceding claims, wherein the covering (4) is stretched over the support (10).

14. Body panel (2) according to any one of the preceding claims, wherein the support (10) comprises at least one support bar (12) of the covering (4).

15. Body panel (2) according to the preceding claim, in which at least one support bar (12) extends on an external face (14) of the covering (4).

16. Body panel (2) according to any one of claims 14 and 15, wherein at least one support bar (12) locally deforms the covering (4).

17. Method for manufacturing a body panel (2) of a motor vehicle according to any one of claims 1 to 16, in which: - at least one support (10) is produced from plastic material, - at least one covering (4) is produced, and - the covering (4) is fixed to the support (4).

18. Manufacturing method according to claim 17, in which several supports (10) are made of plastic material, at least one covering (4) is fixed on the supports (10), and the body panel (2) is folded back on itself.

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