U.S. patent application number 15/082554 was filed with the patent office on 2016-07-21 for composite panel for joining with a clinch joint and method of forming a clinch joint.
The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Aindrea McKelvey CAMPBELL, Amanda Kay FREIS, Daniel Quinn HOUSTON.
Application Number | 20160207282 15/082554 |
Document ID | / |
Family ID | 53520583 |
Filed Date | 2016-07-21 |
United States Patent
Application |
20160207282 |
Kind Code |
A1 |
FREIS; Amanda Kay ; et
al. |
July 21, 2016 |
Composite Panel for Joining with a Clinch Joint and Method of
Forming a Clinch Joint
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.
Inventors: |
FREIS; Amanda Kay; (Ann
Arbor, MI) ; CAMPBELL; Aindrea McKelvey; (Beverly
Hills, MI) ; HOUSTON; Daniel Quinn; (Dearborn,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
53520583 |
Appl. No.: |
15/082554 |
Filed: |
March 28, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14155694 |
Jan 15, 2014 |
9346241 |
|
|
15082554 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 15/18 20130101;
B32B 2307/726 20130101; B29C 66/723 20130101; B29K 2995/0068
20130101; B32B 7/05 20190101; B32B 1/00 20130101; B29C 66/21
20130101; B29C 66/8322 20130101; B32B 15/08 20130101; B32B 15/20
20130101; B32B 2605/00 20130101; B32B 2262/101 20130101; Y10T
29/4998 20150115; B32B 7/08 20130101; B29C 65/56 20130101; B29L
2031/30 20130101; Y10T 428/24545 20150115; B29C 66/721 20130101;
B29C 66/54 20130101; B32B 27/20 20130101; Y10T 428/24521 20150115;
B32B 2607/00 20130101; B29C 65/608 20130101; B32B 27/08 20130101;
B32B 2262/106 20130101; B29C 66/1312 20130101 |
International
Class: |
B32B 7/04 20060101
B32B007/04; B29C 65/00 20060101 B29C065/00; B32B 7/08 20060101
B32B007/08; B32B 27/20 20060101 B32B027/20; B32B 15/18 20060101
B32B015/18; B32B 15/20 20060101 B32B015/20; B32B 27/08 20060101
B32B027/08; B29C 65/56 20060101 B29C065/56; B32B 15/08 20060101
B32B015/08 |
Claims
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.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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.
TECHNICAL FIELD
[0002] A composite panel and method of making the composite panel
that is adapted to be joined to another panel with a clinch
joint.
BACKGROUND
[0003] 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.
[0004] 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.
[0005] The above problems and other problems are addressed by this
disclosure as summarized below.
SUMMARY
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] The above aspects and other aspects of this disclosure are
described in greater detail below with reference to the attached
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a fragmentary perspective view of a prior art
clinch joint joining a composite fiber reinforced panel to another
panel.
[0016] FIG. 2 is a cross-sectional view taken along the line 2-2 in
FIG. 1.
[0017] 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.
[0018] FIG. 4 is a cross-sectional view taken along the line 4-4 in
FIG. 3.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] FIGS. 8A and 8B are fragmentary cross-sectional views of the
panels shown in FIGS. 7A and 7B, respectively, being joined to a
second panel by a clinch joint.
DETAILED DESCRIPTION
[0023] 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.
[0024] Referring to FIGS. 1 and 2, a prior art clinch joint 10 is
shown connecting a fiber reinforced composite panel 12 to a
substrate panel 14. The panels 12, 14 are partially shown in FIGS.
1 and 2. The clinch joint 10 would in most cases be located in a
flange area of a larger panel.
[0025] The stippling in FIG. 1 is provided to denote exposed fibers
16 that are exposed in the course of forming the clinch joint 10.
Fibers from the fiber reinforced panel 12 may extend into the
clinch joint 10, as shown in FIG. 2. The exposed fibers 16 may
absorb moisture and lead to a reduction in the holding force of the
clinch joint 10. The fibers, especially if they are carbon fibers,
may also result in galvanic corrosion as water or other moisture
absorbed by the fibers 16 comes into contact with metal parts or
fasteners.
[0026] 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 to FIGS. 1 and 2. The
improved clinch joint 20 is formed in an encased fiber reinforced
composite part 22, or first part. The first part 22 is connected to
a substrate panel 24, or second part, by the clinch joint 20. The
fiber reinforced part 22 includes a layer 25 that is reinforced
with fibers 26. This layer 25 is also referred to in this
disclosure as a first layer. The layer reinforced with fibers 26
may be reinforced with carbon fibers, glass fibers, natural fibers,
or talc that are encased in a resin composition.
[0027] A neat resin layer 28, or second layer, forms part of the
fiber reinforced composite part 22. The neat resin layer 28
consists essentially of the resin used to form the fiber reinforced
composite part 22.
[0028] 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 the resin layer 28. The textured surface may
function to exclude fibers from the layer reinforced with fibers 26
and thereby form the neat 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.
[0029] The improved clinch joint 20 includes a pressed out portion
30 formed in the fiber reinforced composite part 22. The pressed
out portion 30 is pressed into a clinching portion 32 formed in the
substrate panel 24. The neat resin layer 28 encases the fibers 26
that would otherwise be exposed during the clinching operation in
the pressed out portion 30 and provides the desired fiber-free
smooth interior surface 36 of the clinch joint 20. By encasing the
fibers 26 with the neat resin layer 28, the tendency of any fibers
26 to become exposed within the clinch joint 20 is eliminated or at
least minimized and thereby reduces the chance of moisture being
absorbed by the fibers 26 in the layer 25 reinforced by the fibers
26.
[0030] The neat resin layer 28 is preferably 0.5 to 1.5 mm thick.
The thickness of the encased fiber reinforced composite part 22 is
preferably 0.5 to 6 mm thick and typically from 2.5 to 3 mm thick.
The substrate 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.
[0031] Referring to FIG. 5, an assembly 40 is partially shown that
includes an inner panel 42 and an outer panel 44 that are joined
together by an inner flange 46 and an outer flange 48. As shown in
FIG. 5, the resin 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 of clinch
joints 20 are shown connecting the inner flange 46 to the outer
flange 48 with the inner flange clinching a pressed out portion 30
of the outer flange 48.
[0032] Referring to FIG. 6, an assembly 40 is shown that includes
an inner panel 42 that is married to an outer panel 44. An inner
flange 46 of the inner panel 42 is connected by a clinch joint 20
to the outer flange 48 of the outer panel 44. A partial area 50 of
the outer flange 48 is provided with a textured surface 52. The
textured 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 the textured surface 52 on the
outer flange 48. Other types of textured surfaces may also be
formed in the compression molding operation.
[0033] Referring to FIGS. 7A and 7B, alternative embodiments of a
composite panel 60 are illustrated that are formed of a polymeric
resin 62 and reinforced with fiber reinforcements 64 in FIG. 7A. In
FIG. 7B, a fiber mat 65 is shown embedded in the resin 62 to
illustrate an alternative to the loose fibers 64. An intended
clinch joint location 66 consists essentially of pure or neat resin
62. The surrounding portions of the panel 60 include the fiber
reinforcements 64 or fiber mat 65. While discontinuous, or loose
fiber reinforcements 64 may be used, a woven mat of fiber having
cut-outs in the intended clinch joint locations 66 may be easier to
process. The woven mat 65 also may be braided or stitched
continuous fiber reinforcements 64.
[0034] Referring to FIGS. 8A and 8B, the composite panels 60 are
illustrated after a clinch joint 68 is formed to join the composite
panel 60 and a second panel 70. The composite panel 60 includes a
pressed out portion 72 that is received in a clinching portion 74
of the second panel 70. The clinch joint 68 does not have any
exposed fibers because no fiber reinforcements 64 (in FIG. 8A) or
fiber mat 65 (shown in FIG. 8B) are disposed in the intended clinch
joint locations 66.
[0035] 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.
* * * * *