FR3104047A1 - Manufacturing process of an object and corresponding object - Google Patents

Abstract

Method of manufacturing an object and corresponding object The object (51) comprises: - a part (13) having a large free face (15); - a plate (17) having a plate thickness of between 0.2 and 4 mm, at least one through slot (19) being formed in the plate (17) and defining in the plate (17) at least one flexible region ( 21). The or each flexible region (21) being pressed against the large free face (15) and being fixed directly to the large free face (15). Figure for the abstract: Figure 3

Description

Method of manufacturing an object and corresponding object

The present invention generally relates to the mutual attachment of two parts having a large contact surface with each other.

More specifically, the invention relates to an object comprising a part having a large free face, and a plate of significant thickness, as well as the corresponding manufacturing method.

It is possible, as shown in Figure 1, to weld by transparency the plate 1 on the large face 3 of the part 5, for example using a laser beam 7. The laser beam 7 moves along the weld bead 9 to create. It heats the material of the plate 1 over the entire thickness thereof, and heats the material of the part 5 located immediately under the plate 1. The molten materials mix, and after cooling the plate and the part are rigidly fixed to each other along the weld bead 9.

Such a method of fixing requires that the gap 11 between the plate 1 and the large face 3 of the part 5 be as small as possible. If the gap 11 is too large (see figure 2), the plate 1 is cut when the laser beam 7 moves, and it is not possible to make the weld. The maximum acceptable height for gap 11 depends on the thickness of plate 1.

Consequently, it is difficult, or in some cases impossible, to weld a large surface plate to a part using this type of process, when the weld line has a complex shape. It is necessary that the plate and the large face have excellent flatness, so that the gap 11 is reduced over the entire surface of the plate and the large face, before the welding operation. The plate and the part must then be manufactured using expensive processes. Alternatively, the flatness of the plate and the large face can be improved by a specific preparation step. In all cases, the process is relatively expensive. In addition, distortions may occur during the welding operation.

In this context, the invention aims to provide an object and a manufacturing method which do not have the above defects.

To this end, the invention relates, according to a first aspect, to an object comprising:

- a part having a large free face, the part having a part thickness;

- a plate having a plate thickness of between 0.2 and 4 mm, at least one through slot being made in the plate and defining in the plate at least one flexible region;

the or each flexible region being pressed against the large free face and being fixed directly to the large free face.

Due to the presence of the through slot or slots, the flexible regions can be pressed more easily against the large free face. It becomes possible to fix them to the large free face much more easily, in particular by welding by transparency.

It is not necessary to provide for this purpose a step aimed at improving the flatness of the large free face or of the plate, or to manufacture the part and the plate according to expensive methods.

The object may also have one or more of the characteristics below, considered individually or in all technically possible combinations:

- several slots are cut in the plate, defining between them a plurality of flexible regions pressed against the large free face and fixed directly to the large free face;

- the or each flexible region is fixed to the large free face by welding, or by brazing, or by gluing said flexible region;

- the plate being fixed to the large free face along a determined number of closed contour fixing lines;

- the plate has a determined surface, a ratio between the length of the slots and the determined surface being greater than 0.05 cm/cm²;

- the lines of attachment are arranged in columns, the slot(s) passing between the columns;

- the or each flexible region carries a plurality of lines of attachment, the or each slot defining said flexible region passing at a distance of less than 20 mm from each of the lines of attachment.

According to a second aspect, the invention relates to a method for manufacturing an object comprising the following steps:

- Obtaining a part having a large free face, the part having a part thickness;

- Obtaining a plate having a plate thickness of between 0.2 and 4 mm;

- production of at least one through slot in the plate, defining in the plate at least one flexible region;

- plating of the plate against the large free face, a support being exerted on the or each flexible region so as to press said flexible region against the large free face;

- Definitive fixing of the or each flexible region (21) directly to the large free face (15).

The process may also have one or more of the characteristics below, considered individually or in all technically possible combinations:

- the method comprises, between the plating step and the final fixing step, a step of partially fixing the or each flexible region against the large free face, typically by spot welding, clinching, crimping, riveting, screwing , gluing, and preferably by spot welding;

- at the final fixing stage, the or each flexible region is fixed to the large free face by welding, the welding being carried out with a laser or a TIG-type tool or by electric welding.

Other characteristics 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:

Figure 1 is a simplified schematic representation of the welding by transparency of a plate on the large face of a part;

FIG. 2 illustrates the situation encountered when the large face of the part has a significant lack of flatness;

Figure 3 is a view similar to that of Figure 2, for an object according to the invention, showing the plate after completion of through slots and temporary attachment to the large face of the part;

[Fig 5][Fig 6] Figures 4 to 6 illustrate various examples of the arrangement of weld lines and slots; And

FIG. 7 is a simplified schematic representation of a heat exchanger plate on which the ends of the heat exchange tubes are fixed, the weld lines of another plate and the slots provided on this other plate being represented in broken lines.

The process illustrated in figures 3 to 7 aims to manufacture all kinds of objects in all types of industries. It is particularly well suited for the manufacture of radiators, evaporators, heat pumps, etc.

It is intended in particular for the manufacture of objects for which it is necessary to attach a large plate, of significant thickness, to the large face of another part.

In particular, this process makes it possible to produce weld lines of complex shapes in plates of significant thickness.

The manufacturing process includes the following steps:

- Obtaining a part 13 having a large free face 15, the part 13 having a thickness of part;

- Obtaining a plate 17 having a plate thickness of between 0.2 and 4 mm.

Part 13 is of any suitable type. Part 13 is for example an element of an exhaust line. Typically, part 13 is a valve body, heat exchanger outer shell, fluid conduit, or some other type of part.

The large free face 15 is typically substantially planar.

The process is particularly suitable for large faces 15 having flatness defects which can range for example up to 1.5 mm. These flatness defects are hollow areas with a depth of less than or equal to 1.5 mm, bumps or protruding areas with a height of less than or equal to 1.5 mm, or all kinds of irregularities.

Part 13 has the shape of a thick plate or has any other shape. The alternative piece 13 is a solid block.

Typically, plate thickness is less than or equal to part thickness.

The plate 17, as indicated above, has a plate thickness comprised between 0.2 and 4 mm, preferably comprised between 1 and 3 mm, and being for example equal to 1.5 mm.

The plate 17 has towards the large free face 15 a surface 18 which is typically substantially planar.

As a variant, the plate 17 has flatness defects which can range for example up to 1.5 mm. These flatness defects are recessed areas with a depth of less than or equal to 1.5 mm, bumps or protruding areas with a height of less than or equal to 1.5 mm, or all kinds of irregularities formed on the surface 18.

The method is particularly suitable for the case where the plate 17 has a significant size. Thus, the plate 17 has for example an area of at least 200 cm², preferably at least 400 cm², with no maximum limit.

The large free face 15 has an area at least as large as that of the plate 17.

The method makes it possible to fix the plate 17 to the large free face 15 by means of multiple points, lines or zones, distributed over the entire surface of the plate 17.

Plate 17 is typically made of a metal such as steel.

As a variant, the plate 17 is made of a plastic, a glass, or a composite material.

Likewise, the large free face 15 is typically made of a metal such as steel.

As a variant, the large free face 15 is made of a plastic, a glass, or a composite material.

Typically, the plate 17 and the large free face 15 are made of the same material.

The process includes the following steps:

- production of at least one through slot 19 in plate 17, defining in plate 17 at least one flexible region21;

- Plating of the plate 17 against the large free face 15, a support being exerted on the or each flexible region 21 so as to press said flexible region 21 against the large free face 15;

- final fixing of the or each flexible region 21 directly to the large free face 15.

Typically, at the production stage, several slots 19 are cut in the plate 17, defining between them a plurality of flexible regions 21.

The number of slots 19, their shapes and their sizes are chosen so as to allow the plate 17 to be pressed over its entire surface against the large face 15, with a very small gap 23 between the plate 17 and the large face 15 over the entire plate surface 17.

The height of this gap 23 is typically less than 0.5 mm, preferably less than 0.3 mm, more preferably less than 0.1 mm.

Slots 19 are typically laser cut.

Alternatively, the slots 19 are cut with a water jet, by electro-erosion, by a saw, by punching with a blade, or even by machining.

The slots 19 are said to be through because they extend over the entire thickness of the plate 17, from one large face to another. They emerge at said two large faces.

Preferably, the plate 17 has a determined surface, a ratio between the length of the slots 19 and the determined surface being greater than 0.05 cm/cm².

This makes it possible to confer on the plate 17 sufficient flexibility to be pressed over its entire surface against the large free face 15.

The plating of the plate 17 against the large free face 15 is achieved by any appropriate means, for example by rollers or pistons.

As a variant, the pressing is obtained by a mechanical, pneumatic, or even hydraulic clamping system, such as for example a pneumatic cylinder, a pressure screw, springs, pneumatic beads, or any other elastic system.

Advantageously, the method comprises, between the flattening step and the final fixing step, a step of partial fixing of the or each flexible region 21 against the large free face 15.

This fixing is typically carried out by spot welds 25 securing the periphery of each flexible region 21 to the large free face 15. Alternatively, the partial fixing is carried out by clinching, crimping, riveting, screwing, or even gluing.

The partial fixing has the function of blocking the or each flexible region 21 in position against the large free face before and during the final fixing step.

During the final fixing step, the or each flexible region 21 is fixed to the large free face 15 by welding, or by brazing, or by gluing said flexible region 21.

For example, the welding is carried out with a laser or a TIG-type tool or by electric welding.

Advantageously, the welding is carried out by transparency through the plate 17, as explained with reference to FIG. 1. One or more welding lines are created in each flexible zone 21.

As a variant, the welding is carried out with lap, that is to say by creating a weld line joining the edge or edges of each flexible region 21 to the large free face 5.

Typically, at the final fixing stage, a determined number of closed contour fixing lines 27 are made, the plate 17 being fixed to the large free face 15 along each closed contour fixing line 27.

The or each flexible region 21 typically carries a plurality of attachment lines 27. These attachment lines 27 are distributed over the flexible region 21 so as to keep the latter pressed against the large free face 15 over its entire surface.

The or each slot 19 defining said flexible region 21 passes at a distance of less than 20 mm from each of the attachment lines 27, preferably less than 10 mm, more preferably less than 5 mm.

This means that each attachment line 27 has at least one point located less than 20 millimeters from the or each slot 19.

This makes it possible to ensure that the area carrying the fixing line 27 will be flexible enough to be pressed against the large free face 5.

These closed-contour attachment lines 27 have any shape suited to the case in point. For example, they are substantially circular, elliptical, oval, rectangular, “racetrack” (racetrack), in the form of elongated strips, or any other suitable shape.

In the example of Figure 4, they are in the form of strips 29 elongated transversely. The strips 29 are parallel to each other and are superimposed in a longitudinal direction. The attachment lines 27 all have substantially the same shape and size.

The strips 29 extend transversely over almost the entire width of the plate 17. Longitudinally, the stack of strips extends over almost the entire length of the plate 17.

In this case, the slots 19 are rectilinear and transverse. Each slot passes between two bands 29. Each slot 19 extends practically from one longitudinal edge 31 of plate 17 to the other longitudinal edge 31.

In the example of Figure 5, the attachment lines 27 are substantially oval and more precisely are in the form of a "racetrack" (racetrack). Each line has two straight sections 33, connected to each other by two arcuate sections 35. The fixing lines all have the same size and the same shape.

The lines of attachment 27 are arranged in longitudinal columns.

The attachment lines 27 of the same column are all arranged in the same orientation. The straight sections 33 in the same column all have the same orientation, that is to say they are all parallel to each other.

The lines of attachment 27 of the columns are arranged alternately in two different orientations.

This means that the attachment lines of a given column 37 are oriented with the straight sections 33 forming a first angle α1 with respect to the longitudinal direction. The attachment lines of the two columns 39 which frame the column 37 are oriented with the straight sections 33 forming a second angle α2 different from α1 with respect to the longitudinal direction. In the example shown, α1 is approximately 45° and α2 is approximately -45°.

The attachment lines 27 of column 37 are longitudinally offset from those of columns 39.

The slot or slots 19 pass between the columns.

Each slot 19 is generally longitudinal in orientation. Each slot 19 passes between two columns, or between a column and one of the longitudinal edges 41. Each slot 19 has a zig-zag shape, with successive sections parallel alternately to the straight sections 33 of the column 37 and to the straight sections 33 of column 37.

Each slot 19 extends practically from one transverse edge 43 of plate 17 to the other longitudinal edge 43.

In the example of Figure 6, the plate 17 is fixed by a single closed contour fixing line 27. This defines a spiral strip 45. The plate 37 has a single slot 19, also in the form of a spiral. Slot 19 extends radially outward from spiral strip 45 and winds parallel thereto.

Figure 7 shows a heat exchanger plate, constituting the part 13 having a large free face 15. The ends 47 of the heat exchange tubes are fixed to the plate 13.

The heat exchanger plate is pierced by holes in which the ends 47 are received. The holes are for example grouped in pairs.

Another plate, corresponding to plate 17 described above, is provided to be attached to heat exchanger plate 13 by attachment lines 27 shown in dashed lines. The other plate is not shown in Figure 7.

Each attachment line 27 is a circle, surrounding a group of two holes.

The lines of attachment 27 are arranged in a matrix comprising several rows and several columns.

The slots 19 provided on this other plate are shown in broken lines. Each slot 19 is of longitudinal orientation. Each slot 19 passes between two columns. Alternatively, the slots are transverse and pass between two rows.

In the various examples described above, the slots 19 do not extend to the edges of the plate 17. Alternatively, one or more slots 19 extends to one of the edges of the plate. However, the slots 19 do not extend at their two opposite ends to the edges of the plate 17, so that the plate 17 remains in one piece.

The slots 19 are not necessarily parallel to each other. They can be inclined relative to each other and even intersect.

Consequently, the flexible regions 21 are not necessarily bands and have any kind of shape: triangular, arcuate, etc.

According to another aspect, the invention relates to an object 51.

This object 51 is typically obtained by the manufacturing method described above.

Conversely, the manufacturing process is specially adapted to produce object 51.

Object 51 includes:

- a piece 13 having a large free face 15, the piece 13 having a piece thickness;

- a plate 17 having a plate thickness of between 0.2 and 4 mm, at least one through slot 19 being made in the plate 17 and defining in the plate 17 at least one flexible region 21;

the or each flexible region 21 being pressed against the large free face 15 and being fixed directly to the large free face 15.

Part 13 is as described above.

Plate 17 is as described above. In particular, it has a plate thickness comprised between 0.2 and 4 mm, preferably comprised between 1 and 3 mm, and for example equal to 1.5 mm.

The plate thickness is preferably less than or equal to the part thickness.

Plate 17 is typically substantially planar.

Plate 17 has an area of at least 200 cm², preferably at least 400 cm², with no maximum limit.

The large free face 15 has an area at least as large as that of the plate 17.

Typically, several slots 19 are cut in the plate 17, defining between them a plurality of flexible regions 21.

The number of slots 19, their shapes and their sizes are chosen so as to allow the plate 17 to be pressed over its entire surface against the large face 15, with a very small gap 23 between the plate 17 and the large face 15 over the entire plate surface 17.

The height of this gap 23 is typically less than 0.5 mm, preferably less than 0.3 mm, more preferably less than 0.1 mm.

The slots 19 are said to be through because they extend over the entire thickness of the plate 17, from one large face to another. They emerge at said two large faces.

Preferably, the plate 17 has a determined surface, a ratio between the length of the slots 19 and the determined surface being greater than 0.05 cm/cm².

This makes it possible to give the plate 17 sufficient flexibility to be pressed over its entire surface against the large free face 15.

The or each flexible region 21 is fixed to the large free face 15 by one or more weld lines, or by a brazing material, or by an adhesive.

Advantageously, the welding is carried out by transparency through the plate 17, as explained with reference to FIG. edges of each flexible region 21 to the large free face 5.

The or each flexible region 21 typically carries a plurality of attachment lines 27. These attachment lines 27 are distributed over the flexible region 21 so as to keep the latter pressed against the large free face 15 over its entire surface.

The or each slot 19 defining said flexible region 21 passes at a distance of less than 20 mm from each of the attachment lines 27, preferably less than 10 mm, more preferably less than 5 mm.

This means that each attachment line 27 has at least one point located less than 20 millimeters from the or each slot 19.

This makes it possible to ensure that the area carrying the fixing line 27 will be flexible enough to be pressed against the large free face 5.

These closed-contour attachment lines 27 have any shape suited to the case in point. For example, they are substantially circular, elliptical, oval, rectangular, “racetrack” (racetrack), in the form of elongated strips, or any other suitable shape.

For example, the attachment line or lines 27 and the slot or slots 19 are as described above with reference to Figure 4, or to Figure 5 or to Figure 6 or even to Figure 7.

The invention has been described in the case where the plate 17 has a plate thickness less than the part thickness. Alternatively, part 13 has a thickness less than that of plate 17, in particular when part 13 is already fixed to tubes and is therefore stiffened by said tubes.

Claims (10)

- Object (51) comprising:
- a part (13) having a large free face (15), the part (13) having a part thickness;
- a plate (17) having a plate thickness of between 0.2 and 4 mm, at least one through slot (19) being made in the plate (17) and defining in the plate (17) at least one flexible region ( 21);
the or each flexible region (21) being pressed against the large free face (15) and being fixed directly to the large free face (15). - Object according to claim 1, wherein several slots (19) are cut in the plate (17), defining between them a plurality of flexible regions (21) pressed against the large free face (15) and fixed directly to the large face free (15). - Object according to claim 1 or 2, wherein the or each flexible region (21) is fixed to the large free face (15) by welding, or by brazing, or by gluing said flexible region (21). - Object according to any one of the preceding claims, in which the plate (17) being fixed to the large free face (15) along a determined number of closed contour fixing lines (27). - Object according to claim 4, in which the plate (17) has a determined surface, a ratio between the length of the slots (19) and the determined surface being greater than 0.05 cm/cm². - Object according to claim 4 or 5, wherein the attachment lines (27) are arranged in columns, the slot or slots (19) passing between the columns. - Object according to any one of claims 4 to 6, wherein the or each flexible region (21) carries a plurality of lines of attachment (27), the or each slot (19) defining said flexible region (21) passing a distance of less than 20 mm from each of the fixing lines (27). - Method of manufacturing an object (51), comprising the following steps:
- Obtaining a part (13) having a large free face (15), the part (13) having a part thickness;
- obtaining a plate (17) having a plate thickness between 0.2 and 4 mm;
- production of at least one through slot (19) in the plate (17), defining in the plate (17) at least one flexible region (21);
- pressing the plate (17) against the large free face (15), a support being exerted on the or each flexible region (21) so as to press said flexible region (21) against the large free face (15);
- Definitive fixing of the or each flexible region (21) directly to the large free face (15). - Method according to claim 8, in which the method comprises, between the plating step and the final fixing step, a step of partially fixing the or each flexible region (21) against the large free face (15), typically by spot welding (25), clinching, crimping, riveting, screwing, gluing, and preferably by spot welding (25). - Method according to claim 8 or 9, in which, in the final fixing step, the or each flexible region (21) is fixed to the large free face (15) by welding, the welding being carried out with a laser or a TIG type tool or by electric welding.