Abstract:
A method of manufacturing a body panel assembly for a vehicle. The method includes providing first and second panels, applying an adhesive, positioning the first and second panels, hemming the first and second panels together to form a subassembly, applying a coating to at least a portion of the subassembly, and heating the subassembly to at least partially melt the adhesive.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part of U.S. application Ser. No. 10/065,361 filed Oct. 9, 2002 and hereby incorporated by reference in its entirety, which, in turn, claims the benefit of U.S. provisional application Ser. No. 60/328,456 filed Oct. 10, 2001. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a method for making a body panel assembly for a vehicle, such as a body panel assembly for a vehicle closure.  
         [0004]     2. Background Art  
         [0005]     Previously, vehicle body panels included a sealant that completely covered a hem area to prevent water from entering and collecting inside the hem, such as that disclosed in U.S. Pat. No. 4,719,689. In such body panels sealant was squeezed out during hemming and/or other manufacturing steps, resulting in waste and contamination of fixtures and other manufacturing equipment.  
       SUMMARY OF THE INVENTION  
       [0006]     In at least one embodiment of the present invention, a method of manufacturing a body panel assembly for a vehicle is provided. The method includes the steps of providing first and second panels, applying an adhesive to a surface of the first panel, positioning the first and second panels, hemming the first and second panels together to form a subassembly, applying a coating to at least a portion of the subassembly, and heating the subassembly to at least partially melt the adhesive such that the adhesive bonds to the first and second panels.  
         [0007]     In at least one other embodiment of the present invention, a method of manufacturing a closure panel assembly for a vehicle is provided. The method includes the steps of providing first and second panels having predetermined shapes, applying an adhesive to a surface of the first panel to define a footprint, positioning the first and second panels proximate each other such that the adhesive faces toward the second panel, hemming the first and second panels together to form a subassembly, applying a coating to at least a portion of the subassembly, and heating the subassembly to at least partially melt the adhesive such that adhesive bonds the first and second panels together and covers the footprint after the subassembly is heated.  
         [0008]     In at least one other embodiment of the present invention, a method of manufacturing a closure panel assembly for a vehicle is provided. The method includes providing an inner panel having a plurality of dimples disposed near an end, providing an outer panel, applying an adhesive to an inner surface to the outer panel to define a footprint, positioning the inner panel near the outer panel such that the inner panel does not contact the adhesive, hemming the outer panel around the inner panel to form a subassembly, cleaning and electrocoating at least a portion of the subassembly, and heating the subassembly to at least partially melt the adhesive such that the adhesive flows into a gap separating the inner and outer panel to bond the first and second panels together. The adhesive may cover the footprint after the subassembly is heated to inhibit corrosion of the inner panel. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is an exploded perspective view of an exemplary vehicle body panel assembly.  
         [0010]      FIG. 2  is a flowchart of a method for making the vehicle body panel assembly.  
         [0011]      FIGS. 3-7  are section views of a portion of the vehicle body panel assembly made in accordance with the method of  FIG. 2 .  
         [0012]      FIG. 8  is a plan view of an exemplary embodiment of a manipulator having a dispensing system. 
     
    
     DETAILED DESCRIPTION  
       [0013]     Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary 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. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.  
         [0014]     Referring to  FIG. 1 , an exploded view of an exemplary embodiment of a body panel assembly  10  for a vehicle is shown. In an automotive application, the body panel assembly  10  may be a body closure panel such as a door, hood, liftgate, tailgate, or decklid. In at least one embodiment, the body panel assembly  10  may include an inner panel  12  and an outer panel  14 .  
         [0015]     The inner and outer panels  12 , 14  may have any suitable configuration and may be made of any suitable material, such as a metallic material like aluminum, magnesium, titanium, or a steel like galvanized steel. Each panel  12 , 14  may be shaped or formed into a predetermined shape using any suitable fabrication process, such as stamping, drawing, hydroforming, or superplastic forming. In addition, each panel  12 , 14  may be a single piece or assembled from multiple pieces.  
         [0016]     The inner and/or outer panels  12 , 14  may include a plurality of protrusions or dimples  16 . The dimples  16  may be provided when the inner and/or outer panels  12 , 14  are shaped or formed or may be provided as a separate manufacturing operation. The dimples  16  may be disposed proximate a hem area, described in more detail below, to help space at least a portion of the inner and outer panels  12 , 14  away from each other. Moreover, the dimples  16  may be disposed proximate to or spaced apart from an end of at least one panel  12 , 14 . In at least one embodiment, the dimples  16  are spaced apart from each other and provided on the inner panel  12  to provide a body panel assembly having an aesthetically pleasing appearance.  
         [0017]     The inner panel  12  and the outer panel  14  may be at least partially joined together with an adhesive  18 . The adhesive  18  may separate the inner and outer panels  12 , 14  from each other to inhibit vibration, rattling, or other undesirable noises. In addition, the adhesive  18  may inhibit water ingression and/or corrosion. The adhesive  18  may be of any suitable type, such as a rubber-based or an epoxy-based material like Uniseal™ product number  2345 . Moreover, the adhesive  18  may be a one-part or multi-part reactant mixture and may be expandable or non-expandable. The adhesive  18  may be adapted to withstand washing, cleaning, and/or coating operations that are associated with body panel fabrication or assembly operations. The adhesive  18  may be applied to the inner panel  12  and/or the outer panel  14  in any suitable location and in any suitable manner as described in more detail below. For example, in the embodiment shown in  FIG. 3 , the adhesive  18  may be spaced apart from at least one end of the outer panel  14 .  
         [0018]     Referring to  FIG. 2 , a flowchart of a method for making a body panel assembly is shown. For convenience, a graphical representation of the flowchart steps is shown in  FIGS. 3-7 . One of ordinary skill in the art will recognize that  FIGS. 3-7  are merely exemplary and may be embodied in various and alternative forms.  
         [0019]     For clarity, the flowchart in  FIG. 2  does not include the shaping and/or forming operations associated with fabricating the inner and outer panels  12 , 14  since such operations were previously described above. One of ordinary skill in the art will recognize that these panel fabrication steps may be included as initial steps of the method of the present invention.  
         [0020]     At  100 , the method begins by applying the adhesive material  18  proximate a surface of at least one panel. For example, a bead of adhesive  18  may be applied proximate an interior surface of the inner and/or outer panels  12 , 14 . In the exemplary embodiment shown in  FIG. 3 , a bead or daub of adhesive material  18  is disposed proximate an interior surface  20  of the outer panel  14 . Alternatively, the adhesive  18  may be disposed on another surface or another panel, such as the inner panel  12  in other embodiments of the present invention. Adhesive application may be accomplished manually or with automated or partially automated equipment. For instance, a manipulator, such as a robot  22 , may be employed that is equipped with a dispensing system  24 , such as that shown in  FIG. 8  and disclosed in U.S. patent application Ser. No. 10/604,462, which is assigned to the assignee of the present invention and hereby incorporated by reference in its entirety.  
         [0021]     At  102 , at least one panel is positioned in a desired location. In the exemplary embodiment shown in  FIG. 4 , the inner panel  12  is positioned near the outer panel  14 . Moreover, the inner panel  12  may be positioned such that it does not contact the adhesive material  18  and/or the outer panel  14  in an area near which hemming operations will be performed to facilitate subsequent cleaning, coating, and or phosphating operations as described in more detail below.  
         [0022]     At  104 , the panels are hemmed together. In the exemplary embodiment shown in  FIG. 5 , at least a portion of the outer panel  14  is hemmed around at least a portion of the inner panel  12 . Alternatively, at least a portion of the inner panel  12  could be hemmed around the outer panel  14  in various embodiments. The panels  12 , 14  may contact each other or may contact dimples  16  on an opposing panel during and/or after the hemming operation. Alternatively, the panels  12 , 14  may be spaced apart after hemming is complete to provide a gap to allow cleaning, coating, and/or phosphating of both sides of the panels  12 , 14  and hem flange area  26 . Optionally, fasteners such as rivets or clips may be used to join the inner panel  12  and the outer panel  14  together.  
         [0023]     At  106 , a coating  28  may be applied to the panels. This step may include washing and cleaning operations that prepare one or more surfaces for coating application. In the exemplary embodiment shown in  FIG. 6 , a coating  28  may be applied to external surfaces of the inner and outer panels  12 , 14 . The coating  28  may inhibit corrosion, provide tinting, and/or to protect the body panel assembly  10  or other coating layers from the environment. For instance, one or more coating layers may be applied by any suitable painting or coating process, such as electrocoating.  
         [0024]     At  108 , heat is applied to at least partially melt the adhesive  18 . Heat may be provided by any suitable source, such as heating or curing ovens employed with the coating process. In other embodiments, the heat source may not be associated with the coating process. The adhesive  18  may contact and/or bond to another surface, such as the inner panel  12  as shown in  FIG. 7 , when heat is provided. Moreover, the adhesive  18  may remain attached to and cover its original application area or footprint  30 . As such, the adhesive  18  provides corrosion protection for localized areas, such as the footprint  30 , in which a coating layer is not applied. The adhesive  18  may help hold the panels together, provide corrosion protection, and/or provide cushioning or inhibit contact between the inner and outer panels  12 , 14  to reduce vibration and/or noise.  
         [0025]     While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.