Reinforced thermoplastic structural joint assembly for a vehicle

Abstract

A structural joint assembly for a vehicle is provided with a first thermoplastic composite member having a protrusion containing fibrous material. A reinforcement member is provided with a receptacle for mating engagement with the protrusion. A second thermoplastic member is mounted to the first thermoplastic member over the protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member but not adhesively bonded or overmolded therebetween. A method of manufacturing a structural joint assembly and a structural joint assembly manufactured by a method are disclosed. The methods include molding a first thermoplastic member with a protrusion with fibrous material and a second thermoplastic member. A reinforcement member has a receptacle and is mounted to the first thermoplastic member. The receptacle is retained by the protrusion without adhesive bonding or overmolding. The second thermoplastic member is joined to the first thermoplastic member.

1 . A structural joint assembly for a vehicle comprising:
 a first thermoplastic member having a protrusion containing fibrous material;   a reinforcement member having a receptacle formed therein for mating engagement with the protrusion; and   a second thermoplastic member mounted to the first thermoplastic member at the protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member but not adhesively bonded or overmolded therebetween.   
   
   
       2 . The structural joint assembly of  claim 1  wherein the first thermoplastic member has a channel formed therein such that the at least one protrusion is formed therein. 
   
   
       3 . The structural joint assembly of  claim 2  wherein the reinforcement member is retained within the channel of the first thermoplastic member. 
   
   
       4 . The structural joint assembly of  claim 1  wherein the first thermoplastic member has a pair protruding surfaces provided proximate a periphery of the first thermoplastic member such that the second thermoplastic member is mounted to the first thermoplastic member at the pair of protruding surfaces. 
   
   
       5 . The structural joint assembly of  claim 1  wherein at least one of the first thermoplastic member and the second thermoplastic member is adapted to be mounted to an automotive vehicle. 
   
   
       6 . The structural joint assembly of  claim 5  wherein at least one of the first thermoplastic member and the second thermoplastic member is adapted to be mounted to a vehicle roof panel and the other of the first thermoplastic member and the second thermoplastic member is adapted to be mounted to a vehicle frame. 
   
   
       7 . (canceled) 
   
   
       8 . The structural joint assembly of  claim 1  wherein the at least one protrusion of the first thermoplastic member has a generally polygonal shape and the receptacle formed in the reinforcement member has a corresponding generally polygonal shape. 
   
   
       9 . The structural joint assembly of  claim 8  wherein the at least one protrusion of the first thermoplastic member has a generally polygonal shape having rounded corners and the receptacle formed in the reinforcement member has a corresponding generally polygonal shape having rounded corners. 
   
   
       10 . The structural joint assembly of  claim 1  wherein the at least one protrusion of the first thermoplastic member has a circular shape and the receptacle formed in the reinforcement member has a corresponding circular shape. 
   
   
       11 . The structural joint assembly of  claim 1  wherein the at least one protrusion of the first thermoplastic member has a rectangular shape and the receptacle formed in the reinforcement member has a corresponding rectangular shape. 
   
   
       12 . The structural joint assembly of  claim 1  wherein the at least one protrusion of the first thermoplastic member has a triangular shape and the receptacle formed in the reinforcement member has a corresponding triangular shape. 
   
   
       13 . A method of manufacturing a structural joint assembly comprising:
 molding a first thermoplastic member having at least one protrusion with fibrous material provided therein;   molding a second thermoplastic member;   providing a reinforcement member sized to be received by the first thermoplastic member and having a receptacle for a mating engagement with the at least one protrusion;   mounting the reinforcement member to the first thermoplastic member such that the receptacle of the reinforcement member is retained by the protrusion without adhesive bonding or overmolding; and   joining the second thermoplastic member to the first thermoplastic member at the at least one protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member thereby increasing load capacity.   
   
   
       14 . The method of manufacturing of  claim 13  further comprising welding the second thermoplastic member to the first thermoplastic member. 
   
   
       15 . The method of manufacturing of  claim 13  further comprising:
 providing the first thermoplastic member with a plurality of protrusions; and   providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member.   
   
   
       16 . The method of manufacturing of  claim 13  further comprising:
 providing the first thermoplastic member with a plurality of protrusions and having a circular shape; and   providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a circular shape.   
   
   
       17 . The method of manufacturing of  claim 13  further comprising:
 providing the first thermoplastic member with a plurality of protrusions and having a rectangular shape; and   providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a rectangular shape.   
   
   
       18 . The method of manufacturing of  claim 13  further comprising:
 providing the first thermoplastic member with a plurality of protrusions and having a triangular shape; and   providing the reinforcement member with a plurality of receptacles corresponding with the plurality of protrusions of the first thermoplastic member and having a triangular shape.   
   
   
       19 . The method of manufacturing of  claim 13  wherein the reinforcement member is further defined as a metal reinforcement member thereby further increasing load capacity. 
   
   
       20 . A structural joint assembly manufactured by a method comprising:
 molding a first thermoplastic member having at least one protrusion with fibrous material provided therein;   molding a second thermoplastic member;   providing a reinforcement member sized to be received by the first thermoplastic member and having a receptacle for a mating engagement with the at least one protrusion;   mounting the reinforcement member to the first thermoplastic member such that the receptacle of the reinforcement member is retained by the protrusion without adhesive bonding or overmolding; and   joining the second thermoplastic member to the first thermoplastic member at the at least one protrusion such that the reinforcement member is provided between the first thermoplastic member and the second thermoplastic member thereby increasing load capacity.