• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The vehicle floor (10) comprises: - an upper floor (19) made of a composite material; a lower floor (21) made of a composite material. The floor (11) comprises between the upper floor (19) and the lower floor (21) a soundproofing layer (23) and an air gap (24).
    公开号:FR3026080A1
    申请号:FR1458842
    申请日:2014-09-18
    公开日:2016-03-25
    发明作者:Philippe Jaunasse；Cyrille Guyon
    申请人:Renault SAS；Faurecia Bloc Avant；
    IPC主号:
    专利说明:

    [0001] Composite floor, vehicle comprising such a floor, floor manufacturing method, vehicle manufacturing method The invention relates generally to the floors of vehicles. More specifically, the invention relates in a first aspect to a vehicle floor, of the type comprising: - an upper floor made of a composite material in one or more parts; a lower floor made of a composite material in one or more parts, extending facing at least a portion of the upper floor, the lower and upper floors being bonded to one another along at least one fixing line and delimiting between them at least one hollow body. Floors of this type are known, for example FR 2 912 108. Such floors are light, but are not entirely satisfactory from the point of view of soundproofing. In this context, the invention aims to provide a floor having improved soundproofing performance. To this end, the invention relates to a floor of the aforementioned type, characterized in that the floor comprises between the upper floor and the lower floor, inside the hollow body, at least one layer of sound insulation and a blade of air superimposed on the soundproofing layer.
    [0002] The integration of a soundproofing layer and an air gap between the upper and lower floors makes it possible to significantly improve the soundproofing provided by the floor, without increasing the bulk in the floor. vehicle interior. Indeed, for reasons of rigidity, the lower and upper floors are not pressed against each other, but instead are spaced from one another so as to delimit between them one or more hollow body. These hollow bodies improve the rigidity of the floor. It is advantageous to take advantage of the space available in the hollow body to accommodate the soundproofing layer and the air gap. For the transmission of noise and vibrations, the floor behaves like a double glazing. Its soundproofing performance is very good.
    [0003] The use of a composite structure presents, in particular with respect to a conventional steel floor, a reduction in the surface density (which is unfavorable to the acoustic performance in mass law) and an increase in the stiffness of the subassembly (which generates a increase of the radiation factor of the floor particularly critical at high frequencies).
    [0004] These phenomena are illustrated in Figure 7 which shows the acoustic attenuation as a function of frequency. Curve A, which offers the best performance, represents a classic steel floor, covered with a soundproofing layer and carpet. It is degraded into a curve B when the weight of the floor is reduced by 40% and a curve C if the stiffness of the floor is increased by 40%, which corresponds to a composite floor. To compensate for these two phenomena and restore the level of acoustic performance of conventional steel floors, a known solution would be to pose on this type of composite floor a carpet / sound-absorbing set of significant weight, so that overall the floor composite solution with carpet / soundproofing would lead to a weight close to or even greater than the conventional floor solution. The solution proposed in the invention on the contrary makes it possible to achieve good acoustic performance by using low weights of soundproofing. In fact, the soundproofing layer and the integrated air gap between the two composite floors allow the lower and upper floors to be decoupled mechanically in order to minimize the solid-state transfers via the floor as well as the radiation, both in medium and high frequencies. . The addition of a low-weight carpet / sound-absorbing material above the upper floor completes the soundproofing and thus achieves superior performance over known steel flooring solutions. The weight of the set nevertheless remains well below the weight of the conventional solution. Figure 8 illustrates the interest of this solution. The performance of a composite floor with soundproofing layer and air gap between the lower floor and the upper floor, plus a soundproofing mat on the upper floor, are represented by the curve D, which can be compared to the curve A (conventional solution with steel floor and soundproofing carpet), curve C (structure identical to that of curve A, with a composite floor instead of the steel floor), and curve E (structure identical to that of curve C, with a thicker layer of soundproofing, the upper floor is typically turned towards the inside of the passenger compartment of the vehicle.On the contrary, the lower floor is normally turned towards the running surface of the vehicle. composite material forming the upper floor comprises long fibers, for example glass fibers and / or carbon fibers and / or aramid fibers and / or vegetable fibers. The fibers are in the form of woven, unidirectional, non-woven fabrics or long staple nonwoven fabrics.
    [0005] These fibers are embedded in a thermoplastic resin, adapted to be shaped by thermo-stamping with short cycle times, of the order of one minute. Heat-stamping is a hot stamping process. The resin is for example a resin based on polyamide, or polypropylene. In a non preferred variant, the fibers are embedded in a thermo-hard resin or vitrimer, for example a resin based on polyester or epoxy, ... The upper floor typically has a thickness of between 1 and 6 MM. The composite material of the lower floor is for example identical to the composite material of the upper floor. Alternatively, it is different. It also comprises long fibers, for example glass fibers and / or carbon fibers and / or aramid fibers and / or vegetable fibers. In a variant, it comprises short fibers. The fibers are arranged in the form of woven fabrics, unidirectional nonwoven fabrics or long staple nonwoven fabrics.
    [0006] These fibers are embedded in a thermoplastic resin, adapted to be shaped by thermo-stamping with short cycle times, of the order of one minute. Heat-stamping is a hot stamping process. The resin is for example a resin based on polyamide, or polypropylene. In a non preferred variant, the fibers are embedded in a thermo-hard resin and / or vitrimer, for example based on polyester or epoxy, ... The lower floor typically has a thickness of between 1 and 6 MM. The lower floor extends opposite most of the upper floor. For example, it extends in front of at least 50% of the surface of the upper floor. In a variant, the lower and / or upper floors are not shaped by heat-sealing but by any other suitable method, depending on the nature of the materials and the shape to be obtained. According to another variant, the floor comprises elements overmoulded on the lower and / or upper floors, to integrate additional functions on the lower and / or upper floors. These elements are for example stiffening ribs, cable ducts, housings for housing various equipment (computers, connectors ...), clips for fixing the floor on the vehicle. These elements are made of a material typically comprising a thermoplastic resin and short fibers embedded in the resin. The resin is preferably the same as that forming the lower and / or upper floors. The floor typically comprises a single layer of sound absorbing inserted into the hollow bodies formed by said floors. Alternatively, it comprises several layers of soundproofing, arranged on top of each other. The soundproofing is of any suitable type: - a foam (eg polyurethane or polyester) - a felt based on cellulosic fibers or a fibrous material having better temperature resistance characteristics (polyester or polyamide).
    [0007] The choice of a fibrous material or a foam will have to be made according to the objectives in depreciation that the sound-absorbing assembly will have to bring to the composite solution. If more needs for acoustic performance are needed, the integrated soundproofing solution combines two layers of different resistivity felts (commonly called waterproof), a layer of foam and a layer of felt, or a layer of spring (foam or felt) and a septum (heavy mass). The heavy mass is generally based on a thermoplastic containing polyolefins or EVA (Ethyl Vinyl Acetate) and mineral fillers. The soundproofing layer preferably covers at least 50% of the surface of the lower floor. According to an advantageous variant, the soundproofing is a foam cast or injected into the hollow bodies formed between the lower and upper floors. This foam is injected through orifices formed in or between the lower and upper floors. The foam is typically cast or injected after the passage of the floor cataphoresis, which is particularly advantageous. Indeed, when the soundproofing is placed in the hollow body before passage in cataphoresis, these hollow bodies must be completely sealed so that the soundproofing is not damaged in the cataphoresis baths. This creates several difficulties: - the floor behaves like a buoy and is difficult to fully immerse in the baths; - There may be a swelling of the sealed hollow bodies and a deformation of the floor during cooking, under the effect of the increase in temperature; - In case of leakage, the cataphoresis liquid is trapped inside the hollow body.
    [0008] These difficulties are avoided if the soundproofing is a cast foam or injected after cataphoresis, since the hollow bodies are not waterproof during cataphoresis. The air gap is a layer typically covering the entire layer of soundproofing, that is to say 100% of the surface of the soundproofing layer. Generally, the soundproofing layer is pressed against the lower floor, the air gap being interposed between the soundproofing layer and the upper floor. Alternatively, the soundproofing layer is plated under the upper floor, the air gap being interposed between the soundproofing layer and the lower floor. In this configuration the soundproofing layer is glued to the upper floor. By fixing line is meant here a line along which the upper floor and the lower floor are fixed to each other, directly or through complementary parts such as stiffening profiles or chassis side members. of the vehicle. The lower and upper floors are rigidly fixed to each other along the fastening line, continuously, for example by means of an adhesive, and / or discontinuously via a plurality of fasteners distributed along the fastening line and / or by a continuous or discontinuous welding line, for example an ultrasonic welding line, or a laser welding line.
    [0009] The fasteners are for example self-punching rivets, nails, or any other type of suitable fastener. These fastening lines surround each hollow body, and give the floor a high rigidity. According to an advantageous characteristic of the invention, the lower and upper floors are directly connected to one another along at least one of the fastening lines. This makes it possible to stiffen the floor, without the addition of heavy elements such as metal profiles. Along said attachment lines, the lower and upper floors are in close proximity to one another, or are in direct contact with each other. This is achieved via floor shape arrangements, for example by creating reliefs in the lower floor projecting towards the upper floor, or conversely by creating in the upper floor reliefs projecting towards the lower floor. According to an advantageous characteristic of the invention, the floor comprises at least one stiffening section disposed in the hollow body.
    [0010] The floor generally comprises several stiffening profiles, distributed at different points of the floor. According to an advantageous characteristic of the invention, the stiffening profile is made of a metal or a composite material. For example it is aluminum, or magnesium, or steel, or any other suitable metal. When the profile is made of a composite material, it is typically pultruded. Alternatively, the profiles are thermoformed with overmoulding, molded, or manufactured by RTM or SMC process ... The profile has a square section, or a rectangular section or a U-shaped section, or an omega section, or any other adapted section .
    [0011] According to an advantageous characteristic of the invention, the stiffening profiles extend mainly in the longitudinal and / or transverse directions, for the greater part of a longitudinal length and / or a transverse width of the floor. This allows in particular to transmit the longitudinal forces associated with frontal shocks and transverse forces related to side impacts and impact pole.
    [0012] The longitudinal and transverse directions, front, rear, right and left are here understood relative to the direction of normal movement of the vehicle. According to an advantageous characteristic of the invention, the stiffening profile is rigidly fixed to the upper floor and the lower floor. The rigidity of the floor is thus increased. The stiffening profile is fixed by an adhesive and / or by a welding line and / or by fasteners such as those described above. According to another advantageous characteristic of the invention, the floor comprises a layer of carpet or carpet, covering the upper floor. The carpet or carpet is an additional layer of soundproofing. It also improves the appearance of the floor.
    [0013] According to another advantageous characteristic of the invention, the lower floor comprises two lateral zones and a central zone projecting towards the upper floor with respect to the two lateral zones, the central zone being interposed longitudinally between the two lateral zones and connecting the two zones. lateral to each other, the central zone delimiting a longitudinal tunnel.
    [0014] This longitudinal tunnel allows the passage of functional organs of the vehicle, for example the exhaust line or a transmission shaft of the engine torque to the rear wheels of the vehicle. It also allows the transmission of effort during shocks. In an exemplary embodiment, the upper floor has two lateral parts, disposed on either side of the central zone projecting from the lower floor, and not directly connected to one another.
    [0015] According to another exemplary embodiment, the upper floor has a shape similar to that of the lower floor, with two lateral parts and a projecting central part, connecting the two lateral parts to one another. The projecting central portion caps the central area projecting from the lower floor. Typically, it is plated on at least a portion of its surface against the central zone projecting from the lower floor. According to another advantageous characteristic of the invention, one or more of the fastening lines together define a closed contour, thus delimiting one or more closed hollow bodies. Such a box structure provides an extremely high rigidity of the floor, greater than that of a sheet steel plate stamped. As a result, it is possible to decrease the rigidity of the rest of the metal structure of the vehicle, which decreases the total mass of the vehicle. The floor typically also comprises other closed hollow bodies, which are partially delimited by fastening lines and partially delimited by other structures of the vehicle: longitudinal members, chassis cross members, etc. According to another advantageous characteristic of the invention, the fastening lines are liquid-tight, especially water and various fluids. This prevents the formation of water retentions in the hollow body or bodies, and thus reduces the risk of degradation of the soundproofing.
    [0016] According to an advantageous embodiment, some hollow bodies are not completely closed, but instead are open at their two opposite longitudinal ends. These hollow bodies thus define passages for technical servitudes set up by threading, such as wiring, brake circuits, fuel, cooling, air conditioning, ... These passages preferably extend over the entire length of the floor. Typically, the soundproofing layer has a thickness of between 5 and 20 mm. This thickness is preferably between 7 and 15 mm. Typically, the air gap has a thickness of between 5 and 50 mm. This thickness is preferably between 10 and 30 mm. It is flexible depending on the size of the floor is the thickness of the soundproofing. Such thicknesses make it possible to obtain a very effective sound attenuation through the floor. According to a second aspect, the invention relates to a vehicle comprising: - a chassis; - a floor having the above characteristics, rigidly fixed to the frame.
    [0017] The vehicle is typically a motor vehicle, for example a car, or a utility, or a truck. The floor typically includes a front floor and a boot floor. The front floor typically extends between the apron of the vehicle and the transverse crossbar called "pare close". The apron is a partition separating the engine compartment of the vehicle from the passenger compartment. The transverse cross member (close pare) is located at the boundary between a front floor, here described, and the trunk floor integrating the seats rank 2 and the trunk of the vehicle. It connects the front floor to the boot floor. The front floor is rigidly fixed not only to the longitudinal longitudinal members of the vehicle, but also to the deck and to the transverse crossbar called "pare close". The vehicle side rails can be used to close some hollow body of the floor. The front floor and the boot floor preferably have the structure described above. Alternatively, only the front floor or only the trunk floor has the structure described above. According to an advantageous aspect of the invention, the floor comprises reinforcing members disposed in the hollow body, the vehicle having seats directly attached to the reinforcing members. This means that the seats are not connected to the reinforcing members through the upper floor, or the lower floor. On the contrary, members such as tie rods or screws or any other fastener directly connect the seat to the reinforcing members through the upper floor. In an exemplary embodiment, the seats are rigidly fixed directly to a stiffening section of the floor, of the type described above. Alternatively, the floor comprises between the upper floor and the lower floor reinforcement members specifically dedicated to the attachment of the vehicle seats. These reinforcement members are distinct from the stiffening section or profiles. These organs have for example the form of pads. More precisely, they have the shape of bowls, concavities turned towards the lower floor. The free edge of the bowl extends outward from the bowl by a peripheral flange, pressed against the lower floor. The peripheral fallen edge is rigidly fixed to the lower floor by one or more of the means mentioned above. The reinforcement members may have other shapes: cylindrical, frustoconical, etc. The reinforcing members are metallic or are made of a composite material.
    [0018] According to a third aspect, the invention relates to a method of manufacturing a floor having the above characteristics, the method comprising the following steps: - obtaining at least two pieces of thermoplastic composite material; - Form the upper and lower floors by hot stamping both parts. This provides short cycle times of the order of one minute for stamping the upper and lower floors. The cycle times for the thermosetting composite materials are much longer, of the order of several minutes. They depend on the polymerization time of the resins. The thermoplastic composite materials used are of the type described above. According to a fourth aspect, the invention relates to a method of manufacturing a vehicle, the method comprising the steps of: - obtaining a floor having the above features; - stick the floor on a metal structure of the vehicle; - Pass the metal structure and the floor in cataphoresis, an anticorrosion product being first deposited on the metal structure, then the metal structure and the floor being subjected to a baking operation, the adhesive being polymerized during cooking.
    [0019] The floor and the metal structure form the white body of the vehicle. The cataphoresis step is to deposit an anti-corrosion product on the metal parts of this box in white. It typically comprises a sub-step during which the white box passes into a cataphoresis bath, the anticorrosion product being deposited electrostatically on the metal parts, followed by a substep of baking of the anti-corrosion product. oven. Advantageously, it takes advantage of the cooking sub-step integrated in the cataphoresis treatment to polymerize the glue. According to an advantageous aspect of the invention, the method further comprises the following steps: - overmolding at least one metal part of pre-maintenance on the floor; between the gluing step and the firing operation, block the floor in position relative to the metal structure by means of the or each pre-holding piece, the or each pre-holding piece being rigidly fixed to the metallic structure.
    [0020] The assembly of a composite floor on the vehicle structure is particularly delicate, since it is necessary to fix a composite, typically a thermoplastic composite, to a metal structure. The bonding allows a very strong bond, but it is necessary to maintain the floor in position relative to the metal structure of the vehicle at least until the polymerization of the glue. The pre-holding part or parts allow such blocking in position. The overmoulding step makes it possible to fix the pre-holding part or parts on the floor. Overmoulding is a process well suited to fixing a metal part on a composite floor. The pre-holding part is embedded in a composite structure of the same nature as the floor. It is then attached to the metal structure by any means suitable for a metal-on-metal fastening: resistive welding by points, by lines, rivets, bolts, etc. After polymerization of the glue, the pre-holding part or parts contribute to the fixing of the floor to the metal structure, in addition to the glue. In a variant, the pre-holding part or parts are not overmolded on the lower or upper floors, they are assembled by a suitable means (gluing, etc.). Alternatively, the pre-holding part or parts are not parts. metal. These are clips made of a thermoplastic material, overmolded on the lower or upper floors. These clips cooperate with complementary parts formed on the metal structure of the vehicle. Other features and advantages of the invention will emerge from the detailed description given below, by way of indication and in no way limiting, with reference to the appended figures, among which: FIG. 1 is a simplified schematic representation of a motor vehicle comprising a floor according to the invention; - Figure 2 is a longitudinal section of the floor of Figure 1; - Figure -3 is a cross section of one half of the floor of Figure 2; - Figure 4 is a cross section of a floor incorporating alternative embodiments of the invention; - Figure 5 is a sectional view of the fixing of the floor of Figure 2 on a spar of the vehicle; this spar member is designated by the term "flap liner"; FIG. 6 is a step diagram illustrating the manufacturing method of the invention; FIG. 7 represents acoustic attenuation as a function of frequency for different floors of the state of the art; FIG. 8 is a graphic representation similar to that of FIG. 7, for various floors of the state of the art and for a floor according to the invention, and FIGS. 9 and 10 illustrate embodiments of the invention. invention. The vehicle 1 shown in Figure 1 comprises a body defining in the vehicle a passenger compartment 3, a engine compartment 5 located at the front of the passenger compartment, and a trunk 7 located at the rear of the passenger compartment. The engine compartment 5 is separated from the passenger compartment by an apron 9. The passenger compartment is bounded down by a floor 10.
    [0021] The front part of the passenger compartment is the zone of occupancy of the front passengers of a motor vehicle. It is delimited at the front by the apron 9 and at the rear by a transverse wall called "pare pare" 15. Finally this front part is delimited downwards by an area of the floor 10 called front floor 11.
    [0022] The rear part of the passenger compartment extends from the base of the closed pare (connection between the front floor 11 and the pare pare 15) at the front to the rear crossmember of the vehicle (not shown). This rear part integrates the seats of the occupants of rank 2 and the trunk. Alternatively, it incorporates tier 3 seats. This rear portion is delimited downwards by an area of the floor 10 called trunk floor 13, slightly raised with respect to the front floor 11. The front floor 11 and the trunk floor 13 are connected to each other at the junction between the closed par 15 and the front floor 11. The vehicle still has seats 17, rigidly fixed to the front floor 11 by means which will be described later.
    [0023] In Figure 1, a seat of the first row is shown and a seat of the second row. The front floor 11 of the vehicle extends from the deck 9 to the base of the closed barrier 15 in a longitudinal direction, and extends transversely substantially over the entire width of the vehicle. It is rigidly fixed forwardly to the deck 9 and / or to any other transverse structural part present in the zone, towards the rear of the closed barrier 15 and laterally on the chassis (not shown) of the vehicle, and more precisely on the spars. This spar member is referred to as the "flap liner".
    [0024] The structure of the front floor 11 will now be described. The boot floor 13 has the same structure in the example, and will not be described in detail. As shown in Figures 2 and 3, the floor 11 comprises: - an upper floor 19 of a composite material; - A lower floor 21 of a composite material, extending facing at least a portion of the upper floor; a soundproofing layer 23 interposed between the upper and lower floors 19 and 21; - An air space 24, superimposed on the soundproofing layer 23. In the example shown, the floor 11 further comprises: - a plurality of stiffening profiles 25, 27, 29, 30 interposed between the upper floors and lower 19, 21; and - a carpet layer (soundproofing mat) 31, preferably covering the upper floor 19. The lower floor 21 is turned towards the rolling surface of the vehicle. It defines an outer surface of the vehicle, exposed to the atmosphere. Towards the front of the vehicle, it has a slightly curved edge 33, which rises longitudinally from rear to front and is rigidly fixed to the deck 9 of the vehicle (or to any cross-section of structure present in the area). As can be seen in FIGS. 4 and 5, the lower floor 21 has two lateral zones 35 located to the left and to the right of the floor, and a central zone 37 projecting towards the upper floor with respect to the two lateral zones 35. The lateral zones 35 and the central zone 37 extend substantially over the entire longitudinal length of the floor. The central zone 37 connects the two lateral zones 35 to one another over the entire length of the floor. As can be seen in FIG. 4, the central zone 37 delimits a tunnel, open opposite the upper floor 19, designed to pass mechanical members of the vehicle and acting as a frontal impact reinforcement. The upper floor 19 extends longitudinally on substantially the same length as the lower floor. It also has a raised edge 39, pressed against the raised edge 33 of the lower floor (FIG. 2). As shown in Figure 4, the upper floor has two side portions 41 and 42 disposed on either side of the central zone 37 of the lower floor, and separated from each other by this central zone.
    [0025] The lower and upper floors 19 and 21 are attached to each other along a plurality of attachment lines. Along the attachment lines 43, 45, 47, 49, 50 and 51, the lower and upper floors 19, 21 are directly attached to each other. Along said fastening lines, the upper and lower floors 19 and 21 are pressed against each other, possibly with the interposition of a layer of glue 53. The upper and lower floors 19 and 21 are pressed against each other. the other over all or part of the length of said lines. They are preferably rigidly fixed to each other, in addition to the optional glue layer 53, by a plurality of fasteners 55, self-piercing rivets in the example shown, and / or by a continuous or discontinuous welding line. These fasteners are evenly distributed along the fastening lines 43, 45, 47, 49, 50 and 51. Only six fastening lines are shown in the figures, but alternatively the floor has other fastening lines not shown. .
    [0026] As can be seen in FIG. 2, the fastening line 43 fixes the front edges 33 and 39 respectively of the lower floor and of the upper floor one to the other. The attachment lines 45 and 47 each fix a relief 56 formed in the upper floor to another relief 56 formed in the lower floor. The reliefs 56 are depressions of transverse orientations, convex to each other. As can be seen in FIG. 3, the fastening line 49 fixes the left side edges of the upper and lower floors to one another. The right side edges of both floors are fixed in the same way. The fastening line 51 fixes a central edge 59 of the portion 41 of the upper floor 19 to the central zone 37 of the lower floor. The central edge 59 extends longitudinally and delimits the portion 41 of the upper floor towards the center of the vehicle, that is to say on the side of the central zone 37. The portion 42 is fixed in the same way to the central zone 37. The fastening line 50 fixes an intermediate band 60 of the upper floor 19 to a relief 61 formed in the lower floor 21. The relief 61 projects towards the upper floor 19. The intermediate band 60 and the relief 61 extend longitudinally over most of the length of the floor. The relief 61 has a U-shaped cross-section, with a central portion 62 fixed to the upper floor 19, and two lateral wings 63 connecting to the remainder of the lower floor 21. In addition, the lower and upper floors 19 and 21 are fixed to the floor. to one another via complementary parts along the fastening lines 64, 65, 66.
    [0027] Along the fastening lines 64 and 65, the lower and upper floors 19 and 21 are fixed to each other through the profiles 25 and 27. These profiles are of transverse orientation. In the example shown in Figures 2 to 4, each cross section 25, 27 comprises two sections, located on either side of the central zone 37. One of the sections is interposed between the portion 41 of the upper floor and the lower floor, and the other portion between the portion 42 and the lower floor 21. The two sections are disjoint. They are located in the extension of one another in the transverse direction.
    [0028] According to an alternative embodiment illustrated in Figure 10, at least one tie T is rigidly fixed under the floor. It extends transversely, between and in the extension of the profiles 25 or 27. It is rigidly fixed by its transverse ends to the two zones 35 of the lower floor, its central portion extending above the central zone 37. Each pulling T has the function of resuming the lateral forces in the event of side impact or post impact, and to send the forces towards the side opposite the impact. As can be seen in FIG. 2, each of the profiles 25, 27 has, in cross-section, a rectangular central core 67 and two flanged edges with two wings 68. The central core 67 is open towards the lower floor 21. It comprises a bottom 69 pressed against the upper floor 19, and two side walls 70 opposite to each other, integral with the bottom 69 and substantially perpendicular thereto. The folded edges 68 extend the lateral walls 70 towards the outside of the profile, opposite the bottom 69. They are pressed against the lower floor 21. The bottom 69 of the profile is rigidly fixed to the upper floor 19, for example by a adhesive layer 71 and / or by welding and / or a plurality of fasteners 72, which are rivets in the example shown. The two edges folded two wings 68 are rigidly attached to the lower floor 21, by a layer of glue 73, and / or by welding and / or a plurality of fasteners 75, which are rivets in the example shown.
    [0029] As shown in Figure 2, a groove 77 is formed transversely in the upper floor 19, and defines an open concavity to the lower floor. It receives the bottom 69 of the profile, and part of the side walls 70. It has a shape substantially conjugate to that of the profile.
    [0030] Along the fixing line 66 (FIG. 3), the lower and upper floors 19 and 21 are fixed to one another via the profile 30, visible in FIG. 3. This profile is oriented longitudinal. The floor comprises for example two profiles 30, arranged on either side of the central zone 37. The profile 30 has a cross section substantially S, with an upper wing fixed to the upper floor 19, a lower wing fixed to the lower floor 21, and an inclined core connecting the upper and lower wings to one another. The upper and lower wings are attached to the upper and lower floors for example by a layer of adhesive and / or by welding and / or a plurality of fasteners such as rivets, these various means not being shown. The attachment lines 43, 45, 47, 49, 50, 51, 64, 65, 66 together define one or more closed contours. These closed contours thus delimit closed hollow bodies 57 formed between the upper floor and the lower floor. The presence of closed hollow bodies 57 and fastening lines gives the floor a high degree of rigidity. The seats 17 of the first row of vehicle seats are attached to the profiles 25 and 27 by means of tie rods 78 shown schematically in Figure 1. The tie rods 78 pass through the carpet 31 and the upper floor 19, and engage with the profiles 25 and 27.
    [0031] According to an alternative embodiment, the floor further comprises at least one stiffening profile 96, placed outside the hollow body 57. In the example shown in Figure 3, the floor comprises two longitudinal sections 96, located on the left and right. other of the central zone 37. Each profile 96 is fixed under the lower floor 21, at the right of the relief 61.
    [0032] As can be seen in FIG. 3, the lateral wings 63 of the relief 61 each have a longitudinal shoulder 97. The profile 96 has a Q-shape, its two folded edges 98 being rigidly fixed to the two shoulders 97. The profile 96 is concave towards the relief 61. The relief 61 and the profile 96 together form a hollow beam with closed section, particularly rigid.
    [0033] According to an alternative embodiment shown in Figure 4, the upper floor 19 comprises, in addition to the two side portions 41 and 42, a central portion 99, connecting the side portions 41 and 42 to one another. The central portion 99 projects away from the lower floor 21 relative to the side portions 41 and 42. It thus forms a longitudinally elongate bump extending over substantially the entire length of the floor 1. The central portion 99 covers the central zone 37, and rests on this central zone. Specifically, the central portion has a flattened top 100 and two sidewalls 101, connecting the flattened top 100 to the side portions 41 and 42. The central area 37 of the lower floor has a similar shape, with also a flattened top 103 and two sidewalls 105. connecting the flattened top 103 to the lateral zones 35. The flattened top 100 rests against the top 103. It is fixed thereto by a layer of adhesive and / or by welding, for example by ultrasonic or laser welding and / or by mechanical fasteners such as rivets.
    [0034] The flanks 101 are parallel to the flanks 105 and rest against them. Each flank 101 is attached to the corresponding sidewall 105 by a glue layer and / or by welding, for example by ultrasonic or laser welding and / or by mechanical fasteners such as rivets. The carpet layer (carpet) 31 covers the central portion 99.
    [0035] In the embodiment illustrated in Figure 4, the central zone 37 of the lower floor has two recessed areas C, extending longitudinally over the entire length of the floor preferably. These recessed areas C are concave towards the upper floor 19. They are for example located at the junctions between the flattened top 103 and the flanks 105. They define with the upper floor each a closed hollow body, increasing the rigidity of the floor. upper part of the tunnel .. According to an alternative embodiment shown in Figure 4, the relief 61 and the section 96 are replaced by a longitudinal profile 106. The section 106 has substantially the same shape as the profiles 25 and 27. It is placed between the lower floor 21 and the upper floor 19. It is fixed to the lower floor 21 and the upper floor 19 as the profiles 25 and 27. In addition, the flange liners 107 of the vehicle frame are shown in FIGS. These flap liners 107 extend longitudinally, one to the right and the other to the left of the vehicle. They are part of the chassis of the vehicle.
    [0036] According to an alternative embodiment, the respective outer edges 109 and 111 of the upper and lower floors are not fixed to each other, but on the contrary are rigidly fixed to the flap liners 107 More precisely, as shown in Figure 4 , the upper floor 19 is delimited laterally by two edges 109, one on the left and one on the right of the floor. The lateral edges 109 extend longitudinally substantially over the entire length of the floor. Similarly, the lower floor 21 is laterally delimited by two side edges 111, located one on the left and one on the right of the vehicle. The lateral edges 111 extend over the entire longitudinal length of the floor. Each of the two edges 109 of the upper floor 19 is rigidly fixed to a flap liner 107, for example by a glue layer 113 and / or by mechanical fasteners 115 such as rivets. Similarly, each of the two side edges 111 is attached to one of the flap liners 107 by a layer of adhesive 117 and by mechanical fasteners 119 such as rivets. In the example shown, the flap liner is a C-section, with a central core 121 which has two folded edges 123. The side edges 109 and 111 of the lower and upper floors 19 and 21 are each directly fixed to a folded edge 123. The core 121 is substantially vertical orientation, that is to say substantially perpendicular to the running surface of the vehicle . In this embodiment, there is therefore at least one closed hollow body 125 to the left of the central zone 37, and a closed hollow body 127 to the right of the central zone 37 which are each partially delimited by a flap liner 107. , the hollow bodies 125 and 127 are delimited upwards by the upper floor 19 downwards by the lower floor 21, towards the inside of the vehicle by the spar 106 and towards the outside of the vehicle by the flap liners 107.
    [0037] The soundproofing layer 23 extends into all the hollow bodies 57 125, 127. It preferably covers the entire surface of the lower floor 21, with the exception of the areas occupied by the stiffening profiles 25, 27, 29, 30 106, and the central zone 37. Alternatively, a soundproofing strip is placed inside each section. Soundproofing is a foam or felt made from cellulosic fibers, polyester fibers or polyamide fibers. The air gap 24 is a layer covering the entire soundproofing layer 23, that is to say 100% of the surface of the soundproofing layer. The sections 25, 27, 29, 30, 106 are also filled with air. The soundproofing layer 23 has at all points a thickness of between 5 and 20 mm. This thickness is preferably between 7 and 15 mm. The air gap 24 has at all points a thickness of between 5 and 50 mm. This thickness is preferably between 10 and 30 mm. In the variant embodiment illustrated in FIG. 9, the floor 10 comprises elements overmoulded on the lower floors 21 and / or higher 19. These elements are, for example, stiffening ribs 170, cable ducts 171, housings 172 intended to house various equipment (computers, connectors ...), or 174 clips for fixing the floor on the vehicle. These elements are made of a material typically comprising a thermoplastic resin and short fibers embedded in the resin. The resin is preferably the same as that forming the lower and / or upper floors. The manufacturing method of the floor 11 or 13 preferably comprises the following steps: - obtain at least two pieces of thermoplastic composite material; forming the upper and lower floors 19, 21 by hot stamping the two pieces. The hot stamping process is known per se. It will not be described in detail here. Each piece is made of one of the thermoplastic materials described above. The hot stamping step makes it possible to give the upper floors 19 and lower 21 their virtually definitive shapes.
    [0038] The method further comprises the following steps: - fixing the stiffening profiles 25, 27, 30, 106 to the lower floor 21; - Establishment of the soundproofing layer 23 on the lower floor 21; - Establishment of the upper floor 19; - Attaching the upper floor 19 to the lower floor 21, along the attachment lines 43, 45, 47, 49, 50 and 51; - Fixing the upper floor 19 to the profiles 25, 27, 30, 106; - Alternatively, fixing the profile 96 to the lower floor; - if applicable, fixing the upper and lower floors 19, 21 to the flap liners 107.
    [0039] Where appropriate, the method comprises a step of overmolding elements of thermoplastic material such as the elements 170, 171, 172, 174 on the lower floors 21 and / or higher 19. The method of manufacturing a vehicle incorporating the floor It will now be described with reference to Figures 5 and 6.
    [0040] The method comprises: a step 131, during which a floor 10 having the above characteristics is provided; - Preferably, a step 132 overmoulding of at least one metal holding piece 141 on the floor. a step 133 for bonding the floor 10 to the metal structure of the vehicle; - Preferably, a step 134 for fixing the or each pre-holding piece of the floor 10 on the metal structure; step 135 of passage of the metal structure and the floor 10 in cataphoresis.
    [0041] The metal structure typically comprises the chassis of the vehicle. This frame comprises, among other things, the sill liners 107. The chassis and the floor together constitute the white body of the vehicle. In step 132, several pre-holding parts 141 are typically overmolded. The parts 141 are typically tabs of which a portion 144 projects from the floor 10. The overmolding step 132 makes it possible to secure each piece of pre-retention. 141 to the floor. Such overmolding is known and will not be described in detail here. The bonding step 133 is performed by depositing a layer of adhesive 145 on the floor 10 and / or on the metal structure, and by plating the floor 10 against the metal structure with the interposition of the adhesive layer 145. This movement simultaneously allows to press each holding piece 141 against the metal structure, as shown in FIG. 5. In step 134 each pre-holding piece 141 is fixed by resistive welding by points, by lines, by rivets such as the rivet 147 shown in Figure 5, by bolts or by any other suitable method. The cataphoresis step 135 comprises two sub-steps: sub-step 149: depositing an anticorrosion product on the metal structure: sub-step 151: subjecting the metal structure and the floor 10 to a cooking operation .
    [0042] As known per se, the white box passes into a cataphoresis bath in the substep 149, the anti-corrosion product being deposited electrostatically on the metal parts. In the sub-step 151, the anti-corrosion product is baked in an oven, the adhesive being polymerized during cooking. The glue does not rigidly fix the floor to the metal structure until the polymerization is completed.
    [0043] Between the bonding step 133 and the firing operation, the floor 10 is locked in position relative to the metal structure by means of the pre-holding part or parts 141. [J Pi] 35
    权利要求:
    Claims (14)
    [0001]
    REVENDICATIONS1. - Vehicle floor, the floor (10) comprising: - an upper floor (19) of a composite material; a lower floor (21) of a composite material extending facing at least a portion of the upper floor (19), the lower and upper floors (19, 21) being connected to each other along at least one fastening line (43, 45, 47, 49, 50, 51, 64, 65, 66) and delimiting between them at least one hollow body (57, 125, 127), characterized in that the floor (10) comprises between the upper floor (19) and the lower floor (21), inside the or each hollow body (57, 125, 127), a sound-absorbing layer (23) and a blade of air superimposed on the soundproofing layer (23).
    [0002]
    Floor according to Claim 1, characterized in that the lower and upper floors (19, 21) are directly connected to one another along at least one of the fastening lines (43, 45, 47). , 49, 50, 51).
    [0003]
    3. Floor according to any one of the preceding claims, characterized in that the floor (10) comprises at least one stiffening section (25, 27, 29, 30) disposed between the upper and lower floors (19, 21). .
    [0004]
    4. Floor according to claim 3, characterized in that the stiffening section (25, 27, 30) is rigidly fixed to the upper floor (19) and / or the lower floor (21).
    [0005]
    5. Floor according to any one of the preceding claims, characterized in that the lower floor (21) comprises two side zones (35) and a central zone (37) projecting towards the upper floor (19) relative to the two lateral zones (35), the central zone (37) being interposed transversely between the two lateral zones (35) and connecting the two lateral zones (35) to one another, the central zone (37) delimiting a longitudinal tunnel .
    [0006]
    6. Floor according to any one of the preceding claims, characterized in that one or more of the attachment lines (43, 45, 47, 49, 50, 51, 64, 65, 66) together define a closed contour, thus delimiting one or more closed hollow bodies.
    [0007]
    7. Floor according to any one of the preceding claims, characterized in that the fastening lines (43, 45, 47, 49, 50, 51, 64, 65, 66) are liquid-tight.
    [0008]
    8. Floor according to any one of the preceding claims, characterized in that the soundproofing layer (23) has a thickness of between 5 and 20 mm.
    [0009]
    9. Floor according to any one of the preceding claims, characterized in that the air gap (24) has a thickness of between 5 and 50 mm.
    [0010]
    10. Vehicle (1) comprising: - a chassis; - A floor (10) according to any one of the preceding claims, rigidly fixed to the frame.
    [0011]
    11. Vehicle according to claim 10, characterized in that the floor (10) comprises reinforcing members (25, 27) arranged between the upper and lower floors (19, 21), the vehicle having seats (17) directly attached to the reinforcing members (25, 27).
    [0012]
    12. A method of manufacturing a floor according to any one of claims 1 to 9, the method comprising the following steps: - obtain at least two pieces of thermoplastic composite material; forming the upper and lower floors (19, 21) by hot stamping the two pieces.
    [0013]
    13. A method of manufacturing a vehicle, the method comprising the following steps: - obtaining a floor (10) according to any one of claims 1 to 9; - sticking the floor (10) on a metal structure (107) of the vehicle; passing the metal structure (107) and the cataphoresis floor, an anticorrosion product being first deposited on the metal structure (107), then the metal structure (107) and the floor (10) being subjected to a cooking operation , the glue being polymerized during cooking.
    [0014]
    14.- Method according to claim 13, characterized in that the method further comprises the following steps: - overmolding at least one metal pre-holding piece (141) on the floor (10); between the gluing step and the firing operation, locking the floor (10) in position relative to the metal structure (107) with the or each pre-holding piece (141), the or each pre-holding piece (141) being rigidly fixed to the metal structure (107).
    类似技术:
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    同族专利:
    公开号 | 公开日
    CN107107969A|2017-08-29|
    US20180050735A1|2018-02-22|
    CN107107969B|2019-07-19|
    EP3194253A1|2017-07-26|
    EP3194253B1|2019-01-23|
    FR3026080B1|2017-10-06|
    WO2016042153A1|2016-03-24|
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    EP2860086A1|2012-06-08|2015-04-15|Honda Motor Co., Ltd.|Fibre-reinforced plastic cabin for vehicle|CN110316258A|2018-03-30|2019-10-11|比亚迪股份有限公司|Preceding floor panel structure, preceding floor assembly and vehicle|
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    法律状态:
    2015-08-27| PLFP| Fee payment|Year of fee payment: 2 |
    2016-03-25| PLSC| Search report ready|Effective date: 20160325 |
    2016-08-22| PLFP| Fee payment|Year of fee payment: 3 |
    2017-08-22| PLFP| Fee payment|Year of fee payment: 4 |
    2018-08-22| PLFP| Fee payment|Year of fee payment: 5 |
    2019-08-20| PLFP| Fee payment|Year of fee payment: 6 |
    2021-06-11| ST| Notification of lapse|Effective date: 20210506 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1458842A|FR3026080B1|2014-09-18|2014-09-18|COMPOSITE FLOOR, VEHICLE COMPRISING SUCH FLOOR, FLOOR MANUFACTURING METHOD, VEHICLE MANUFACTURING METHOD|FR1458842A| FR3026080B1|2014-09-18|2014-09-18|COMPOSITE FLOOR, VEHICLE COMPRISING SUCH FLOOR, FLOOR MANUFACTURING METHOD, VEHICLE MANUFACTURING METHOD|
    EP15766488.9A| EP3194253B1|2014-09-18|2015-09-18|Method for the production of a vehicle and vehicle comprising a composite floor|
    PCT/EP2015/071503| WO2016042153A1|2014-09-18|2015-09-18|Composite floor, vehicle comprising such a floor, method for the production of the floor and method for the production of the vehicle|
    CN201580062429.6A| CN107107969B|2014-09-18|2015-09-18|Composite floor board, the vehicle comprising this floor, the manufacturing method on the floor and the vehicle manufacturing method|
    US15/512,803| US20180050735A1|2014-09-18|2015-09-18|Composite floor, vehicle comprising such a floor, method for the production of the floor and method for the production of the vehicle|
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