Method of manufacturing a device for reinforcing a vehicle side member, reinforcing device, side member, underbody assembly and motor vehicle

Abstract

Method for manufacturing a reinforcement device for a vehicle side member, reinforcement device, side member, underbody assembly and motor vehicle. The invention relates to a method for manufacturing a reinforcement device (15) for a longitudinal lateral side member of a motor vehicle underbody assembly (3), said device comprising a set (19) of main reinforcement partitions (25) arranged in said side member, the number of said main reinforcement partitions being defined as a function of a predetermined length of said side member. According to the invention, the method comprises a step aimed at assembling at least one additional reinforcement partition (41) to said set of main reinforcement partitions (25) when said side member has a length greater than said predetermined length, said additional reinforcement partition (41) having characteristics identical to those of said main reinforcement partitions (25).The invention also relates to a reinforcement device, a side member, an underbody assembly and a motor vehicle. Figure 5.

Description

Title of the invention: Method for manufacturing a device for reinforcing a vehicle side member, reinforcing device, side member, underbody assembly and motor vehicle Technical field

[0001] The invention relates to the field of motor vehicles, and more particularly concerns a method of manufacturing a device for reinforcing a vehicle side member.

[0002] The invention also relates to a reinforcement device obtained by said method, a longitudinal lateral side member comprising such a reinforcement device, an underbody assembly comprising such a side member and a motor vehicle comprising such a underbody assembly. Prior art

[0003] A motor vehicle body structure comprises a set of sheet metal structural elements providing stiffness to the motor vehicle, assembled together and forming the frame of the motor vehicle.

[0004] The body structure comprises, in particular, among these sheet metal elements, a left side structure and a right side structure. Each side structure comprises a set of upper and lower horizontal elements, extending substantially longitudinally relative to the body, and a set of vertical elements, extending substantially vertically relative to the body.

[0005] The lower horizontal elements comprise longitudinal lateral side members defining part of the perimeter of the body underbody.

[0006] The left and right side structures are connected to each other in the lower part of the vehicle by a floor, defining a part of the platform of the passenger compartment of the motor vehicle.

[0007] The floor belongs to a vehicle underbody assembly and is bordered laterally by the right and left longitudinal side members.

[0008] Among the different types of side impacts, a so-called "pole" impact consists of projecting the motor vehicle at a speed of approximately 30 km / h laterally against a rigid pole, so that the vehicle defines an angle of approximately 75° relative to the pole. During a side impact, the pole becomes embedded in the motor vehicle, at the level of the front door, driver's side or passenger's side.

[0009] The impact absorption capacities at the level of the vehicle underbody assembly are, in part, provided by the longitudinal side members, which absorb part of the forces occurring when the vehicle is subjected to such an impact. lateral.

[0010] A recurring problem thus consists of increasing the capacity of the longitudinal side members to absorb the forces.

[0011] Also, when the vehicle is an electric motor vehicle with battery (motor vehicle called "BEV", an English acronym for "Battery Electric Vehicle"), the vehicle comprises a traction battery powering the electric motor of the motor vehicle. The traction battery comprises a set of battery modules, mounted in a battery tray. The battery tray is mounted under the floor of the underbody assembly. The battery tray defines one of the silhouettes on board the underbody assembly when the vehicle is an electric vehicle. The sizing of the battery tray differs depending on the dimensions of the vehicle.

[0012] When the motor vehicle is subjected to a side impact, the electric battery must be protected in order to avoid damage to the battery and to limit the risk of fire.

[0013] Therefore, there is a need to reinforce the longitudinal side members, particularly when the vehicle is an electric motor vehicle with battery.

[0014] A solution known from the prior art consists of using a reinforcement device for each longitudinal lateral spar, comprising a longitudinal hollow body and a set of reinforcement partitions defining a core of the reinforcement device of the spar and being arranged in the longitudinal hollow body of the reinforcement device.

[0015] The number of reinforcing partitions making up the set of reinforcing partitions of the reinforcing device is defined as a function of the length of the longitudinal hollow body of the reinforcing device, this length itself being defined for a predetermined wheelbase of the vehicle, the wheelbase being defined by the distance between the front and rear axles of the vehicle.

[0016] Thus, for a given length of the longitudinal hollow body of the reinforcement device, corresponding to a given wheelbase of the motor vehicle, the reinforcement device of the longitudinal lateral side member comprises a certain number of reinforcement partitions defining the set of reinforcement partitions of the reinforcement device.

[0017] The set of reinforcement partitions, corresponding to a given wheelbase of the motor vehicle, is obtained by a specific tool dedicated to its manufacture.

[0018] Also, the set of reinforcement partitions obtained is referenced by the manufacturer as a unit part assigned to a given wheelbase of the motor vehicle and classified according to an internal referencing system of the motor vehicle manufacturer.

[0019] When the wheelbase of the motor vehicle changes, for example in particular when the wheelbase increases, it is necessary, on the one hand, to review the internal referencing system and, on the other hand, to design and manufacture a new tool.

[0020] Reviewing the internal referencing system complicates the internal logistics of the car manufacturer and increases the associated cost.

[0021] Furthermore, the design and manufacture of a new specific tool, dedicated to the manufacture of the set of reinforcement partitions, represents an extremely high cost for the manufacturer. Statement of the invention

[0022] The present invention aims to overcome the aforementioned drawbacks, and to do so relates to a method of manufacturing a device for reinforcing a longitudinal lateral side member of a motor vehicle underbody assembly, said reinforcing device comprising a set of main reinforcing partitions arranged in said longitudinal lateral side member, the number of said main reinforcing partitions being defined as a function of a predetermined length of said longitudinal lateral side member, said method being remarkable in that it comprises a step aimed at assembling at least one additional reinforcing partition to said set of main reinforcing partitions when said longitudinal lateral side member has a length greater than said predetermined length, said additional reinforcing partition having characteristics identical to those of said main reinforcing partitions.

[0023] Thus, when the vehicle has a wheelbase greater than a predetermined wheelbase, the manufacturing method of the invention provides for using one or more reinforcing partitions of the type present in the devices for reinforcing the longitudinal side members mounted in vehicles of shorter length to manufacture the devices for reinforcing the longitudinal side members intended to equip vehicles having a longer wheelbase.

[0024] Thanks to the present invention, the need to develop a tool dedicated to the manufacture of the set of reinforcement partitions for a vehicle having a longer wheelbase is thus avoided, which makes it possible to limit the costs which would be associated with the development of such a tool.

[0025] Also, thanks to the present invention, the internal referencing system of the automobile manufacturer is not impacted, which makes it possible to improve internal logistics and optimize the associated costs.

[0026] According to optional characteristics of the method according to the invention: - said predetermined length of said longitudinal side member is defined for a wheelbase of said motor vehicle between approximately 2540mm and approximately 2595mm; - said length greater than said predetermined length of said longitudinal side member is defined for a wheelbase of said motor vehicle greater than or equal to approximately 2705mm; - said at least one additional reinforcing partition is assembled to said set of main reinforcing partitions by welding; - said reinforcing device comprises a longitudinal hollow body in which said set of main reinforcing partitions and said at least one additional reinforcing partition are arranged; - said longitudinal hollow body comprises an upper bracket and a lower bracket and in that said set of main reinforcing partitions and said at least one additional reinforcing partition are fixed by welding to said upper and lower brackets.

[0027] The invention also relates to a device for reinforcing a longitudinal lateral side member of a motor vehicle underbody assembly, remarkable in that it is obtained by the manufacturing method according to the invention.

[0028] The invention also relates to a longitudinal lateral side member of a motor vehicle underbody assembly, said side member comprising a reinforcing device, remarkable in that said reinforcing device is according to the invention.

[0029] The invention also relates to an underbody assembly for a motor vehicle, comprising: - a floor, - lateral longitudinal side members, laterally bordering said floor, said underbody assembly being remarkable in that at least one of said lateral longitudinal side members is according to the invention.

[0030] The invention also relates to a motor vehicle comprising an underbody assembly, remarkable in that said underbody assembly is according to the invention. Brief description of the drawings

[0031] Other characteristics, aims and advantages of the invention will appear on reading the detailed description which follows, for the understanding of which reference will be made to the appended drawings in which:

[0032] [Fig-1] shows an underbody assembly of a motor vehicle according to the invention, seen in perspective from above, partially cut away.

[0033] [Fig.2] is a perspective view showing the reinforcement device.

[0034] [Fig.3] is a perspective view of a reinforcing partition of the reinforcement device necessarily.

[0035] [Fig.4] shows an example of the embodiment of the base assembly in which the length of the longitudinal side member is greater than that of the member of [Fig.l].

[0036] [Fig.5] shows a step in the manufacturing process of the reinforcement device according to the invention. Description of the embodiments

[0037] In the remainder of the description, elements having an identical structure or similar functions are designated by the same reference.

[0038] By convention, longitudinal, vertical and transverse orientations indicated by the direct trihedron (L, V, T) designating the longitudinal, vertical and transverse axes of the vehicle will be adopted, without limitation.

[0039] In the following, the terms “left”, “right”, “lower” and “upper” are understood in relation to the vehicle.

[0040] Similarly, the terms “front” and “rear” are understood in relation to the general orientation of the vehicle as taken in its normal direction of travel.

[0041] Reference is made to [Fig.l] showing an underbody assembly 1 of a motor vehicle 3, seen in perspective from above, partially cut away.

[0042] The underbody assembly 1 belongs to a body structure comprising a set of sheet metal structural elements conferring stiffness to the motor vehicle 3, assembled together and forming the frame of the motor vehicle.

[0043] Among these sheet metal elements, the body structure comprises a left side structure 5g and a right side structure 5d.

[0044] The body structure has a longitudinal median plane of symmetry. Thus, the description given for the left lateral structure 5g applies by analogy to the right lateral structure of the body structure.

[0045] Each lateral structure comprises a set of upper and lower horizontal elements, extending substantially longitudinally relative to the body, and a set of vertical elements, extending substantially vertically relative to the body.

[0046] The lower horizontal elements comprise lateral longitudinal side members 7g, 7d extending substantially longitudinally relative to the motor vehicle 3.

[0047] At the front, the lateral longitudinal side members 7g, 7d are connected to a front block 9 of the motor vehicle 3. At the rear, the lateral longitudinal side members 7g, 7d are connected to the rear axle 11 of the motor vehicle 3.

[0048] The left and right lateral structures 5g, 5d are connected to each other in the lower part of the motor vehicle 3 by a floor 13.

[0049] In the exemplary embodiment illustrated in the figures, the motor vehicle 3 is a electric motor vehicle with battery (motor vehicle known as “BEV”, an English acronym for “Battery Electric Vehicle”). For this purpose, the motor vehicle 3 comprises a traction battery (not shown) powering the electric motor (not shown) of the motor vehicle 3.

[0050] The traction battery comprises a set of battery modules, mounted in a battery tray mounted under the floor 13.

[0051] The longitudinal side rails 7d, 7g (only the right longitudinal side rail 7d being visible in [Fig.l]) each comprise a reinforcing device 15 designed to reinforce the longitudinal side rails 7d, 7g in the event of a lateral impact suffered by the motor vehicle.

[0052] In the exemplary embodiment illustrated in the figures, the reinforcement device 15 comprises a longitudinal hollow body 17 and a set 19 of reinforcement partitions arranged transversely relative to the longitudinal hollow body 17.

[0053] In other words, the reinforcing partitions extend transversely relative to the motor vehicle 3 when the longitudinal side member 7d is mounted in the motor vehicle 3.

[0054] Reference is made to [Fig.2] showing the reinforcement device 15 seen in perspective.

[0055] The longitudinal hollow body 17 of the reinforcement device 15 comprises an upper bracket 21, defining an upper closing envelope, and a lower bracket 23, defining a lower closing envelope.

[0056] In the embodiment illustrated in the figures, the lower bracket 23 has an L-shaped cross-section. The assembly formed by the upper bracket 21 and by the lower bracket 23 has a substantially U-shaped cross-section.

[0057] The set 19 of reinforcing partitions is arranged in the longitudinal hollow body 17 of the reinforcing device 15, between the upper bracket 21 and the lower bracket 23.

[0058] The set 19 of reinforcing partitions is for example fixed by welding to the upper 21 and lower 23 brackets.

[0059] Similarly, the lower bracket 23 is for example fixed to the longitudinal lateral side member 7d, 7g for example by welding.

[0060] The set 19 of reinforcing partitions comprises a plurality of reinforcing partitions 25 called “main”.

[0061] Reference is made to [Fig.3] showing a unitary main reinforcement partition 25 seen in perspective.

[0062] The main reinforcing partition 25 comprises an upper half-partition 27 and a lower half-partition 29.

[0063] The upper 27 and lower 29 half-partitions are each constituted by a double U-shaped fin.

[0064] The upper half-partition 27 comprises two horizontal faces 31, extending substantially horizontally relative to the longitudinal hollow body 17 in which the upper half-partitions 27 are intended to be mounted. Each horizontal face 31 of the upper half-partition 27 is bordered by two transverse faces 33 extending substantially transversely relative to the longitudinal hollow body 17.

[0065] In the same way, the lower half-partition 29 comprises two horizontal faces 35, extending substantially horizontally relative to the longitudinal hollow body 17 in which the lower half-partitions 29 are intended to be mounted. Each horizontal face 35 of the lower half-partition 29 is bordered by two transverse faces 37 extending substantially transversely relative to the longitudinal hollow body 17.

[0066] Each upper half-partition 27 is assembled to the corresponding lower half-partition 29 at the level of the horizontal faces 31 of the upper half-partitions 27 and the horizontal faces 35 of the lower half-partitions 29.

[0067] The assembly between the upper half-partitions 27 and the lower half-partitions 29 is for example carried out by welding.

[0068] In the embodiment illustrated in [Fig. 1], the predetermined length Li of the longitudinal lateral side member 7d is defined for a wheelbase Ei of the motor vehicle 3 of between approximately 2540mm and approximately 2595mm.

[0069] In the embodiment illustrated in the figures, when the wheelbase Ei of the motor vehicle 3 is between approximately 2540 mm and approximately 2595 mm, the longitudinal lateral side member 7d receives eight unitary main reinforcing partitions 25.

[0070] Reference is made to [Fig.4] showing an exemplary embodiment of the underbody assembly 1 in which the length L2 of the longitudinal lateral side member 7d, defined for a wheelbase E2 of the motor vehicle 3, is greater than the predetermined length Li defined in [Fig.l].

[0071] Reference is made to [Fig.5] showing a step in the method of manufacturing the reinforcement device 15 according to the invention.

[0072] When the longitudinal lateral spar 7d has a length L2 greater than the predetermined length Li, the length of the longitudinal hollow body 17 is increased, as represented by the arrow 39 in [Fig.5].

[0073] The method for manufacturing the reinforcement device 15 comprises a step aimed at assembling an additional reinforcement partition 41 to the set 19 of main reinforcement partitions 25, the additional reinforcement partition 41 having characteristics identical to those of the main reinforcement partitions 25.

[0074] In the embodiment illustrated in the figures, a single additional reinforcing partition 41 is added to the set 19 of main reinforcing partitions 25. However, depending on the length L2, it may be considered to add more additional reinforcing partitions which are assembled to the set 19 of main reinforcing partitions 25.

[0075] As an illustrative and non-limiting example, the length L2 is defined for a wheelbase E2 of the motor vehicle 3 greater than or equal to approximately 2705 mm.

[0076] In the embodiment illustrated in the figures, when the wheelbase E2 of the motor vehicle 3 is equal to approximately 2705 mm, the longitudinal lateral side member 7d receives eight main reinforcing partitions 25 and a single additional reinforcing partition 41.

[0077] In one embodiment, the additional reinforcing partition 41 is assembled to the set 19 of main reinforcing partitions 25 by welding.

[0078] The set 19 of main reinforcing partitions 25 and the additional reinforcing partition 41 are arranged in the longitudinal hollow body 17. The additional reinforcing partition 41 can for example be fixed by welding to the upper 21 and lower 23 brackets.

[0079] The set 19 of main reinforcing partitions 25 and the additional reinforcing partition 41 define a core of the reinforcing device 15.

[0080] As goes without saying, the present invention is not limited to the sole embodiments of this manufacturing method, of this reinforcement device, of this side member, of this underbody assembly and of this motor vehicle, described above solely as illustrative examples, but on the contrary it embraces all the variants involving the technical equivalents of the means described as well as their combinations if these fall within the scope of the invention.

Claims

Claims

1. A method of manufacturing a reinforcement device (15) for a longitudinal side member (7d, 7g) of a motor vehicle (3) underbody assembly (1), said reinforcement device (15) comprising a set (19) of main reinforcement partitions (25) arranged in said longitudinal side member (7d, 7g), the number of said main reinforcement partitions (25) being defined as a function of a predetermined length (Li) of said longitudinal side member (7d, 7g), said method being characterized in that it comprises a step of assembling at least one additional reinforcement partition (41) to said set (19) of main reinforcement partitions (25) when said longitudinal side member (7d, 7g) has a length (L2) greater than said predetermined length (LJ), said additional reinforcement partition (41) having characteristics identical to those of said main reinforcement partitions (25).

2. Method according to claim 1, characterized in that said predetermined length (LJ) of said longitudinal lateral side member (7d, 7g) is defined for a wheelbase (EJ) of said motor vehicle (3) between approximately 2540mm and approximately 2595mm.

3. Method according to one of claims 1 or 2, characterized in that said length (L2) greater than said predetermined length (LJ) of said longitudinal lateral side member (7d, 7g) is defined for a wheelbase (E2) of said motor vehicle (3) greater than or equal to approximately 2705mm.

4. Method according to any one of claims 1 to 3, characterized in that said at least one additional reinforcing partition (41) is assembled to said set (19) of main reinforcing partitions (25) by welding.

5. Method according to any one of claims 1 to 4, characterized in that said reinforcing device (15) comprises a longitudinal hollow body (17) in which said set (19) of main reinforcing partitions (25) and said at least one additional reinforcing partition (41) are arranged.

6. Method according to claim 5, characterized in that said longitudinal hollow body (17) comprises an upper bracket (21) and a bracket lower (23) and in that said set (19) of main reinforcing partitions (25) and said at least one additional reinforcing partition (41) are fixed by welding to said upper (21) and lower (23) brackets.

7. Reinforcing device (15) for a longitudinal lateral side member (7d, 7g) of a base assembly (1) of a motor vehicle (3), characterized in that it is obtained by the manufacturing method according to any one of claims 1 to 6.

8. Longitudinal lateral side member (7d, 7g) of a base assembly (1) of a motor vehicle (3), said longitudinal lateral side member (7d, 7g) comprising a reinforcing device (15), characterized in that said reinforcing device (15) is according to claim 7.

9. Underbody assembly (1) of a motor vehicle (3), comprising: - a floor (13), - lateral longitudinal side members (7g, 7d), laterally bordering said floor (13), said underbody assembly (1) being characterized in that at least one of said lateral longitudinal side members (7d, 7g) is according to claim 8.

10. Motor vehicle (3) comprising an underbody assembly (1), characterized in that said underbody assembly (1) is according to claim 9.

Images