Multi-material vehicle roof stiffener

• US 10,661,838 B2
• Filed: 05/31/2017
• Issued: 05/26/2020
• Est. Priority Date: 05/31/2017
• Status: Active Grant

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Sheldon, Allen B., Hoffman, Benjamin, Detwiler, Duane T., Hahnlen, Ryan M.
• Primary Examiner(s): Gutman, Hilary L
• Application Number:
  US15/610,146
• Publication Number:
  US 20180346034A1
• Time in Patent Office: 1,091 Days
• CPC Class Codes: B29C 70/023 with reinforcing inserts
• CPC Class Codes: B29C 70/304 In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
• CPC Class Codes: B29C 70/54 Component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29L 2031/3002 Superstructures characterized by combining metal and plastics, i.e. hybrid parts
• CPC Class Codes: B29L 2031/3055 Cars
• CPC Class Codes: B62D 25/06 Fixed roofs non-fixed roofs or like shelters B60J7/00; roof liners B60R13/02; insulating elements B60R13/08
• CPC Class Codes: B62D 27/026 Connections by glue bonding in general F16B11/00; processes C09J5/00
• CPC Class Codes: B62D 29/001 characterised by combining metal and synthetic material
• CPC Class Codes: B62D 29/008 predominantly of light alloys, e.g. extruded

Abstract

A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Claims

1. A vehicle roof stiffener, comprising:

a fiber reinforced polymer (FRP) portion including at least one transition structure comprising a metal or a metal alloy, at least some of the fibers of the FRP portion are embedded in the transition structure; and

at least one metal or metal alloy portion secured to the transition structure of the FRP portion,

wherein an interface, between the at least one metal portion and the at least one FRP portion, includes an offset flange in the at least one metal portion, wherein the transition structure fills at least a portion of an offset between the offset flange and a top surface of the at least one metal portion.

2. The vehicle roof stiffener of claim 1, wherein the at least one metal portion and the at least one FRP portion define a central opening.

3. The vehicle roof stiffener of claim 2, further comprising studs attached to a surface of the FRP portion proximate the central opening for mounting a glass assembly.

4. The vehicle roof stiffener of claim 3, further comprising fasteners extending through the at least one metal portion proximate the central opening for mounting the glass assembly.

5. The vehicle roof stiffener of claim 1, further comprising at least one elongated transition structure, wherein at least some of the fibers of the FRP are embedded within a metal or metal alloy tab of the elongated transition structure extending along an edge of the FRP portion.

6. The vehicle roof stiffener of claim 5, further comprising a vehicle frame attached to the at least one elongated transition structure, wherein the vehicle frame is a metal alloy and the at least one elongated transition structure comprises aluminum.

7. The vehicle roof stiffener of claim 5, further comprising a vehicle roof panel welded to the at least one elongated transition structure, wherein the vehicle roof panel comprises aluminum and the at least one elongated transition structure comprises aluminum.

8. The vehicle roof stiffener of claim 1, wherein the transition structure is connected to the at least one metal portion via at least one spot weld.

9. The vehicle roof stiffener of claim 1, wherein the at least one metal portion extends parallel to a longitudinal axis of a vehicle and the at least one FRP portion extends transverse to the longitudinal axis.

10. The vehicle roof stiffener of claim 9, wherein the at least one FRP portion comprises a front FRP portion and a rear FRP portion.

11. The vehicle roof stiffener of claim 10, wherein the front FRP portion forms two corners of the vehicle roof stiffener and the rear FRP portion forms two corners of the vehicle roof stiffener, wherein the at least one metal portion includes two metal portions forming sides of the vehicle roof stiffener.

12. The vehicle roof stiffener of claim 11, wherein each of the at least one transition structure is located on one of the sides of the vehicle roof stiffener.

13. The vehicle roof stiffener of claim 10, wherein the front FRP portion forms two corners of the vehicle roof stiffener and the at least one metal portion includes two metal portions forming sides of the vehicle roof stiffener that extend to form rear corners of the vehicle roof stiffener.

14. The vehicle roof stiffener of claim 1, wherein the at least one transition structure includes a region with no embedded fiber where the transition structure is to be joined to the at least one metal portion.

15. A vehicle roof stiffener, comprising:

a fiber reinforced polymer (FRP) portion including at least one transition structure comprising a metal or a metal alloy, at least some of the fibers of the FRP portion are embedded in the transition structure; and

at least one metal or metal alloy portion secured to the transition structure of the FRP portion, wherein the at least one metal or metal alloy portion extends parallel to a longitudinal axis of a vehicle and the at least one FRP portion extends transverse to the longitudinal axis wherein the at least one FRP portion comprises a front FRP portion and a rear FRP portion, wherein the front FRP portion forms two corners of the vehicle roof stiffener and the rear FRP portion forms two corners of the vehicle roof stiffener, wherein the at least one metal portion includes two metal portions forming sides of the vehicle roof stiffener.

16. The vehicle roof stiffener of claim 15, wherein the at least one metal portion and the at least one FRP portion define a central opening, further comprising:

studs attached to a surface of the FRP portion proximate the central opening for mounting a glass assembly; and

fasteners extending through the at least one metal portion proximate the central opening for mounting the glass assembly.

17. The vehicle roof stiffener of claim 15, further comprising at least one elongated transition structure, wherein at least some of the fibers of the FRP are embedded within a metal or metal alloy tab of the elongated transition structure extending along an edge of the FRP portion, further comprising:

a vehicle frame attached to the at least one elongated transition structure, wherein the vehicle frame is a metal alloy and the at least one elongated transition structure comprises aluminum; and

a vehicle roof panel welded to the at least one elongated transition structure, wherein the vehicle roof panel comprises aluminum.

18. The vehicle roof stiffener of claim 15, wherein the transition structure is connected to the at least one metal portion via at least one spot weld.

19. The vehicle roof stiffener of claim 15, wherein each of the at least one transition structure is located on one of the sides of the vehicle roof stiffener.

20. The vehicle roof stiffener of claim 15, wherein the at least one transition structure includes a region with no embedded fiber where the transition structure is to be joined to the at least one metal portion.