Method of making a cross car beam assembly using a structural adhesive

Abstract

A method for manufacturing a cross car beam assembly for use with a vehicle includes joining first and second support brackets to opposite ends of a cross car beam using an adhesive, such that the adhesive is a primary attachment means for joining the support brackets to the cross car beam. Furthermore, the support brackets are attachable to the vehicle so as to support the cross car beam in the vehicle.

What is claimed is:  
     
         1 . A method for manufacturing a cross car beam assembly for use with a vehicle, the method comprising: 
 joining first and second support brackets to opposite ends of a cross car beam using an adhesive, such that the adhesive is a primary attachment means for joining the support brackets to the cross car beam, wherein the support brackets are attachable to the vehicle so as to support the cross car beam in the vehicle.    
     
     
         2 . The method of  claim 1  wherein the cross car beam comprises metal.  
     
     
         3 . The method of  claim 2  wherein the support brackets comprise metal.  
     
     
         4 . The method of  claim 1  wherein the cross car beam comprises plastic.  
     
     
         5 . The method of  claim 1  wherein the cross car beam comprises a composite material.  
     
     
         6 . The method of  claim 1  wherein the joining step comprises allowing the adhesive to cure.  
     
     
         7 . The method of  claim 6  wherein the step of allowing the adhesive to cure comprises heating the support brackets and the cross car beam so as to cure the adhesive.  
     
     
         8 . The method of  claim 7  wherein the heating step comprises heating the support brackets and the cross car beam in an oven for at least thirty minutes, wherein the oven is heated to at least 350 degrees Fahrenheit.  
     
     
         9 . The method of  claim 6  further comprising mechanically connecting together the support brackets and the cross car beam at least until the adhesive has substantially cured.  
     
     
         10 . The method of  claim 9  wherein the step of mechanically connecting together the support brackets and the cross car beam comprises connecting together the support brackets and the cross car beam with temporary connecting members.  
     
     
         11 . The method of  claim 10  further comprising removing the temporary connecting members after the adhesive has substantially cured.  
     
     
         12 . The method of  claim 11  wherein each support member and the cross car beam comprises metal.  
     
     
         13 . The method of  claim 6  further comprising welding the support brackets to the cross car beam so as to secure each support bracket in a desired location on the cross car beam at least until the adhesive has substantially cured.  
     
     
         14 . The method of  claim 1  further comprising joining at least one component to the cross car beam using additional adhesive, such that the additional adhesive is a primary attachment means for joining the at least one component to the cross car beam, wherein the at least one component is selected from a group consisting of a steering column support bracket, a center support bracket, and a glove box frame.  
     
     
         15 . The method of  claim 14  wherein the support brackets, the cross car beam and the at least one component each comprise metal.  
     
     
         16 . A method for manufacturing a cross car beam assembly for use with a vehicle, the method comprising: 
 joining together first and second metal cross car beam portions with an adhesive so as to form a cross car beam that is adapted to be attached to the vehicle, wherein the adhesive is a primary attachment means for joining together the cross car beam portions.    
     
     
         17 . The method of  claim 16  wherein the joining step comprises allowing the adhesive to cure.  
     
     
         18 . The method of  claim 17  wherein the step of allowing the adhesive to cure comprises heating the cross car beam so as to cure the adhesive.  
     
     
         19 . The method of  claim 18  wherein the heating step comprises heating the cross car beam in an oven for at least thirty minutes, wherein the oven is heated to at least 350 degrees Fahrenheit.  
     
     
         20 . The method of  claim 17  further comprising mechanically connecting together the cross car beam portions at least until the adhesive has substantially cured.  
     
     
         21 . The method of  claim 20  wherein the step of mechanically connecting together the cross car beam portions comprises connecting together the cross car beam portions with temporary connecting members.  
     
     
         22 . The method of  claim 21  further comprising removing the temporary connecting members from the cross car beam after the adhesive has substantially cured.  
     
     
         23 . The method of  claim 17  further comprising welding the cross car beam portions together at sufficient locations so as to secure together the cross car beam portions at least until the adhesive has substantially cured.  
     
     
         24 . The method of  claim 16  further comprising joining at least one component one of the cross car beam portions using additional adhesive, such that the additional adhesive is a primary attachment means for joining the at least one component to the cross car beam portion, wherein the at least one component is selected from a group consisting of a steering column support bracket, a center support bracket, and a glove box frame.  
     
     
         25 . A method for manufacturing a cross car beam assembly for use with a vehicle, the method comprising: 
 applying adhesive to at least one of two metal, cross car beam portions, wherein each cross car beam portion has opposite ends;    clinching together the cross car beam portions;    applying additional adhesive to first and second end brackets;    clinching the first end bracket to one end of one cross car beam portion;    clinching the second end bracket to the opposite end of the one cross car beam portion; and    heating the cross car beam portion and the end brackets so as to substantially cure the adhesive and the additional adhesive, thereby adhesively joining together the cross car beam portions, and adhesively joining together the end brackets and the one cross car beam portion;    wherein the adhesive is a primary attachment means for joining together the cross car beam portions, and the additional adhesive is a primary attachment means for joining together the end brackets and the one cross car beam portion.