Reinforced thermoplastic structural joint assembly for a vehicle

• US 9,403,319 B2
• Filed: 09/18/2013
• Issued: 08/02/2016
• Est. Priority Date: 09/25/2008
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Jaranson, John W., Fernholz, Kedzie Davis, Wykoff, Richard Howard
• Primary Examiner(s): Hong, John C
• Application Number:
  US14/030,631
• Publication Number:
  US 20140015272A1
• Time in Patent Office: 1,049 Days
• US Class Current: 1/1
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• 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 27/02 rigid
• CPC Class Codes: B62D 27/023 Assembly of structural joints
• CPC Class Codes: B62D 29/041 Understructures
• CPC Class Codes: B62D 29/048 Connections therefor, e.g. joints B62D29/045 takes precedence
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/4995 Nonthreaded
• CPC Class Codes: Y10T 29/49956 Riveting
• CPC Class Codes: Y10T 29/49961 At least one part nonmetallic
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 403/472 including mechanical interlock

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.

Claims

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.

2. The method of manufacturing of claim 1 further comprising:

providing the first thermoplastic member with a plurality of protrusions; and

providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member.

3. The method of manufacturing of claim 1 further comprising:

providing the first thermoplastic member with a plurality of protrusions and having a circular shape; and

providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a circular shape.

4. The method of manufacturing of claim 1 further comprising:

providing the first thermoplastic member with a plurality of protrusions and having a rectangular shape; and

providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a rectangular shape.

5. The method of manufacturing of claim 1 further comprising:

providing the first thermoplastic member with a plurality of protrusions and having a triangular shape; and

providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a triangular shape.

6. The method of manufacturing of claim 1 wherein the reinforcement member is further defined as a metal reinforcement member thereby further increasing load capacity.

7. The method of manufacturing of claim 1 further comprising:

molding first thermoplastic member and the second thermoplastic member with flanges; and

mounting the first thermoplastic member and the second thermoplastic member to structural components in an automotive vehicle with the flanges.

8. The method of manufacturing of claim 1 further comprising:

mounting at least one of the first thermoplastic member and the second thermoplastic member to a vehicle roof panel; and

mounting the other of the first thermoplastic member and the second thermoplastic member to a vehicle frame.

9. The method of manufacturing of claim 1 further comprising molding the second thermoplastic without any openings.

10. A structural joint assembly manufactured by a method comprising:

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.

11. The structural joint assembly of claim 10 wherein the first thermoplastic member is molded with a pair protrusions and the reinforcement member has a pair of corresponding pre-formed receptacles formed therein, the pair of protrusions mating with the pair of receptacles to align the reinforcement member with the first thermoplastic member.

12. The structural joint assembly of claim 10 wherein at least one of the first thermoplastic member and the second thermoplastic member is molded with a flange which is mounted to a structural component in an automotive vehicle.

13. The structural joint assembly of claim 12 wherein at least one of the first thermoplastic member and the second thermoplastic member is mounted to a vehicle roof panel and the other of the first thermoplastic member and the second thermoplastic member is mounted to a vehicle frame.

14. The structural joint assembly of claim 10 wherein the reinforcement member is formed from a metallic material.

15. A manufacturing method comprising:

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.

16. The manufacturing method of claim 15 further comprising molding the first thermoplastic member with a pair of protrusions and the reinforcement has a pair of corresponding preformed receptacles formed therein, the pair of protrusions mating with the pair of receptacles to align the reinforcement with the first thermoplastic member.

17. The manufacturing method of claim 15 further comprising:

abutting an inner surface of the second thermoplastic member to the first thermoplastic member along the peripheral ribs and the at least one protrusion;

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.

18. The manufacturing method of claim 15 further comprising:

molding first thermoplastic member and the second thermoplastic member with flange; and

mounting the first thermoplastic member and the second thermoplastic member to structural components in an automotive vehicle with the flanges.

19. The manufacturing method of claim 15 further comprising:

mounting the first thermoplastic member to a first automotive structural component; and

mounting the second thermoplastic member to a second automotive structural component.