WO1999025982A1 - Composite plate joint for use in forming trailer walls - Google Patents

Composite plate joint for use in forming trailer walls Download PDF

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Publication number
WO1999025982A1
WO1999025982A1 PCT/US1998/023973 US9823973W WO9925982A1 WO 1999025982 A1 WO1999025982 A1 WO 1999025982A1 US 9823973 W US9823973 W US 9823973W WO 9925982 A1 WO9925982 A1 WO 9925982A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite plate
overlapping
head portion
plate member
rivet
Prior art date
Application number
PCT/US1998/023973
Other languages
French (fr)
Inventor
Rodney P. Ehrlich
Original Assignee
Wabash National Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Wabash National Corporation filed Critical Wabash National Corporation
Priority to AU14552/99A priority Critical patent/AU1455299A/en
Publication of WO1999025982A1 publication Critical patent/WO1999025982A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/04—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of riveting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/02—Riveting procedures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/02—Riveting procedures
    • B21J15/04—Riveting hollow rivets mechanically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/10—Riveting machines
    • B21J15/14—Riveting machines specially adapted for riveting specific articles, e.g. brake lining machines
    • B21J15/147—Composite articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/10—Riveting machines
    • B21J15/36—Rivet sets, i.e. tools for forming heads; Mandrels for expanding parts of hollow rivets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B62D29/045—Van bodies composed of substantially rectangular panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/048—Connections therefor, e.g. joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D33/00—Superstructures for load-carrying vehicles
    • B62D33/04—Enclosed load compartments ; Frameworks for movable panels, tarpaulins or side curtains
    • B62D33/048—Enclosed load compartments ; Frameworks for movable panels, tarpaulins or side curtains for refrigerated goods vehicles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B19/00—Bolts without screw-thread; Pins, including deformable elements; Rivets
    • F16B19/04—Rivets; Spigots or the like fastened by riveting

Definitions

  • This invention is generally directed to a novel joint for use in forming trailer walls. More particularly, the invention contemplates a novel joint between composite panels which uses tapered rivets to form the joint. Standard rivets are commonly used to engage solid metal plates to form a trailer side wall . Such rivets are formed from a head have a flat undersurface and a shank extending therefrom.
  • the present invention presents a novel joint for forming a trailer side wall.
  • Features and advantages of the present invention will become apparent upon a reading of the attached specification, along with a study of the drawings .
  • a general object of the present invention is to provide a novel joint for forming a trailer side wall.
  • An object of the present invention is to provide a novel joint for a trailer side wall which is formed from a plurality of composite plate members which are joined together using a plurality of tapered rivets.
  • Another object of the present invention is to provide a novel joint for a trailer side wall which uses a plurality of tapered rivets to joins composite plates together, such tapered rivets providing a much larger contact area around the rivet than is provided with a standard rivet .
  • the present invention discloses a joint for joining plates together for use in a trailer wall.
  • the joint is formed from composite plate members which are joined together by a plurality of tapered rivets.
  • Each composite plate is formed from first and second metal skins with a foamed thermal plastic core sandwiched therebetween.
  • a skin member overlaps a portion of the first skin of one plate member and is adapted for joining to another one of the plate members.
  • a plurality of the tapered rivet members are engaged through the overlapping member and the composite plate member.
  • Each rivet member has a head portion having a frustoconical surface and a shank portion extending therefrom.
  • a recess is provided in an end thereof which is opposite to the head portion.
  • a portion of the composite plate member and the overlapping member surrounding the frustoconical surface of the head portion are rolled and conform to the frustoconical surface when the tapered rivet is engaged therewith. The opposite end of the rivet shank portion is upset.
  • a composite plate member a skin member which overlaps a portion of the first skin and is adapted for joining another plate member to the composite plate member, and a rivet member are provided.
  • the shank portion of the rivet member is engaged through aligned apertures provided in the overlapping member and the composite plate member.
  • the frustoconical head portion is engaged through the aligned apertures provided in the overlapping member and the composite plate member by using a ram, thereby causing a portion of the overlapping skin member and a portion of the first skin surrounding the frustoconical head portion to roll and conform to the frustoconical head portion which compresses the plastic core proximate to the rolled portions of the first skin and the overlapping skin member.
  • the opposite end of the shank portion is upset by engaging the opposite end with a shaped die and causing the opposite end to curl and engage the second skin of the composite plate.
  • FIGURE 1 is a perspective view of a trailer having composite plates joined together by the novel joint configuration which incorporates the features of the invention
  • FIGURES 2-5 are cross-sectional views illustrating the formation of the novel joint
  • FIGURE 6 is a side elevational view of the exterior surface around a rivet used to form the novel joint configuration.
  • FIGURE 7 is a side elevational view of the interior surface around a rivet used to form the novel joint configuration .
  • a plurality of tapered rivets 20 are used to join together a pair of composite plates 22, 24 to form a wall of a vehicle, such as a trailer 26, as shown in FIGURE 1, van -or the like.
  • the trailer 26 is generally comprised of a floor 28, a roof 30, a front wall 32, a pair of opposite side walls 34, 36, rear cargo doors 38, a landing gear 40, and an undercarriage assembly 42.
  • the trailer 26 may be connected to a tractor (not shown) by conventional means, such as a fifth wheel.
  • each wall 32, 34, 36 of the trailer 26 is formed from an upper foamed core composite plate 22 and a lower foamed core composite plate 24 which are fastened together by a plurality of the tapered rivets 20 as described herein.
  • the upper composite plate 22 is connected to the roof 30 and extends downwardly therefrom and is attached to an upper rail of the trailer 26 by suitable joining members, such as bolts or studs;
  • the lower composite plate 24 is connected to the floor 24 and extends upwardly therefrom and is attached to the lower rail of the trailer 26 by suitable joining members, such as bolts or studs.
  • the upper composite plate 22 includes an inner metal skin 43 and an outer metal skin 44 which are bonded by a thin adhesive layer of a known flexible adhesive bonding film to a foamed thermal plastic core member 45, which is sandwiched therebetween.
  • the lower composite plate 24 includes an inner metal skin 46 and an outer metal skin 48 which are bonded by a thin adhesive layer of a known flexible adhesive bonding film to a foamed thermal plastic core member 50 which is sandwiched therebetween.
  • the foamed thermal plastic core member 45, 50 used in each plate 22, 24 is described more fully herein.
  • the metal skins 43, 44, 46, 48 used in the composite plate 22, 24 are preferably formed of aluminum or full hard, high strength, high tension, galvanized steel.
  • each of the skins 43, 44, 46, 48 is formed from galvanized steel and preferably, each inner skin 43, 46, is over nineteen thousandths of an inch in thickness and each outer skin 44, 48 is over nineteen thousandths of an inch in thickness.
  • the core member 45, 50 provided in each composite plate 22, 24 is formed from a foamed thermal plastic, such as foamed low density polyethylene and, preferably made from foamed high density polyethylene (HDPE) or high density polypropylene, which makes each core member 45, 50 resilient. As shown in FIGURE 2, each core member 45, 50 includes a plurality of air bubbles 52 interspersed with the plastic material 54.
  • the foaming of the thermal plastic core member 45, 50 reduces the weight of each composite plate 22, 24 versus prior art solid core composite plates because the amount of plastic resin used in formation of the core member 45, 50 is reduced versus prior art solid core composite plates.
  • this overlapping skin member 56 is integrally formed as part of the outer skin 44 of the upper composite plate 22, however, it is envisioned that the overlapping skin member 56 may be a separate member attached to the upper composite plate 22 by a tapered rivet 20 in the manner described herein.
  • tapered rivets 20 used in the present invention are disclosed in United States Patent No. 5,439,266, which disclosure is herein incorporated by reference.
  • Each rivet 20 is preferably made of aluminum and includes a head portion 58 having a frustoconical work-engaging surface 60 and a top surface 61.
  • An elongated shank portion 62 extends from the head portion 58.
  • a recess 64 is provided in the end of the shank portion 62 opposite to the head portion 58 for reasons described more fully herein.
  • the rivets 20 are heat-treated and hardened so that the aluminum material thereof is harder than the steel or aluminum material of the overlapping skin member 56 and the outer skin 48 of the lower composite plate 24.
  • the frustoconical surface 60 of the head portion 58 is formed so that the included angle thereof is between about 10° and about 45°, as distinguished from a 76° included angle of a conventional rivet.
  • FIGURES 2-5 Attention is now directed to FIGURES 2-5.
  • the composite plates 22, 24, with the overlapping skin member 56 are placed on a die 66 such that the inner skins 43, 46 rest on the die 66 and the overlapping skin member 56 overlaps a portion of the outer skin 48 of composite plate 24.
  • the lower composite plate 24 and the overlapping skin member 56 have been provided with aligned apertures 68, 70 respectively therethrough, both of which are aligned with an aperture 72 provided in the die 66.
  • the shank portion 62 of the rivet 20 has a diameter which is substantially equal to the aligned apertures 68, 70.
  • the shank portion 62 of the rivet 20 is inserted into the aligned apertures 68, 70 until the head portion 58 engages a top surface of the overlapping skin member 56.
  • a ram 74 is engaged with the top surface 61 of the rivet head portion 58 and pushes the rivet 20 further into the aligned apertures 68, 70.
  • the head portion 58 rolls and curls the portions 76, 78 into the plastic core 50, thereby compressing the foamed thermal plastic core member 50 around the head portion 58 and providing a much larger contact area for the rivet 20 with the plate 24 than is normally provided with a standard rivet .
  • This rolling and curling action also locks the skin 44 and the core 50 together.
  • the ram 74 pushes the rivet 20 through the apertures 68, 70 until the top surface 61 of the rivet 20 is substantially flush with the overlapping skin member 56 and the opposite end of the shank portion 62 extends from the inner skin 46 and into the aperture 72.
  • the ram 74 is retracted and the composite plates 22, 24 and overlapping member 56 are lifted from the die 66.
  • a second die 80 having an aperture 82 provided therein is moved under the composite plate 24.
  • a shaped portion 84 of the die 80 is provided in the aperture 82 and aligns with the recess 64 in the shank portion 62.
  • the ram 74 is engaged with the top surface 61 of the rivet head portion 58 and pushes the end of the rivet shank portion 62 against the shaped portion 84 and causes the composite plates 22, 24 to sit against the die 80.
  • the shaped portion 84 causes the portion of the shank portion 62 around the recess 64 to roll and curl to form a rolled portion 86 and to engage the inner skin 46 of the composite plate 24. After the end of the shank portion 62 has been rolled, the ram 74 is lifted.
  • FIGURE 6 illustrates how the head portion 58 of the rivet 20 looks after installation and
  • FIGURE 7 illustrates how the shank portion 62 looks after installation.
  • the joint could be provided vertically instead of horizontally.
  • a plurality of composite plates could be used to form the walls of the trailer 26.
  • the overlapping skin member 56 could be integrally formed as part of the lower plate 24 and attached to the upper plate 22 by the tapered rivets 20 in the manner described herein. Even further, the skins of the composite plates can be coined or stepped so as to provide a flush inner or outer surface .

Abstract

A joint for joining plates (22, 24) together for use in a trailer wall (32, 34, 36) is formed from composite plate members (22, 24) which are joined together by a plurality of tapered rivets (20). Each composite plate (22, 24) is formed from first and second metal skins (48, 50; 43, 44) with a plastic core (50; 45) sandwiched therebetween. A skin member (56) overlaps a portion of the first skin (48) of one plate member (24) and is adapted for joining to another one of the plate members (22). A plurality of the tapered rivet members (20) are engaged through the overlapping member (56) and the composite plate member (24). Each rivet member (20) has a head portion (58) having a frustoconical surface (60) and a shank portion (62) extending therefrom. A portion of the composite plate member (24) and the overlapping member (56) surrounding the frustoconical surface (60) of the head portion (58) are rolled and conform to the frustoconical surface (60) when the tapered rivet (20) is engaged therewith. The opposite end (86) of the rivet shank portion (62) is upset to lock the rivet (20) with the composite plate (24) and the overlapping member (56).

Description

COMPOSITE PLATE JOINT FOR USE IN FORMING TRAILER WALLS
BACKGROUND OF THE INVENTION
This invention is generally directed to a novel joint for use in forming trailer walls. More particularly, the invention contemplates a novel joint between composite panels which uses tapered rivets to form the joint. Standard rivets are commonly used to engage solid metal plates to form a trailer side wall . Such rivets are formed from a head have a flat undersurface and a shank extending therefrom.
The present invention presents a novel joint for forming a trailer side wall. Features and advantages of the present invention will become apparent upon a reading of the attached specification, along with a study of the drawings . OBJECTS .AND SUMMARY OF THE INVENTION
A general object of the present invention is to provide a novel joint for forming a trailer side wall. .An object of the present invention is to provide a novel joint for a trailer side wall which is formed from a plurality of composite plate members which are joined together using a plurality of tapered rivets.
.Another object of the present invention is to provide a novel joint for a trailer side wall which uses a plurality of tapered rivets to joins composite plates together, such tapered rivets providing a much larger contact area around the rivet than is provided with a standard rivet .
Briefly, and in accordance with the foregoing, the present invention discloses a joint for joining plates together for use in a trailer wall. The joint is formed from composite plate members which are joined together by a plurality of tapered rivets. Each composite plate is formed from first and second metal skins with a foamed thermal plastic core sandwiched therebetween. A skin member overlaps a portion of the first skin of one plate member and is adapted for joining to another one of the plate members. A plurality of the tapered rivet members are engaged through the overlapping member and the composite plate member. Each rivet member has a head portion having a frustoconical surface and a shank portion extending therefrom. A recess is provided in an end thereof which is opposite to the head portion. A portion of the composite plate member and the overlapping member surrounding the frustoconical surface of the head portion are rolled and conform to the frustoconical surface when the tapered rivet is engaged therewith. The opposite end of the rivet shank portion is upset.
To form the joint, a composite plate member, a skin member which overlaps a portion of the first skin and is adapted for joining another plate member to the composite plate member, and a rivet member are provided. The shank portion of the rivet member is engaged through aligned apertures provided in the overlapping member and the composite plate member. Next, the frustoconical head portion is engaged through the aligned apertures provided in the overlapping member and the composite plate member by using a ram, thereby causing a portion of the overlapping skin member and a portion of the first skin surrounding the frustoconical head portion to roll and conform to the frustoconical head portion which compresses the plastic core proximate to the rolled portions of the first skin and the overlapping skin member. Thereafter, the opposite end of the shank portion is upset by engaging the opposite end with a shaped die and causing the opposite end to curl and engage the second skin of the composite plate. BRIEF DESCRIPTION OF THE DRAWINGS
The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein like reference numerals identify like elements in which:
FIGURE 1 is a perspective view of a trailer having composite plates joined together by the novel joint configuration which incorporates the features of the invention;
FIGURES 2-5 are cross-sectional views illustrating the formation of the novel joint;
FIGURE 6 is a side elevational view of the exterior surface around a rivet used to form the novel joint configuration; and
FIGURE 7 is a side elevational view of the interior surface around a rivet used to form the novel joint configuration .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, a specific embodiment with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein.
In the present invention, a plurality of tapered rivets 20 are used to join together a pair of composite plates 22, 24 to form a wall of a vehicle, such as a trailer 26, as shown in FIGURE 1, van -or the like. The trailer 26 is generally comprised of a floor 28, a roof 30, a front wall 32, a pair of opposite side walls 34, 36, rear cargo doors 38, a landing gear 40, and an undercarriage assembly 42. The trailer 26 may be connected to a tractor (not shown) by conventional means, such as a fifth wheel.
As shown in FIGURE 1, each wall 32, 34, 36 of the trailer 26 is formed from an upper foamed core composite plate 22 and a lower foamed core composite plate 24 which are fastened together by a plurality of the tapered rivets 20 as described herein. The upper composite plate 22 is connected to the roof 30 and extends downwardly therefrom and is attached to an upper rail of the trailer 26 by suitable joining members, such as bolts or studs; the lower composite plate 24 is connected to the floor 24 and extends upwardly therefrom and is attached to the lower rail of the trailer 26 by suitable joining members, such as bolts or studs.
The upper composite plate 22 includes an inner metal skin 43 and an outer metal skin 44 which are bonded by a thin adhesive layer of a known flexible adhesive bonding film to a foamed thermal plastic core member 45, which is sandwiched therebetween. The lower composite plate 24 includes an inner metal skin 46 and an outer metal skin 48 which are bonded by a thin adhesive layer of a known flexible adhesive bonding film to a foamed thermal plastic core member 50 which is sandwiched therebetween. The foamed thermal plastic core member 45, 50 used in each plate 22, 24 is described more fully herein.
The metal skins 43, 44, 46, 48 used in the composite plate 22, 24 are preferably formed of aluminum or full hard, high strength, high tension, galvanized steel. Preferably, each of the skins 43, 44, 46, 48 is formed from galvanized steel and preferably, each inner skin 43, 46, is over nineteen thousandths of an inch in thickness and each outer skin 44, 48 is over nineteen thousandths of an inch in thickness.
The core member 45, 50 provided in each composite plate 22, 24 is formed from a foamed thermal plastic, such as foamed low density polyethylene and, preferably made from foamed high density polyethylene (HDPE) or high density polypropylene, which makes each core member 45, 50 resilient. As shown in FIGURE 2, each core member 45, 50 includes a plurality of air bubbles 52 interspersed with the plastic material 54. The foaming of the thermal plastic core member 45, 50 reduces the weight of each composite plate 22, 24 versus prior art solid core composite plates because the amount of plastic resin used in formation of the core member 45, 50 is reduced versus prior art solid core composite plates. It has been found that molecular integrity of the core member 45, 50 is not lost by the foaming of the thermal plastic core member 45, 50, and peel strength is increased versus prior art composite plates which use a solid core member. These findings are more fully described in Applicant's co- pending patent application, Serial No. 08/942,173, entitled "Foamed Core Composite Plate For Use In Trailer Walls and Doors", filed on October 1, 1997, and which disclosure is herein incorporated by reference. An overlapping skin member 56 is provided for overlapping the outer skin 44 of the lower composite plate 24. Preferably, this overlapping skin member 56 is integrally formed as part of the outer skin 44 of the upper composite plate 22, however, it is envisioned that the overlapping skin member 56 may be a separate member attached to the upper composite plate 22 by a tapered rivet 20 in the manner described herein.
The tapered rivets 20 used in the present invention are disclosed in United States Patent No. 5,439,266, which disclosure is herein incorporated by reference.
Each rivet 20 is preferably made of aluminum and includes a head portion 58 having a frustoconical work-engaging surface 60 and a top surface 61. An elongated shank portion 62 extends from the head portion 58. A recess 64 is provided in the end of the shank portion 62 opposite to the head portion 58 for reasons described more fully herein. The rivets 20 are heat-treated and hardened so that the aluminum material thereof is harder than the steel or aluminum material of the overlapping skin member 56 and the outer skin 48 of the lower composite plate 24. The frustoconical surface 60 of the head portion 58 is formed so that the included angle thereof is between about 10° and about 45°, as distinguished from a 76° included angle of a conventional rivet.
Attention is now directed to FIGURES 2-5. Initially, the composite plates 22, 24, with the overlapping skin member 56, are placed on a die 66 such that the inner skins 43, 46 rest on the die 66 and the overlapping skin member 56 overlaps a portion of the outer skin 48 of composite plate 24. The lower composite plate 24 and the overlapping skin member 56 have been provided with aligned apertures 68, 70 respectively therethrough, both of which are aligned with an aperture 72 provided in the die 66. The shank portion 62 of the rivet 20 has a diameter which is substantially equal to the aligned apertures 68, 70.
As shown in FIGURE 2, initially, the shank portion 62 of the rivet 20 is inserted into the aligned apertures 68, 70 until the head portion 58 engages a top surface of the overlapping skin member 56.
Thereafter, a ram 74 is engaged with the top surface 61 of the rivet head portion 58 and pushes the rivet 20 further into the aligned apertures 68, 70. As shown in FIGURE 3, when the conical surface 60 of the head portion 58 engages the overlapping skin member 56 and the outer skin 48 of the lower composite plate 24, a portion 76 of the overlapping skin member 56 and a portion 78 of the outer skin 48 of the lower composite plate 24 surrounding the aligned apertures 68, 70 and being engaged by the conical surface 60 of the head portion 58 rolls and curls so as to conform to the conical surface 60 of the head portion 58. The head portion 58 rolls and curls the portions 76, 78 into the plastic core 50, thereby compressing the foamed thermal plastic core member 50 around the head portion 58 and providing a much larger contact area for the rivet 20 with the plate 24 than is normally provided with a standard rivet . This rolling and curling action also locks the skin 44 and the core 50 together. The ram 74 pushes the rivet 20 through the apertures 68, 70 until the top surface 61 of the rivet 20 is substantially flush with the overlapping skin member 56 and the opposite end of the shank portion 62 extends from the inner skin 46 and into the aperture 72.
Next, as shown in FIGURE 4, the ram 74 is retracted and the composite plates 22, 24 and overlapping member 56 are lifted from the die 66. As shown in FIGURE 5, a second die 80 having an aperture 82 provided therein is moved under the composite plate 24. A shaped portion 84 of the die 80 is provided in the aperture 82 and aligns with the recess 64 in the shank portion 62. Thereafter, the ram 74 is engaged with the top surface 61 of the rivet head portion 58 and pushes the end of the rivet shank portion 62 against the shaped portion 84 and causes the composite plates 22, 24 to sit against the die 80. The shaped portion 84 causes the portion of the shank portion 62 around the recess 64 to roll and curl to form a rolled portion 86 and to engage the inner skin 46 of the composite plate 24. After the end of the shank portion 62 has been rolled, the ram 74 is lifted. FIGURE 6 illustrates how the head portion 58 of the rivet 20 looks after installation and FIGURE 7 illustrates how the shank portion 62 looks after installation.
While the trailer 26 has been described with respect to only having upper and lower plates 22, 24, it is to be understood that the joint could be provided vertically instead of horizontally. Also, a plurality of composite plates could be used to form the walls of the trailer 26. Further, the overlapping skin member 56 could be integrally formed as part of the lower plate 24 and attached to the upper plate 22 by the tapered rivets 20 in the manner described herein. Even further, the skins of the composite plates can be coined or stepped so as to provide a flush inner or outer surface .
While a preferred embodiment of the present invention is shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims.

Claims

THE INVENTION CLAIMED IS:
1. A joint for joining plates (22, 24) together for use in a trailer wall (32, 34, 36) or similar construction, said joint comprising: a composite plate member (24) including first and second metal skins (48, 46) with a core (50) sandwiched therebetween; a member (56) overlapping a portion of said first skin (48) and adapted for joining another plate member (22) to said composite plate member (24) ; a rivet member (20) engaged through said overlapping member (56) and said composite plate member (24) , said rivet member (20) having a head portion (58) and a shank portion (62) extending therefrom, said head portion (58) having a surface (60) , wherein a portion of said composite plate member (24) and said overlapping member (56) surrounding said surface (60) of said head portion (58) are rolled and conform to said surface (60) .
2. A joint as defined in claim 1, wherein said surface of said head portion (58) is frustoconical such that said portion of said composite plate member (24) and said overlapping member (56) surrounding said frustoconical surface (60) of said head portion (58) are rolled and conform to said frustoconical surface (60) .
3. A joint as defined in claim 1, further including an end (86) of said shank portion (62) opposite from said head portion (58) being upset.
4. A joint as defined in claim 1, wherein said core (50) is formed from plastic.
5. A joint as defined in claim 1, wherein said core (50) is formed from high or low density polypropylene or polyethylene.
6. A joint as defined in claim 1, wherein said core (50) is formed from foamed thermal plastic.
7. A joint as defined in claim 1, wherein said skins (46, 48) and said overlapping member (56) are formed from aluminum or steel.
8. A joint as defined in claim 1, further including a compressed portion of said plastic core (50) proximate to rolled portions (78, 76) of said composite plate member (24) and said overlapping member (56) .
9. A method of forming a joint for joining plates (22, 24) together for use in a trailer wall (32, 34, 36) or similar construction, comprising the steps of: providing a composite plate member (24) including first and second metal skins (48, 46) with a core (50) sandwiched therebetween; providing an overlapping member (56) for overlapping a portion of said first skin (48) and adapted for joining another plate member (22) to said composite plate member (24); providing a rivet member (20) having a head portion (58) and a shank portion (62) extending therefrom; overlapping said overlapping member (56) over said composite plate member (24) ; engaging said shank portion (62) of said rivet member (20) through aligned apertures (70, 68) provided in said overlapping member (56) and said composite plate member (24) ; engaging said head portion (58) into said aligned apertures (70, 68) provided in said overlapping member (56) and said composite plate member (24) , thereby- causing a portion (76) of said overlapping member (58) and a portion (78) of said first skin (48) surrounding said head portion (58) to roll and conform to said head portion (58) .
10. A method as defined in claim 9, wherein said head portion (58) has a frustoconical surface (60) , and wherein during said step of engaging said head portion
(58) into said aligned apertures (70, 68) provided in said overlapping member (56) and said composite plate member (24) , said portion (76) of said overlapping member
(58) and said portion (78) of said first skin (48) surrounding said head portion (58) roll and conform to said frustoconical surface (60) .
11. A method as defined in claim 9, wherein during said step of engaging said head portion (58) into said aligned apertures (70, 68) provided in said overlapping member (56) and said composite plate member (24) , said plastic core (50) proximate to said rolled portions (78, 76) of said first skin (48) and said overlapping member (56) is thereby compressed.
12. A method as defined in claim 9, further including the step of upsetting an end (86) of said shank portion (62) opposite said head portion (58) .
13. A method as defined in claim 9, wherein said shank portion (62) of said rivet member (20) includes a recess (64) in an end thereof which is opposite to said head portion (58) , and further including the step of upsetting said opposite end by engaging said opposite end with a shaped die (84) and causing said opposite end of said shank portion (62) to curl and lock said rivet member (20) with said composite plate member (24) .
PCT/US1998/023973 1997-11-14 1998-11-10 Composite plate joint for use in forming trailer walls WO1999025982A1 (en)

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US97103597A 1997-11-14 1997-11-14
US08/971,035 1997-11-14

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EP1229254A3 (en) * 2001-02-02 2003-05-14 Richard Bergner Verbindungstechnik GmbH & Co KG Punch riveting and hollow punch rivet
US7117578B2 (en) * 2001-05-23 2006-10-10 Basf Aktiengesellschaft Process for producing a composite component
EP2811179A1 (en) * 2013-05-16 2014-12-10 Newfrey LLC Structure and method for mounting a metal collar

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1229254A3 (en) * 2001-02-02 2003-05-14 Richard Bergner Verbindungstechnik GmbH & Co KG Punch riveting and hollow punch rivet
US7117578B2 (en) * 2001-05-23 2006-10-10 Basf Aktiengesellschaft Process for producing a composite component
EP2811179A1 (en) * 2013-05-16 2014-12-10 Newfrey LLC Structure and method for mounting a metal collar

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