Reinforced thermoplastic structural joint assembly for a vehicle
First Claim
1. A method of manufacturing a structural joint assembly comprising:
- molding a first thermoplastic member with fibrous material and having peripheral ribs defining a recessed channel with at least one protrusion extend from the channel;
molding a second thermoplastic member;
providing a reinforcement member sized to be received within the channel of the first thermoplastic member and having a receptacle for a mating engagement with the at least one protrusion;
mounting the reinforcement member to the first thermoplastic member such that the receptacle of the reinforcement member is retained by the protrusion without adhesive bonding or overmolding and the reinforcement member; and
abutting an inner surface of the second thermoplastic member to the first thermoplastic member along the peripheral ribs and the at least one protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member;
welding the second thermoplastic member to the first thermoplastic member by applying thermoplastic welding to an outer surface of the second thermoplastic member to entirely enclose the reinforcement within the first and second thermoplastic members with a thermoplastic weld along the peripheral ribs thereby increasing load capacity.
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Abstract
A structural joint assembly for a vehicle is provided with a first thermoplastic composite member having a protrusion containing fibrous material. A reinforcement member is provided with a receptacle for mating engagement with the protrusion. A second thermoplastic member is mounted to the first thermoplastic member over the protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member but not adhesively bonded or overmolded therebetween. A method of manufacturing a structural joint assembly and a structural joint assembly manufactured by a method are disclosed. The methods include molding a first thermoplastic member with a protrusion with fibrous material and a second thermoplastic member. A reinforcement member has a receptacle and is mounted to the first thermoplastic member. The receptacle is retained by the protrusion without adhesive bonding or overmolding. The second thermoplastic member is joined to the first thermoplastic member.
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Citations
19 Claims
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1. A method of manufacturing a structural joint assembly comprising:
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molding a first thermoplastic member with fibrous material and having peripheral ribs defining a recessed channel with at least one protrusion extend from the channel; molding a second thermoplastic member; providing a reinforcement member sized to be received within the channel of the first thermoplastic member and having a receptacle for a mating engagement with the at least one protrusion; mounting the reinforcement member to the first thermoplastic member such that the receptacle of the reinforcement member is retained by the protrusion without adhesive bonding or overmolding and the reinforcement member; and abutting an inner surface of the second thermoplastic member to the first thermoplastic member along the peripheral ribs and the at least one protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member; welding the second thermoplastic member to the first thermoplastic member by applying thermoplastic welding to an outer surface of the second thermoplastic member to entirely enclose the reinforcement within the first and second thermoplastic members with a thermoplastic weld along the peripheral ribs thereby increasing load capacity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A structural joint assembly manufactured by a method comprising:
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molding a first thermoplastic member with fibrous material having peripheral ribs defining a channel with at least one protrusion provided therein; molding a second thermoplastic member; providing a reinforcement member sized to be received by channel in the first thermoplastic member and having a receptacle for a mating engagement with the at least one protrusion; mounting the reinforcement member to the first thermoplastic member such that the receptacle of the reinforcement member is retained in the channel by the protrusion without adhesive bonding or overmolding; and joining the second thermoplastic member to the first thermoplastic member along the ribs and the at least one protrusion such that the reinforcement member is entirely enclosed within the first thermoplastic member and the second thermoplastic member thereby increasing load capacity. - View Dependent Claims (11, 12, 13, 14)
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15. A manufacturing method comprising:
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molding a first thermoplastic member with fibrous material having a peripheral ribs defining a recessed channel with a protrusion disposed therein; mounting a metal reinforcement having a preformed receptacle such that the receptacle is retained on the protrusion and within the channel; welding a second thermoplastic member to the first thermoplastic member along the protrusion and ribs such that the reinforcement is entirely enclosed within the first and second thermoplastic members. - View Dependent Claims (16, 17, 18, 19)
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Specification