# US 2014/0197226 A1 · Methods for determining a minimum weld distance for adhesives

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- Number: US 2014/0197226 A1
- Document ID: US20140197226A1
- Status: Published application
- Kind: A1
- Application number: 13/744,311
- Filed: 2013-01-17
- Published: 2014-07-17
- Earliest claimed: 2013-01-17
- Assignees: Ford Global Technologies, LLC
- Applicants: Ford Global Technologies, LLC
- Inventors: Sanjay Mehta; Xiaoming Chen; John Martin Knittel; Jeff A. Wallace
- Web page: https://patentgrep.com/patent/US20140197226A1

## CPC

- F16B 11/006: {by gluing (gluing of plastics material B29C65/48)}
- B23K 31/12: relating to investigating the properties, e.g. the weldability, of materials
- B23K 2101/006: {Vehicles}
- 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)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM

## Abstract

A method of manufacturing a vehicle frame assembly, includes: (i) receiving threshold temperature data for an adhesive; (ii) defining an adhesive zone wherein which adhesive will be applied with respect to a first and second vehicle structural member; and (iii) determining a minimum distance a weld can be applied on the first structural member with respect to the adhesive zone based on empirical data.

## Claims

### Claim at position 1

1-20. (canceled)

### Claim 21

A method for assembling a frame comprising:
fitting an interconnecting member about a cross member;
applying an adhesive to the cross member and interconnecting member; and
welding the interconnecting member to a side rail at a weld location spaced at least a threshold distance from the adhesive, the threshold distance corresponding to a minimum distance based on test data, wherein at the minimum distance a sensor remained below a threshold temperature during a test weld.

### Claim 22 (depends on 21)

The method of claim 21, wherein the test weld comprises positioning thermocouples on a member at a plurality of distances from a test weld location on the interconnecting member, welding the interconnecting member at the test weld location, and monitoring a plurality of temperatures in the thermocouples, and wherein the minimum distance from test data at which a sensor remained below a threshold temperature during a test weld corresponds with the least distance from the test weld location to a thermocouple that remained below the threshold temperature during the test weld.

### Claim 23 (depends on 22)

The method of claim 22, wherein positioning thermocouples on a member at a plurality of distances from a test weld location comprises fitting an interconnecting member about a cross member, applying an adhesive to the cross member and interconnecting member, and positioning a plurality of thermocouples on the cross member and interconnecting member.

### Claim 24 (depends on 21)

The method of claim 21, wherein the threshold temperature is 400° F.

### Claim 25 (depends on 21)

The method of claim 21, wherein the cross member is aluminum and the interconnecting member and rail are steel.

### Claim 26 (depends on 21)

The method of claim 21, further comprising crimping together the cross member and interconnecting member to mechanically interlock the cross member and interconnecting member.

### Claim 27

A method of assembling a vehicle frame, the method comprising:
applying an adhesive to an adhesive zone on at least one of a first tubular member and a second tubular member;
fitting the second tubular member about the first tubular member; and
welding one of the first tubular member and second tubular member to a third tubular member, where the welding comprises selecting a weld line displaced at least a threshold distance from the adhesive zone, the threshold distance corresponding to a minimum distance based upon a rate of heat transfer through the first and second tubular members from the weld line to the adhesive zone.

### Claim 28 (depends on 27)

The method of claim 27, wherein the minimum distance based upon a rate of heat transfer is a minimum distance among a set of test measurements at which a temperature remained below a threshold temperature during a test weld.

### Claim 29 (depends on 28)

The method of claim 28, wherein the minimum distance among a set of test measurements at which a temperature remained below a threshold temperature during a test weld is a least distance from a test weld location to a thermocouple at which a temperature remained below a threshold temperature during a test weld, where the thermocouple is one of a plurality of thermocouples disposed at a plurality of distances from the test weld location.

### Claim 30 (depends on 27)

The method of claim 27, wherein welding one of the first tubular member and second tubular member to a third tubular member comprises welding the second tubular member to the third tubular member, the first tubular member comprising aluminum and the second and third tubular members comprising steel.

### Claim 31 (depends on 27)

The method of claim 27, further comprising crimping the first and second tubular members together.

### Claim 32

A method of testing tubular members, comprising:
selecting a cross member, interconnecting member, and side rail,
fitting the cross member about the interconnecting member;
applying an adhesive to the cross member and interconnecting member;
disposing thermocouples at a plurality of distances from a test weld location, the test weld location being selected to weld the interconnecting member to the side rail;
welding the interconnecting member to the side rail at the test weld location;
monitoring temperatures of the thermocouples at the plurality of distances from the test weld location while welding; and
selecting a weld distance corresponding with the least distance from the weld location to a thermocouple at which a temperature reading remained below a threshold temperature while welding.

### Claim 33 (depends on 32)

The method of claim 32, wherein disposing thermocouples at a plurality of distances from a test weld location comprises disposing a plurality of thermocouples on the cross member and interconnecting member.

### Claim 34 (depends on 32)

The method of claim 32, wherein disposing thermocouples at a plurality of distances from a test weld location comprises disposing at least one thermocouple within the cross member or interconnecting member.

### Claim 35 (depends on 32)

The method of claim 32, wherein disposing thermocouples at a plurality of distances from a test weld location comprises disposing at least one thermocouple on the adhesive.