CN102463882A - 制造用于车辆的组件的方法 - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/24—Grouping of fuel cells, e.g. stacking of fuel cells
- H01M8/2465—Details of groupings of fuel cells
- H01M8/247—Arrangements for tightening a stack, for accommodation of a stack in a tank or for assembling different tanks
- H01M8/2475—Enclosures, casings or containers of fuel cell stacks
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- H—ELECTRICITY
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
- H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
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- H—ELECTRICITY
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
- Y10T29/49622—Vehicular structural member making
Abstract
本发明提供一种制造用于车辆的组件的方法和一种用于车辆的组件，该组件包括具有向外延伸的多个弹性可变形定位突出部第一构件，和限定出向内延伸的空腔且包括设置在该空腔中的多个弹性可变形挤压结构特征的第二构件。第一构件的定位突出部以与第二构件的挤压结构特征压配合接合的方式设置在第二构件的空腔，以将第一构件相对于第二构件太固定。第一构件的所有定位突出部和第二构件的所有挤压结构特征之间的弹性变形的平均性紧缺地将第一构件相对于第二构件对准。组件可包括但不限于多个单元电池组，多个单元燃料电池组，仪表盘组件或连结的车身板。
Description
技术领域
本发明通常涉及制造用于车辆的组件方法的，且更具体地涉及使用弹性可变形结构特征部的平均弹性变形来固定和对准第一构件和第二构件的方法。
背景技术
当制造用于车辆的各种不同组件时，通常非常重要的是精确地让第一构件相对于第二构件对准，以对准堆叠的组件或出于功能或美观的目的获得小且均匀的间隙。各种不同车用组件(其中第一构件必须精确地与第二构件对准)可包括但不限于用于电动车的多个电池组的板件，用于氢燃料电池的燃料电池组的多个板件，相对于彼此或支撑结构的、仪表盘组件的一个或多个部件，相对于支撑结构的车身板，或相对于车身板的内饰板。
不同构件可以与基准面参考结构(datum reference structure)对准，其中不同构件的一个或多个表面被压靠到基准面参考结构以消除不同构件之间各种程度的运动。替换地，定位结构特征部可被机加工到或以其他方式附接到不同构件。但是，为了计入定位结构特征部之间的部件变化，必须在定位结构特征部中设计一定量的公差，这会减小对准的精确性。
发明内容
提供一种制造用于车辆的组件的方法。方法包括形成第一构件以包括多个弹性可变形定位突出部。定位突出部从第一构件的外表面向外延伸。形成第二构件以限定出空腔，并包括设置在空腔中的多个弹性可变形挤压结构特征部。方法还包括以与多个挤压结构特征部压配合接合的方式将多个定位突出部插入到空腔中。定位突出部和挤压结构特征部之间的压配合接合将第一构件和第二构件相对于彼此固定。所有多个定位突出部和所有多个挤压结构特征部之间的弹性变形的平均性精确地将第一构件相对于第二构件对准。
还提供一种能量存储装置。能量存储装置包括多个构件，所述多个构件彼此面对面相邻地、沿纵向轴线布置，以限定出构件的连续堆叠结构。多个构件每一个包括多个弹性可变形定位突出部，所述突出部从第一面向外延伸。每个多个构件限定出空腔，所述空腔向内延伸到第二面(与第一面相对)中，每个多个构件包括设置在空腔中的多个挤压结构特征部。每个相邻的一对多个构件包括设置在第二构件的空腔中的第一构件的多个定位突出部设置在，从而多个挤压结构特征部通过定位突出部造成的弹性变形将第一构件和第二构件相对于彼此固定。第一构件的所有多个定位突出部和第二构件的所有挤压结构特征部之间的弹性变形的平均性精确地将第一构件相对于第二构件沿堆叠结构的纵向轴线对准。每个构件上的多个定位突出部每一个从每个构件的外表面沿中心轴线向外延伸。每个定位突出部包括垂直于它们各自中心轴线的截面形状，该形状限定为圆形、七边形、八边形、十边形或十二边形中的一种。多个挤压结构特征部包括将至少一个挤压突出部、至少一个挤压肋和至少一个挤压突脊的组合。
因而，在组件的制造过程中第一构件的定位突出部和第二构件的挤压结构特征部之间的干涉配合接合将第一构件和第二构件固定在一起。多个弹性可变形定位突出部和多个弹性可变形挤压结构特征部限定出第一构件和第二构件之间的多个接触点。因而，定位突出部和挤压结构特征部之间的弹性变形的平均性提供了第一构件相对于第二构件的精确且高度可重复的对准，由此精确地将第一构件相对于第二构件定位而不需要昂贵的基准面对准工具。多个接触部还增加了连接部的结构刚性。
当结合附图时，从下面的用于执行如所附权利要求限定的本发明的一些较佳方式和其它实施例的具体描述可容易地明白本发明的上述特征和优点，以及其它特征和优点。
附图说明
图1是用于车辆的组件的示意性透视图，其中该组件包括用多个构件制造的能量存储装置。
图2是图1所示能量存储装置的其中一个构件的第一面的示意性视图。
图3是图1所示能量存储装置的其中一个构件的第二面的示意性视图。
图4是沿图2的4-4线截取的能量存储装置其中一个构件的一部分的示意性侧视图。
图5是图2所示的能量存储装置其中一个构件的一部分的放大示意图，显示了多个定位突出部。
图6是图3所示的能量存储装置其中一个构件的一部分的放大示意图，显示了多个挤压结构特征部。
图7是其中一个定位突出部的第一替换形状的示意图。
图8是其中一个定位突出部的第二替换形状的示意图。
图9是其中一个定位突出部的第三替换形状的示意图。
图10是其中一个定位突出部的第四替换形状的示意图。
图11是用活性材料制造的多个定位突出部的放大示意侧视图，且其以最初和/或最终形状示出。
具体实施方式
参见附图，其中几幅图中相同的附图标记指示相同的部件，用于车辆的组件通常以20示出。如图所示，组件20包括能量存储装置22，例如但不限于电池组或燃料电池组。但是，组件20可包括一些其他车用组件20(未示出或未在本文描述)，包括但不限于仪表盘组件20或车身板组件20。尽管如本文所述的本发明被描述为并入到能量存储装置22中，但是应理解本发明可并入到其他车用组件20中，且能量存储装置22仅是被描述为是包括本发明的车用组件20的一个示例性实施例。
参见图1到3，能量存储装置22包括多个大致平坦的构件24。每个构件包括第一面26(图2所示)和第二面28(图3所示)。通过将每个平坦构件24的表面相对置(即相反的)而限定出多个平坦构件24的第一面26和第二面28。多个平坦构件24布置为沿纵向轴线30面对面地彼此相邻，以限定出平坦构件24的连续堆叠结构32。因而，一个平坦构件24的每个第一面26被设置为邻近另一平坦构件24的第二面28。平坦构件24的堆叠结构32可包括任何数量的平坦构件24。例如，能量存储装置22可包括数百个平坦构件24。应理解堆叠结构32的端部构件的露出面并不被设置为邻近另一平坦构件24。
出于描述本发明的目的，多个平坦构件24以第一构件34(图2所示)和第二构件36(图3所示)的方式在本文进行描述。但是，应理解平坦构件24的堆叠结构32可以包括但不是必须包括比第一构件34和第二构件36更多的构件，且第一构件34和第二构件36的描述可应用到所有多个平坦构件24。
还参见图4到6，每个第一构件34和第二构件36可包括多个弹性可变形定位突出部38，所述突出部从第一面26的外表面向外延伸。第一构件34和第二构件36上的定位突出部38分别从每个构件的第一面26沿每个定位突出部38的中心轴线40向外延伸。每个定位突出部38包括垂直于它们各自的中心轴线40的截面形状。定位突出部38的截面形状可限定为而不是限制为如图4所示的圆形、如图7所示的七边形、如图8所示的八边形、如图9所示的十边形、或如图10所示的十二边形中的一种。各个定位突出部38还可以在同一组件20和或构件24中具有不同尺寸或变化的比例，并入粗糙和精细的定位顺序。
每个第一构件34和第二构件36可限定出空腔42，所述空腔分别向内延伸到第一构件34和第二构件36的第二面28。优选地，空腔42向内延伸一深度44，该深度等于或大于定位突出部38的长度46。每个第一构件34和第二构件36还可包括多个挤压结构特征部48、50、52，它们分别设置在第一构件34和第二构件36的空腔42中。多个挤压结构特征部48、50、52可包括但不限于至少一个挤压突出部48、至少一个挤压肋50和至少一个挤压突脊52的组合。每个挤压突出部48大致是圆柱形的轴，所述轴分别沿与每个定位突出部38的中心轴线40平行的轴线延伸。每个挤压肋50是中间或内部壁，所述壁分别在第一构件34和第二构件36的相对侧壁之间延伸，且其分别沿与每个定位突出部38的中心轴线40平行的平面延伸。每个挤压突脊52是材料突脊，其分别在第一构件34和第二构件36的侧壁周围周向地设置，且分别沿与每个定位突出部38的中心轴线40平行的线向内朝向空腔42的中心延伸。挤压突出部48、挤压肋50和挤压突脊52都彼此间隔开，以在它们之间限定出基本相等但仍略小于其中一个定位突出部38的至少一个区域。因而，将定位突出部38插入到各个挤压结构特征部48、50、52之间的区域中能迫使定位突出部38和/或至少一个挤压结构特征部48、50、52进行挤压。
因而，每个第一构件34和第二构件36优选地相同，每个第一构件34和第二构件36包括多个弹性可变形定位突出部38，且每个第一构件34和第二构件36限定出空腔42并包括设置在它们各自空腔中的多个弹性可变形挤压结构特征部48、50、52。
定位突出部38和挤压结构特征部48、50、52包括并用弹性可变形材料制造。例如，定位突出部38和挤压结构特征部48、50、52可包括并用聚合物材料制造，包括但不限于塑料。此外，定位突出部38可包括但不是必须包括活性材料(active material)，其能响应于信号而在第一形状和第二形状之间改变，所述信号例如但不限于电信号或热信号。如下文更详细描述的，在施加信号时，形成定位突出部38的活性材料从非赋能形状(non-energizedshape)变化为暂时的赋能形状(energized shape)，即第一形状。在去除信号时，活性材料便回到非赋能形状，例如第二形状。
每个相邻的一对构件，即第一构件34和第二构件36，包括设置在第二构件36的空腔42中的第一构件34的定位突出部38。第一构件34的定位突出部38以与第二构件36的挤压结构特征部48、50、52压配合接合的方式设置在第二构件36的空腔42。将定位突出部38插入到空腔42中能使得其中一个定位突出部38和/或其中一个挤压结构特征部48、50、52弹性变形。每个定位突出部38和至少一个挤压结构特征部48、50、52之间的弹性变形将第一构件34和第二构件36相对于彼此固定在一起。第一构件34的所有定位突出部38和第二构件36的所有挤压结构特征部48、50、52之间的平均弹性变形精确地且一致地将第一构件34相对于第二构件36沿堆叠结构32的长度方向轴线30对准。
尽管本发明目前被描述为包括多个相同的构件，其每个都限定了定位突出部38和挤压结构特征部48、50、52，但是应理解构件不必相同。例如，如图1所示，组件20可包括限定出定位结构特征和挤压结构特征48、50、52中之一的每个大致平坦的构件24，而细长构件56限定出定位结构特征和挤压结构特征部48、50、52中的另一个。如图所示，大致平坦的构件24限定出挤压结构特征部48、50、52，而细长构件56限定出定位突出部38。细长构件56跨过平坦构件24的堆叠结构32的长度46，由此将大致平坦的构件24固定在一起并将大致平坦的构件24相对于彼此定位。
提供一种制造组件20的方法。尽管针对附图所示的示例性能量存储装置22描述了该方法，但是应理解本发明方法的范围并不限于制造能量存储装置22，而是能制造其他组件20。
该方法包括形成第一构件34以包括多个弹性可变形定位突出部38。第一构件34形成为使得定位突出部38从第一构件34的外表面(即第一面26)向外延伸。定位突出部38可以形成在第一面26的任何所需区域中。优选地，定位突出部38形成在具有重要对准需求的区域中，包括但不限于冷却槽道，侧部结构，前轮连接杆孔(tie rod hole)，电池单元，密封区域等。
形成第一构件34可包括用同一材料与第一构件34一起形成多个定位突出部38。例如，第一构件34和定位突出部38可通过注塑模制工艺等用聚合物形成，即塑料材料。替换地，第一构件34和定位突出部38可通过常规机加工工艺机加工到第一构件34中。
替换地，形成第一构件34以包括多个定位突出部38的步骤可包括与第一构件34分开地形成定位突出部38。分开且单独的定位突出部38可用用于第一构件34的同一材料形成，或替换地可用与用于形成第一构件34的不同材料形成，例如但不限于活性材料。如果定位突出部38与第一构件34分开形成，则形成第一构件34以包括多个定位突出部38的步骤包括将定位突出部38安装到预先形成的第一构件34。定位突出部38可以以任何合适的方式安装，例如但不限于紧固件、化学连结、焊接或包覆模制。例如，如果定位突出部38与第一构件34分开形成，则与第一构件34分开形成定位突出部38可包括将多个定位突出部38包覆模制到预先形成的第一构件34上。
该方法还包括形成第二构件36以限定出空腔42，并包括设置在空腔42中的多个弹性可变形挤压结构特征部48、50、52。如上所述，每个构件可包括在第一面26和空腔42二者上的定位突出部38，而在第二面28上具有挤压结构特征部48、50、52，或替换地包括分开的构件，如上所述的细长构件56。具有挤压结构特征部48、50、52的空腔42沿第二构件的、基本对应于或对准于第一构件34的定位突出部38的一些位置上。
形成第二构件36可包括用同一材料与第二构件36整体地形成多个挤压结构特征部48、50、52。例如，第二构件36和挤压结构特征部48、50、52可通过用聚合物(即塑料材料)通过注塑模制工艺等形成。替换地，第二构件36和挤压结构特征部48、50、52可通过常规机加工工艺机加工到第二构件36中。
该方法还包括以与多个挤压结构特征48、50、52压配合接合的方式将第一构件34的定位突出部38插入到第二构件36的空腔42中。以压配合接合的方式将多个定位突出部38插入到空腔42中的步骤包括使得定位突出部38和/或至少一个挤压结构特征部48、50、52弹性变形。如此，定位突出部38和/或至少一个挤压结构特征部48、50、52的弹性变形将第一构件34和第二构件36相对于彼此固定。此外，所有多个定位突出部38和所有多个挤压结构特征部48、50、52之间的弹性变形的平均性精确地且可重复地将第一构件34相对于第二构件36对准。
如果用于形成多个定位突出部38的材料包括活性材料，其中该活性材料的定位突出部38包括在赋能状态时的第一形状和在解除赋能状态时的第二形状，则该方法还包括赋能该定位突出部38，以使得在将多个定位突出部38插入到空腔42中之前多个定位突出部38每一个变为第一形状。本方法还包括解除对定位突出部38的赋能，以使得在将多个定位突出部38插入到空腔42中之后每个定位突出部38变为第二形状。如果第二形状是最初和/或最终形状，且第一形状是暂时的安装形状，则对定位突出部38赋能使得定位突出部38的形状从最初形状(即第二形状)变为暂时的安装形状(即第一形状)。在定位突出部38被插入到空腔42中并与挤压结构特征部48、50、52接合时，定位突出部38可被解除赋能，以使得定位突出部38由此变回到最初和/或最终形状。
例如，第一形状(例如暂时安装形状)可包括但不限于圆柱形，且第二形状(例如最初和/或最终形状)可包括但不限于沿每个相应定位突出部38的中心轴线40延伸的倒锥形，如图11的58所示。因而，定位突出部38的倒锥形被楔入到或更牢固地抓持到挤压结构特征部48、50、52，以更好地将定位突出部38固定在空腔42中。
一旦定位突出部38被插入到空腔中进入与挤压结构特征部48、50、52的压配合状态，则该方法还包括将第一构件34和第二构件36固定在一起。将第一构件34和第二构件36固定的步骤可包括永久地将第一构件34和第二构件36附接在一起。第一构件34和第二构件36可以以任何合适的专用于所制造的组件20类型的方式永久地附接。例如，将第一构件34和第二构件36固定在一起的步骤可包括但不限于用紧固件将第一构件34和第二构件36紧固在一起，将第一构件34和第二构件36焊接在一起，或用化学粘接剂将第一构件34和第二构件36结合在一起。如此，第一构件34的定位突出部38和第二构件36的挤压结构特征部48、50、52之间的压配合接合的目的仅是暂时地对准和附接，并通过其他固定工艺实现最终且永久的附接。
虽然用于执行本发明的较佳方式已经被详细描述，与本发明相关的本领域技术人员应认识到在所附的权利要求的范围内的执行本发明的各种替换设计和实施例。
本发明要求于2010年11月9日提交的美国临时专利申请No.61/411,614和于2011年9月12日提交的美国专利申请No.13/229926的权益，所述申请的全部内容通过参考全部合并于此。
Claims (10)
1.一种制造用于车辆的组件的方法，该方法包括：
形成第一构件以包括多个弹性可变形定位突出部，所述突出部从第一构件的外表面向外延伸；
形成第二构件以便限定出空腔和以便包括设置在该空腔中的多个弹性可变形挤压结构特征部；
以与多个挤压结构特征部压配合接合的方式将所述多个定位突出部插入到所述空腔中，从而第一构件和第二构件相对于彼此固定且所有多个定位突出部和所有多个挤压结构特征部之间的弹性变形的平均性精确地将第一构件相对于第二构件对准。
2.如权利要求1所述的方法，其中以压配合接合的方式将多个定位突出部插入到空腔中包括使得多个挤压结构特征部中的至少一个弹性变形。
3.如权利要求1所述的方法，还包括将第一构件和第二构件固定在一起。
4.如权利要求3所述的方法，其中将第一构件和第二构件固定在一起包括将第一构件和第二构件用紧固件紧固在一起。
5.如权利要求3所述的方法，其中将第一构件和第二构件固定在一起包括将第一构件和第二构件焊接在一起。
6.如权利要求3所述的方法，其中将第一构件和第二构件固定在一起包括用化学粘接剂将第一构件和第二构件结合在一起。
7.如权利要求1所述的方法，其中形成第一构件包括用同一材料将多个定位突出部与第一构件整体形成。
8.如权利要求7所述的方法，其中用聚合物材料将第一构件和多个定位突出部整体形成在一起。
9.如权利要求1所述的方法，其中形成第二构件包括用同一材料将多个挤压结构特征部与第二构件整体形成。
10.如权利要求9所述的方法，其中用聚合物材料将第二构件和多个挤压结构特征部整体形成在一起。
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|---|---|---|---|
| US41161410P | 2010-11-09 | 2010-11-09 | |
| US61/411,614 | 2010-11-09 | ||
| US13/229,926 US9812684B2 (en) | 2010-11-09 | 2011-09-12 | Using elastic averaging for alignment of battery stack, fuel cell stack, or other vehicle assembly |
| US13/229,926 | 2011-09-12 |
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| CN102463882A true CN102463882A (zh) | 2012-05-23 |
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- 2011-11-08 CN CN2011103490278A patent/CN102463882A/zh active Pending
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2013
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US9812684B2 (en) | 2010-11-09 | 2017-11-07 | GM Global Technology Operations LLC | Using elastic averaging for alignment of battery stack, fuel cell stack, or other vehicle assembly |
| CN104343788A (zh) * | 2013-08-07 | 2015-02-11 | 通用汽车环球科技运作有限责任公司 | 提供可密封舱室的部件的精确对齐和固定的对齐系统 |
| US9863454B2 (en) | 2013-08-07 | 2018-01-09 | GM Global Technology Operations LLC | Alignment system for providing precise alignment and retention of components of a sealable compartment |
| US9511802B2 (en) | 2013-10-03 | 2016-12-06 | GM Global Technology Operations LLC | Elastically averaged alignment systems and methods |
| US9669774B2 (en) | 2013-10-11 | 2017-06-06 | GM Global Technology Operations LLC | Reconfigurable vehicle interior assembly |
| CN104973133A (zh) * | 2014-04-02 | 2015-10-14 | 通用汽车环球科技运作有限责任公司 | 用于可侧向滑动地接合的适配部件的对准和保持系统 |
| CN104973133B (zh) * | 2014-04-02 | 2018-05-22 | 通用汽车环球科技运作有限责任公司 | 用于可侧向滑动地接合的适配部件的对准和保持系统 |
| US9657807B2 (en) | 2014-04-23 | 2017-05-23 | GM Global Technology Operations LLC | System for elastically averaging assembly of components |
| US9758110B2 (en) | 2015-01-12 | 2017-09-12 | GM Global Technology Operations LLC | Coupling system |
Also Published As
| Publication number | Publication date |
|---|---|
| DE102011117562A1 (de) | 2012-05-10 |
| US9812684B2 (en) | 2017-11-07 |
| US20140080036A1 (en) | 2014-03-20 |
| US20120115010A1 (en) | 2012-05-10 |
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