Vehicle body structure and method for producing a vehicle body structure

Abstract

Disclosed is a vehicle body structure comprising multiple tubular bars, made of a fibre-reinforced composite material, the tubular bars having corresponding ends interconnected by node elements, each node element including tubular connectors, wherein an end of each tubular bar and the corresponding tubular connector of the node element are tightly fitted together, thus defining a tubular space therebetween, the tubular space being delimited between a first hermetic seal and a second hermetic seal, such that the tubular space defines an adhesion chamber; a port for injecting adhesive, which provides access to the adhesion chamber; and an adhesive material that fills the adhesion chamber. Also disclosed is a method for producing a vehicle body structure, a vehicle comprising a vehicle body structure according to the invention, and the use of a vehicle body structure according to the invention.

Description

[0001] Description

[0002] VEHICLE BODY STRUCTURE AND METHOD OF MANUFACTURING A VEHICLE BODY STRUCTURE

[0003] Technical field

[0004] The present invention relates to a vehicle body structure comprising multiple tubular bars and to a method of manufacturing a vehicle body structure. The present invention also relates to a vehicle comprising a vehicle body structure according to the present invention and to the use of a vehicle body structure according to the present invention in a vehicle.

[0005] Background of the invention

[0006] Vehicle body structures made of tubular bars joined together are widely used in all types of vehicles. In recent years, the use of tubular bars made from fiber-reinforced composite materials has increased, as these composite materials provide greater strength with reduced weight.

[0007] One drawback of vehicle body structures, or any other type of structure, that use fiber-reinforced composite materials is that the different tubular bars that make up the structure cannot be joined by welding, as is the case with structures made with metal tubular bars, such as steel or aluminum tubular bars, among others.

[0008] To address or minimize the aforementioned drawback, vehicle body structures have been disclosed in which tubular bars made of fiber-reinforced composite materials are joined together by means of nodes comprising one or more tubular connectors for receiving corresponding tubular bars to be joined at a given node. Once the tubular bar is positioned in the corresponding tubular connector, the two are joined by means of a suitable adhesive material. For example, EP 3145798 A1 and US 2016 / 0297479 A1 disclose such structures. One drawback of the aforementioned structures is that it is cumbersome to efficiently apply the adhesive material to the joining area between the fiber-reinforced composite tubular bar and the corresponding tubular connector of a node.

[0009] Description of the invention

[0010] The present invention solves the above-mentioned problem of known vehicle body structures comprising tubular bars made of fiber-reinforced composite materials, providing, according to a first aspect of the present invention, a vehicle body structure as defined in claim 1, comprising multiple tubular bars made of a fiber-reinforced composite material, the tubular bars having corresponding ends interconnected by node elements, each node element including multiple tubular connectors, wherein: one end of each tubular bar and a corresponding tubular connector of the node element are inserted tightly into each other defining a tubular gap therebetween having an annular outlet around it, said tubular gap being delimited between a first seal,provided by a first portion of at least one plug partially inserted into a hollow interior of the tubular bar, and a second seal, provided by a second portion of said at least one plug partially inserted into a hollow interior of the tubular connector, such that the tubular hollow defines an adhesion chamber; an adhesive injection port spaced apart from the annular outlet providing access to the adhesion chamber; and an adhesive material filling the adhesion chamber.

[0011] In accordance with the first aspect of the present invention, the adhesive material filling the adhesion chamber may further be partially overflowed out of the adhesion chamber through the annular outlet into an overflow region, providing a visual mark of the filling of the adhesion chamber.

[0012] According to the first aspect of the present invention, the vehicle body structure may further comprise a transparent or translucent film firmly adhered over said overflow area. According to the first aspect of the present invention, the at least one plug may comprise a conduit having an inlet aligned with the adhesive injection port and at least one outlet to the adhesion chamber.

[0013] According to the first aspect of the present invention, an annular edge of the tubular connector or an annular edge of the tubular bar, surrounding the annular outlet, may extend through projecting perimeter elements defining a corrugated annular outlet.

[0014] According to the first aspect of the present invention, the tubular bar and the corresponding tubular connector may have corresponding polygonal cross-sections with several faces, at least some of the faces including at least one projecting perimeter element.

[0015] According to the first aspect of the present invention, the edges, between adjacent faces, may be devoid of protruding perimeter elements and correspond to valley areas of the wavy annular outlet.

[0016] According to the first aspect of the present invention, the tubular gap may be substantially uniform around the perimeter of the tubular bar.

[0017] According to the first aspect of the present invention, the tubular bar may be inserted into the tubular connector. Alternatively, the tubular connector may be inserted into the tubular bar.

[0018] The first aspect of the present invention is specifically intended for use in land vehicles, although it may also be applied to aircraft and / or ships.

[0019] According to a second aspect of the present invention, there is also provided a method of manufacturing a vehicle body structure according to the first aspect of the present invention, the method comprising the steps of: providing at least one node element including multiple tubular connectors; providing multiple tubular bars made of a fiber-reinforced composite material; introducing, at least partially, a first sealing portion of at least one plug into the hollow interior of one of the first tubular bars at a first end thereof, providing a first hermetic seal;tightly inserting the first end of the first tubular bar into a first tubular connector of the node element or inserting a first tubular connector of the node element into the first end of the first tubular bar, such that a first tubular space is defined between the first tubular bar and the first tubular connector with an annular outlet therearound and; providing a second hermetic seal by a second sealing portion of the at least one plug partially inserted into the hollow interior of the tubular connector, such that the tubular space defines a first adhesion chamber; injecting an adhesive material into the first adhesion chamber through an adhesive injection port spaced apart from the annular outlet providing access to the first adhesion chamber;inserting at least partially a first sealing portion of at least one plug into the hollow interior of a second tubular bar at a first end thereof, providing a first hermetic seal; tightly inserting the first end of the second tubular bar into a second tubular connector of the node element or inserting a second tubular connector of the node element into the first end of the second tubular bar, such that a second tubular space is defined between the second tubular bar and the second tubular connector with an annular outlet therearound, and providing a second hermetic seal by a second sealing portion of the at least one plug partially inserted into the hollow interior of the tubular connector, such that the tubular space defines a second adhesion chamber;injecting an adhesive material into the second adhesion chamber through an adhesive injection port separate from the annular outlet providing access to the second adhesion chamber;

[0020] In accordance with the second aspect of the present invention, the adhesive material may be injected into the first adhesion chamber until it partially overflows out of the first adhesion chamber through the annular outlet into a first overflow region, providing a visual indication of the filling of the first adhesion chamber; and / or the adhesive material may be injected into the second adhesion chamber until it partially overflows out of the second adhesion chamber through the annular outlet into a second overflow region, providing a visual indication of the filling of the second adhesion chamber.

[0021] According to the second aspect of the present invention, the method may further comprise the steps of providing a first firmly adhered transparent or translucent film over said first overflow area and / or a second firmly adhered transparent or translucent film over said second overflow area.

[0022] According to a third aspect of the present invention, a vehicle is provided comprising a vehicle body structure according to the first aspect of the present invention. Preferably, said vehicle is a land vehicle, although it may also be a vessel or an aircraft.

[0023] According to the third aspect of the present invention, the vehicle may be a bus, a car, a truck, a van, etc.

[0024] According to a fourth aspect of the present invention, there is provided the use of a vehicle body structure according to the first aspect of the present invention in a vehicle.

[0025] Although the present invention has been described above with tubular bars made of a fiber-reinforced composite material, it can also be applied to tubular bars made of other materials, such as, for example, steel, aluminum, wood, concrete, etc.

[0026] In the present invention, the node elements are preferably made of metallic materials, such as steel, aluminum, iron, etc., although they can also be made of polymers, composite materials, etc. A single structure according to the present invention may comprise node elements made of different materials, for example, depending on the structural requirements of each of them. It will be understood that references to geometric position, such as parallel, perpendicular, tangent, etc., allow deviations of up to ± 5° with respect to the theoretical position defined by this nomenclature.

[0027] It will also be understood that any given range of values ​​may not be optimal at extreme values ​​and may require adaptations of the invention to make these extreme values ​​applicable, such adaptations being within the reach of one skilled in the art.

[0028] Brief description of the drawings

[0029] The above and other advantages and features will be better understood from the following detailed description of an embodiment with reference to the attached drawings, which will be taken as illustrative and not limiting, in which:

[0030] Fig. 1 is a perspective view of an exemplary embodiment of a vehicle body structure according to the present invention;

[0031] Fig. 2 is an enlarged view of detail A of Fig. 1 showing two tubular bars interconnected by a first node element;

[0032] Fig. 3 is a perspective view of the node element of Fig. 2 shown in isolation;

[0033] Fig. 4 is a partial perspective view of one end of one of the tubular bars shown in Fig. 2 with a plug inserted therein;

[0034] Fig. 5 is a perspective view of the plug of Fig. 4 shown in isolation;

[0035] Fig. 6 is an elevation view of the plug of Fig. 5;

[0036] Fig. 7 is a cross-sectional view of the plug of Figs. 4 and 5 along plane VII-

[0037] VII of Fig. 6;

[0038] Fig. 8 is a perspective view of a stop plate to be fixed to a node member of a vehicle body structure according to the present invention;

[0039] Fig. 9 is a perspective view of a second node element of an exemplary embodiment of a vehicle body structure according to the present invention; Fig. 10 is a cross-sectional view of the second node element shown in Fig. 9 showing the tubular bars inserted into the node element in cooperation with the corresponding stop plates and the adhesion chambers formed therebetween;

[0040] Fig. 11 is a perspective view of a third node element of an exemplary embodiment of a vehicle body structure according to the present invention; and

[0041] Fig. 12 is a sectional perspective view of the third node element of Fig. 11.

[0042] Detailed description of a particular embodiment

[0043] Referring first to Fig. 1 , there is shown a vehicle body structure according to an exemplary embodiment of the present invention. The vehicle body structure comprises multiple tubular bars 1 made of a fiber-reinforced composite material, such as a carbon fiber composite, and multiple node elements 2 made of a metallic material, such as steel or aluminum. However, in other embodiments, the node elements 2 may be made of other materials, such as polymers, fiber-reinforced composite materials, etc.

[0044] Although the present invention is particularly intended for vehicle body structures comprising tubular bars made of fiber-reinforced composite materials, it could also be applied to other types of structures, i.e. to non-vehicle-related structures, and / or to structures comprising tubular bars made of other materials, such as wood, steel, aluminum, titanium, concrete or any other material having good structural properties.

[0045] The node element 2 of the exemplary embodiment shown in Fig. 2 comprises two tubular connectors 3. However, other node elements 2 may comprise more than two tubular connectors, as can be seen in Fig. 1 . Two of the tubular bars 1 have their respective ends interconnected with each other through the node elements 2. More specifically, each of the two tubular bars 1 has one end tightly inserted into a corresponding tubular connector 3 of the node element 2 and adhered thereto by a suitable adhesive. In an alternative embodiment (see Figs. 11 and 12 ), the tubular connectors 3 of the node element 2 are tightly inserted into the ends of the tubular bars 1 and adhered thereto.It is also possible that one or more node elements 2 of a vehicle body structure according to the present invention comprise one or more tubular bars 1 inserted into corresponding tubular connectors and one or more tubular connectors 3 inserted into the corresponding tubular bars 1.

[0046] Referring now to Fig. 3, the tubular connectors 3 of the node element 2 shown have a polygonal cross-section, with several faces, in this case, a square cross-section with four faces. In this example, the entire node element 2 has four faces that are formed by four plate members. It is also possible for embodiments of a vehicle body structure according to the present invention to comprise one or more nodes 2 comprising tubular connectors 3 and corresponding tubular bars 1 having a polygonal cross-section and one or more nodes 2 comprising tubular connectors 3 and corresponding tubular bars 1 having a non-polygonal, e.g., circular, cross-section.It is also possible that one or more nodes 2 of a vehicle body structure according to the present invention comprises one or more tubular connectors 3 and corresponding tubular bars 1 having a polygonal cross-section and one or more tubular connectors 3 and corresponding tubular bars 1 having a non-polygonal cross-section.

[0047] The node element 2 shown can be manufactured using various suitable manufacturing methods, such as casting, sheet metal bending, welding, 3D printing, stamping, etc., or any combination of the aforementioned processes.

[0048] Some of the plate members of node 2 shown in Fig. 3 include one or more peripheral protruding elements 10 that fit into the gaps of adjacent plate members. The plate members of node element 2 have one or more projecting portions 3a that together define opposing undulating annular edges.

[0049] Each plate member of the node element 2 shown in Fig. 3 further comprises two grooves 11 in a central region thereof. One of the plate members of the node element 2 further has two adhesive injection ports 6, one for each tubular connector 3, adjacent to the grooves 11. In other embodiments, an injection port 6 may not be adjacent to a groove 11. The function of the grooves 11 and the adhesive injection ports 6 will be explained below.

[0050] As shown in Fig. 4, the tubular bar 1 of this exemplary embodiment has a polygonal, in particular square, cross-section, which matches the polygonal cross-sectional shape of the tubular connectors 3 of the node element 2. One of the ends of the tubular bar 1 has a plug 4 attached to it. The plug 4 is inserted and held in place by dimensional interference. The plug 4 is made, for example, of a plastic or polymeric material. However, other suitable materials may also be used.

[0051] The plug 4, shown in isolation in Figs. 5 and 6, has a first sealing portion 4a configured to be inserted into a hollow interior of a tubular bar 1 (see, for example, Fig. 4 or 10) forming a first hermetic seal therebetween, and a second sealing portion 4b configured to be inserted into a hollow interior of the tubular connector 3 of the node element 2 forming a second hermetic seal therebetween. The first sealing portion 4a dimensionally interferes with the interior of the tubular bar 1 and prevents adhesive from seeping into the interior of the tubular bar 1. The second sealing portion 4b dimensionally interferes with the interior of the tubular connector 3 of the node element 2. The first and second sealing portions 4a, 4b define an adhesion chamber 5. The plug 4 further comprises a conduit 12 having an inlet 12a and one or more outlets 12b (see Fig. 7).

[0052] In the exemplary embodiment shown, the first sealing portion 4a and the second sealing portion 4b comprise a plurality of projections or ridges which, together with the inner walls of the tubular bar 1 provide a labyrinth seal that prevents the flow of adhesive into the interior of the tubular bar 1.

[0053] Fig. 8 shows a stop plate 13 alone, having a polygonal shape, for example a square shape, preferably matching the inner cross-section of the tubular connectors 3 of the node element 2. In the exemplary embodiment shown, the stop plate 13 has four sides and each side has a projecting rib 13a configured to snap fit into one of the slots 11 formed in the plate members of the node element 2. In other embodiments, the stop plate 13 may not have a shape matching that of the tubular bar 1. It is sufficient for the stop plate 13 to have a shape that acts as a stop for the plug 4 when inserted into the tubular bar 1, as explained below.

[0054] Figs. 9 and 10 show, respectively, a perspective view and a cross-sectional view of a second node element 2 of an exemplary embodiment of a vehicle body structure according to the present invention.

[0055] Each tubular connector 3 of this second node element 2 comprises a stop plate 13 as described in Fig. 8, with its projecting ribs 13a inserted into the corresponding grooves 11 of the corresponding tubular connector 3, such that the stop plates 13 are fixed and act as a stop for the insertion of the corresponding tubular bar 1 with its corresponding plug 4 into the corresponding tubular connector 3.

[0056] The grooves 11 are located in the node element 2 such that when one of the tubular bars 1 with the corresponding plug 4 is inserted into the corresponding tubular connector 3 until the plug 4 makes contact with the corresponding stop plate 13, as shown in Fig. 10, the inlet 12a of the conduit 12 of the plug 4 is aligned with the adhesive injection port 6 of the node element 2.

[0057] In the exemplary embodiment shown, said grooves 11 and stop plates 13 are positioned such that the inlet 12a of the conduit 12 of each plug 4 is aligned with the adhesive injection port 6 positioned in the tubular connector 3, speeding up the manufacturing process and ensuring correct alignment of the inlet 12a of the conduit 12 with the adhesive injection port 6, resulting in more uniform adhesive injection and increased manufacturing quality. Said stop plates 13 may also further enhance the structural integrity of node 2 and its corresponding tubular bars 1 . Although advantageous, said stop plates 13 are not required and other nodes 2 of a vehicle body structure according to the present invention may lack them.

[0058] The sectional view of Fig. 10 shows a first hermetic seal provided by the first sealing portion 4a of the plug 4 which is inserted into the hollow interior of the tubular bar 1 , and a second hermetic seal provided by the second sealing portion 4b of the plug 4 which is inserted into the hollow interior of the tubular connector 3. A tubular gap 9 is delimited by the first and the second hermetic seal and is formed between an outer surface of the tubular bar 1 and an inner surface of the tubular connector 3 of the node element 2. Preferably, the tubular gap 9 is substantially uniform around the entire perimeter of the tubular bar 1 , as in the present case, allowing for a uniform distribution of the adhesive material 15 fixing the tubular bar 1 to the node element 2 and in particular to the corresponding tubular connector 3.

[0059] In the embodiment shown, the tubular hollow 9 defines an adhesion chamber 5 which is in communication with the one or more outlets 12b of the conduit 12 formed in the plug 4, and the tubular hollow 9 has a corrugated annular outlet 9a around which is delimited by the corrugated annular edge of the projecting portions 3a of the tubular connector 3.

[0060] The tubular bar 1 is attached to the node element 2 by means of an adhesive material 15 that fills the adhesion chamber 5. The adhesive material 15 is injected into the adhesion chamber 5, as represented by arrow 7 in Fig. 10, through the adhesive injection port 6 formed in the node element 2, through the inlet 12a of the conduit 12 formed in the plug 4 and through one or more outlets 12b of the conduit 12.

[0061] Preferably, the adhesive material 15 filling the adhesion chamber 5 overflows, at least partially, out of the adhesion chamber 5 through the annular outlet 9a into an overflow area (see Fig. 9). The overflow of the adhesive material provides a visual indication of the complete filling of the adhesion chamber 5 during an injection operation. Said overflow may be left in the overflow area or may be subsequently removed to improve the visual appearance of the bond. The overflow of adhesive material from the adhesion chamber 5 through the annular outlet 9 is achieved by the first and second sealing portions 4a, 4b allowing the adhesive material to exit only through said annular outlet.

[0062] In Figs. 9 and 10, the vehicle body structure further comprises an optional transparent or translucent film 14 firmly adhered to the outer surfaces of the tubular connector 3 and the tubular bar 1 , extending over the overflow area. Among other advantages, this transparent or translucent film 14 prevents dripping of the adhesive 15 in the overflow area and maintains a substantially constant pressure of the adhesive material 15 as it overflows into the overflow area. This transparent or translucent film 14 may be peeled off or removed once the adhesive material 15 has hardened or cured. Subsequently, the adhesive material 15 in the overflow area may be removed. Said transparent or translucent film 14 may also be left covering the corresponding overflow area.

[0063] For illustrative purposes, in Figs. 9 and 10, the adhesive material 15 is only shown on the upper tubular bar 1 and the corresponding upper tubular connector 3 (following the orientation of the elements in the image, which may not correspond to the actual orientation in the vehicle body structure), although it should be understood that the adhesive material 15 is present at all junctions between a tubular bar 1 and the corresponding tubular connector 3 in a vehicle body structure according to the present invention. Likewise, also for illustrative purposes, the transparent or translucent film 14 is only shown on the upper tubular bar 1 and the corresponding upper tubular connector 3, although it may be present at any junction between a tubular bar 1 and the corresponding tubular connector 3 in a vehicle body structure according to the present invention.

[0064] Although in Figs. 2, 9 and 10 the tubular bars 1 are inserted into a corresponding tubular connector 3, in other embodiments the tubular connector 3 may be inserted into the tubular bar 1 , as shown in Figs. 11 and 12. In this case, the tubular bar 1 is the outermost element of the joint between the tubular connector 3 and the tubular bar 1 and the tubular bar 1 comprises the adhesive injection port 6 aligned with the inlet 12a of the conduit 12 of the corresponding plug 4. It is also possible for a node 2 to comprise one or more tubular bars 1 inserted into a corresponding tubular connector 3 and one or more tubular connectors 3 inserted into a corresponding tubular bar 1 .

[0065] Figs. 11 and 12 show a third node element 2 of an exemplary embodiment of a vehicle body structure according to the present invention. As mentioned above, in this third node element 2 the arrangement between the tubular connector 3 and the corresponding tubular bar 1 is the reverse of that shown in Figs. 2, 9 and 10, that is, in the third node element 2 the tubular connector 3 is inserted into the corresponding tubular bar 1 , the latter being the external element of said connection. The node element 2 shown in these figures comprises two tubular connectors 3 for connection to corresponding tubular bars 1 , although for illustrative purposes the representation of one of them has been omitted.In the node example shown, the projecting ribs 13a of the stop plate 13 protrude through the corresponding slots 11 and act as a stop for the insertion of the tubular connector 3 into the corresponding tubular bar 1, such that the adhesive injection port 6 is aligned with the inlet 12a of the conduit 12 of the corresponding plug 4, thus facilitating the injection of the adhesive material. In order to facilitate a more uniform distribution of the adhesive, the conduit 12 of the plug 4 shown in Fig. 12 comprises three outlets 12b, one being on the side opposite to the inlet 12a and the other two on the sides adjacent to said inlet 12a. This distribution may vary in other plugs 4.

[0066] In the node element 2 shown in Figs. 11 and 12 , the tubular connector 3 and the tubular bar 1 also define a tubular space 9 between them, and more specifically, the outer surface of the tubular connector 3 and the inner surface of the tubular bar 1 define said tubular space 9 with an annular outlet 9a around it. Said tubular space 9 is delimited by a first seal provided by a first sealing portion 4a and a second seal provided by a second sealing portion 4b of the plug 4 so that said tubular space 9 defines an adhesion chamber 5.

[0067] Although in Figs. 4 to 7, 10 and 12 the plug 4 is shown to be made of a single piece, in other embodiments the plug 4 may be made of two or more pieces, which when inserted into the corresponding tubular bar 1 function as a single plug 4, as described above.

[0068] Figures 1 to 12 also serve to illustrate a method of manufacturing a vehicle body structure according to the present invention. The method comprises the steps of:

[0069] • provide at least one node element 2 that includes multiple tubular connectors 3;

[0070] • provide multiple tubular bars 1 made of a fiber-reinforced composite material;

[0071] • at least partially inserting a first sealing portion 4a of the at least one plug 4 into the hollow interior of one of the first tubular bars 1 at a first end thereof, providing a first hermetic seal; • tightly inserting the first end of the first tubular bar 1 into a first tubular connector 3 of the node element 2 or inserting a first tubular connector 3 of the node element 2 into the first end of the first tubular bar 1 , such that a first tubular space 9 is defined between the first tubular bar 1 and the first tubular connector 3 with an annular outlet 9a around it, and;

[0072] • providing a second hermetic seal by a second sealing portion 4b of the at least one plug 4 partially inserted into the hollow interior of the tubular connector 3, such that the tubular space 9 defines a first adhesion chamber 5;

[0073] • injecting an adhesive material into the first adhesion chamber 5 through an adhesive injection port 6 separated from the annular outlet 9a giving access to the first adhesion chamber 5;

[0074] • inserting at least partially a first gasket portion 4a of the at least one plug 4 into the hollow interior of a second tubular bar 1 at a first end thereof, providing a first hermetic seal;

[0075] • tightly inserting the first end of the second tubular bar 1 into a second tubular connector 3 of the node element 2 or inserting a second tubular connector 3 of the node element 2 into the first end of the second tubular bar 1 , so that a second tubular space 9 is defined between the second tubular bar 1 and the second tubular connector 3 with an annular outlet 9a around it, and;

[0076] • providing a second hermetic closure by a second sealing portion 4b of the at least one plug 4 partially inserted into the hollow interior of the tubular connector 3, so that the tubular space 9 defines a second adhesion chamber 5;

[0077] • injecting an adhesive material 15 into the second adhesion chamber 5 through an adhesive injection port 6 separated from the annular outlet 9a giving access to the second adhesion chamber 5.

[0078] In case the node elements 2 join more than two tubular bars 1, see e.g. Fig. 1 , the mentioned method also applies to the third or any subsequent tubular bar 1 and to the corresponding tubular connector 3. Preferably, the adhesive material 15 is injected into the first adhesion chamber 5 until it partially overflows out of the first adhesion chamber 5 through the annular outlet 9a into a first overflow zone, providing a visual mark of the complete filling of the first adhesion chamber 5, and the adhesive material 15 is injected into the second adhesion chamber 5 until it partially overflows out of the second adhesion chamber 5 through the annular outlet 9a into a second overflow zone, providing a visual mark of the complete filling of the second adhesion chamber 5.Said visual mark aids the manufacturing process, as it is easy to perceive when the adhesion chamber 5 is full, thus helping to avoid defects in the joining process between a tubular bar 1 and the corresponding tubular connector 3 due to insufficient filling of the adhesion chamber 5. Furthermore, said visual mark, with or without the presence of the optional transparent or translucent film 14, allows stopping the injection of the adhesive material 15 just when the adhesion chamber 5 is full, avoiding waste of adhesive material 15 due to excessive filling, among other benefits.

[0079] It will be understood that various parts of an embodiment of the invention may be freely combined with parts described in other embodiments, even if such combination is not explicitly described, provided that such combination is within the scope of the claims and that there is no prejudice in such combination.

Claims

CLAIMS 1. Vehicle body structure comprising multiple tubular bars (1 ), made of a fiber-reinforced composite material, the tubular bars (1 ) having corresponding ends interconnected by node elements (2), each node element (2) including multiple tubular connectors (3);wherein one end of each tubular bar (1 ) and the corresponding tubular connector (3) of the node element (2) are inserted tightly into each other defining a tubular space (9) therebetween having an annular outlet (9a) around it, said tubular space (9) being delimited between a first seal provided by a first sealing portion (4a) of at least one plug (4) partially inserted into a hollow interior of the tubular bar (1 ), and a second seal, provided by a second sealing portion (4b) of said at least one plug (4) partially inserted into a hollow interior of the tubular connector (3), so that the tubular space (9) defines an adhesion chamber (5); an adhesive injection port (6) spaced apart from the annular outlet (9a) providing access to the adhesion chamber (5); and an adhesive material (15) filling the adhesion chamber (5).

2. The vehicle body structure according to claim 1, wherein the adhesive material (15) filling the adhesion chamber (5) further partially overflows out of the adhesion chamber (5) through the annular outlet (9a) in an overflow zone, providing a visual mark of the filling of the adhesion chamber (5).

3. The vehicle body structure according to claim 2, further comprising a transparent or translucent film (14) firmly fixed over said overflow area.

4. The vehicle body structure according to any one of claims 1 to 3, wherein the at least one plug (4) comprises a conduit (12) having an inlet (12a) aligned with the adhesive injection port (6) and at least one outlet (12b) towards the adhesion chamber (5).

5. The vehicle body structure according to any one of claims 1 to 4, wherein an annular edge of the tubular connector (3) or an annular edge of the tubular bar (1), surrounding the annular outlet (9a), extends through projecting perimeter portions (3a) defining a corrugated annular outlet (9a).

6. The vehicle body structure according to claim 5, wherein the tubular bar (1) and the corresponding tubular connector (3) have corresponding polygonal cross sections with several faces, and at least some of the faces include at least one projecting perimeter element (3a).

7. The vehicle body structure according to claim 6, wherein the edges, between adjacent faces, are devoid of projecting perimeter portions (3a) and correspond to valley areas of the wavy annular outlet (9a).

8. The vehicle body structure according to one of the preceding claims, wherein the tubular space (9) is substantially uniform around the perimeter of the tubular bar (1).

9. The vehicle body structure according to one of the preceding claims, wherein the tubular bar (1) is inserted into the tubular connector (3).

10. The vehicle body structure according to any one of claims 1 to 8, wherein the tubular connector (3) is inserted into the tubular bar (1)- 11. A method of manufacturing a vehicle body structure, comprising the steps of: providing at least one node element (2) including multiple tubular connectors (3); providing multiple tubular bars (1) made of a fiber-reinforced composite material; introducing, at least partially, a first sealing portion (4a) of at least one plug (4) into the hollow interior of one of the first bars tubular bars (1 ) at a first end thereof, providing a first hermetic seal; tightly inserting the first end of the first tubular bar (1 ) into a first tubular connector (3) of the node element (2) or inserting a first tubular connector (3) of the node element (2) into the first end of the first tubular bar (1 ), so that a first tubular space (9) is defined between the first tubular bar (1 ) and the first tubular connector (3) with an annular outlet (9a) around it, and providing a second hermetic seal by a second sealing portion (4b) of the at least one plug (4) partially inserted into the hollow interior of the tubular connector (3), so that the tubular space (9) defines a first adhesion chamber (5); injecting an adhesive material (15) into the first adhesion chamber (5) through an adhesive injection port (6) spaced apart from the annular outlet (9a) giving access to the first adhesion chamber (5);inserting at least partially a first sealing portion (4a) of at least one plug (4) into the hollow interior of a second tubular bar (1 ) at a first end thereof providing a first hermetic seal; tightly inserting the first end of the second tubular bar (1 ) into a second tubular connector (3) of the node element (2) or inserting a second tubular connector (3) of the node element (2) into the first end of the second tubular bar (1 ), so that a second tubular space (9) is defined between the second tubular bar (1 ) and the second tubular connector (3) with an annular outlet (9a) around it, and providing a second hermetic seal by a second sealing portion (4b) of the at least one plug (4) partially inserted into the hollow interior of the tubular connector (3), so that the second tubular space (9) defines a second adhesion chamber (5); injecting an adhesive material (15) into the second adhesion chamber (5) through an adhesive injection port (6) separated from the annular outlet (9a) that provides access to the second adhesion chamber (5).

12. The method according to claim 11, wherein the adhesive material (15) is injected into the first adhesion chamber (5) until it partially overflows out of the first adhesion chamber (5) through the annular outlet (9a) in a first overflow zone, providing a visual mark of the filling of the first adhesion chamber (5); and wherein the adhesive material (15) is injected into the second adhesion chamber (5) until it partially overflows out of the second adhesion chamber (5) through the annular outlet (9a) in a second overflow zone, providing a visual mark of the filling of the second adhesion chamber (5).

13. The method according to claim 12, further comprising the steps of providing a first transparent or translucent film (14) firmly adhered over said first overflow area and / or a second transparent or translucent film (15) firmly adhered over said second overflow area.

14. Vehicle comprising a body structure according to any one of claims 1 to 10.

15. Use of a vehicle body structure according to any of claims 1 to 10 in a vehicle.

Images