METHOD OF MANUFACTURE OF A STRUCTURE AND A STRUCTURAL MEMBER FOR USE IN THE METHOD

Abstract: The present invention relates (with reference to the figure) to a method of manufacture of a structure which comprises a plurality of structural members (10, 11) bonded together, the method comprising the steps of extruding a first structural member (11) with a chosen cross section, and joining the first structural member (11) to a second structural member (10) by bonding with an adhesive, wherein the depth of the adhesive between the structural members (10, 11) is chosen so as to enhance the performance of the adhesive bond. The present invention also provides a method of manufacture of a structure wherein the first structural member (11) is provided on a first surface with a plurality of spaced-apart exterior ribs (12) which abut an adjacent surface on the second structural member (10) and which define between them a gap for receiving adhesive, whereby the ribs (12) define a chosen depth of adhesive in order to optimise the bond between the first and second structural members (10, 11).

Description: METHOD OF MANUFACTURE OF A STRUCTURE AND A STRUCTURAL MEMBER FOR USE IN THE METHOD The present invention relates to a method of manufacture of a structure and to a structural member for use in the method. The invention particularly relates to the manufacture of a space frame structure for an automobile, but should not be considered limited to such an application. Recently there has been interest in reducing the weight of automobiles in order to improve fuel economy and performance. There has consequently been a move to use aluminium in place of steel in the manufacture of automobiles. Whilst aluminium has many advantages over steel, in particular in terms of weight saving, it is difficult to form a space frame for a vehicle from aluminium since welding of aluminium is difficult. US-A-5209541 discloses a method of manufacture of a space frame for an automobile from aluminium structural members. The method involves the bonding of the aluminium structural members together with a suitable bonding material such as an acrylic adhesive. The method requires that two structural members to be joined together are each provided with a shaped channel and that an interconnecting member is provided to be inserted into both the channels of the two aluminium members, with the interconnecting member being secured there by adhesive. The method involves complications since the structural members must be machined to give a specific cross section in the areas of joints and also since interconnectors must be used. DE-A-3525830 shows how a bootlid for an automobile can be made by the bonding together of two metal sheets which are shaped with grooves which provide a gap for adhesive. DE-A-3811427 shows how two tubular members of an automobile space frame can be joined together end to end by providing the tubular members with specifically manufactured end portions which cooperate together to define a series of channels for receiving adhesive and also two apertures through which adhesive can be injected in order to adhere the two components together. EP-A-0523831 shows how a motor car structure can be built up from flat panels joined together, each panel comprising two mutually parallel spaced apart structural skins braced with respect to each other by a core of expanded material united to both skins. Each joint between the two panels comprises a series of integral projections formed on a first panel formed by cutting the first panel to a required shape and also recesses in the second panel which correspond to the projections, the projections being inserted into and bonded in the recesses by means of an adhesive. DE-A-4202391 shows how two automobile panels can be connected together by a joint with an L-shaped cross section, which acts as an interconnecting member. The L-shaped joint has two channels, one for each of the panels to which it is joined. Each channel is formed with a cross section which defines a groove for receiving adhesive in order that a panel inserted into the channel can be adhered to the channel by adhesive in the groove. DE-A-4124627 shows how a body panel for a vehicle can be provided with a corrugated edge section so that the panel can be joined to another panel by inserting the corrugated edge into a channel provided at the edge of the second panel. The corrugated edge serves to locate the first panel in the channel at the edge of the second panel whilst the adhesive is setting and also serves to define a gap for the adhesive. The present invention in a first aspect provides a method of manufacture of a structure which comprises a plurality of structural members bonded together, the method comprising the steps of extruding a structural member with a chosen cross-section, and joining extruded structural member to another structural member by bonding with an adhesive, wherein when the extruded structural member is bonded to the structural member the depth of the adhesive between the two structural members varies with variations in the cross-section of the extruded structural member, characterised in that the cross-section of the extruded structural member is chosen so as to enhance the performance of the adhesive bond between the structural members. In a second aspect the present invention provides a structural member for use in the method of manufacture described above which is a hollow, elongate extrusion of aluminium or an alloy of aluminium and which has a plurality of longitudinally extending spaced apart ribs for defining a gap between the structural member and a further structural member bonded thereto. In a third aspect the present invention provides a method of manufacture of a structure wherein first and second structural members are bonded together with adhesive, characterised in that the first structural member is provided on a first surface with a plurality of spaced apart exterior ribs which abut an adjacent surface of the second structural member when the structural members are bonded together and which define between the first surface of the first structural member and the adjacent surface of the second structural member a gap for receiving adhesive, whereby the ribs define a chosen depth of adhesive between the first and second structural members in order to optimise the bond between the first and second structural members. In a fourth aspect the present invention provides a structural member for use in the above described method which is an extrusion and which has a plurality of longitudinally extending exterior ribs provided on a first surface to define between the first surface and an adjacent surface of a second structural member bonded to the structural member a gap for receiving adhesive, whereby the ribs can define a chosen depth of adhesive. In a further aspect of the present invention there is provided a method of manufacture of a structure which comprises a tubular elongate structural member, the method comprising the steps of forming the tubular elongate structural member with a chosen cross-section, and joining the tubular elongate structural member to a second structural member by bonding with an adhesive, wherein when the tubular elongate structural member is bonded to the second structural member the depth of the adhesive between facing surfaces of the tubular elongate structural member and the second structural member varies with variations in the cross-section of the tubular elongate structural member, characterised in that the cross-section of the tubular elongate structural member is chosen to enhance the performance of the adhesive bond between the tubular elongate structural member and the second structural member. Bonding of structural members with adhesive and optionally with mechanical fasteners in addition to adhesive, is advantageous over welding and over the use of mechanical fasteners alone. The resulting bond does not suffer from heat distortion and does not suffer from reduction in material properties occasioned by the heat of welding. The resulting joint is also stiffer that a joint which would result from purely mechanical fastening (e.g. with nuts and bolts) . Furthermore, the bonding process enables the use of hollow tubular members of a wall thickness thinner than that which would be necessary if welding is used as a joining method (welding causes some depletion of metal and consequent weakening of the structural members) . However, the strength, efficiency and durability of a bonded joint depends on the thickness of adhesive between the two structural elements joined. Therefore it is very important to control the thickness of the adhesive layer between the two structural members. The present invention solves this problem in all of its aspects by shaping the members to be joined in a fashion that the depth of adhesive is a planned and controlled depth. The extrusion of material to form a structural member with a chosen cross-section is a very efficient way of forming the structural member, particularly if the member is made of aluminium or an alloy of aluminium. The required cross-section is obtained in one operation and the formed member requires little or no further machining. Preferred embodiments of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 is a drawing illustrating a typical joint in a structure according to the present invention. Figure 2 is a cross-section through the joint illustrated in Figure 1. Figure 3 is a figure which illustrates the distribution of stress through a prior art joint. Figure 4 is an illustration of a second type of joint in a structure according to the present invention. In Figure 1 a first hollow extruded aluminium structural member 10 is joined to a second hollow extruded aluminium structural member 11 by bonding. This figure shows a joint between two structural members in a space frame for an automobile. It will be understood that the total space frame will comprise a number of different aluminium structural members, all joined together to form the required space frame shape. Figure 1 shows only a joint between two such extruded hollow aluminium structural members, but it should be understood that the figure is representative of how the extruded hollow aluminium structural members are joined throughout the space frame. The hollow extruded aluminium structural member 10 is formed with a constant cross-section of a generally rectangular form. Four planar regions are provided on the exterior of the structural member 10, each planar surface being orthogonal to its two nearest planar surfaces and joined thereto by curved regions of the structural member 10 which define the four corners of a cross-section through the structural member. The structural member 10 is formed by an extrusion process, aluminium being particularly suited to an extrusion type of manufacturing. Manufacturing by extrusion is a particularly useful and cost effective method for low volume manufacture of space frames. In the past, space frame manufacturers have bonded a hollow extruded aluminium structural member such as member 10 directly to a member of identical cross-section, with two planar surfaces being brought together within a layer of adhesive between the surfaces. This is illustrated in Figure 3. The disadvantage of doing this arises from the fact that bond thickness in a joint is a very important factor in determining the strength efficiency and durability of the bonded joint. When two planar surfaces are brought together, it is difficult to control the bond thickness between the surfaces and therefore the resulting joints are very variable in their strength efficiency and durability. The present invention overcomes this problem by manufacturing the second structural element 11 with a specially chosen cross- section. The structural member 11 is manufactured in the preferred embodiment from aluminium using an extrusion process. The structural element is provided with small ribs 12 on one exterior surface of a planar region of the structural member. Since the structural member is manufactured by extrusion, it is a very easy, low cost process to provide the small ribs 12. Providing the small ribs 12 by any other manufacturing process would be difficult to do cost effectively. However, extrusion is a very good process for providing a member with a consistent cross-section manufactured to high tolerances which does not require any general further machining in order to bring it into a form suitable for use. Also, extruded sections tend to have a very good surface finish, and generally do not require further operations in order to bring the surface finish to an acceptable quality. As can be seen clearly in Figures 1 and 2, the extruded aluminium structural member 11 is provided with a plurality of parallel ribs 12 which extend along the length of the elongate structural member 11. When the elongate hollow aluminium extruded structural member 11 is to be bonded to the structural member 10 then the surface of the member 11 is coated with adhesive in a desired region and then the two structural members 10 and 11 are clamped tightly together by an assembly fixture while the adhesive sets. Alternatively, it may be desired that the formed joint is reinforced by means of mechanical fastenings, such as nuts and bolts, rivets or screws. It is particularly preferred that EJOTS screws are used since these are easy to use and a high tear out force must be applied to loosen them. In this case, the structural members 10 and 11 are bolted or screwed or otherwise connected to each other whilst the bonding adhesive remains fluid. When the structural members 10 and 11 are mechanically clamped together, the top of the ribs 12 on the structural member 11 come into direct abutment with the adjacent planar surface of the structural member 10. Thus, this ribs 12 define a bond thickness over almost the entire area of the joint. A bond thickness of 0.2mm is the optimal bond thickness for an epoxy adhesive. Obviously, the ribs could be formed with different heights for different types of adhesive in order always provide the optimal bond thickness. The longitudinal ribs 12 allow adhesive to flow along channels between the ribs 12 along the structural member 11 so that an excess of adhesive can be applied to the surface of the structural member 11 before the two structural members 10 and 11 are joined, with the excess adhesive flowing along the channels when the structural member 10 is brought into abutment with the top of the ribs 12. Alternatively, it may be preferred to bring the structural member 10 into abutment with the ribs 12 first and then use the defined channels as channels into which bonding material can be injected. Since the ribs 12 extend all along the elongate structural member 11 the member 10 can be bonded to the member 11 at any point along its length. As mentioned above, Figure 3 shows a typical bonded joint according to the prior art. In the original bonded joint, the stress distribution in the adhesive is uneven as illustrated by the graph of stress distribution shown in Figure 3 when a tangential force F is applied to the member 10 in the direction indicated by the arrow in Figure 3. The stress in the adhesive is very much greater at the edges of the bond areas that in the rest of the area; this makes the bond susceptible to peel. This is clearly unsatisfactory as optimum strength of a bond is achieved only if the adhesive is stressed to the same level over the joint. When the prior art joint is highly loaded then the adhesive begins cracking at the lines of highest stress, whilst the stress in the rest of the adhesive is much lower. The cracks can initiate failure of the joint at loads significantly below the optimum load which the joint should be capable of carrying. The present invention deals with the problem of uneven stress loading by providing one of the structural members to be joined with a cross-section which acts to define a varying adhesive depth across the joint, the varying adhesive depth acting to optimise the strength of the joint. Figure 4 shows this by showing how two structural members 20 and 21 can together define a varying bond thickness. In Figure 4 three different distinct regions can be seen in the joint. Area Q-R has the optimal small thickness of adhesive (e.g. 0.2mm for an epoxy adhesive) . The thickness of adhesive in this region is preferably controlled as described above, by the use of ribs (although these are not strictly necessary and therefore are not shown in Figure 4) . Areas P-Q and R-S are areas of increasing thickness. The profile of the structural member 20 is defined in order to provide the variation of bond thickness required, the cross-section of the structural member 20 being defined simply and cheaply by an extrusion process. The profile of the structural member 20 in the areas P-Q and R-S may be straight, convex or concave according to the requirements of the particular adhesive used in the bonds. By defining thicker areas of adhesive at the edges of the joint the performance of the joint is improved. This arises since the areas of greater thickness towards the edges of the bond area are less stiff than the area of bond in the region Q-R and therefore when the joint is loaded tangentially by a force F in the direction shown in Figure 4 the strain imparted on the edges of the bond will be determined by the overall stiffness of the joint in reaction to the imposed load, since the less stiff edge regions will deform to allow strain in the central portion of the joint which thus shares the loading. Thus, an imposed load will result in a lower level of stress in the adhesive at the edges of the bonded joint and the performance of the joint as a whole is improved. A joint between the two structural members 20 and 21 is formed by coating the structural member 21 with a layer of adhesive and then bringing the structural member 20 into engagement with the adhesive. The structural members 20 and 21 could be mechanically clamped together (either by external clamps or by mechanical fasteners if the joint is to be both mechanically fastened and bonded) . The curved edge profile shown in Figure 4 (or indeed any curved edge profile) would be avoided in the prior art since square sharp edges such as shown in Figure 4 are preferred for welding purposes. It is difficult to weld a component with curved edges since the welding process would lead to inclusion in the weld. For this reason square edged sections have been preferred in the prior art. In contrast the present invention teaches the skilled man to design the edge profiles to match the stress distribution across the join. In the above illustrated embodiments of the invention it will be appreciated that the cross- sections required are obtained by extrusion of aluminium to form a member with a required cross- section. As mentioned above, extrusion makes cost effective forming of members with particular cross- sections viable, since if an extruded section will have close tolerances and will require little in the way of material treatment after forming. Whilst the invention as described in preferred embodiments is applied to tubular elongate members for use in a space frame of an automobile, it should be appreciated that the elongate structural members can be used to form other structures. Also, the invention has a wider scope in that it can also be applied to other sorts of structural members such as panels, which can be provided with surface ribs or with a chosen cross-section in order provide beneficial bonding effects. The invention is less preferably applied to panels, since panels are difficult to extrude and the invention is ideally suited to the extrusion process. The invention is, however, not limited in its broadest scope to extruded structural members, since, for instance, it is possible to make structural members which ribs defining bond thickness by other less preferable methods, e.g. rolling or casting. The present invention becomes particularly important when high modulus (high stiffness) adhesives are used since the detrimental effects of having a wrong thickness or a disadvantageous stress distribution are enhanced. It will be appreciated that many types of adhesive could be used in the invention, but the preferred types are acrylic adhesives or epoxy adhesives.

Claims: CLAIMS 1. A method of manufacture of a structure which comprises a plurality of structural members bonded together, the method comprising the steps of extruding a first structural member with a chosen cross-section, and joining the first structural member to a second structural member by bonding with an adhesive, wherein when the first structural member is bonded to the second structural member the depth of the adhesive between the first and second structural members varies with variations in the cross-section of the first extruded structural member, characterised in that the cross-section of the first extruded structural member is chosen so as to enhance the performance of the adhesive bond between the first and second structural members. 2. A method of manufacture as claimed in claim 1 wherein the cross-section of the first extruded structural member is chosen such that the structural member has means to define between facing surfaces of the two bonded structural members a gap to be filled with adhesive. 3. A method of manufacture as claimed in claim 2 wherein the means defining the gap comprises a plurality of ribs on the exterior of the first extruded structural member. 4. A method of manufacture as claimed in claim 3 wherein the adhesive used is an epoxy adhesive and the ribs define a gap with a depth in the range 0.15 to 0.25m . 5. A method of manufacture as claimed in claim 3 or 4 wherein the first extruded structural member is a hollow aluminium elongate member with four planar regions each of which is joined to two other planar surfaces by a curved corner region and a series of longitudinally extending ribs provided externally on an external surface of one of the planar regions. 6. A method of manufacture as claimed in any one of the preceding claims wherein the adhesive is spread over a bonding area between the first and second structural members and the cross-section of the first extruded structural member is chosen such that there is a region of adhesive near an edge of the bonding area which is of greater depth than the adhesive at the centre of the bonding area. 7. A method of manufacture as claimed in claim 6 wherein the cross-section chosen for the extruded structural member is chosen to define a region of constant adhesive depth in the centre of the bonding area and a region of increasing adhesive depth extending from the central region of constant depth towards an edge of the bonding area. 8. A method of manufacture as claimed in claim 7 wherein the first extruded structural member is a hollow aluminium elongate member with a transverse cross-section having four generally planar regions and curved regions joining each two adjacent planar regions, two of the curved regions each defining a region of increasing adhesive depth when the first extruded structural member is joined to the second structural member. 9. A method of manufacture as claimed in claim 8 wherein the hollow aluminium elongate member has a plurality of longitudinally extending exterior ribs which set the depth of the adhesive in the region of constant adhesive depth. 10. A method of manufacture as claimed in any one of the preceding claims wherein the structure manufactured by the method is a space frame for an automobile. 11. A structural member for use in the method of manufacture of claim 5 or claim 9 which is a hollow, elongate extrusion of aluminium or an alloy of aluminium and which has a plurality of longitudinally extending spaced apart ribs for defining a gap between the structural member and a further structural member bonded thereto. 12. A structural member as claimed in claim 11 which has four planar regions and four curved regions, each curved region joining together two planar regions, wherein the longitudinal extending ribs are provided on an exterior surface of only one of the planar regions. 13. A structural member as claimed in claim 11 or claim 12 wherein the longitudinally extending ribs extend over substantially the whole length of the first structural member and are parallel to one another. 14. A method of manufacture of a structure wherein first and second structural members are bonded together with adhesive, characterised in that the first structural member is provided on a first surface with a plurality of spaced apart exterior ribs which abut an adjacent surface of the second structural member when the structural members are bonded together and which define between the first surface of the first structural member and the adjacent surface of the second structural member a gap for receiving adhesive, whereby the ribs define a chosen depth of adhesive between the first and second structural members in order to optimise the bond between the first and second structural members. 15. A method as claimed in claim 14 wherein the adhesive used is an epoxy adhesive and the chosen depth of adhesive is in the range 0.15mm to 0.25mm. 16. A method as claimed in claim 14 or claim 15 wherein the first structural member is composed of aluminium or an alloy of aluminium. 17. A method as claimed in any one of claims 14 to 16 wherein the first structural member is an extrusion and the ribs are formed during extrusion of the first structural member. 18. A method as claimed in claim 17 wherein the first structural member is a hollow elongate member. 19. A method as claimed in any one of claims 14 to 18 wherein the manufactured structure is a space frame for an automobile. 20. A structural member for use in the method of any of claims 14 to 19 which is an extrusion and which has a plurality of longitudinally extending exterior ribs provided on a first surface to define between the first surface and an adjacent surface of a second structural member bonded to the structural member a gap for receiving adhesive, whereby the ribs can define a chosen depth of adhesive. 21. A structural member as claimed in claim 20 which is composed of aluminium or an alloy of aluminium. 22. A structural member as claimed in claim 20 or claim 21 which is hollow and elongate. 23. A structural member as claimed in claim 22 which has four planar regions and four curved regions, each curved region joining together two planar regions, wherein the longitudinal ribs are provided on an exterior surface of one planar region. 24. A structural member as claimed in claim 22 or claim 23 wherein the ribs extend over substantially the entire length of elongate member in parallel spaced apart relationship. 25. A method of manufacture of a structure which comprises a tubular elongate structural member, the method comprising the steps of forming the tubular elongate structural member with a chosen cross- section, and joining the tubular elongate structural member to a second structural member by bonding with an adhesive, wherein when the tubular elongate structural member is bonded to the second structural member the depth of the adhesive between facing surfaces of the tubular elongate structural member and the second structural member varies with variations in the cross-section of the tubular elongate structural member, characterised in that the cross-section of the tubular elongate structural member is chosen to enhance the performance of the adhesive bond between the tubular elongate structural member and the second structural member. 26. A method of manufacture of a structure as claimed in claim 25 wherein the second structural member is also a tubular elongate structural member which in the method is formed with a cross-section chosen to enhance the performance of the adhesive bond between the elongate tubular structural member and the second structural member. 27. A method of manufacture of a structure as claimed in claim 25 wherein the adhesive is spread over a bonding area between the tubular elongate structural member and the second structural member and the cross-section of the tubular elongate structural member is chosen such that there is a region of adhesive near an edge of the bonding area which is of greater depth than the adhesive at the centre of the bonding area. 28. A method of manufacture as claimed in claim 27 wherein the cross-section chosen for the tubular elongate structural member is chosen to define a region of constant adhesive depth in the centre of the bonding area and a region of increasing adhesive depth extending from the central region of the constant depth towards an edge of bonding area. 29. A method of manufacture as claimed in any one of claims 26 to 28 wherein the joint between the tubular elongate structural member has a chosen strength and the tubular elongate structural member has a wall thickness chosen to be smaller than the wall thickness which would be necessary if the tubular elongate structural member were to be welded to the second structural member with the chosen joint strength. 30. A method of manufacture of a structure which has first and second structural members bonded together with adhesive, the method being substantially as hereinbefore described with reference to Figures 1, 2 and 4 of the accompanying drawings. 31. A structural member for use in a method of manufacture of a structure which has first and second structural members bonded together with adhesive, the structural member being substantially as hereinbefore described with reference to Figures 1, 2 and 4 of the accompanying drawings.

Inventors: GREIG JOHN DARYL, SEARS KENNETH JOHN, GREIG, JOHN, DARYL, SEARS, KENNETH, JOHN
Applicants: GREIG JOHN DARYL, LOTUS CAR, SEARS KENNETH JOHN, GREIG, JOHN, DARYL, LOTUS CARS LIMITED, SEARS, KENNETH, JOHN
Application year: 1996
Main classification: F16B11
IPC codes: B62D27, C09J5, F16B11