Automotive vehicle structure made of composite materials and the resulting vehicle.

Abstract

The invention relates to a motor vehicle structure (1). The invention consists in the fact that the structure (1) is made up of the assembly of: a central structural module (10) defining at least the vehicle passenger compartment, two front (11) and rear (12) high-energy shock-absorbing structural modules, and two front and rear structural modules (13, 14) medium- and low-energy shock-absorbing structural modules, each of these structural modules (10, 11, 12, 13, 14) being made up of structural and semi-structural elements of composite materials. Figure 1.

Description

Title of the invention: Structure of a motor vehicle made of composite materials and vehicle thus obtained.

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

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

[0003] Recommendations and regulations concerning CO2 emissions have led car manufacturers to offer lighter vehicles, thus reducing their consumption of fossil fuels. 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, the bodywork with parts made of materials lighter than steel such as aluminium or composite materials, thus allowing a reduction in mass 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 brought a molded upper structure also 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 including 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-frames 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 offers a significant weight saving, there is also a major drawback in terms of manufacturing; it is necessary to provide molds for each vehicle profile, which implies specific production lines and therefore fairly expensive manufacturing costs.

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

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

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

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

[0012] The present invention therefore aims to provide a structure for motor vehicles, in particular those with electric motors, allowing a gain in terms of mass but also a structure which meets safety standards while having a limited number of parts.

[0013] To this end, the invention has as its main object 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, two front and rear high energy shock absorption structural modules, and two front and rear medium and low energy shock absorption structural modules, each of these structural modules being made up of structural and semi-structural elements in composite materials.

[0014] Advantageously, the structure according to the invention thus offers the advantage of having a number of structural elements in composite material which are in the form of five assembleable 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 is preferably made of a plastic, metallic, or natural material in the form of foam, a cellular structure, or a solid. The outer skins are made of a polymer matrix composite reinforced with continuous or discontinuous fibers. All structural elements are preferably made of a polymer matrix composite reinforced with continuous or discontinuous fibers. Other structural elements of the structure are made of a polymer matrix composite reinforced with continuous or discontinuous fibers.

[0016] By vehicle structure, we mean all the elements which in a vehicle form a virtually undeformable central 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 related 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 quasi-undeformable zone of the structure is therefore formed by the central structural module which includes a structural sub-module of platform 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 includes a platform structural sub-module which includes 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 receive respectively a powertrain and assembled respectively with the front structural bulkhead element and the rear structural bulkhead element.

[0020] This central structural module is advantageously dimensioned to promote the dissipation of energy related to a lateral impact in the lower part of the passenger compartment and more specifically at the level of the structural sub-module of the platform.

[0021] According to a secondary object of the invention, said structural sub-module of platform 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 receive respectively a powertrain and assembled respectively with the front structural bulkhead element and the rear structural bulkhead element.

[0022] It is therefore possible to propose a structural sub-module for the platform 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, and the structural support elements to accommodate the traction means, which can remain the same. The platform sub-module thus offers greater modularity without requiring a wide variety of parts.

[0023] According to yet another object of the invention, the structural floor element consists of two structural panels extending apart from each other, separated by an internal framework, and two lateral structural stiffeners assembled on the edges lateral structural panels and at least two structural closure panels assembled on the front and rear edges of the structural panels.

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

[0025] According to a preferred embodiment, the structural floor element further includes a central structural stiffener, which allows it to further increase its mechanical resistance.

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

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

[0028] In addition, this "box" shape of the structural floor element advantageously allows for the proposal of a structural floor element which includes 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 receiving space.

[0031] Advantageously, the platform sub-module also includes, positioned at the front on either side of the structural support element and against the front structural bulkhead element, two shock-absorbing elements in the shape of a half-arch. 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 post, one structural reinforcement element of the rear window frame, and one rear structural panel element with a window.

[0033] Furthermore, the structural sub-module constituting the upper and lateral parts of the passenger compartment includes a structural roof module element comprising at least one front structural roof element, less one rear structural roof element, less one intermediate structural roof element, and at least one structural roof panel. The structural roof elements are in the form of front, rear, and intermediate structural cross members extending between the two lateral structural sub-module elements.

[0034] Said structural roof pavilion consists of 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 with a core having a lattice, a honeycomb or a foam.

[0035] The upper part of the passenger compartment module is therefore also totally modular, which also makes it easy to modify the geometry of the central structural module according to 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 an intermediate structural roof beam, form a transverse structural arch. This arch advantageously constitutes the mid-supports 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 form the front and rear supports of the structure, respectively.

[0037] The front or rear structural partition element consists of two structural panels made of composite materials, spaced apart, preferably parallel to each other, the front or rear structural partition element 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 includes structural support elements, each structural support element being intended to receive a powertrain at the front or rear and consisting of three structural panels made of composite material assembled to present a U shape.

[0039] At the front and rear ends of the central module, high-energy shock-absorbing front and rear modules are provided, which consist of two elements lateral structural elements spaced apart 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 absorption structural modules are positioned around the support elements of the front and rear traction elements of the platform structural sub-module and fixed against the front structural bulkhead element and the rear structural bulkhead element 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 the high-energy rear shock absorber module is placed on the rear structural support module positioned along the side panels.

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

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

[0044] The invention makes it possible to propose a structure for a motor vehicle allowing a gain in terms of mass, the structural elements constituting said modules being made of composite materials, said structural elements being arranged further to form a structure which meets safety standards while presenting a limited number of parts.

[0045] The invention also relates to a motor vehicle comprising a modular structure as defined above and in which the visible exterior part of said vehicle consists of structural and semi-structural elements of said modular structure which are apparent and structural and / or semi-structural trim elements attached to said structure.

[0046] By proposing to allow certain elements of the structure to appear as visible elements instead of added cladding elements as in In conventional vehicles, the rigidity in bending and torsion of the vehicle is increased with the same shape compared to a body-in-white with added bodywork elements, and costs are also limited by reducing the number of parts required for manufacturing.

[0047] The bodywork elements of the central module also include two side panels of the floor module, and two doors.

[0048] The front body module includes a hood and the rear body module includes an underbody and a tailgate.

[0049] 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 structure for a motor vehicle according to the invention; [Fig.2] Lateral perspective view of the structure of [Fig.1]; [Fig.3] a perspective view from the top of the central module of the structure, with a part partially torn away, from [Fig.2]; [Fig.4a] a perspective view from above of the habitable platform sub-module; [Fig.4b] a perspective view of the platform sub-module of the habitable [Fig.4a] with wheels; [Fig.5] a cross-sectional view of the floor element; [Fig.6] a cross-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. 1 1] A front view of the front face of a front structural partition element, [Fig. 12] a rear perspective view of a front structural partition element, with a wall torn away; [Fig.13] a cross-sectional view of the element of [Fig.11]; [Fig. 14] a front view of the rear face of a rear structural partition element; [Fig. 15] a perspective view of the rear face of a rear structural partition element, with a wall torn away; [Fig. 16] a cross-sectional view of the element of [Fig. 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 lateral perspective view of a lateral sub-module; [Fig.20] a perspective view from above of a high energy shock absorber front module; [Fig.21] an exploded perspective view of [Fig.20]; [Fig.22] a perspective view from above of a high energy shock absorber rear module; [Fig.23] an exploded perspective view of [Fig.22]; [Fig.24] a top view of a low energy shock absorber front module and a high energy shock absorber front module; [Fig.25] a cross-sectional view of the front low energy shock absorber module of [Fig.24]; [Fig.26] a perspective view of the rear low-energy shock-absorbing module; [Fig.27] a view of the module according to [Fig.26] without absorbent foam; [Fig.28] a lateral perspective view of the front end of the structure according to the invention; [Fig. 29] a lateral perspective view of the rear end of the structure according to the invention; and [Fig.30] an exploded perspective view of the apparent structural, semi-structural and non-structural elements of the vehicle according to the invention.

[0050] As can be seen in [Fig.1], the structure 1 for an electric motor vehicle according to the invention comprises several assembled modules, namely a central structural module 10 defining the vehicle's passenger compartment, two front and rear modules intended to absorb high-energy shocks 11, 12, and two front and rear medium and low-energy shock-absorbing modules 13, 14.

[0051] 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.

[0052] As can be seen in Figures 3, 4a and 4b, this structural sub-module of platform 101 comprises a structural floor element 1010, a front structural partition element 1011 and a rear structural partition element 1012 and two structural support elements 1013, 1014 placed respectively in front and behind the structural floor element 1010 and intended to receive respectively front and rear MP powertrains of the vehicle (cf [Fig.4b]).

[0053] The structural platform sub-module 101 further comprises half-arch-shaped elements 61 which are positioned along the rear structural support element 1014 or front structural support element 1013 and against the rear structural bulkhead element 1012 or front structural bulkhead element 1011, said elements 61 being complementary to a similarly half-arch-shaped element 62 carried by the high-energy shock-absorbing structural modules rear 12 and front 11 to form wheel arches 6 when fitting the rear / front high energy shock absorber module 12 / 11 around the rear / front structural support element 1014,1013 as will be described later.

[0054] The structural floor element 1010 consists of 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.

[0055] The composite material constituting the structural panels 1010A, 1010B has a sandwich structure consisting of 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, a honeycomb structure or a solid.

[0056] Such a composite material is therefore lighter, stronger, recyclable, and has optimal energy absorption. Furthermore, such a material is manufactured in such a way as to achieve interfacial adhesion between the fibers and the matrix, in order to maintain the integrity of the structures during the aging of the composites.

[0057] The two panels 1010A and 1010B extend apart from each other, preferably parallel, and are supported by the frame 1010H made of a composite material with a polymer matrix reinforced by continuous or discontinuous fibers which includes lateral uprights 1010K and at least one central upright 1010L, preferably two, and reinforcing cross members 1010T which extend between the lateral uprights 1010K and central uprights 1010L of the frame 1010H thus defining cells.

[0058] The central uprights 1010L, along with central uprights 1010M extending parallel to and away from the central uprights 1010L, form a central structural stiffener 1010E projecting above the main plane of the frame 1010H and forming a central channel, a front and rear axle coupler made of a polymer matrix composite material reinforced with continuous or discontinuous fibers. This upper face of the structural floor element 1010 is covered by the upper panel 1010A.

[0059] The structural floor element 1010 thus has a central structural stiffener 1010E, forming a path for absorbing frontal or rear shock energy.

[0060] Each lateral structural stiffener 1010R comprises a C-shaped structural profile element 1010C. A honeycomb structure 1010D is housed in the space between the arms of the C-shaped structural profile element 1010C, the walls of which preferably extend orthogonally between the web of the profile element. structural C-shaped 1010C and a structural closure profile element 10101 of said structural C-shaped profile element.

[0061] 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 [Fig.6]).

[0062] The lateral structural stiffeners 1010R are made of a polymer matrix composite material reinforced with continuous or discontinuous fibers, in particular manufactured by pultrusion, and are flexural, thus stiffening the structural floor element 1010 against frontal and rear impacts. They are also torsionally stiff, thus further stiffening said structural floor element 1010 against lateral impacts. These lateral structural stiffeners 1010R therefore also act as lateral shock absorbers, contributing to the dissipation of energy related to lateral impacts as well as frontal and rear impacts.

[0063] Structural panels referred to as 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 better withstand front and rear impacts.

[0064] 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.

[0065] 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 space or housing for receiving 1010J, in which an energy storage module 31 can be installed.

[0066] The panel 1010B thus preferably has a plurality of cutouts or openings 1010G provided opposite the cells of the frame 1010H, provided between the cross members 1010T, on either side of the central structural stiffener 1010E (cf [Fig.8]).

[0067] An energy storage module set 3 is then provided comprising a plurality of modules 31 (see [Fig.9]), each of which can be engaged through a cutout 1010G in a corresponding receiving space 1010J, the peripheral edge 33 of the set 3 allowing its attachment to the lower panel 1010B.

[0068] The central structural stiffener 1010E also defines a space in which at least one energy storage module 32 can be installed, as can be seen in [Fig. 9]. These modules 32 can be engaged by longitudinal sliding. the front and from the rear in the delimited space, between the upper panels 1010A and 1O1OB, at the level of the central structural stiffener 1O1OE.

[0069] At the front and rear ends of the structural floor element 1010 thus constituted, the front structural partition elements 1011 and rear 1012 are positioned.

[0070] Figures 11 to 13 show the front structural partition element 1011 of the platform structural sub-module 101. This front structural partition element 1011 consists of two composite material panels of the type already described above, extending apart from each other, preferably parallel to each other.

[0071] 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 101 IA, 101 IB, positioned along the longitudinal edge of the front structural partition element 1011 opposite the base 101 IC 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.

[0072] A transverse structural element 1011E is fitted to the upper part of the front bulkhead 1011. This element serves, in particular, as a support for the vehicle's dashboard and also reinforces the passenger compartment's impact resistance. The reinforcing elements 41 and 44, together with the structural element 1011E, form the equivalent of a front beam of the central structural module 10. Such a front structural bulkhead element 1011 is thus suitable for increasing the central module's resistance to frontal and lateral impacts and for absorbing kinetic energy during a high-energy crash.

[0073] 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.

[0074] This structural partition element before 1011 also has in its lower part a complementary cutout of the central structural stiffener 1010E.

[0075] The rear structural partition element 1012 described in Figures 14 to 16 consists of two structural panels 1012A, 1012B made of composite material, at least partially separated 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 to the structural floor element 1010.

[0076] This rear structural partition element 1012 further includes reinforcement elements 51, 52 such as a reinforcement 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 cross beam element.

[0077] Also present are structural reinforcement elements 52 such as structural foam blocks distributed over said rear structural partition element 1012.

[0078] These structural partition elements front 1011 and rear 1012 therefore have a substantially similar structure, consisting of two composite material panels made of a sandwich-type composite material such as that described previously.

[0079] 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 leg or leg A, and the rear leg or leg C of the central structural module or passenger compartment 10, to which the ends of a structural roof arch 1022A are attached. In particular, a closing element 1011F is provided for the junction between the front structural partition element 1011 and a structural roof arch 1022A (see [Fig. 13]).

[0080] As can be seen in figures 4a, 4b and 10, the structural floor element 1010 includes stiffening elements of the structural sub-module of platform 101 which are made up of connecting and reinforcing elements 4, 4a extending between the front structural partition element 1011 or rear 1012 and the structural floor element 1010. These stiffening elements 4, 4a are preferably positioned at the front and rear ends of the central structural stiffener 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 structural partition element 1011 or rear 1012 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.

[0081] As can be seen in Figures 17 and 18, at each end of the structural sub-module of platform 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 group as can be seen in [Fig.4b].

[0082] Each front 1013, rear 1014 structural support element consists of three sandwich-structure composite panels 1013A, 1013B, 1014A, 1014B assembled in a U-shape, namely two parallel sandwich-structure composite side panels 1013A, 1014A, and a third frame-shaped panel 1013B, 1014B between them. Each side panel 1013A, 1014A has an opening 1013C, 1014C for the passage of traction means, through which a drive shaft from a powertrain MP to wheels 7 can extend.

[0083] The structural panels 1013A, 1013B, 1014A, 1014B and the structural floor element 1010 include mechanical fixing means for geared motor housings of said MP power units.

[0084] As can be seen in [Fig.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 consists of a lateral and upper structural sub-module 102. Such a lateral and upper structural sub-module 102 comprises two lateral structural module elements 1022 and a roof structural module element 1021.

[0085] A lateral structural module element 1022 comprises - a structural roof arch 1022A, - a structural frame element for door 1022E, - a structural element of a 1022S door threshold, - a lateral structural member 1022B, constituting the middle pillar or B-pillar of the passenger compartment 10 - a rear structural panel element with window 1022C - a structural reinforcement element for the rear window frame 1022D.

[0086] 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 foot or foot A, formed by the lateral ends of the front structural partition element 1011 and the rear foot or foot C of the vehicle formed by the lateral ends of the rear structural partition element 1012.

[0087] The structural roof module element 1021 comprises at least one front structural roof element such as a front cross member 1021Tav, one rear structural roof element (rear cross member) 1021Tar, one intermediate structural roof element (intermediate cross member) 1021Ti, and at least one structural roof canopy 1021Pav extending between the front structural cross members 1021Tav and the rear structural cross members 1021Tar. Each structural roof element or cross member extends between the lateral structural module elements and is reinforced by an internal tubular element.

[0088] The lateral structural uprights 1022B (middle pillar) and the intermediate structural roof element 1021Ti thus form a transverse structural arch of the passenger compartment contributing to the strength of the passenger compartment 10.

[0089] Preferably, the structural roof pavilion 1021Pav consists of a structural panel made of composite material of the sandwich structure type consisting of a core and two outer skins, said structural panel being reinforced with a core having a lattice, for example of carbon fibers, a honeycomb or a foam.

[0090] Each lateral structural module element 1022 is thus connected to the other via the roof cross members 1021Tav, 1021Tar and 1021Ti.

[0091] Between the intermediate structural cross member 1021Ti and the rear structural cross member 1021Tar, the rear portion of the structural roof pavilion 1021Pav in the example shown has an opening provided with a structural opening frame element 1021Par of the pavilion 1021Pav. Similarly, the front opening of the structure defining the vehicle's windshield receives a front windshield structural frame element 1023 Av. Similarly, the rear opening of the structure receives a rear window frame element.

[0092] Advantageously, some of the structural elements of this central structural module 10 constitute structural elements that are apparent on the vehicle.

[0093] All of these structural elements are preferably made of composite material with a polymer matrix reinforced by continuous or discontinuous fibers, such as thermoplastics (for example copolyamide) / mineral fibers and / or carbon fibers.

[0094] To this central structural module 10 are attached at the front and rear 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, are thus made up of 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 lateral structural elements 110, 120. In addition, a reinforcement element 113, 123 extends obliquely from the edge of each lateral 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.

[0095] This reinforcement element 113, 123 is a structural panel in the shape of a right triangle, the sides of which form the right angle extend, one along the edge of the side panel 1013A, 1014A and, the other along a frame 112, 121, the panel 113, 123 being positioned so as to extend outwards relative to the side panel 1013A, 1014A.

[0096] The high-energy shock-absorbing modules front 11 and rear 12 are dimensioned to be fitted respectively onto the front support modules 1013 and rear 1014 of the central structural module 10 and fixed against the front structural partition element 1011 and the rear structural partition element 1012 of the central structural module 10.

[0097] Half-arch shaped shock-absorbing elements 62 are positioned on the rear structural module 12 high-energy shock absorber and half-arch shaped elements 61 are positioned against the rear structural partition 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.

[0098] The same applies to the shock-absorbing module 11, as can be seen in [Fig. 24]. The semi-arch-shaped shock-absorbing 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 partition element 1011 along the front structural support element 1013, said elements 61, 62 being complementary to form wheel arches 6 when the front structural shock absorber module 11 is fitted onto the front structural support element 1013.

[0099] The rear high energy shock absorption structural module 12 further comprises two shock-absorbing elements 124, each having a flat 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 fixed to the frames 121, 122 of said rear high energy shock-absorbing structural module 12.

[0100] To these high energy shock absorber modules are added medium and low energy shock absorber modules 13, 14 as can be seen in [Fig.24].

[0101] These medium and low energy shock absorber modules 13, 14 consist of a cross member 131, 141 with a W cross section. This cross member 131, 141 is covered with a layer of shock-absorbing foam such as a low-density memory foam 132, 142.

[0102] The cross member 131, 141 extends between two elongated crush-absorbing shock elements, known by the English term "crashbox" 135, 145, the latter being made of composite material shells assembled by bonding. These elements 135, 145 are connected respectively to the frame of the corresponding high-energy shock-absorbing module 11, 12 and to one end of the cross member 131, 141 by means of two interface elements 133 interposed between said cross member 131, 141 and the elongated crush-absorbing shock elements 135, 145, also constituting a receiving box for a stack of honeycomb-type cellular structures 134.

[0103] The cross member 131 or 141 has edges 131a for defining a space in which the foam 132, 142 is embedded. The cross member 131, 141 further has at least two transverse grooves 136 in the W-shaped section in which a rib 137, 147 is positioned for connecting the cross member 131, 141 to the front bumper 23 and rear bumper 24.

[0104] The high-energy shock absorbers front 13 and rear 14 have a structure following the same concept, however geometric adaptations and adjustments to the length of certain elements can be made.

[0105] Figures 28 and 29 show the stages of the shock absorption function at the front and rear depending on the type of shock.

[0106] Thus, the zones la) 1b) correspond to the very low energy shock structure involved for pedestrian impact protection.

[0107] Zones 2a) 2b) correspond to the structural zones involved in a low energy shock.

[0108] 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.

[0109] The concepts of low, medium or high energy impact are given in relation to an unladen vehicle weight of approximately 1,500 kg.

[0110] Thus, a low-energy impact is an impact at a speed of 4 km / h (typical case ECE R42), a medium-energy impact is an impact at a speed of around 15 km / 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 15 km / h. The typical case in Europe is the reference test ECE R137 corresponding to an impact at 50 km / h.

[0111] Fig. 30 represents all the apparent or external vehicle elements, some of which are composed of apparent structural elements of 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.

[0112] These apparent elements are preferably also made up of semi-structural elements such as the door 20, the semi-structural front hood 21, the semi-structural front wings 22, the semi-structural rear wings 25, the semi-structural rear flap 26.

[0113] Other non-structural elements complete the vehicle's bodywork, such as the front bumper 23 and rear bumper 24, as well as the diffuser 27.

[0114] List of references: 1. Motor vehicle structure 10 central structural module 101 structural platform sub-module 1010 structural floor element 1010A structural panel 1010B structural panel 1010R lateral structural stiffener 1010C C-shaped structural profile element 1010D alveolar structure 10101 structural profile element for closing the C-shaped structural profile element 1010E central structural stiffener 1010F structural closure panel 1010G cutout in the 1010B structural panel 1010H frame 1010K side frame upright 1010L central frame upright 1010M central upright of the central structural stiffener 1010T frame reinforcement cross member 1010J reception area MP powertrain 1011 front structural partition element 101 IA, 101 IB structural panels of the front structural partition element 101 IC base of the front structural partition element 1011D front structural partition element side panel 1011E transverse structural element of the front structural partition element 1011F closing element for the junction between the front structural bulkhead element and the roof arch 1012 rear structural bulkhead element 1012A, 1012B structural panels of the rear structural partition element 1012C rear structural bulkhead element base 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 opening for the 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 opening for the 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 102 ITi intermediate structural roof element 1021 Structural Roof Pavilion 1021 Per structural frame element of rear opening of the roof pavilion 1022 lateral structural module element 1022A structural roof arch 1022B lateral structural member 1022C rear structural panel element with window 1022D structural reinforcement element of the rear window frame 1022E structural door frame element (exposed) 1022S structural element of door threshold (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 modules 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-absorbing elements 13 structural module for medium and low energy shock absorption 131 traverse 131a edge of the crossbeam 132 layers of shock-absorbing foam 133 interface element between the cross member and a crushable shock-absorbing element 134 deformable element of alveolar structure housed in the interface element 135 crushable shock-absorbing element 136 throat 137 rib 14 medium and low energy shock absorption rear structural module 141 traverse 142 layers of shock-absorbing foam 143 interface element between the cross member and a crushable shock-absorbing element 145 crushable shock-absorbing element 147 rib 20 doors 21 semi-structural front hood 22 front structural wing 23 front bumpers 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. Linking and reinforcement element of the platform sub-module 4a. Linking and reinforcing element of the platform sub-module 41, 42, 43, 44 reinforcement elements of the front structural partition element 51, 52 Reinforcement elements of the rear structural bulkhead element 61 semi-arch shock-absorbing element supported by the central structural module, which partly forms the wheel arch 62 semi-arch shock-absorbing element carried by the front or rear high-speed shock energy absorption structural module 7 wheel la, 1b medium and low energy shock absorption 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

Claims

Demands

1. Motor vehicle structure (1) characterized in that it consists of the assembly of: a central structural module (10) defining at least the vehicle passenger compartment, two front (11) and rear (12) high-energy shock-absorbing structural modules, and two front and rear (13, 14) medium- and low-energy shock-absorbing structural modules, each of these structural modules (10, 11, 12, 13, 14) being made up of structural and semi-structural elements of composite materials, characterized in that the central structural module includes a platform structural sub-module (101) which includes: - a structural floor element (1010) consisting of 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) and at least two structural closure panels (1010F) assembled on the front and rear edges of the structural panels (1010A, 1010B), - 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 receive a powertrain (P) respectively and assembled respectively with the front structural bulkhead element (1011) and the rear structural bulkhead element (1012).

2. Structure according to claim 1, characterized in that the structural floor element (1010) comprises a central structural stiffener (1010E) which extends between the front (1011) and rear (1012) structural bulkhead elements, coupler of the front and rear axles carried by the structural support elements (1013) and (1014).

3. Structure according to claim 1 or 2, characterized in that a lateral structural stiffener (1010R) comprises a C-shaped structural profile element (1010C), a honeycomb structure (1010D) housed in the space between the arms of the element C-shaped profile (1010C), and whose walls preferably extend orthogonally between the core of the C-shaped profile element (1010C) and a structural closing profile element (10101) of said C-shaped profile element, a space being provided between each branch of the C-shaped profile element (1010C) and the honeycomb structure (1010D), space in which the lateral edge of a structural panel (1010A, 1010B) is fixed.

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

5. Structure according to any one of claims 1 to 4, 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), one structural door frame element (1022E), one structural door sill element (1022S), one lateral structural post (1022B), one structural reinforcement element of the rear window frame (1022D), one rear structural panel element with window (1022C).

6. Structure according to claim 5, 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), one rear structural roof element (1021Tar), one intermediate structural roof element (1021Ti) and at least one structural roof pavilion (1021Pav).

7. Modular structure according to claim 5, characterized in that the structural roof pavilion (1021Pav) is made of a structural panel of composite material of the sandwich structure type consisting of a core and two outer skins, said structural panel being reinforced with a core having a lattice, a honeycomb or a foam.

8. Structure according to any one of claims 1 to 7, characterized in that the front structural partition element (1011) is made up of two structural panels (101 IA, 101 IB) 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.

9. Structure according to claim 1 to 8, characterized in that the rear structural partition element (1012) consists of two structural panels (1012A, 1012B) made of composite materials, at least partly separated 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).

10. Structure according to any one of claims 1 to 9, characterized in that each structural support element (1013, 1014) intended to receive a powertrain (P) respectively at the front or rear consists of three structural panels made of composite materials (1013A, 1013B, 1014A, 1014B), assembled to present a U-shape.

11. Modular structure according to claim 10, characterized in that the structural panels (1013A, 1013B, 1014A, 1014B) and the structural floor element (1010) have mechanical fixing means for geared motor housings of said powertrains (PM).

12. Modular structure according to any one of claims 1 to 11, characterized in that the front (11) and rear (12) high energy shock absorption modules are made up of two lateral structural elements (110, 120) spaced apart and connected to each other by a structural frame (111, 112; 121, 122) positioned at each end of said lateral structural elements (110, 120).

13. Modular structure according to claim 12, characterized in that each front and rear high-energy shock-absorbing module comprises a reinforcing element (113, 123), consisting of a structural panel positioned to extend obliquely between a projecting portion of one of the frames (112, 121) that 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 support elements structural (1013, 1014) of said structural sub-module of platform (101).

14. Modular structure according to any one of claims 12 and 13, 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).

15. A modular structure according to any one of claims 12 to 14, characterized in that: semi-arch shock-absorbing elements (61) are positioned on the platform structural sub-module (101) at the front and rear thereof at the level of the structural partition elements (1011, 1012), on either side of the front and rear structural support elements (1013, 1014); semi-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 semi-arch shock-absorbing elements (61, 62) being complementary to form wheel arches when the front (11) and rear (12) high-energy shock-absorbing structural modules are assembled on the platform structural sub-module (101).

16. Modular structure according to any one of claims 12 to 14, characterized in that the rear high energy shock absorption structural module (12) comprises two shock-absorbing elements (124), each having a flat 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 over the half-arch shock-absorbing element and fixed to the frames (121, 122) of said rear high energy shock-absorbing structural module (12).

17. Modular structure according to any one of claims 1 to 16, characterized in that each medium and low energy shock absorption module (13, 14) comprises: a cross member (131, 141), a shock-absorbing foam layer (132, 142) fixed to the cross member (131, 141), two crushing shock-absorbing elements (135, 145), fixable respectively to a front (11) or rear (12) high energy structural shock-absorbing 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).

18. Structure according to any one of claims 1 to 17, 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 outer skins, the core being preferably made of a plastic, metallic or natural material in the form of foam, of cellular or solid structure, the outer skins being made of a polymer matrix composite reinforced by continuous or discontinuous fibers and all the structural elements are preferably made of a polymer matrix composite material reinforced by continuous or discontinuous fibers.

19. Motor vehicle comprising a modular structure according to any one of claims 1 to 18, characterized in that the visible external part of said vehicle consists of structural and semi-structural elements of said modular structure which are apparent and of structural and / or semi-structural trim elements attached to said structure.

20. Motor vehicle according to claim 19, characterized in that the structural and semi-structural elements of the structure (1) constituting elements of the visible exterior part of the vehicle are constituted by: the roof panel (1021Pav), the roof arches (1022A), the structural frame elements of the vehicle openings (1023Av, 1023Ar), the structural elements of the front and rear side wings (22, 25).

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