US20160207282A1 - Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint - Google Patents
Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint Download PDFInfo
- Publication number
- US20160207282A1 US20160207282A1 US15/082,554 US201615082554A US2016207282A1 US 20160207282 A1 US20160207282 A1 US 20160207282A1 US 201615082554 A US201615082554 A US 201615082554A US 2016207282 A1 US2016207282 A1 US 2016207282A1
- Authority
- US
- United States
- Prior art keywords
- layer
- fibers
- resin
- assembly
- clinch
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- B32B7/045—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
- B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
- B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a general shape other than plane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/18—Layered products comprising a layer of metal comprising iron or steel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/08—Interconnection of layers by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
- B29C65/60—Riveting or staking
- B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
- B29C65/608—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being pushed in blind holes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0068—Permeability to liquids; Adsorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
- Y10T428/24545—Containing metal or metal compound
Abstract
An assembly comprising a first composite fiber reinforced part that is joined to a second part by a clinch joint. The first part includes a first layer of resin that is reinforced with fibers and a second layer of resin that is devoid of fibers and applied to one side of the first layer of fiber reinforced resin. The second part contacts the first layer of the first part. The first part and second part are joined by a clinch joint including a pressed out portion that is pressed into a clinching portion. The second layer of resin contains the fibers in the first part.
Description
- This application is a continuation of U.S. application Ser. No. 14/155,694, filed Jan. 15, 2014, currently pending, the disclosure of which is hereby incorporated in its entirety by reference herein.
- A composite panel and method of making the composite panel that is adapted to be joined to another panel with a clinch joint.
- Composite panels are used to manufacture structural and body panels for vehicles and in other products. Composite panels are made of polymeric resins that are reinforced with carbon fibers, glass fibers, natural fibers, or the like. Composite panels are strong, light weight and may be used in a wide variety of product applications.
- Composite panels may be assembled to other panels made of aluminum, steel or composites. Common fasteners, rivets or clinch joints may be used to join the panels together. One problem with clinch joints is that the reinforcing fibers may break through the surface of the composite panel. Carbon or natural fiber reinforcing fibers may absorb moisture if they break through the surface of the composite panel. Fibers that absorb moisture can be objectionable because they may cause corrosion and may weaken the joints. Carbon fibers when exposed to moisture may cause galvanic corrosion when they come into contact with metal parts or fasteners.
- The above problems and other problems are addressed by this disclosure as summarized below.
- According to one aspect of this disclosure, an assembly is provided that is joined by a clinch joint. The assembly comprises a first part including a first layer of resin reinforced with fibers and a second layer of resin applied to one side of the first layer of resin. A second part contacts the first layer of first part and is joined to the first part by the clinch joint. The clinch joint includes a pressed-out portion of the first part that is pressed into a clinching portion of the second panel with the second layer of resin containing the fibers in the first part.
- According to other aspects of this disclosure as it relates to the assembly, the first part may be formed in a compression molding process with the first layer being formed in a first step and the second layer being applied to the first layer after the first layer is formed. Alternatively, the first part may be formed in a compression molding process with the first layer and the second layer being formed in a single step. The second layer may be formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer.
- The second layer may be provided on a partial area on the one side of the first layer where the clinch joint joins the first part to the second part. A plurality of clinch joints may be formed to join the first part to the second part and the second layer may be provided on a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part. Alternatively, the second layer may be provided on the entire one side of the first layer.
- The fibers may be carbon fibers, glass fibers, talc, or natural fibers. The second part may be formed of steel, aluminum, magnesium, or composite resin.
- According to another aspect of this disclosure, a method is provided for forming a clinch joint for joining a plurality of panels. The method comprises molding a first part that includes a first layer of resin reinforced with fibers. A second layer of resin is molded onto one side of the first layer of resin. A second part is assembled to the first layer of first part and the first part is joined to the second part by pressing a pressed-out portion of the first part into a clinching portion of the second panel. The second layer of resin inhibits the fibers in the first layer from protruding from the first part in the area of the clinch joint.
- According to other aspects of the method, the molding steps may be performed in a compression molding process wherein the first layer is formed in a first step and the second layer is applied to the first layer in a second step after the first layer is formed. Alternatively, the molding steps may be performed in a compression molding process wherein the first layer and the second layer are formed in a single step, and wherein the second layer is formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer.
- The step of molding the second layer may further comprise molding the second layer to a partial area on the one side of the first layer where the clinch joint joins the first part to the second part. A plurality of clinch joints may be formed to join the first part to the second part and the step of molding the second layer may further comprise molding the second layer to a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part. Alternatively, the step of molding the second layer may further comprise molding the second layer on one entire side of the first layer.
- According to another aspect of this disclosure, an assembly including a first composite panel formed of a fiber reinforced resin that has no fibers in a predetermined intended clinch joint forming area. A clinch joint formed in the intended clinch joining area joins the first panel to a second panel and exposed fibers are avoided on the clinch joint.
- The above aspects and other aspects of this disclosure are described in greater detail below with reference to the attached drawings.
-
FIG. 1 is a fragmentary perspective view of a prior art clinch joint joining a composite fiber reinforced panel to another panel. -
FIG. 2 is a cross-sectional view taken along the line 2-2 inFIG. 1 . -
FIG. 3 is a fragmentary perspective view of a clinch joint joining a composite fiber reinforced panel to another panel in accordance with one aspect of this disclosure. -
FIG. 4 is a cross-sectional view taken along the line 4-4 inFIG. 3 . -
FIG. 5 is a fragmentary perspective view of a plurality of clinch joints in a flange of a composite fiber reinforced panel that has a fiber-free coating of resin applied to one side being joined to a mating flange of another panel. -
FIG. 6 is a fragmentary perspective view of a plurality of clinch joints in a flange of a composite fiber reinforced panel that has a fiber-free coating of a resin applied to only selected portions of the flange being joined to a mating flange of another panel. -
FIGS. 7A and 7B are fragmentary cross-sectional views of alternative embodiments of a first composite panel that has fiber reinforcements in resin except where a clinch joint is to be formed. -
FIGS. 8A and 8B are fragmentary cross-sectional views of the panels shown inFIGS. 7A and 7B , respectively, being joined to a second panel by a clinch joint. - A detailed description of the illustrated embodiments of the present invention is provided below. The disclosed embodiments are examples of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed in this application are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art how to practice the invention.
- Referring to
FIGS. 1 and 2 , a priorart clinch joint 10 is shown connecting a fiber reinforcedcomposite panel 12 to asubstrate panel 14. Thepanels FIGS. 1 and 2 . Theclinch joint 10 would in most cases be located in a flange area of a larger panel. - The stippling in
FIG. 1 is provided to denote exposedfibers 16 that are exposed in the course of forming theclinch joint 10. Fibers from the fiber reinforcedpanel 12 may extend into theclinch joint 10, as shown inFIG. 2 . The exposedfibers 16 may absorb moisture and lead to a reduction in the holding force of theclinch joint 10. The fibers, especially if they are carbon fibers, may also result in galvanic corrosion as water or other moisture absorbed by thefibers 16 comes into contact with metal parts or fasteners. - Referring to
FIGS. 3 and 4 , an improved clinch joint 20 is shown that is directed to solving the problem of exposed fibers in the clinch joint 10 described with reference toFIGS. 1 and 2 . The improved clinch joint 20 is formed in an encased fiber reinforcedcomposite part 22, or first part. Thefirst part 22 is connected to asubstrate panel 24, or second part, by theclinch joint 20. The fiber reinforcedpart 22 includes alayer 25 that is reinforced withfibers 26. Thislayer 25 is also referred to in this disclosure as a first layer. The layer reinforced withfibers 26 may be reinforced with carbon fibers, glass fibers, natural fibers, or talc that are encased in a resin composition. - A
neat resin layer 28, or second layer, forms part of the fiber reinforcedcomposite part 22. Theneat resin layer 28 consists essentially of the resin used to form the fiber reinforcedcomposite part 22. - The fiber reinforced
composite part 22 is preferably formed in a compression molding operation in a compression molding die. The compression molding die may include a textured surface on the surface facing theresin layer 28. The textured surface may function to exclude fibers from the layer reinforced withfibers 26 and thereby form theneat resin layer 28. Compression molding tools for forming fiber reinforced composite parts are well known and such tools are also well known that include a textured surface for esthetics. - The improved clinch joint 20 includes a pressed out
portion 30 formed in the fiber reinforcedcomposite part 22. The pressed outportion 30 is pressed into a clinchingportion 32 formed in thesubstrate panel 24. Theneat resin layer 28 encases thefibers 26 that would otherwise be exposed during the clinching operation in the pressed outportion 30 and provides the desired fiber-free smoothinterior surface 36 of theclinch joint 20. By encasing thefibers 26 with theneat resin layer 28, the tendency of anyfibers 26 to become exposed within theclinch joint 20 is eliminated or at least minimized and thereby reduces the chance of moisture being absorbed by thefibers 26 in thelayer 25 reinforced by thefibers 26. - The
neat resin layer 28 is preferably 0.5 to 1.5 mm thick. The thickness of the encased fiber reinforcedcomposite part 22 is preferably 0.5 to 6 mm thick and typically from 2.5 to 3 mm thick. Thesubstrate panel 24 is preferably 0.5 to 6 mm thick and typically between 2.5 to 3 mm thick. The substrate layer is preferably metal such as aluminum, steel, magnesium, or may also be another fiber reinforced composite part. - Referring to
FIG. 5 , anassembly 40 is partially shown that includes aninner panel 42 and anouter panel 44 that are joined together by aninner flange 46 and anouter flange 48. As shown inFIG. 5 , theresin layer 28 is provided on the top surface and is indicated by shading stripes extending across the entire top surface to denote a smooth resin surface. A plurality ofclinch joints 20 are shown connecting theinner flange 46 to theouter flange 48 with the inner flange clinching a pressed outportion 30 of theouter flange 48. - Referring to
FIG. 6 , anassembly 40 is shown that includes aninner panel 42 that is married to anouter panel 44. Aninner flange 46 of theinner panel 42 is connected by a clinch joint 20 to theouter flange 48 of theouter panel 44. Apartial area 50 of theouter flange 48 is provided with atextured surface 52. Thetextured surface 52 is formed in the compression molding operation by providing an orange peel textured surface on the surface of the compression molding die that forms thetextured surface 52 on theouter flange 48. Other types of textured surfaces may also be formed in the compression molding operation. - Referring to
FIGS. 7A and 7B , alternative embodiments of acomposite panel 60 are illustrated that are formed of apolymeric resin 62 and reinforced withfiber reinforcements 64 inFIG. 7A . InFIG. 7B , afiber mat 65 is shown embedded in theresin 62 to illustrate an alternative to theloose fibers 64. An intended clinchjoint location 66 consists essentially of pure orneat resin 62. The surrounding portions of thepanel 60 include thefiber reinforcements 64 orfiber mat 65. While discontinuous, orloose fiber reinforcements 64 may be used, a woven mat of fiber having cut-outs in the intended clinchjoint locations 66 may be easier to process. The wovenmat 65 also may be braided or stitchedcontinuous fiber reinforcements 64. - Referring to
FIGS. 8A and 8B , thecomposite panels 60 are illustrated after a clinch joint 68 is formed to join thecomposite panel 60 and asecond panel 70. Thecomposite panel 60 includes a pressed outportion 72 that is received in a clinchingportion 74 of thesecond panel 70. The clinch joint 68 does not have any exposed fibers because no fiber reinforcements 64 (inFIG. 8A ) or fiber mat 65 (shown inFIG. 8B ) are disposed in the intended clinchjoint locations 66. - While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
Claims (20)
1. An assembly comprising:
a first part including:
a first layer of resin reinforced with fibers;
a second layer of resin applied to one side of the first layer; and
a second part contacting the first layer of the first part, joined by a clinch joint including a pressed-out portion of the first part pressed into a clinching portion of the second part, wherein the second layer of resin retains the fibers within the first part.
2. The assembly of claim 1 wherein the first part is formed in a compression molding process with the first layer being formed in a first step and the second layer being applied to the first layer after the first layer is formed.
3. The assembly of claim 1 wherein the first part is formed in a compression molding process with the first layer and the second layer being formed in a single step, wherein the second layer is formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer.
4. The assembly of claim 1 wherein the second layer is provided to a partial area on the one side of the first layer where the clinch joint joins the first part to the second part.
5. The assembly of claim 1 wherein a plurality of clinch joints are formed to join the first part to the second part and the second layer is provided to a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part.
6. The assembly of claim 1 wherein the second layer of resin covers the one side of the first layer.
7. The assembly of claim 1 wherein the fibers are selected from a group consisting essentially of:
carbon fibers;
glass fibers;
talc; and
natural fibers.
8. The assembly of claim 1 wherein the second part is formed of a material selected from a group consisting essentially of:
steel;
aluminum;
magnesium; and
composite resin.
9. A method of forming a clinch joint for joining a plurality of panels comprising:
molding a first part that includes a first layer of resin reinforced with fibers;
molding a second layer of resin onto one side of the first layer of resin;
assembling a second part to the first layer of the first part; and
joining the first part to the second part by pressing a pressed-out portion of the first part into a clinching portion of the second part, wherein the second layer of resin inhibits the fibers in the first layer from protruding from the first part proximate the clinch joint.
10. The method of claim 9 wherein the molding steps are performed in a compression molding process wherein the first layer is formed in a first step and the second layer is applied to the first layer in a second step after the first layer is formed.
11. The method of claim 9 wherein the molding steps are performed in a compression molding process wherein the first layer and the second layer are formed in a single step, and wherein the second layer is formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer.
12. The method of claim 9 wherein the step of molding the second layer further comprises molding the second layer to a partial area on the one side of the first layer where the clinch joint joins the first part to the second part.
13. The method of claim 9 wherein a plurality of clinch joints are formed to join the first part to the second part and wherein the step of molding the second layer further comprises molding the second layer to a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part.
14. The method of claim 9 wherein the step of molding the second layer further comprises molding the second layer covering one side of the first layer.
15. The method of claim 9 wherein the fibers are selected from a group consisting essentially of:
carbon fibers;
glass fibers;
talc; and
natural fibers.
16. An assembly comprising:
a first panel including a composite layer of resin and fibers, and a fiber-free layer of resin applied to the composite layer; and
a second panel contacting and joined to the composite layer by a clinch joint, wherein the fiber-free layer prevents the fibers in the composite layer from being exposed due to the clinch joint.
17. The assembly of claim 16 wherein the clinch joint further includes a pressed-out portion of the first panel that is disposed within a clinching portion of the second panel.
18. The assembly of claim 16 wherein the first panel further includes a first flange and the second panel further includes a second flange that is disposed against the first flange, wherein the clinch joint connects the first flange to the second flange.
19. The assembly of claim 18 wherein the clinch joint further includes a pressed-out portion of the first flange that is disposed within a clinching portion of the second flange.
20. The assembly of claim 16 wherein the fiber-free layer and the second panel sandwich the composite layer therebetween.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/082,554 US20160207282A1 (en) | 2014-01-15 | 2016-03-28 | Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/155,694 US9346241B2 (en) | 2014-01-15 | 2014-01-15 | Composite panel for joining with a clinch joint and method of forming a clinch joint |
US15/082,554 US20160207282A1 (en) | 2014-01-15 | 2016-03-28 | Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/155,694 Continuation US9346241B2 (en) | 2014-01-15 | 2014-01-15 | Composite panel for joining with a clinch joint and method of forming a clinch joint |
Publications (1)
Publication Number | Publication Date |
---|---|
US20160207282A1 true US20160207282A1 (en) | 2016-07-21 |
Family
ID=53520583
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/155,694 Expired - Fee Related US9346241B2 (en) | 2014-01-15 | 2014-01-15 | Composite panel for joining with a clinch joint and method of forming a clinch joint |
US15/082,554 Abandoned US20160207282A1 (en) | 2014-01-15 | 2016-03-28 | Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/155,694 Expired - Fee Related US9346241B2 (en) | 2014-01-15 | 2014-01-15 | Composite panel for joining with a clinch joint and method of forming a clinch joint |
Country Status (2)
Country | Link |
---|---|
US (2) | US9346241B2 (en) |
CN (1) | CN104772948B (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP7000827B2 (en) * | 2017-12-08 | 2022-01-19 | トヨタ自動車株式会社 | Joined structure |
CN111015175B (en) * | 2019-12-31 | 2021-05-04 | 湘潭大学 | Bidirectional internal locking press-riveting connection method |
US11780185B2 (en) * | 2021-03-05 | 2023-10-10 | GM Global Technology Operations LLC | Reinforced composite assemblies and methods of manufacturing the same |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4207282A (en) * | 1978-06-01 | 1980-06-10 | Armco Inc. | Method for molding reinforced polymeric articles |
DE3543895A1 (en) * | 1985-12-12 | 1987-06-19 | Thyssen Stahl Ag | HEAT-RESISTANT, LIGHT AND PERMANENTLY PAINTABLE LIGHT COMPONENT, IN PARTICULAR FOR THE VEHICLE INDUSTRY |
US5884386A (en) * | 1991-11-27 | 1999-03-23 | Henrob Ltd. | Panel clinching methods and apparatus |
DE19755581A1 (en) * | 1997-12-13 | 1999-06-17 | Hans Hall | Track for crawler tracks of caterpillars, especially for piste or cross-country trackers |
DE19800038A1 (en) | 1998-01-02 | 1999-07-08 | Volkswagen Ag | Joining reinforced plastic structural components of vehicle bodywork |
DE102009006130B4 (en) * | 2009-01-26 | 2011-09-15 | Daimler Ag | Composite component with cover layer |
US8650730B2 (en) * | 2009-02-23 | 2014-02-18 | Btm Corporation | Clinching tool |
DE102010014539A1 (en) | 2010-04-10 | 2011-10-13 | Daimler Ag | Metal-plastic-composite component i.e. hat shelf, for car, has plastic base body molded at deep drawing sheet, and connection area formed by metallic joining elements that are enclosed by plastic base body area-wise |
ES2510365T3 (en) | 2011-03-23 | 2014-10-21 | Smp Deutschland Gmbh | Set of hybrid material and a procedure and a device for its manufacture |
DE102011050701A1 (en) * | 2011-05-30 | 2012-12-06 | Benteler Automobiltechnik Gmbh | Method for producing a hybrid component and cover for use in the manufacture |
DE102011051301A1 (en) | 2011-06-24 | 2012-12-27 | Technische Universität Chemnitz | Method for producing metal-plastic connection between two components, involves carrying out coupling of ultrasonic vibrations in region, which encircles punch from direction of punch or from direction of die |
US8739388B2 (en) * | 2012-04-17 | 2014-06-03 | Ford Global Technologies, Llc | Method of fastening parts to a composite part |
US9023455B2 (en) * | 2013-01-30 | 2015-05-05 | Ford Global Technologies, Llc | Method of making reinforced composite articles with reduced fiber content in local areas and articles made by the method |
-
2014
- 2014-01-15 US US14/155,694 patent/US9346241B2/en not_active Expired - Fee Related
-
2015
- 2015-01-15 CN CN201510020908.3A patent/CN104772948B/en not_active Expired - Fee Related
-
2016
- 2016-03-28 US US15/082,554 patent/US20160207282A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
US20150197070A1 (en) | 2015-07-16 |
US9346241B2 (en) | 2016-05-24 |
CN104772948B (en) | 2020-02-18 |
CN104772948A (en) | 2015-07-15 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
KR102362595B1 (en) | Method for manufacturing hybrid-structural parts of motor vehicles and hybrid-structural parts | |
JP7136625B2 (en) | Design features of dissimilar material reinforced blanks and extrudates for molding | |
US20160207282A1 (en) | Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint | |
KR101757721B1 (en) | Multi-layer assembly with retention feature | |
US20130122246A1 (en) | Structural members and methods of making a structural joint | |
US20130278018A1 (en) | Assembly including a compression-molded, composite panel with a hinged mounting flange | |
JP6222003B2 (en) | Part-to-part connecting structure and part-to-part connecting method | |
JP2016221999A (en) | Structure for joining vehicular member and method for joining vehicular member | |
KR101500353B1 (en) | Composite vehicle body and manufacturing method thereof and vehicle body structure using the same | |
US20110006562A1 (en) | Modular floor system for vehicles | |
US8361583B2 (en) | Resistive implant welding for adhesive curing for thermoplastic and thermoset applications | |
JP5793216B2 (en) | Dissimilar material joint and dissimilar material joining method | |
RU2011117641A (en) | AIRCRAFT COMPONENT ASSEMBLY | |
US2679305A (en) | Structural joint | |
JP6417915B2 (en) | Fastening structure of carbon fiber reinforced resin material | |
JP2009539672A (en) | Aircraft fuselage structure and manufacturing method thereof | |
US20140186133A1 (en) | Joint connection between two components, rivet sleeve and blind rivet for such a joint connection and method for producing such a joint connection | |
JP2019509931A (en) | Profile strip composition | |
DE102004062646B4 (en) | Steering wheel decorative shells and interior trim elements and method for their production | |
JP2017124554A (en) | Wrapping decorative sheet and method | |
EP1641611A2 (en) | Laminate with fill layer | |
KR20180044623A (en) | Adhering structure and method of different kinds materials | |
WO2019224984A1 (en) | Body side panel | |
CN105156419B (en) | Composite component with spot welding connection and the method for manufacturing the composite component | |
KR101689570B1 (en) | Adhering method of different kinds of materials |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCV | Information on status: appeal procedure |
Free format text: REPLY BRIEF FILED AND FORWARDED TO BPAI |
|
STCV | Information on status: appeal procedure |
Free format text: ON APPEAL -- AWAITING DECISION BY THE BOARD OF APPEALS |
|
STCV | Information on status: appeal procedure |
Free format text: BOARD OF APPEALS DECISION RENDERED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION |