Multi-material vehicle roof stiffener

Patent metadata

Field	Value
Publication number	US-2018346034-A1
Application number	US-201715610146-A
Country	US
Kind code	A1
Filing date	May 31, 2017
Priority date	May 31, 2017
Publication date	Dec 6, 2018
Grant date	—

Abstract

A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

First claim

What is claimed is:

1 . A vehicle roof stiffener, comprising:
a fiber reinforced polymer (FRP) portion including at least one transition structure comprising a metal or a metal alloy, at least some of the fibers of the FRP portion are embedded in the transition structure; and at least one metal or metal alloy portion secured to the transition structure of the FRP portion.

2 . The vehicle roof stiffener of claim 1 , wherein the at least one metal portion and the at least one FRP portion define a central opening.

3 . The vehicle roof stiffener of claim 2 , further comprising studs attached to a surface of the FRP portion proximate the central opening for mounting a glass assembly.

4 . The vehicle roof stiffener of claim 3 , further comprising openings within the at least one metal portion proximate the central opening for mounting the glass assembly.

5 . The vehicle roof stiffener of claim 1 , further comprising at least one elongated transition structure, wherein at least some of the fibers of the FRP are embedded within a metal or metal alloy tab of the elongated transition structure extending along an edge of the FRP portion.

6 . The vehicle roof stiffener of claim 5 , further comprising a vehicle frame attached to the at least one elongated transition structure, wherein the vehicle frame is a metal alloy and the at least one elongated transition structure comprises aluminum.

7 . The vehicle roof stiffener of claim 5 , further comprising a vehicle roof panel welded to the at least one elongated transition structure, wherein the vehicle roof panel comprises aluminum and the at least one elongated transition structure comprises aluminum.

8 . The vehicle roof stiffener of claim 1 , wherein an interface, between the at least one metal portion and the at least one FRP portion, includes an offset flange in the at least one metal portion, wherein the transition structure fills at least a portion of the offset.

9 . The vehicle roof stiffener of claim 1 , wherein the transition structure is connected to the at least one metal portion via at least one spot weld.

10 . The vehicle roof stiffener of claim 1 , wherein the at least one metal portion extends parallel to a longitudinal axis of a vehicle and the at least one FRP portion extends transverse to the longitudinal axis.

11 . The vehicle roof stiffener of claim 10 , wherein the at least one FRP portion comprises a front FRP portion and a rear FRP portion.

12 . The vehicle roof stiffener of claim 11 , wherein the front FRP portion forms two corners of the vehicle roof stiffener and the rear FRP portion forms two corners of the vehicle roof stiffener, wherein the at least one metal portion includes two metal portions forming sides of the vehicle roof stiffener.

13 . The vehicle roof stiffener of claim 12 , wherein each of the at least one transition structure is located on one of the sides of the vehicle roof stiffener.

14 . The vehicle roof stiffener of claim 11 , wherein the front FRP portion forms two corners of the vehicle roof stiffener and the at least one metal portion includes two metal portions forming sides of the vehicle roof stiffener that extend to form rear corners of the vehicle roof stiffener.

15 . The vehicle roof stiffener of claim 1 , wherein the at least one transition structure includes a region with no embedded fiber where the transition structure is to be joined to the at least one metal portion.

16 . A method of manufacturing a vehicle roof, comprising:
providing at least one fiber reinforced polymer (FRP) portion of a roof stiffener including a plurality of metal tabs having fiber tows embedded therein; and joining the plurality of metal tabs of the FRP portion to at least one metal portion to form the roof stiffener having a central opening.

17 . The method of claim 16 , further comprising mounting the roof stiffener on a vehicle frame by joining at least one of the plurality of metal tabs to the vehicle frame.

18 . The method of claim 16 , further comprising mounting a roof panel to the roof stiffener by joining at least one of the plurality of metal tabs to the roof panel.

19 . The method of claim 16 , wherein providing the at least one FRP portion comprises:
providing a plurality of transition components comprising the plurality of metal tabs having the embedded fiber tows extending therefrom; interleaving the embedded fiber tows with layers of fiber fabric; and consolidating the layers of fiber fabric to form the FRP portion.

20 . The method of claim 16 , wherein joining the plurality of metal tabs of the FRP portion to the at least one metal portion comprises welding the plurality of metal tabs to the at least one metal portion.

Assignees

• Honda Motor Co Ltd

Inventors

• Sheldon Allen B
• Hoffman Benjamin
• Detwiler Duane T
• Hahnlen Ryan M

Classifications

• B62D25/06 Primary

  Fixed roofs (non-fixed roofs or like shelters B60J7/00; roof liners B60R13/02; insulating elements B60R13/08) · CPC title

• B29L2031/3055

  Cars · CPC title

• B62D27/026

  Connections by glue bonding (in general F16B11/00; processes C09J5/00) · CPC title

• B62D29/001

  characterised by combining metal and synthetic material · CPC title

• B29L2031/3002

  Superstructures characterized by combining metal and plastics, i.e. hybrid parts · CPC title