Vehicle frame structural member assembly and method

A vehicle frame structural member assembly method includes an elongated frame member and a reinforcement member. The reinforcement member is complementarily arranged adjacent the elongated frame member.

BACKGROUND

Vehicle frames and constructions therefor are increasingly complex as vehicle manufacturers look for new ways to improve structural integrity of the vehicle frame while maintaining and/or reducing the overall weight of the vehicle frame. These are often competing concerns. That is, increasing the structural integrity of the vehicle frame (e.g., improving crash performance) often involves adding weight to the vehicle frame. Conversely, reducing the weight of the vehicle frame must be done carefully so as to avoid adversely changing the structural integrity of the vehicle frame. A number of technologies and methods are known for improving the integrity of the vehicle frame and some of these are also concerned with limiting the amount of weight added to the vehicle frame.

In particular, current mass production structural design for vehicles is dominated by stamped metal, which uses section size, material gauge and grade, and typically spot welding to achieve performance requirements. To facilitate fuel economy improvement, supported by weight reduction, new concepts are needed to deliver fundamental weight reduction at a reasonable value. Concepts which can avoid exotic lightweight materials are preferred, particularly those that preserve current manufacturing infrastructure related to spot welding and stamped metal. One known countermeasure is the employment of structural reinforcements. However, the choice of materials and/or execution of designs using such structural reinforcements have been lacking thus far.

SUMMARY

According to one aspect, a vehicle frame structural member assembly includes an elongated frame member, a reinforcement member and a structural foam. The reinforcement member is complementarily arranged adjacent the elongated frame member. The reinforcement member is formed from a plastic material. The structural foam is attached to the reinforcement member.

According to another aspect, a vehicle frame structural member assembly method is provided. More particularly, according to one aspect, the method includes attaching a structural foam to a reinforcement member and complementarily positioning the reinforcement member adjacent an elongated frame member. The reinforcement member is formed from a plastic material.

According to still another aspect, a vehicle frame structural member assembly includes an elongated frame member, a fiber reinforced plastic reinforcement member and a structural foam. The fiber reinforced plastic reinforcement member is complementarily positioned adjacent the elongated frame member for reinforcing the elongated frame member. The structural foam is overmolded onto the reinforcement member.

According to still yet another aspect, an internal reinforcement includes an elongate body including a base positioned opposite a crown, a shelf extending along the crown and a compressive member extending along the base. The shelf includes a surface positionable parallel to a first leg of a concave frame structure. The compressive member includes a first wall with a surface positionable parallel to a second leg of the concave frame structure.

According to a further aspect, a vehicle frame structural member assembly includes an elongated structural member and a reinforcement positioned in a hollow chamber of the hollow structural member. The elongated structural member includes a concave frame member having a body with a first leg and a second leg extending therefrom, and an inner frame member extending from the first leg to the second leg. The elongated frame member and the inner frame member define the hollow chamber therein. The reinforcement includes an elongate body having a base positioned opposite a crown, a shelf extending along the crown and a compressive member extending along the base. The shelf includes a surface positioned parallel to the first leg of the concave frame member. The compressive member includes a first wall with a surface positioned parallel to the second leg of the concave frame member. The vehicle frame assembly further includes a first adhesive positioned between the shelf and the first leg and a second adhesive positioned between the first wall and the second leg.

DETAILED DESCRIPTION

FIG. 7illustrates a known vehicle frame structural member assembly generally indicated by reference numeral10. As will be understood and appreciated by those skilled in the art, the illustrated assembly can be the A-pillar, and particularly an upper section of the A-pillar disposed along a vehicle windshield (not shown). The assembly10includes an outer frame member12having mating flanges12a,12band an inner frame member14having mating flanges14a,14b. As is known, the mating flanges12a,12band14a,14bcan be spot welded to one another to form the closed profile structural member assembly10. The assembly10further includes an internal stiffener or reinforcement16comprised of an outer stiffener member18having mating flanges18a,18band an inner stiffener member20having flanges20a,20b.

As shown, the mating flange18acan be sandwiched between the mating flanges12a,14aof the inner and outer frame members12,14. Likewise, the mating flange18bcan be sandwiched between the mating flanges12b,14bof the outer and inner frame members12,14. Accordingly, the mating flanges16a,16bcan be spot welded together with the mating flanges12a,12b,14a,14bas is known and understood by those skilled in the art. The flanges20a,20bof the inner stiffener member20can be welded to, respectively, lower and upper sections18c,18dof the outer stiffener member18as shown.

The outer frame member12, the inner frame member14, the outer stiffener member18and the inner stiffener member20generally comprise the components of the assembly10. These components are each typically formed of a metal, such as steel or aluminum. Conventionally, these are stamped metal pieces. To provide desired performance characteristics, these components tend to be formed of stamped steel and have relatively thick gauges. For example, the outer frame member12can be formed of a mild steel having a gauge of 0.65 mm to 0.75 mm (e.g., 0.7 mm), the inner frame member14can be formed from an advanced high strength steel (AHSS) sheet having a gauge of 1.8 mm to 2.33 mm (e.g., 1.8 mm), the outer stiffener member18can be formed from an ultra-high strength steel (UHSS) sheet having a gauge of 1.6 mm to 2.00 mm (e.g., 1.6 mm) and the inner stiffener member20can be formed from an AHSS sheet having a gauge of 2.0 mm to 2.3 mm (e.g., 2.0 mm).

Referring now toFIGS. 1-4wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting the same, a vehicle frame structural member assembly according to an exemplary embodiment is generally designated by reference numeral30. As shown, the assembly10includes an elongated frame member32(also referred to as a concave frame structure) and a reinforcement member34complementarily arranged adjacent the elongated frame member32. As shown, the elongated frame member32of the assembly30can be an A-pillar frame member with the reinforcement member34disposed along an upper or windshield portion of the A-pillar frame member (as best shown inFIG. 1). In one embodiment, the elongated frame member32can be similar to the stiffener member18of the known design, though can be of a reduced gauge thickness due to the performance enhancing characteristics of the reinforcement member34and/or the various structural advantages of the assembly30that will be described in further detail below. Thus, the elongated frame member32can be a stamped metal member, such as a stamped steel or stamped aluminum member. In an exemplary embodiment, the elongated frame member32is formed via hot stamping of a high strength boron-containing steel having an aluminum silicate coating. An example of such a steel with an AlSi coating is commercially available under the designation Usibor® 1500 from ArcelorMittal.

As will be described in further detail below, the reinforcement member34, which can also be referred to as an internal reinforcement, has an elongate body34athat can be formed from a polymeric material. In one embodiment, the reinforcement member34is formed from a fiber reinforced plastic including a plastic matrix material that encapsulates a fiber material. Polymeric materials include, but are not limited to, nylon, polyamide, polyester, polypropylene, polyethylene, or others. The polymeric material may be filled or unfilled. For example, the polymeric material may be filled with glass, carbon, or other reinforcement fibers. In another example, the matrix material can be nylon and/or the fiber material can be a plurality of glass fibers. As a more specific example, the matrix material can be nylon that is PA66 or better and/or the glass fibers can be provided in different lengths. In another specific example, the plastic component of the matrix material can be nylon PPA (polyphthalamide), nylon PA9T (poly 1,9-nonamethylene terephthalamide), or some other nylon having a relatively high glass transition temperature (Tg), such as relative to nylon PA66.

Additionally, as best shown inFIG. 4, the assembly30can include a structural foam36attached to the reinforcement member34. The structural foam36can be a heat activated epoxy foam. The structural foam36can be overmolded onto the reinforcement member34to thereby attach the structural foam36to the reinforcement member34. In one embodiment, the structural foam36is a heat activated epoxy foam that is initially overmolded onto the reinforcement member34and later heat activated to expand and bond with the reinforcement member34. For example, the structural foam36can be a heat-activated epoxy-based resin having foamable characteristics upon activation through the use of heat such as is received in an e-coat or other automotive/vehicle paint oven operation. In particular, as the structural foam36is heated, it expands, cross-links, and structurally bonds to adjacent surfaces. An example of a preferred formulation is an epoxy-based material that may include polymer modificis such as an ethylene copolymer or terpolymer that is commercially available from L&L Products, Inc. of Romeo, Mich., under the designations that include L-5204, L-5207, L-5214, L-5234, L-5235, L-5236, L-5237, L-5244, L-5505, L-5510, L-5520, L-5540, L-5573 or combinations thereof. Such materials may exhibit properties including relatively high strength and stiffness, promote adhesion, rigidity, and impart other valuable physical and chemical characteristics and properties. In one exemplary embodiment, the structural foam is the commercially available material sold under the designation L-5520 by L&L Products, Inc., or an equivalent material. In another exemplary embodiment, the structural foam is the commercially available material sold under the designation L5505 by L&L Products, Inc., or an equivalent material. This latter exemplary embodiment (i.e., using L5505) can impart higher energy absorption characteristics and/or a higher peak load limit to the assembly30as compared to the former exemplary embodiment (i.e., using L5520).

The assembly30can further include an inner frame member38having mating flanges38a,38bthat mate with inner sides40,42of mating flanges32a,32bof the reinforcement member34. As shown in the illustrated embodiment, the structural foam36can be interposed between the reinforcement member34and the inner frame member38. Optionally, the inner frame member38can be constructed the same or similar to the inner frame member14of the known assembly10. The assembly30can additionally include an outer frame member44having mating flanges44a,44bthat mate with outer sides46,48of the mating flanges32a,32bof the reinforcement member34on an opposite side of the reinforcement member34relative to the mating flanges38a,38bof the inner frame member38. As shown, the outer frame member44can be constructed the same or similar as the outer frame member12of the known assembly10.

With reference toFIGS. 15A, 15B and 15C, partial schematic views of several variations of inner frame members are shown according to exemplary embodiments. Each of these can be applied to the inner frame member38(or the inner frame member338ofFIG. 14). In particular,FIG. 15Ashows the inner frame member38having a notch38cdisposed along the flange38a. In one embodiment, the notch38cis disposed at or near a midpoint of the inner frame member38relative to a longitudinal extent of the inner frame member38for imparting a deformation zone to the inner frame member38at or near the midpoint of the inner frame member38. As shown, the inner frame member38ofFIG. 15Acan define a plurality of apertures, which in the illustrated embodiment includes an elongated apertures38d,38ethan can be trim mounting holes, a round aperture38fthat can be a harness mounting hole and aperture set38gthat can be for mounting an orienting a side curtain airbag (not shown). Of course, more or fewer apertures could be provided and/or any of the provided apertures can vary in shape, size, function, etc. Weld locations W are schematically shown disposed in spaced apart relation along the flanges38aand38b. In particular, inFIG. 15A, the weld locations W are spaced apart equally along the flanges38aand38b(i.e., the spacing between adjacent weld locations is generally constant).

FIG. 15Bshows a variation for the inner frame member38(or the inner frame member338ofFIG. 14). In particular, the inner frame member38ofFIG. 15Bdoes not include a notch and includes the apertures38d-38grearranged and/or repositioned relative to those ofFIG. 15A. In particular, the round aperture38fis moved so as to be located between the elongated apertures38dand38e. This arrangement moves the deformation zone away from the midpoint of the inner frame member (e.g., slightly to the left inFIG. 15B). The weld locations W and relative spacing therebetween are shown as being the same inFIG. 15Bas shown inFIG. 15A.

FIG. 15Cshows a further variation for the inner frame member38(or the inner frame member338ofFIG. 14). In particular, inFIG. 15C, the inner frame member38again does not include a notch and includes the apertures38d-38grearranged and/or repositioned relative to those ofFIGS. 15A and 15B. In particular, the elongated aperture38dis moved nearer to the left side end shown inFIG. 15C, the elongated aperture38eis moved to the approximate midpoint of the inner frame member38and the round aperture38fis moved nearer the right side end shown inFIG. 15D(i.e., round aperture38fcan be at the same location betweenFIGS. 15A and 15C). Also, the weld locations W and the relative spacing therebetween are varied inFIG. 15Crelative toFIGS. 15A and 15B. In particular, no weld locations are provided at or near the midpoint of the inner frame member38ofFIG. 15C. The positioning of the apertures38d-38gand/or the lack of centrally located weld locations imparts a deformation zone to the inner frame member38at or near the midpoint of the inner frame member38without the need for a notch (e.g., notch38cofFIG. 15A).

Of course, other variations are possible and the foregoing is only provided as non-limiting examples to show that notching, aperture location/positioning and/or weld location/spacing can be varied to impart the deformation zone to desired locations (e.g., centrally) on the inner frame member38. It should be understood that other notches (including other sized notches and/or configurations), apertures, aperture locations and/or weld locations could be used to impart desired deformation characteristics to the inner frame member38.

As best shown inFIG. 4, reinforcement member34includes a base50,54positioned opposite a crown58. In particular, the base50,54is formed by a lower wall50and an inner wall54, the inner wall54extending away from the lower wall50. The lower wall50mates against a lower section52of the elongated frame member32, the lower section52and an upper section60of the elongated frame member32together forming the elongated frame member32as a concave frame structure and alternately referred to as first and second legs of the concave frame structure. The inner wall54extends away from the lower section52of the elongated frame member32. The reinforcement member34also includes the crown58formed by and alternatively referred to as an upper wall. The upper wall58mates against the upper section60of the elongated frame member32. The reinforcement member34further includes an angled wall62extending upward from the inner wall54, and particularly upward from a distal portion54aof the inner wall54relative to the lower wall52, to an outer end58aof the upper wall58. The upper wall58can be referred to as a shelf and has a surface58bpositionable parallel to the upper section60, which can also be referred to as a first leg. As shown, adhesive64can be interposed between the lower wall50and the lower section52of the elongated frame member32. Likewise, adhesive66can be interposed between the upper wall58and the upper section60of the elongated frame member32.

The adhesive64and/or the adhesive66can have one component or two components. Suitable two-component adhesives can be room temperature curing or precuring two-component epoxy resin adhesives or polyurethane adhesives or (meth)acrylate adhesives. Room temperature precuring two-component epoxy resin adhesives or polyurethane adhesives or (meth)acrylate adhesives can be epoxy resin adhesives or polyurethane adhesives or (meth)acrylate adhesives which consist of two components, the mixing of which causes a reaction between the components, thus achieving at least a certain degree of crosslinking (“precured” or “precrosslinked”). Such adhesives are capable, in a further curing step, of reacting further, for example at elevated temperature. These adhesives can have so-called precuring or pregelation in the first stage, and a heat-curing reaction stage at elevated temperature. Two-component epoxy resin adhesives can have a resin component comprising a glycidyl ether, a diglycidyl ether of bisphenol A and/or bisphenol F. In addition, they can have a hardener component comprising polyamines and/or polymercaptans. Such two-component epoxy resin adhesives can cure rapidly at room temperature after mixing of the two components, and are known to those skilled in the art. Two-component polyurethane adhesives can have polyisocyanates in one component, such as in the form of prepolymers having isocyanate groups, and polyols and/or polyamines in a second component. Such two-component polyurethane adhesives can cure rapidly at room temperature after mixing of the two components and are known to those skilled in the art. Two-component (meth)acrylate adhesives can have acrylic acid and/or methacrylic acid and/or esters thereof in one component. The second component can comprise a free-radical former, such as a peroxide. Such two-component (meth)acrylate adhesives cure rapidly at room temperature after mixing of the two components and are known to those skilled in the art.

As is known by those skilled in the art, room temperature curing two-component adhesives can also be cured under the influence of heat. This can lead to a more rapid reaction and thus to a shortening of the period of time until an adhesive bond produced therewith can be stressed with forces. Moreover, a heat treatment of such room temperature curing two-component adhesives can lead to higher strengths compared to those which do not undergo any such heat treatment.

In one exemplary embodiment, the adhesive64and/or the adhesive66can also be a heat-curing one-component epoxy resin adhesive. An example heat-curing one-component epoxy resin adhesive can comprise at least one epoxy resin and at least one thermally activable catalyst or a hardener B for epoxy resins which is activated by elevated temperature. Heating of such a one-component heat-curing one-component epoxy resin adhesive causes crosslinking. The heating is effected typically at a temperature of more than 70° C. Exemplary adhesives of this type include those commercially available in the SikaPower® product line from Sika Automotive AG of Switzerland, including adhesives sold by Sika Automotive AG under the designation SikaPower® 961 and SikaPower® 968. Preference may be given to the adhesive sold under the designation SikaPower® 968 as this adhesive has an adhesive strength that allows failure between adhered components in the assembly30to occur in the adhesive64or66and not in the components that are adhered together (e.g., not in the elongated frame member32, such as between a boron-containing steel and its aluminum silicate coating).

As shown, the elongate body34aof the reinforcement member34includes a base34bpositioned opposite a crown34c. The upper wall58forms a shelf that extends along the crown34cthat includes a surface58a(FIG. 2) that is positionable parallel to the upper section60, which can also be referred to as a first leg of the elongated frame member32. The elongate body34afurther includes a first side34dpositioned opposite a second side34e. The shelf (i.e., the upper wall58) extends outward from the first side34d.

As best shown inFIG. 2, a compressive member68extends along the base34b. The compressive member68includes the lower wall50, which can be referred to as a first wall of the compressive member68, having a surface50apositionable parallel to the lower section52of the reinforcement member32. The lower wall50extends outward from the second side34e. The compressive member68also includes the inner wall54, which can be referred to as a second wall of the compressive member68, and an energy absorbing structure68aextending between the first wall50and the second wall54. In the illustrated embodiment, the energy absorbing structure68ais a honeycomb structure formed of honeycomb patterned walls68b.

In the illustrated embodiment, the honeycomb structure68acan be disposed between the lower wall50and the inner wall54. Advantageously, the honeycomb structure68aefficiently distributes compressive loads in the reinforcement member34. Along a longitudinal length of the reinforcement member34, the thickness or gauge of the walls68bforming the honeycomb structure68acan have varying wall thicknesses. For example, referring toFIG. 1, the honeycomb structure68alocated along a central portion70can have a first thickness that is different or varies relative to the honeycomb structure68adisposed along flanking portions72,74. By way of example, the wall thickness of the honeycomb structure68aalong the central portion70can be 1.5 mm and the honeycomb structure68aalong the flanking portions72,74can be 2.0 mm. Arranging the honeycomb structure68awith differing thicknesses can be strategically determined to get desired deformation from the assembly30at a desired location or locations therealong.

Again as best shown inFIG. 4, a larger cross-sectional area or thickness may be provided adjacent or at the apex76defined by the lower wall50and the inner wall54. This has the benefit of better orienting long fibers, such as glass fibers, within the reinforcement member34along the longitudinal length thereof. Thus, the configuration of the reinforcement member34at the lower wall50and the inner wall54is sufficiently thick to orient the fibers, including also providing an area for an injection mold gate (not shown). More particularly, this configuration allows for more highly oriented flow with reduced shear stress during the injection molding process. This increases the likelihood that longer fibers will be parallel with a longitudinal length of the reinforcement member34, particularly at or near the apex76, With reference toFIG. 3, apertures, such as recesses or pockets78, can be defined in the inner wall54near a lower edge54a. As shown, the recesses78can have an “ice cube tray” configuration. These can assist in providing a varying contour to which the structural foam36can be overmolded during the overmolding step wherein the structural foam36is attached to the reinforcement member34and can reduce the potential for abnormal shrinkage or cracking.

A plurality of spaced apart ribs80, which can also be referred to as a plurality of reinforcements, can be distributed along the longitudinal length of the reinforcement member32. In the illustrated embodiment, the ribs80protrude from both sides of the angled wall62as shown. Also in the illustrated embodiment, a plurality of spaced part apertures82can be defined through the angled wall62and arranged between the spaced apart ribs80.

In the illustrated embodiment, the reinforcement member34additionally includes clip structures90,92extending toward the elongated frame member32. In particular, in the illustrated embodiment, the clip structures90,92are integrally formed with the spaced apart ribs80and can be referred to as integrally molded clip structures, though this is not required. Each of the clip structures can be at least one of: a drain tube clip that includes an aperture in which a sunroof drain tube is accommodated and/or an attachment clip that provides an attachment flange with an aperture in which an attachment clip is accommodated. For example, in the illustrated embodiment, the clip structures90are attachment clips that provide attachment flanges94with apertures96defined therein in which an attachment clip98is accommodated.

As shown, the attachment clip98can be used to at least temporarily secure the relative position of the reinforcement member34on the elongated frame member32, such as during assembly of the elongated frame member32and the reinforcement member34. More particularly, each attachment clip98can be received through a respective aperture96of a respective attachment flange94and then received through a respective aperture100defined in the elongated frame member32. An exemplary function for the attachment clips98is to temporarily secure the reinforcement member34in position on the elongated frame member32until the adhesive64,66and/or the structural foam36cures to permanently secure the reinforcement member34in position on the elongated frame member32.

The clip structures90additionally are drain tube clips that include an aperture102in which a sunroof drain tube104is accommodated. In contrast, the clip structure92is only a drain tube clip that includes an aperture (not shown) in which the sunroof drain tube104is accommodated. Though not shown in the illustrated embodiment, the reinforcement member34could include clip structures that are only attachment clips and not drain tube clips.

With reference now toFIG. 14, a vehicle frame structural member assembly330is shown in cross section according to an alternate exemplary embodiment. Except as indicated hereinbelow and/or shown inFIG. 14, the assembly330can be the same or similar to the assembly30described above in reference toFIG. 1-4. More particularly, the assembly330ofFIG. 14can include an elongated frame member332and a reinforcement member334complementarily arranged adjacent the elongated frame member332. With the exception of the variance in shape shown inFIG. 14, the elongated frame member332can be like the elongated frame member32ofFIG. 4. Likewise, with the exception of the variance in shape shown inFIG. 14, the reinforcement member334can be like the reinforcement member34ofFIG. 4. Though not shown, the reinforcement member334can include spaced apart ribs and spaced apart rib apertures like those (e.g., ribs and apertures80,82) of the assembly30ofFIG. 4. Additionally, the assembly330can include a structural foam336that is like the structural foam36. In particular, the structural foam336can be overmolded onto the reinforcement member334to attach the structural foam336to the reinforcement member334.

Further, the assembly330can include an inner frame member338that is the same or similar to the inner frame member38ofFIG. 4, and can include an outer frame member344. The outer frame member344can be like the outer frame member44ofFIG. 4but, as shown inFIG. 14, the outer frame member344can have a different shape and can have a mating flange344aarranged to overlap a lower section352of the elongated frame member332and not mate directly with flange332aof the elongated frame member or flange338aof the inner frame member338. The shape changes to the elongated frame member332and the outer frame member344and/or the altered location to which the flange344aoverlaps onto the elongated frame member332significantly increases the peak force of the assembly330(i.e., the force at which the assembly330will fail) and significantly increases the energy absorption of the assembly330.

With reference now toFIGS. 5A-5DandFIG. 6, a vehicle frame structural member assembly method will now be described. In particular, the method can be used with the vehicle frame structural member assembly30described hereinabove and will be described with reference thereto, though this is not required and other vehicle frame structural member assemblies can be used. In the method ofFIG. 6, at S200, structural foam36is attached to reinforcement member34, which can be formed from a plastic material. The attaching of the structural foam36to the reinforcement member34in S200can include overmolding the structural foam36onto the reinforcement member34. In particular, the structural foam36can be overmolded onto the inner wall54of the reinforcement member34and at least a portion of the structural foam36can be received within the apertures78defined in the inner wall54. Optionally, and not shown inFIG. 6, the sunroof drain tube104can be attached to the reinforcement member34. This can include installing the sunroof drain tube104in the apertures102of the clip structures90.

Next, at S202, the reinforcement member34can be complementarily positioned adjacent elongated frame member32. Complementarily positioning the reinforcement member34adjacent the elongated frame member32in S202can include aligning the reinforcement member34along the elongated frame member32. In addition or in the alternative, complementarily positioning the reinforcement member34in S202can include temporarily securing the reinforcement member34to the elongated frame member32as shown inFIG. 5B.

Temporarily securing the reinforcement member34in S202can include applying the adhesive64,66to at least one of the reinforcement member34and the elongated frame member32. In particular, and as best shown inFIG. 5A, the adhesive64,66can be applied as beads64a,64b,66a. More specifically, beads64a,64bcan be applied to the lower section52of the elongated frame member32and the beads66acan be applied to the upper section60of the elongated frame member32. Though not shown in the illustration inFIG. 5A, in the alternative or in addition, beads of the adhesive64,66could be applied to the reinforcement member34instead of or in addition to the beads64a,64b,66abeing applied to the elongated frame member32.

Alternatively or in addition, and as shown inFIG. 5B, temporarily securing the reinforcement member34to the elongated frame member32in S202can include mechanically fastening the reinforcement member34to the elongated frame member32. For example, this can be achieved by receipt of the attachment clips98in the apertures100of the elongated frame member32. Notably, the attached structural foam36remains in the non-expanded state, as illustrated inFIGS. 5A and 5B.

The method ofFIG. 6can additionally include installing the outer frame member44at S204and installing the inner frame member38at S206. Installing the outer frame member44at S206can be done by welding the mating flanges44a,44bof the outer frame member44to the outer sides46,48of the mating flanges32a,32bof the elongated frame member32. Installation of the inner frame member38at S206can include welding mating flanges38a,38bof the inner frame member38to inner sides40,42of the mating flanges32a,32bof the elongated frame member32.FIG. 5Cshows the inner frame member38installed and continues to show the structural foam36in the non-expanded state. Once the inner frame member38is installed, the structural foam36is disposed between the structural member34and the inner frame member38.

Next, as shown at S208inFIG. 6, the structural foam36can be heated. As already described herein, the structural foam36can be heat activated epoxy foam that expands and bonds to components in which it is in contact. The heating of the structural foam in S208causes the structural foam36to fully fill the gap distance between the reinforcement member34and the inner frame member38as shown inFIG. 5D. In addition, as cured, the structural foam36bonds to the reinforcement member34and the inner frame member38thereby securing the reinforcement member34and the inner frame member38together. Heating of the structural foam in S208can additionally include heating of the adhesive64,66, which can have the effect of curing the adhesive64,66. In one embodiment, the heating in S208occurs during the paint oven process in which the vehicle or at least the vehicle frame has paint applied thereto that is then heated in a paint oven as is known and understood by those skilled in the art.

Advantageously, temporarily attaching the reinforcement member34to the elongated frame member32via the clips98allows relative positioning of the reinforcement member34to remain intact until the structural foam36and/or the adhesive64,66fully cures. Also advantageously, the expanding structural foam36allows for complex gap conditions to be managed (i.e., allows for greater tolerance variations). Further advantages of the foregoing assembly30and method include replacement of heavier stamped metal parts of the known assembly10with relatively lighter weight parts, such as the composite reinforcement member34. Additionally, more tuning is available for an injection molded part versus a stamped part. Yet a further advantage is realized in that the gauge thickness of the remaining sheet metal parts can be reduced relative to the known assembly10ofFIG. 7. For example, the elongated frame member32can be formed from an UHSS sheet having a gauge thickness of about 1 mm, the inner frame member38can be formed from an AHSS sheet having a gauge thickness of about 1.22 mm, and/or the outer frame member44can be formed of mild steel having a gauge thickness of about 0.7 mm, though alternate materials and/or gauge thicknesses can be used.

Illustrative methods of making the reinforcement member34are provided. Although described with respect to glass fibers, the fibers are not limited to such and may be a different fiber or blends of one or more types of fibers.

In an non-limiting example, the reinforcement member34may be made by an injection molding process wherein pre-compounded resin pellets containing glass fibers are used. The glass fibers in the pellets have an average length of 1 mm to 20 mm. In another non-limiting example, the glass fibers in the pellet have an average length of 10 mm to 15 mm. In another non-limiting, the glass fibers have an average length of about 1 mm to 3 mm. In a non-limiting example, the glass fibers in the resulting reinforcement member34have an average length of 0.1 mm to about 3 mm. In another non-limiting example, the glass fibers in the resulting reinforcement member34have an average length of 0.1 mm to 0.5 mm, or 0.5 mm to 1.5 mm.

In a non-limiting example as shown inFIGS. 8A and 8B, the reinforcement member34may be made by an in-line compounding injection molding process wherein the glass fibers are fed separate from the resin pellets. For example, as schematically shown, glass fibers can be fed at110and resin pellets can be fed at112inFIG. 8Aand glass fibers can be fed at114and resin pellets can be fed at116inFIG. 8B. In a non-limiting example, the glass fibers fed to the process have an average length of about 40 mm to about 50 mm. In a non-limiting example, the glass fibers in the resulting reinforcement member34have an average length of 5 mm to 15 mm. In another non-limiting example, the pellets may contain glass fibers.

In a non-limiting example as shown inFIGS. 9A and 9B, a fabric118or120may be provided in the mold prior to injection of the resin material and glass fibers. The fabric118or120may include, but is not limited to, glass fibers, carbon fibers, aramid fibers, or mixtures thereof. The fabric may be continuous, and may extend substantially the entire length and/or width of the part. In a non-limiting example, the fabric has a thickness of 0.05 mm to 6.0 mm. The fabric118or120is placed in the mold and is shaped during the closing of the injection mold. The resin (with or without glass fibers) is then injected in the mold to make the reinforcement member34or334.

Typically, as shown inFIG. 10, a feed gate122for the production of an injection molded part124is positioned at the center or middle of the part124so that the resin may flow outward toward the ends. In a non-limiting example as shown inFIG. 11, the reinforcement member34(or, alternatively, the reinforcement member334) is produced by locating a resin feed gate126at an end or side128of the elongated body of the reinforcement member34.

For example, with additional reference toFIG. 12, the reinforcement member34may be provided with a large diameter “D” extending along the length of the reinforcement member34that is parallel or coaxial to the feed gate126, or at least substantially parallel or substantially coaxial to the feed gate126(e.g., the reinforcement member34can have a large radius of curvature that forms the reinforcement member with a slight curve shape). The diameter D is sized to retain fiber length and fiber orientation and may be directly gated. In a non-limiting example, the diameter D is about 1-7 mm. In another non-limiting example, the diameter D is about 4-5 mm. The diameter D may be the same size as the gate for feeding the resin to the mold, 75% of the size of the gate, or 50% of the size of the gate. In a non-limiting example, the diameter D is the apex76formed by the intersection of the lower wall50and the inner wall56as best shown inFIG. 4. Such arrangements provide overlap between the resin feed gate and the diameter D, which allows for the fibers to avoid (or at least reduce the occurrence of) being subjected to shear and bending stresses. In other words, having the injection flow gate direction aligned with the apex76does not substantially disrupt the flow of the injecting resin thereby maximizing final fiber characteristics.

In another non-limiting example as shown inFIG. 13, the reinforcement member34(or, alternatively, the reinforcement member334) is produced by locating at least two resin feed gates130,132along the reinforcement member34and operating the at least two resin feed gates130,132sequentially. In particular, and only as a non-limiting example, the feed gate130can be opened first to begin filling the mold and forming the reinforcement member34from the side128and then subsequently (e.g., when the reinforcement member is partially formed) the feed gate132can be opened. In one non-limiting example, the feed gate132is opened after the reinforcement member34is at least 25% formed. In another non-limiting example, the feed gate132is opened after the reinforcement member34is at least 33% formed. In a further non-limiting example, the feed gate132is opened after the reinforcement member34is near or at least 50% formed.