# US 10,864,682 B2 · Method of joining of polymeric composites > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,864,682 B2 - Document ID: US10864682B2 - Status: Granted - Kind: B2 - Application number: 15/911,683 - Filed: 2018-03-05 - Published: 2019-09-05 - Granted: 2020-12-15 - Earliest claimed: 2018-03-05 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Steven Cipriano; Bradley J. Blaski; Richard C. Janis; Pei-chung Wang - Web page: https://patentgrep.com/patent/US10864682B2 ## CPC - B29C 65/561: {using screw-threads being integral at least to one of the parts to be joined} - B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding} - B29C 65/483: {Reactive adhesives, e.g. chemically curing adhesives} - B29C 65/564: {hidden in the joint, e.g. dowels or Z-pins (B29C65/603 takes precedence)} - B29C 65/72: by combined operations {or combined techniques}, e.g. welding and stitching - B29C 66/02: {Preparation of the material, in the area to be joined, prior to joining or welding (B29C66/32 takes precedence)} - B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)} - B29C 66/21: {said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding} - B29C 66/30321: {making use of protrusions belonging to at least one of the parts to be joined} - B29C 66/30325: {making use of cavities belonging to at least one of the parts to be joined} - B29C 66/41: {Joining substantially flat articles (B29C66/47 and subgroups take precedence); Making flat seams in tubular or hollow articles (B29C66/51 and subgroups take precedence)} - B29C 66/7212: {characterised by the composition of the fibres} - B29C 66/73921: {characterised by the materials of both parts being thermoplastics} - B29C 66/8322: {Joining or pressing tools reciprocating along one axis} - F16B 11/006: {by gluing (gluing of plastics material B29C65/48)} - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts - B29K 2907/04: Carbon - F16B 5/02: by means of fastening members using screw-thread ({F16B5/0004 takes precedence}; construction of screw-threaded connections F16B25/00 - F16B39/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A method of joining first and second layers of polymeric composite material includes disposing a portion of a molded insert having a bottom end into a top surface of a first layer of material and then applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness. Next, a top surface of the second layer is pierced with a headless end of a fastener and interlocked into the molded insert. A layer of protective coating is then applied to the top surface of the second layer of material to cover the interlocked fastener. ## Claims ### Claim 1 A method of joining first and second layers of material, the method comprising: disposing a portion of a molded insert having a bottom end into a top surface of a first layer of material; applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness; piercing through a top surface of the second layer of material with a headless end of a fastener; interlocking the headless end of the fastener into the molded insert; and applying a layer of protective coating to the top surface of the second layer of material to cover the interlocked fastener. ### Claim 2 (depends on 1) The method of claim 1 wherein the fastener is a flow screw. ### Claim 3 (depends on 2) The method of claim 2 further comprising positioning the first and second layers on a fastener insertion machine after applying the adhesive layer between the first and second layers and before piercing the second layer of material with the headless end of the flow screw. ### Claim 4 (depends on 3) The method of claim 3 further comprising interlocking the flow screw until the headless end pierces the bottom end of the molded insert. ### Claim 5 (depends on 1) The method of claim 1 wherein the first and second layers each include a carbon fiber composite material. ### Claim 6 (depends on 1) The method of claim 1 wherein the bond line thickness is in a range of 0.1 mm to 1.5 mm. ### Claim 7 (depends on 1) The method of claim 1 further comprising allowing a top end of the molded insert to protrude above the top surface of the first layer of material a predetermined distance equal to the bond-line thickness. ### Claim 8 (depends on 1) The method of claim 1 further comprising allowing the adhesive layer to at least partially cure. ### Claim 9 (depends on 8) The method of claim 8 further comprising piercing through a top surface of the second layer of material with a headless end of the fastener after the adhesive layer is at least partially cured. ### Claim 10 A method of joining first and second layers of material, the method comprising: disposing a portion of a molded insert having a bottom end into a top surface of a first layer of material; applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness; piercing through a top surface of the second layer of material with a headless end of a flow screw; interlocking the headless end of the flow screw into the molded insert; and applying a layer of protective coating to the top surface of the second layer of material to cover the interlocked flow screw. ### Claim 11 (depends on 10) The method of claim 10 further comprising positioning the first and second layers on a fastener insertion machine after applying the adhesive layer between the first and second layers and before piercing the second layer of material with the headless end of the flow screw. ### Claim 12 (depends on 11) The method of claim 11 further comprising interlocking the flow screw until the headless end pierces the bottom end of the molded insert. ### Claim 13 (depends on 10) The method of claim 10 wherein the first and second layers each include a carbon fiber composite material. ### Claim 14 (depends on 10) The method of claim 10 wherein the bond line thickness is in a range of 0.1 mm to 1.5 mm. ### Claim 15 (depends on 10) The method of claim 10 further comprising allowing a top end of the molded insert to protrude above the top surface of the first layer of material a predetermined distance equal to the bond-line thickness. ### Claim 16 (depends on 10) The method of claim 10 further comprising allowing the adhesive layer to at least partially cure. ### Claim 17 (depends on 16) The method of claim 16 further comprising piercing through a top surface of the second layer of material with a headless end of a flow screw after the adhesive layer is at least partially cured. ### Claim 18 A method of joining first and second layers of material, the method comprising: disposing a portion of a solid molded insert having a bottom end into a top surface of a first layer of material; applying a layer of adhesive between the top surface of the first layer and a bottom surface of a second layer of material to create a bond-line thickness; piercing through a top surface of the second layer of material and the molded insert with a headless end of a fastener; interlocking the headless end of the fastener into the molded insert; and after the step of interlocking, applying a layer of protective coating to the entire top surface of the second layer of material to cover the interlocked fastener.