Device and method for assembling a plurality of elements of a motor vehicle

Abstract

The invention relates to a method for assembling a plurality of insoluble elements (12, 14) of a motor vehicle, the method comprising a step of installing at least one soluble support (16) on a first of the elements, a step of positioning the first element with respect to a second of the elements by means of the soluble support, a step of attaching the first element and the second element, either to one another, to separate bases or to the same base, and a step of dissolving the soluble support. The insoluble elements comprise either an electric battery (12) and an electric charger (14), the base comprising a floor structure of the motor vehicle; or a first portion (120) of a steering column rigidly attached to a rack of the motor vehicle and a second portion (140) of the steering column rigidly attached to a steering wheel of the motor vehicle. The installation, positioning, attachment and dissolution steps are adapted according to the insoluble elements.

Description

TITLE OF THE INVENTION: DEVICE AND METHOD FOR MOUNTING SEVERAL ELEMENTS OF A MOTOR VEHICLE TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates generally to the assembly of a motor vehicle.

[0002] It relates more particularly to a method of assembling several elements of such a vehicle.

[0003] The invention finds a particularly advantageous application in the manufacture of electric or hybrid motor vehicles.

[0004] STATE OF THE ART

[0005] The manufacture of motor vehicles requires a large number of assembly steps.

[0006] It is known from JP2023048893A to connect a fitting to a pipe using a template which widens the pipe and which is intended to be removed when assembling the fitting, this template being able to be made of a water-soluble material.

[0007] On the other hand, DE2118062A discloses a device for connecting plastic pipes, one of which comprises a water-soluble stopper.

[0008] These techniques cannot be transposed to the assembly of a battery and a charger, nor to the assembly of first and second parts of steering columns.

[0009] During the various stages of assembly, some elements may be difficult for the assembly operator to install due, for example, to the presence of masking elements. The positioning and fixing of some of these elements then become difficult or even impossible to achieve.

[0010] This is particularly the case when assembling electric or plug-in hybrid vehicles.

[0011] Such a motor vehicle comprises at least one electric motor, powered by an electric battery, and enabling the vehicle to be propelled.

[0012] It also includes an electric charger allowing the conversion of an alternating electric current supplied by a local electricity distribution network into a direct electric current storable in the form of chemical energy by the electric battery of the electric vehicle.

[0013] The electric charger and electric battery are, on certain vehicle models, fixed under the floor of the vehicle.

[0014] One of the known solutions is to raise the chassis of the vehicle, then to mount the electric battery under the floor. The charger can be positioned elsewhere on the vehicle.

[0015] The assembly of these two elements is therefore done in two separate stages, which does not reduce assembly time and can prove costly in terms of wiring if the charger is positioned at a distance from the battery.

[0016] This problem of assembling two components of a vehicle arises more generally when installing and fixing many other components, including parts of a steering column. PRESENTATION OF THE INVENTION

[0017] The invention aims to provide a solution to these various problems and to facilitate the assembly of the various elements of a motor vehicle. The proposed solution consists of using a soluble support facilitating the positioning of insoluble elements of a motor vehicle. The invention thus relates more specifically to a method of mounting several insoluble elements of a motor vehicle, comprising: - a step of placing at least one soluble support on a first of said elements, - a step of positioning the first element relative to a second of said elements by means of said soluble support, - a step of fixing the first and second elements together and / or to separate bases and / or to the same base, and - a step of dissolving the soluble support, in which the insoluble elements comprise an electric charger and an electric battery, the base comprises a floor structure of the motor vehicle, and: - the installation step includes the installation of the soluble support on the electric battery, - the positioning step includes positioning the electric charger on the soluble support, so that the electric charger and the electric battery are not in contact, - the fixing step comprises fixing the electric battery and the electric charger to the floor structure of the vehicle, or in which the elements comprising a first part of a steering column, secured to the steering wheel of a vehicle, and a second part of the steering column, secured to the rack of the vehicle, and: - the installation step includes the installation of the soluble support on the first part of the steering column, - the positioning step includes positioning the soluble support, so that the two parts of the steering column are in the fixing position with each other, - the fixing step comprises fixing the first part of the steering column to the second part of the steering column.

[0018] Whether in the case where the insoluble elements comprise an electric charger and an electric battery or in the case where these elements comprise a first part of a steering column and a second part of the steering column, the method of the invention makes it possible to facilitate the positioning and fixing of the various insoluble elements of a motor vehicle during the various assembly steps carried out during the manufacture of the vehicle. The use of a soluble support also allows the removal and elimination of the latter (if necessary). The characteristics common to the two possible cases of insoluble elements therefore stem from the same inventive concept.

[0019] Typically, when attaching an electric battery and charger to a vehicle chassis, it is possible to position such a soluble bracket over the battery and charger on that bracket before lifting that assembly under the vehicle floor and then attaching the battery and charger to it.

[0020] Indeed, the subsequent removal of the soluble support will allow clearance to be maintained between the electric charger and the electric battery in order to limit noise and corrosion phenomena during use of the vehicle.

[0021] Other advantageous and non-limiting characteristics of the method according to the invention, taken individually or in all technically possible combinations, are the following: - the dissolution step is carried out using water, - the soluble support is made of a copolymer of butenediol and vinyl alcohol, - the installation step is carried out by additive manufacturing or molding of the soluble support on the electric battery, - the soluble support has on two opposite faces hollow and / or projecting reliefs cooperating with reliefs of identical shapes, in negative, present on the electric charger and the electric battery, - the method further comprises a step of fixing the soluble support to the electric charger, - the method further comprises a step of fixing the soluble support to the electric battery,

[0022] The invention also provides a device comprising: - a first insoluble element, - a second insoluble element, and - a soluble support in contact with the first insoluble element and / or the second insoluble element, characterized in that the elements comprise an electric battery (12) and an electric charger (14) or a first part (120) of a steering column, integral with a rack of the motor vehicle, and a second part (140) of the steering column, integral with a steering wheel of the motor vehicle. DETAILED DESCRIPTION OF THE INVENTION

[0023] The description which follows with reference to the appended drawings, given as non-limiting examples, will make it clear what the invention consists of and how it can be implemented.

[0024] On the attached drawings:

[0025] [Fig. 1] is a schematic plan view of a device according to a first embodiment of the invention during a step of the method according to the invention.

[0026] [Fig. 2] is a schematic plan view of the device of Fig. 1 during another step of the process.

[0027] [Fig. 3] is a schematic plan view of the device of Fig. 1 during another step of the process.

[0028] [Fig. 4] is a schematic three-quarter view of a steering column of a motor vehicle.

[0029] [Fig.5] is a three-quarter schematic view of a device according to a second embodiment of the invention, installed on the steering column of Figure 4.

[0030] [Fig.6] is a three-quarter schematic view of a device according to a third embodiment of the invention.

[0031] Figure 1 shows a device used for assembling a motor vehicle. This vehicle could be of any type: car, truck, bus, plane, etc.

[0032] This device comprises two components of the vehicle, namely a first insoluble element 12 and a second insoluble element 14 to be assembled within the vehicle. The device also comprises a soluble support 16 to facilitate this assembly.

[0033] Within the device, the soluble support 16 is in contact with the first insoluble element 12 and / or the second insoluble element 14, for example by being included between the two insoluble elements 12, 14. A first surface of the soluble support 16 is, for example, in contact with the insoluble element 12 and a second surface of the soluble support 16, for example opposite the first surface of the soluble support 16, is in contact with the insoluble element 14.

[0034] Preferably, the soluble support 16 is soluble in water while the first and second insoluble elements 12, 14 are insoluble in water. By soluble in water is meant that the soluble support 16 can be dissolved in the presence of a sufficient volume of water, for example, by spraying the soluble support with water until it is completely dissolved. If necessary, the first and second insoluble elements 12, 14 are also watertight.

[0035] In this embodiment, the soluble support 16 is made of a copolymer of butenediol and vinyl alcohol (also known by the commonly used acronym “BVOH”). Advantageously, BVOH is an economical, robust material that dissolves quickly in an aqueous medium. BVOH also has the advantage of being easy to print at low temperature and of having good adhesion to many materials, facilitating its use in implementing the method described below.

[0036] Of course, as an alternative, one could have chosen a support soluble in another liquid, for example in alcohol. However, the use of water to make the soluble support disappear will be preferred because water is more accessible, easier to use and less expensive.

[0037] A device according to one embodiment of the invention is shown in Figures 1 to 3.

[0038] In this embodiment, the first insoluble element 12 is an electric vehicle charger and the second insoluble element 14 is an accumulator battery of the electric vehicle (hereinafter referred to as an electric battery).

[0039] The electric battery 12 comprises electrochemical cells stored in a substantially parallelepipedal casing which is intended to be placed horizontally under the floor of the vehicle (when the latter is on a horizontal road). The casing of this electric battery 12 has in particular an upper face 12a facing the floor side. It will be said that it extends horizontally in length (depending on the length of the vehicle) and in width, and vertically in height. This electric battery 12 has over its entire periphery a rim 24 which is pierced with openings for its attachment to the chassis of the vehicle.

[0040] The electric charger 14 also comprises a housing which has a parallelepiped shape, but of a smaller size than that of the electric battery. This housing is flanked by two tabs pierced with openings for its attachment to the chassis of the vehicle, between the floor 26 of the vehicle and the electric battery 12. It also has a lower face 14a facing the ground. This lower face 14a is here flat.

[0041] The soluble support 16 is therefore interposed between the upper face 12a of the housing of the electric battery 12 and the lower face 14a of the housing of the charger 14. It comprises an upper face 16a in contact with the electric charger 14 and a lower face 16b in contact with the electric battery 12. It therefore makes it possible to “preposition” the electric charger 14 and the electric battery 12 in the position that they will have relative to each other when they are brought and then fixed under the floor of the motor vehicle. Thus, in this embodiment, the electric charger 12 and the electric battery 14 are not in contact.

[0042] Preferably, this “prepositioning” does not only consist of offsetting the electric charger 12 in height relative to the electric battery 14. It also consists of placing the electric charger 12 in a particular position (in width, length and orientation) relative to the electric battery 14.

[0043] For this, centering means are provided to facilitate the placement in the desired position of the soluble support 16 on the electric battery 12 and of the electric charger 14 on the soluble support 16.

[0044] These centering means work here by cooperation of forms.

[0045] Thus, the soluble support 16 has reliefs configured to cooperate with reliefs of corresponding shapes provided on the electric charger 14 and the electric battery 12.

[0046] These are projecting and / or hollow reliefs cooperating respectively with the hollow and / or projecting reliefs of the electric charger 14 and the electric battery 12.

[0047] In practice, the upper face 12a of the housing of the electric battery 12 is here substantially flat, with the exception of an area where it has a bulge 18 projecting relative to the plane of this upper face 12a.

[0048] The lower face 16b of the soluble support 16 is also substantially flat, with the exception of an area where it has a cavity 20 hollow relative to the plane of this lower face, of a shape identical in negative to that of the bulge 18.

[0049] The lower face 14a of the housing of the electric charger 14 is here flat. It will be considered that it forms by itself a bulge projecting relative to the rest of the housing.

[0050] The upper face 16a of the soluble support 16 is also substantially flat and has dimensions identical to those of the lower face 14a of the charger housing. It is bordered by a rim 22 which internally delimits a cavity in which the electric charger 14 can be wedged.

[0051] Thus, when the soluble support 16 is placed on the electric battery 12 and the electric charger 14 is attached to the soluble support 16, these elements are positioned adequately and can no longer move as long as the electric battery 12 remains horizontal. In other words, their respective means of attachment to the vehicle body are well positioned relative to each other.

[0052] The soluble support 16 can be manufactured in different ways. For example, it can be obtained by additive manufacturing, typically by 3D printing, or by molding. Typically, the soluble support 16 could be molded directly on the upper face of the electric battery 12 or under the lower face of the charger 14.

[0053] In addition, the maintenance of the different elements of the device between them can be reinforced by fixing means. The soluble support 16 can, for example, be glued to the electric charger 14 and / or to the electric battery 12. Thus, the movement of the entire device will not risk moving these elements relative to each other.

[0054] The invention generally relates to a method for mounting several insoluble elements of a motor vehicle, comprising: a step S1 of placing at least one soluble support 16 on a first of said insoluble elements 12, a step S2 of positioning the first element 12 relative to a second of said elements 14 by means of said soluble support 16, a step S3 of fixing the first insoluble element 12 and the second insoluble element 14 together and / or to separate bases and / or to the same base, a step S4 of dissolving the soluble support 16.

[0055] In the embodiment illustrated in Figures 1 to 3, the objective is therefore to assemble the device described above to the rest of the motor vehicle, here in the underbody position.

[0056] During the installation step S1, the soluble support 16 is placed on the electric battery 12, in the position described above.

[0057] The soluble support 16 is, for example, produced upstream of step S1 and placed on the electric battery 12 during step S1. Alternatively, the soluble support 16 is produced directly during step S1 on this electric battery 12, for example, by additive manufacturing using a 3D printer or by molding the soluble support 16 directly on this electric battery 12.

[0058] During the positioning step S2 shown in Figure 1, the electric charger 14 is positioned on the soluble support 16.

[0059] As explained above, by positioned, we mean that it is placed in a very particular position and with a very particular orientation relative to the soluble support 16 and to the electric battery 12. Alternatively, this positioning could simply consist of placing it at a given height above the electric battery 12, to which case the soluble support 16 would simply serve as a wedge.

[0060] The soluble support 16 is, in our example, configured to prevent any contact between the electric charger 14 and the electric battery 12. Alternatively, the soluble support 16 could be used to keep two insoluble elements in contact with each other or to place a first insoluble element in a position facilitating the positioning of a second insoluble element relative to the first insoluble element.

[0061] Alternatively, the mounting method further comprises a fixing step S21 during which the soluble support 16 is fixed to the electric charger 14 and / or to the electric battery 12, for example by screwing and / or gluing and / or any other fixing means known to those skilled in the art.

[0062] During the fixing step S3 shown in Figures 2 and 3, the electric battery 12 and the electric charger 14 are fixed together and / or to different bases and / or to the same base, for example, by screwing and / or gluing and / or any other fixing method known to those skilled in the art.

[0063] In practice, here, the electric battery 12 and the electric charger 14 are fixed to the floor structure of the vehicle. The device is firstly, as shown in Figure 2, brought into position under the body and brought into contact with the floor structure of the vehicle. Typically, the device is mounted on a mounting plate and brought into contact with the floor of the vehicle by a vertical translational movement of the mounting plate. In a second step, as shown in Figure 3, the element(s) accessible from below the floor structure of the vehicle, here the electric battery 12, are fixed from below, for example by riveting through the openings provided in the tabs of the housing of the electric battery 12. The element(s) which are not accessible from below, for example, the electric charger 14, are fixed from inside the vehicle, here by screwing.

[0064] During the dissolution step S4, the soluble support 16 is dissolved. Preferably, the dissolution of the soluble support 16 is carried out by using liquid water. The liquid water is brought into contact with the soluble support 16, for example, by spraying or by immersion. The water used for the dissolution and containing the soluble support 16 in solution is removed, for example, by suction. Thus, the soluble support 16 is removed quickly and easily. It will be noted here that the electric battery 12 and the electric charger 14 naturally have, due to their positions under the body, a water protection index which allows them not to be degraded by water.

[0065] Advantageously, the implementation of such an assembly process is quick and inexpensive.

[0066] Advantageously, the process also ensures functional play and geometric between the electric charger 14 and the electric battery 12. Indeed, once the soluble support 16 has been evacuated, these two components find themselves at a distance from each other.

[0067] The present invention can advantageously be adapted to the assembly of other elements of a motor vehicle.

[0068] Typically, it can be used when installing the vehicle's steering system.

[0069] Thus, in Figure 4, a steering column is shown, a first part 120 of which is secured to the rack of the vehicle and a second part 140 of which is secured to the steering wheel of the vehicle. These two parts are designed to be coupled, here by screwing. Indeed, during the assembly of the vehicle, the chassis of the vehicle is already equipped with the second part 140 when the front axle of the vehicle (which is equipped with the rack) is attached under the chassis. It is therefore appropriate, during this assembly operation, to connect the two parts 120, 140 of the steering column.

[0070] In Figure 5, a second possible embodiment of the invention applicable to the assembly of these two parts is shown. In this embodiment, the first insoluble element is the first part 120 of the steering column, the second insoluble element is the second part 140 of the steering column (not visible in Figure 5). The soluble support 160 then constitutes a tool for guiding the first part 120 of the steering column, making it possible to guarantee the correct positioning of this first part 120 relative to the chassis of the vehicle. In the embodiment considered, the shape of the soluble support 160 matches the shape of a part of the first part 120 of the steering column. It thus has a sheath-shaped body whose internal surface is in contact with the cylindrical external surface of the first part 120 of the steering column of the motor vehicle.The soluble support 160 is thus slidably mounted on this first part 120. It also comprises at least one holding element 30. In the embodiment considered, the holding element 30 comprises a protuberance whose shape is configured to fit into a cavity 32 present in the chassis of the vehicle so that the first part 120 of the steering column is held in a suitable position. In this position, it will be easier to couple the second part of the steering column to the first.

[0071] In a third embodiment shown in Figure 6, the soluble support 160 is rather intended to be fixed not to the chassis of the vehicle, but directly to the rack in order to lock the first part 120 in a suitable position.

[0072] In this third mode, the soluble support here again comprises a sheath-shaped body slidably mounted on the first part 120 of the steering column. It further comprises a holding element 30' in the form of a sort of split tube, configured to clip onto the steering rack 34 of the vehicle so that the first portion 120 of the steering column is held in position. In this position, the second portion 140 of the steering column can then be easily attached to the first portion 120 of the steering column. Thus, in this embodiment, the first portion 120 of the steering column and the second portion 140 of the steering column are in contact.

[0073] In a variant of the invention not shown, the soluble support could be placed at the junction between the first part and the second part of the steering column. In this variant, the shape of a first part of the soluble support matches the shape of a part of the first part of the steering column and the shape of a second part of the soluble support matches the shape of a part of the second part of the steering column.

[0074] In the second and third embodiments, during the installation step S1, the soluble support 160 is installed on the first part 120 of the steering column in the position described above, that is to say, imposing a very particular orientation on the first part 120 of the steering column relative to the chassis. The maintenance of the orientation of the assembly constituted by the first part 120 of the steering column and the soluble support 160 is ensured by the holding element 30 (30' in the third embodiment) of the soluble support 160.

[0075] During the positioning step S2, the free end of the first part 120 of the steering column is positioned in contact with the free end of the second part 140 of the steering column.

[0076] As explained above, by positioned, we mean that it is placed in a very particular position and with an orientation relative to the free end of the second part 140 of the steering column.

[0077] During the fixing step S3, the free end of the second part 140 of the steering column is fixed to the free end of the first part 120 of the steering column, for example, by screwing and / or gluing and / or any other fixing method known to those skilled in the art.

[0078] Advantageously, the method makes it possible to maintain the first part 120 of the steering column in position, facilitating its attachment to the second part 140 of the steering column.

[0079] Advantageously also, the method makes it possible to easily eliminate the soluble support 160 while it is located in a part that is difficult to access for the assembly operator.

[0080] The present invention is in no way limited to the embodiments described and represented, but those skilled in the art will be able to make any variation in accordance with the invention.

[0081] Typically, one could use several soluble supports between two insoluble elements.

Claims

CLAIMS 1. Method for mounting several insoluble elements (12, 14; 120, 140) of a motor vehicle, comprising: - a step of placing (S1) at least one soluble support (16; 160) on a first of said elements (12; 120), - a step of positioning (S2) the first element (12; 120) relative to a second of said elements (14; 140) by means of said soluble support (16; 160), - a step of fixing (S3) the first element (12; 120) and the second element (14; 140), together or to separate bases or to the same base, and - a step of dissolving (S4) the soluble support (16; 160) characterized in that, the insoluble elements comprising an electric battery (12) and an electric charger (14), the base comprising a floor structure of the motor vehicle: - the installation step (S1) comprises the installation of the soluble support (16) on the electric battery (12), - the positioning step (S2) comprises positioning the electric charger (14) on the soluble support (16), so that the electric charger (14) and the electric battery (12) are not in contact, - the fixing step (S3) comprises fixing the electric battery (12) and the electric charger (14) to the floor structure of the vehicle, or in that, the insoluble elements comprising a first part (120) of a steering column, integral with a rack of the motor vehicle, and a second part (140) of the steering column, integral with a steering wheel of the motor vehicle: - the installation step (S1) comprises the installation of the soluble support (160) on the first part (120) of the steering column, - the positioning step (S2) comprises positioning the second part (14) of the steering column on the soluble support (160), so that the two parts (120, 140) of the steering column are in a position allowing their attachment to each other, - the fixing step (S3) comprises fixing the first part (120) of the steering column to the second part (140) of the steering column.

2. Mounting method according to claim 1, in which the dissolving step (S4) is carried out using water.

3. Mounting method according to claim 2, in which the soluble support (16) comprises a copolymer of butenediol and vinyl alcohol.

4. Mounting method according to one of claims 1 to 3, in which the installation step (S1) is carried out by additive manufacturing or molding of the soluble support (16) on the electric battery (12).

5. Mounting method according to one of claims 1 to 4, in which the soluble support (16) has on two opposite faces hollow and / or projecting reliefs cooperating with reliefs of identical shapes, in negative, present on the electric charger (14) and the electric battery (12).

6. Mounting method according to one of claims 1 to 5, further comprising a step (S21) of fixing the soluble support (16) to the electric charger (14).

7. Mounting method according to one of claims 1 to 6, further comprising a step (S22) of fixing the soluble support (16) to the electric battery (12).

8. Device for motor vehicle, comprising: - a first insoluble element (12; 120), - a second insoluble element (14; 140), and - a soluble support (16; 160) in contact with the first insoluble element (12; 120) and / or the second insoluble element (14; 140), characterized in that the elements comprise an electric battery (12) and an electric charger (14) or a first part (120) of a steering column, integral with a rack of the motor vehicle, and a second part (140) of the steering column, integral with a steering wheel of the motor vehicle.

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