# US 8,739,388 B2 · Method of fastening parts to a composite part

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- Number: US 8,739,388 B2
- Document ID: US8739388B2
- Status: Granted
- Kind: B2
- Application number: 13/448,464
- Filed: 2012-04-17
- Published: 2013-10-17
- Granted: 2014-06-03
- Earliest claimed: 2012-04-17
- Assignees: Ford Global Technologies, LLC
- Applicants: Aindrea McKelvey Campbell; Daniel Quinn Houston; Amanda Kay Freis
- Inventors: Aindrea McKelvey Campbell; Daniel Quinn Houston; Amanda Kay Freis
- Web page: https://patentgrep.com/patent/US8739388B2

## CPC

- B21J 15/025: {Setting self-piercing rivets}
- B21J 15/147: {Composite articles}
- B29C 65/562: {using extra joining elements, i.e. which are not integral with the parts to be joined (using plastic snap elements B29C65/58; using plastic rivets B29C65/601)}
- B29C 65/564: {hidden in the joint, e.g. dowels or Z-pins (B29C65/603 takes precedence)}
- B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)}
- 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 66/41: {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 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)}
- B29C 66/72143: {Fibres of discontinuous lengths}
- B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)}
- B29C 66/742: {to metals or their alloys}
- B29C 66/81422: {being convex}
- B29C 66/81429: {comprising a single tooth}
- B29C 66/81431: {comprising a single cavity, e.g. a groove}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B32B 1/00: Layered products having a non-planar shape
- B32B 7/08: by mechanical means
- B32B 15/08: of synthetic resin
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- F16B 19/04: Rivets; Spigots or the like fastened by riveting (lead seals G09F3/00)
- B29C 65/602: {using hollow rivets (B29C65/607 takes precedence)}
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/72321: {consisting of metals or their alloys}
- B29C 66/7392: {characterised by the material of at least one of the parts being a thermoplastic}
- B29C 66/7394: {characterised by the material of at least one of the parts being a thermoset}
- B29C 66/7422: {Aluminium or alloys of aluminium}
- B29C 66/74283: {Iron or alloys of iron, e.g. steel}
- B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2605/00: Vehicles
- Y10T 29/49936: Surface interlocking
- Y10T 29/49947: by applying separate fastener
- Y10T 29/49954: Fastener deformed after application
- Y10T 29/49956: Riveting
- Y10T 428/24331: including nonapertured component
- Y10T 428/249953: Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T 428/251: Mica
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T 428/269: including synthetic resin or polymer layer or component
- B21J: FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES (rolling of metal B21B; making particular products by forging or pressing B21K; cladding or plating B23K; finishing surfaces by hammering B23P9/04; compacting surfaces by blasting with particulate material B24C1/10; general features of presses, presses for consolidating scrap B30B; furnaces in general F27)
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method of joining parts together with a self-piercing rivet that is inserted through a part and partially through a second part. The second part includes a fiber-filled layer and a resin matrix layer that together form a composite part. A self-piercing rivet extends into the second part, but does not penetrate completely through the matrix layer. An assembly, including a first part and a second part that includes a reinforced layer and a resin layer in which a fastener is inserted, but does not extend through the second layer. A composite part including a first layer of resin matrix reinforces the filler and a second layer of resin matrix that does not include a filler and is more than 3 microns thick.

## Claims

### Claim 1

A method comprising:
selecting a first part;
selecting a second part including a first layer of a resin reinforced with a filler and a second layer of a resin without a filler on one side of the second part;
forming the second part as an integral piece in a compression molding die by: placing the filler, which includes a fiber reinforcement, in the compression molding die; and depositing the resin into the compression molding die;
inserting the first and second parts between a fastener in a tool and a die, and
driving the fastener through the first part without penetrating completely through the second layer of the second part.

### Claim 2 (depends on 1)

The method of claim 1 further comprising providing a textured surface on a predetermined portion of the compression molding die where the second layer is formed, wherein the textured surface inhibits the filler from becoming part of the second layer.

### Claim 3 (depends on 1)

The method of claim 1 wherein the step of depositing the resin into the compression molding die is performed in two steps, in one step the resin is deposited in the compression molding die to encase the filler in the first layer and in another step the resin is deposited in the compression molding die in the second layer.

### Claim 4 (depends on 1)

The method of claim 1 wherein the fastener is a self-piercing rivet, and the tool is a riveting tool.

### Claim 5 (depends on 1)

The method of claim 1 wherein the second layer is more than 3 microns thick.