Abstract:
A system for assembling vehicle components includes a die assembly securing first and second vehicle components having first and second apertures, respectively. The die assembly positions the first and second vehicle components with the first and second apertures overlapping, and at least one of the first and second vehicle components including a polymeric material. The system further includes a joining component extending through the first and second apertures. The die assembly supports the joining component, and the joining component including a support shank and a moldable body at least partially encasing the support shank. The system also includes a punch member selectively engaging and deforming the moldable body of the joining component. The die assembly guides the moldable body into engagement with the first and second vehicle components, and the die assembly locates the support shank within at least one of the first and second apertures.

Description:
BACKGROUND 
       [0001]    Vehicles, such as automobiles, pick-up trucks, sport-utility vehicles, minivans, vans and other passenger vehicles, have traditionally utilized steel for their structure. However, the need for more efficient vehicles has led to consideration of a variety of structural and body materials, depending on particular vehicle design specifications. For example, to help meet fuel efficiency targets or requirements, e.g., Corporate Average Fuel Economy (CAFE) regulations, vehicles may incorporate non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics, in place of and/or in addition to traditional metallic components to reduce weight while maintaining suitable strength and stiffness performance. The integrity and robustness of the attachments of such components and materials impact the performance of the vehicle in a variety of ways, including the strength of the vehicle and the noise, vibration and harshness (NVH) characteristics of the vehicle. However, traditional manufacturing methods may not be applicable to alternative material needs. For example, reinforced composite materials cannot be welded, and they can cause metallic fasteners to corrode. Other joining techniques do not fit into mass-market cycle times. In another example, if the vehicle materials and the fasteners have significantly different thermal expansion properties, joint integrity may be compromised due to thermal cycling. As such, it is currently difficult to provide an attachment for non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics, sufficiently robust to be applied in mass market passenger vehicles. 
     
    
     
       DRAWINGS 
         [0002]      FIG. 1  is a cross-sectional view of an exemplary assembly of vehicle components according to the principles of the present disclosure. 
           [0003]      FIG. 2  is a cross-sectional view of exemplary vehicle structural members positioned with overlapping apertures therethrough, respectively. 
           [0004]      FIGS. 3A-3C  are cross-sectional views of exemplary fastening components for an assembly according to the principles of the present disclosure, the fastening components including a reinforced outer moldable body encasing a support body. 
           [0005]      FIG. 4  is a cross-sectional view of another exemplary support body for an exemplary fastening component for an assembly according to the principles of the present disclosure. 
           [0006]      FIGS. 5A-5C  are cross-sectional views of system for forming an assembly according to the principles of the present disclosure. 
           [0007]      FIG. 6  illustrates an exemplary process for forming an assembly according to the principles of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0008]      FIG. 1  is an exemplary cross-sectional view of an exemplary assembly  10  of vehicle components according to the principles of the present disclosure. The exemplary assembly  10  includes first and second structural components  12  and  14 . In one example, first and second components  12  and  14  are body components for a vehicle such as a passenger car, sport-utility vehicle, minivan, etc. In this exemplary implementation, the first and second components  12  and  14  abut each other. It should be understood that the principles of the present disclosure may be applicable to a variety of vehicle assemblies, including an assembly with more than two components. 
         [0009]    According to the principles of the present disclosure, at least one of the first and second components  12  and  14  are formed from and/or include non-metallic, plastic, composite and/or reinforced materials such as, e.g., fiber-reinforced plastics. In one example, one of the first and second components  12  and  14  may be formed of a carbon fiber reinforced plastic material, and the other may also be formed of a carbon fiber reinforced plastic material, another non-metallic, plastic, composite and/or reinforced material, or a metallic material. The first and second components  12  and  14  may have substantially identical material compositions. 
         [0010]    With further reference to  FIG. 2 , the first and second components  12  and  14  include first and second apertures  16  and  18 , respectively. First and second components  12  and  14  are positioned with the first and second apertures  16  and  18  overlapping each other. In some implementations, as shown in the exemplary illustration of  FIG. 2 , the first and second components  12  and  14  may be posited to center, i.e., concentrically align, the first and second apertures  16  and  18 . 
         [0011]    The assembly  10  further includes a fastener or joining component  20  extending through the first and second apertures  16  and  18  of the first and second components  12  and  14 . The joining component  20  includes a moldable outer body  22  at least partially encasing a relatively rigid support shank or body  24 . It should be understood that the description herein of the outer body “at least partially encasing” the support body includes, in some implementations, where a portion or portions of a support body or shank, or feature thereof, may protrude through the outer body to the exterior surface of the joining component, but the outer body extends sufficiently around the support body to maintain the support body fixed relative to the outer body. Furthermore, as used herein, “moldable” refers to both materials that may, under certain conditions, be repeatedly deformed and melted, e.g., thermoplastic polymer materials, and materials, e.g., thermosetting polymer materials, that may substantially irreversibly cure or otherwise chemically change due to applied deformation conditions i.e., heat, pressure, etc. Accordingly, the outer body  22  may include one of a thermoplastic material, e.g., nylon, and a thermoset material, e.g., epoxy or polyester. In addition to such a moldable material, the outer body  22  may include a reinforcement material  32 . 
         [0012]    With further reference to  FIGS. 3A-C , additional joining components  20 ′ and  20 ″, along with the joining component  20 , are all illustrated in an exemplary pre-deformed state, e.g., in a substantially cylindrical shape. The additional joining components  20 ′ and  20 ″ have outer bodies  22 ′ and  22 ″, respectively, which include varying reinforcement materials  32 ′ and  32 ″, respectively. For example, the reinforcement materials  32 ,  32 ′ and  32 ″ may include one or more of a variety of fibrous and/or particulate materials, e.g., carbon, glass, aramid and other natural fibers; talc and metallic flakes; and glass beads. It should be understood that, apart from the variation in reinforcement materials, the description herein of joining component  20  equally applies to joining components  20 ′ and  20 ″. 
         [0013]    As illustrated in  FIGS. 1 and 3A -C, support bodies  24 ,  24 ′ and  24 ″ are respectively at least partially encased by the moldable outer bodies  22 ,  22 ′ and  22 ″ and each may have a substantially cylindrical shape. Referring to  FIG. 4 , another support body  24 ′″ includes ribbed locking members  34 ′″ protruding from the radially outer surface thereof. The locking members  34 ′″ help mechanically fix the support body  24 ′″ relative to the moldable outer body of the respective joining component in a vehicle component assembly according to the principles of the present disclosure. For example, the locking members  34 ′″ would provide additional resistance to lengthwise movement of the support body  24 ′″ relative to an at least partially encasing outer body. It should be understood that a support body or shank according to the principles of the present disclosure may include many geometries, including protruding locking members in a variety of configurations, such as a spaced apart knobs or a thread. Such features may significantly affect the cross sectional area of the support body or shank. It should also be understood that, apart from inclusion of locking members in the support body  24 ′″, the description herein of the support bodies  24 ,  24 ′,  24 ″ and  24 ′″ are equally applicable to each other. 
         [0014]    The system and a process  100  for forming the assembly  10  with the first and second components  12  and  14  and the joining component  20  is illustrated in  FIGS. 5A-C  and  6 . With particular reference to  FIG. 5A  and a block  102  of  FIG. 6 , a die assembly  50  secures the first and second components  12  and  14 , with the first and second apertures  16  and  18  overlapping, with a base component  52  and a nose component  54 . The base component  52  has a molding recess  56 , and the nose component  54  has a through aperture  58  overlapping with the molding recess  56 . The first and second components  12  and  14  are positioned in the die assembly  50  with the first and second apertures  16  and  18  overlapping with the molding recess  56  and the through aperture  58 . As illustrated in  FIGS. 5A-C , the first and second apertures  16  and  18  may be centered, i.e., concentrically aligned, with the molding recess  56  and the through aperture  58 . 
         [0015]    Referring in particular to  FIG. 5B  and a block  104  of  FIG. 6 , with the first and second components  12  and  14  secured in the die assembly  50 , the joining component  20  may be extended through the through aperture  58  of the nose component  54  and the first and second apertures  16  and  18  and into engagement with the molding recess  56 . In the exemplary illustrated implementation, the joining component  20  is positioned through the first and second components  12  and  14  in a substantially cylindrical, pre-deformed configuration. 
         [0016]    Referring in particular to  FIG. 5C  and a block  106  of  FIG. 6 , with the joining component  20  positioned between the first and second vehicle components  12  and  14 , a punch member  60  of the die assembly  50  extends into the through aperture  58  of the nose component  54  and engages the joining component  20 , as illustrated in  FIG. 5C . The punch member  60  deforms the moldable outer body  22  of the joining component  20  into the molding recess  56 , the first and second apertures  16  and  18 , and the region of the through aperture  58  between the punch  60  and the first vehicle component  12 . 
         [0017]    As illustrated in  FIGS. 5A-C , a temperature control apparatus  62  may be thermally coupled to the die assembly  50  to provide heating or cooling to aid the curing and/or the deformation process of the moldable outer body  22 . For example, referring to a block  108  of  FIG. 6 , one portion of the process  100  may be determining whether such temperature control is needed or desired. If not, referring to a block  110  of  FIG. 6 , the outer body  22  of the joining component  20  is deformed through force applied by the punch member  60  primarily, e.g., when the moldable material of the outer body  22  is a thermoplastic material. 
         [0018]    Referring again to the block  108  of  FIG. 6 , if temperature control of the die assembly  50  is needed or desired, e.g., the moldable material of the outer body  22  is in the form of a thermosetting material and heat is required to cure the outer body  22 , or heat facilitates deformation thereof. For example, the temperature control apparatus  62  may include a heater in thermodynamic communication with the die assembly  50  to operate as required for the particular materials and operating conditions. In another example, to facilitate manufacturing, e.g., by speeding up the process  100 , the temperature control apparatus  62  may also have a cooler in thermodynamic communication with the die assembly  50  to speed the curing or hardening of the moldable outer body  22  in the deformed shape. Accordingly, referring to a block  112  of  FIG. 6 , the temperature control apparatus  62  is operated as desired or needed, and the process  100  continues to the block  110 , where deformation through force and/or temperature control occurs. 
         [0019]    As deformed by the punch member  60  according to the principles of the present disclosure, the joining component  20  includes first and second flanges  72  and  74  of the outer body  22  clamping the first and second components  12  and  14  together. In this exemplary illustrated implementation, the first flange  72  directly engages an outer surface  82  of the first component  12 , and the second flange  74  directly engages an outer surface  84  of the second component  14 . In some implementations, e.g., where the moldable material of the outer body  22  is a thermosetting material, one or both of the first flange  72  and the second flange  74  may adhesively bond to the first and second vehicle components  12  and  14 , respectively. In such an implementation, the first flange  72  may have a bond  86  with the outer surface  82  of the first component  12 , and the second flange  74  may have a bond  88  with the outer surface  84  of the second component  14 . 
         [0020]    In the deformation of the moldable outer body  22 , the support body  24  is positioned to extending into the first and second apertures  16  and  18 . In other implementations, the support body or shank  24  may extend into only one of the first and second apertures  16  and  18 . 
         [0021]    As shown in the exemplary illustrations, the first and second apertures  16  and  18  may be substantially centered relative to each other, and the deformed joining component  20  and the support body  24  thereof may be substantially centered relative to the first and second apertures  16  and  18 . In other implementations, the deformed joining component  20  and the support body  24  thereof may be substantially centered relative to at least one of the first and second apertures  16  and  18 . 
         [0022]    In the drawings, the same reference numbers indicate the same elements. Further, some or all of these elements could be changed. Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It should be understood that, as used herein, exemplary refers to serving as an illustration or specimen, illustrative, or typical. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims. 
         [0023]    All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.