Assembly of Subassemblies Having a Mating Bond Interface for a Motor Vehicle

• US 20200122787A1
• Filed: 10/23/2018
• Published: 04/23/2020
• Est. Priority Date: 10/23/2018
• Status: Active Grant

• Current Assignee: Global IP Holdings LLC
• Original Assignee: Global IP Holdings LLC
• Inventors: Grajek, Scott Allen, Straight, Jesse Brian, Fowler, Dustin Martin, Morse, Shane Caird
• Granted Patent: US 10,640,157 B1
• Time in Patent Office: Days
• CPC Class Codes: B62D 29/04 predominantly of synthetic material working of plastics or substances in a plastic state B29
• CPC Class Codes: B62D 29/048 Connections therefor, e.g. joints B62D29/045 takes precedence
• CPC Class Codes: B62D 35/007 Rear spoilers B62D35/001 takes precedence
• CPC Class Codes: B62D 37/02 by aerodynamic means
• CPC Class Codes: Y02T 10/82 Elements for improving aerodynamics

Abstract

An assembly of subassemblies having a mating bond interface for a motor vehicle is provided. The assembly includes a first subassembly of molded composite material and a second subassembly of molded composite material. An adjustable mating interface couples the subassemblies together. The interface includes a groove and a flange disposed on the first subassembly and bonded within the groove. The groove is sized and shaped relative to the size and shape of the flange to allow a bonding position of the flange within the groove to be adjusted during assembly of the subassemblies so that the mating interface is adjustable.

Claims

1. An assembly of subassemblies having a mating bond interface for a motor vehicle, the assembly comprising:

a composite molded first subassembly;

a composite molded second subassembly; and

an adjustable mating interface for coupling the subassemblies together, the interface including (i) a groove formed on the second subassembly and (ii) a first flange disposed on the first subassembly and bonded within the groove wherein the groove is sized and shaped relative to the size and shape of the first flange to allow a bonding position of the first flange within the groove to be adjusted during assembling of the subassemblies so that the mating interface is adjustable.

2. The assembly as claimed in claim 1 wherein the first subassembly includes a first opening which extends into an interior of the first subassembly from an exterior of the first subassembly, the first flange extending about the periphery of the first opening of the first subassembly.

3. The assembly as claimed in claim 2 wherein the second subassembly includes a second opening which extends into an interior of the second subassembly from an exterior of the second subassembly, the groove extending about the periphery of the second opening of the second subassembly and wherein the first opening of the first subassembly and the second opening of the second subassembly are in fluid communication with one another.

4. The assembly as claimed in claim 1 wherein the first and second subassemblies are adhesively bonded together by an adhesive disposed within the groove.

5. The assembly as claimed in claim 1 wherein the composite material of the first and second subassemblies comprises multiple plies of fiber-reinforced composite material.

6. The assembly as claimed in claim 5 wherein the composite material is carbon-fiber reinforced plastic (CFRP).

7. The assembly as claimed in claim 2 wherein the interface further includes a second flange disposed on the second subassembly and received within the first opening of the first subassembly for locating the subassemblies relative to each other during assembling of the subassemblies.

8. The assembly as claimed in claim 1 wherein the interface comprises composite material.

9. The assembly as claimed in claim 8 wherein the composite material of the first and second subassemblies and the interface comprises multiple layers of fiber, prepreg sheets which are compression molded.

10. The assembly as claimed in claim 9 wherein each of the subassemblies and the interface is made of woven carbon fiber, prepreg material.

11. The assembly as claimed in claim 3 wherein exterior surfaces of the subassemblies are class A, automotive vehicle surfaces.

23. The assembly as claimed in claim 2 wherein the second subassembly includes a second opening which extends into an interior of the second subassembly from an exterior of the second subassembly, wherein the first opening of the first subassembly and the second opening of the second subassembly are in fluid communication with one another;

and

the interface further includes a second flange disposed on the second subassembly, the second flange extending about the periphery of the second opening of the second subassembly and at least partially defining the groove, and the second flange being received within the first opening of the first subassembly for locating the subassemblies relative to each other during assembling of the subassemblies.

12. A vehicle rear spoiler assembly of composite materials, the assembly comprising:

a hollow wing subassembly of molded composite material;

a hollow end cap subassembly of molded composite material; and

an adjustable mating interface for coupling the subassemblies together, the interface including (i) a groove formed on the end cap subassembly and (ii) a first flange disposed on the wing subassembly and bonded within the groove wherein the groove is sized and shaped relative to the size and shape of the first flange to allow a bonding position of the first flange within the groove to be adjusted during assembling of the subassemblies so that the mating interface is adjustable.

13. The assembly as claimed in claim 12 wherein the wing subassembly includes a first opening which extends into an interior of the wing subassembly from an exterior of the wing subassembly, the first flange extending about the periphery of the first opening of the wing subassembly.

14. The assembly as claimed in claim 13 wherein the end cap subassembly includes a second opening which extends into an interior of the end cap subassembly from an exterior of the end cap subassembly, the groove extending about the periphery of the second opening of the end cap subassembly and wherein the first opening of the wing subassembly and the second opening of the end cap subassembly are in fluid communication with one another.

15. The assembly as claimed in claim 12 wherein the wing subassembly and the end cap subassembly are adhesively bonded together by an adhesive disposed within the groove.

16. The assembly as claimed in claim 12 wherein the composite material of the wing subassembly and the end cap subassembly comprises multiple plies of fiber-reinforced composite material.

17. The assembly as claimed in claim 16 wherein the composite material is carbon-fiber reinforced plastic (CFRP).

18. The assembly as claimed in claim 13 wherein the interface further includes a second flange disposed on the end cap subassembly and received within the first opening of the wing subassembly for locating the subassemblies relative to each other during assembling of the subassemblies.

19. The assembly as claimed in claim 12 wherein the interface comprises composite material.

20. The assembly as claimed in claim 19 wherein the composite material of the wing subassembly and the end cap subassembly and the interface comprises multiple layers of fiber, prepreg sheets which are compression molded.

21. The assembly as claimed in claim 20 wherein each of the subassemblies and the interface is made of woven carbon fiber, prepreg material.

22. The assembly as claimed in claim 14 wherein exterior surfaces of the subassemblies are class A, automotive vehicle surfaces.

24. The assembly as claimed in claim 13 wherein the end cap subassembly includes a second opening which extends into an interior of the end cap subassembly from an exterior of the end cap subassembly, wherein the first opening of the wing subassembly and the second opening of the end cap subassembly are in fluid communication with one another;

and

the interface further includes a second flange disposed on the end cap subassembly, the second flange extending about the periphery of the second opening of the end cap subassembly and at least partially defining the groove, and the second flange being received within the first opening of the wing subassembly for locating the subassemblies relative to each other during assembling of the subassemblies.