Method of adhering members and an assembly formed thereby

Abstract

The method of adhering members includes positioning of an adhesive material between an attachment surface of a first member (e.g., a door beam) and a second member (e.g., a bracket). Thereafter, the adhesive material is at least partially cured to adhere the material to the attachment surface to form an assembly and the assembly is assembled to an article of manufacture (e.g., an automotive vehicle).

1 - 30 . (canceled)  
     
     
         31 . A method of reinforcing a door of an automotive vehicle, the method, comprising: 
 providing an elongated reinforcement member;    providing a bracket; and    at least partially curing an adhesive material such that the adhesive material adheres to the reinforcement member and the bracket, the adhesive material located substantially entirely between the bracket and the elongated reinforcement member.    
     
     
         32 . A method as in  claim 31 , further comprising: 
 assembling the reinforcement member to the door of the automotive vehicle; and    further curing the structural adhesive material to further secure the bracket to the reinforcement member.    
     
     
         33 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material includes exposing the adhesive material to at least one of heat, pressure, radiation, microwaves, electricity or a combination thereof.  
     
     
         34 . A method as in  claim 31 , further comprising: 
 at least partially supporting a foam block with the bracket.    
     
     
         35 . A method as in  claim 31  wherein the adhesive material is epoxy based.  
     
     
         36 . A method as in  claim 31  wherein the adhesive material is a thermosettable material that includes an amine curing agent.  
     
     
         37 . A method as in  claim 31  wherein the adhesive material includes a blowing agent.  
     
     
         38 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material leaves the adhesive material between about 30% and about 97% cured.  
     
     
         39 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material includes substantially fully curing the adhesive material.  
     
     
         40 . A method as in  claim 31 , further comprising: 
 further curing the adhesive material by exposing the adhesive material to elevated temperatures in a painting or e-coat process.    
     
     
         41 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material includes exposing the adhesive material to heat for a time period that results in a partial cure.  
     
     
         42 . A method as in  claim 31  wherein the time period is between about 3 minutes and about 10 minutes.  
     
     
         43 . A method as in  claim 31  further comprising: 
 substantially fully curing the adhesive material in a painting or e-coat process.    
     
     
         44 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material includes placing the door beam, bracket and adhesive material within a heating structure.  
     
     
         45 . A method as in  claim 31  wherein the step of at least partially curing the adhesive material includes only locally exposing the material to heat without exposing a substantial portion of the door beam to heat.  
     
     
         46 . A method of reinforcing a door of an automotive vehicle, the method, comprising: 
 providing an elongated reinforcement member, the reinforcement member being a door reinforcement beam having a first attachment at a first end of the beam and a second attachment at the second end of the beam, wherein the first end is opposite the second end and the first attachment and the second attachment are configured for attachment to a door of the vehicle adjacent opposite sides of the door;    providing a bracket comprised of a first member and second member;    welding flanges of the first member to flanges of the second member; and    an at least partially heat curing an adhesive material in an oven such that the adhesive material adheres to the reinforcement member and the bracket, the adhesive material located substantially entirely between the bracket and the elongated reinforcement member.    
     
     
         47 . A method as in  claim 46 , further comprising: 
 at least partially supporting a foam block with the bracket.    
     
     
         48 . A method as in  claim 46  wherein the adhesive material is epoxy based.  
     
     
         49 . A method as in  claim 46  wherein the step of at least partially curing the adhesive material includes placing the door beam, bracket and adhesive material within a heating structure.  
     
     
         50 . A method of reinforcing a door of an automotive vehicle, the method, comprising: 
 providing an elongated reinforcement member, the reinforcement member being a door reinforcement beam having a first attachment at a first end of the beam and a second attachment at the second end of the beam, wherein the first end is opposite the second end and wherein the beam includes a tubular member extending between the first end and second end of the beam;    providing a bracket comprised of a first member and second member;    welding flanges of the first member to flanges of the second member such that the bracket surrounds at least a portion of the tubular member; and    at least partially heat curing adhesive material by placing the door beam, bracket and adhesive material within a heating structure to adhere the reinforcement member to the bracket, the adhesive material located substantially entirely between the bracket and the elongated reinforcement member wherein the adhesive material is epoxy based;    transporting the reinforcement after the adhesive material adheres to the bracket and the reinforcement.    attaching a mass of foam attached to the bracket;    attaching the first attachment and the second attachment to a door of the vehicle adjacent opposite sides of the door; and    further curing the structural adhesive material to further secure the bracket to the reinforcement member.