Composite Part Assembly

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.

1 - 6 . (canceled) 
     
     
         7 . An assembly comprising:
 a first part;   a second part having a first layer of a resin that is reinforced with a filler and a second layer of a resin without the filler on at least part of one side of the second part; and   a fastener that extends through the first part and partially through the second part, the fastener extending into the second layer without extending through the second layer.   
     
     
         8 . The assembly of  claim 7  wherein the fastener is a self-piercing rivet having a tubular portion that extends fully through the filler material, and wherein the filler is not exposed on a side of the second part that is opposite the first part. 
     
     
         9 . The assembly of  claim 8  wherein the tubular portion is spread apart within the second part to secure the first part to the second part. 
     
     
         10 . The assembly of  claim 8  wherein the second layer is provided in localized areas on the first layer where the self-piercing rivet is disposed in the assembly. 
     
     
         11 . The assembly of  claim 10  wherein the second layer defines voids across areas of the first layer. 
     
     
         12 . The assembly of  claim 7  wherein the filler is a fiber reinforcement that is randomly deposited in the resin. 
     
     
         13 . The assembly of  claim 7  wherein the resin is selected from a group consisting essentially of:
 a thermoplastic resin; and 
 a thermoset resin. 
 
     
     
         14 . The assembly of  claim 7  wherein the filler material is selected from a group consisting essentially of:
 carbon fiber; 
 glass fiber; 
 mica; and 
 natural fiber. 
 
     
     
         15 . A composite part comprising:
 a first layer of a resin matrix that is reinforced with a filler material; and   a second layer of the resin matrix that does not include the filler material on at least part of one side of the second part, wherein the second layer is more than 3 microns thick.   
     
     
         16 . The composite part of  claim 15  wherein the filler material is a fiber reinforcement that is randomly deposited in the resin matrix. 
     
     
         17 . The composite part of  claim 15  wherein the second layer defines voids across areas of the first layer. 
     
     
         18 . The composite part of  claim 15  wherein the resin matrix is a thermoplastic resin. 
     
     
         19 . The composite part of  claim 15  wherein the resin matrix is a thermoset resin. 
     
     
         20 . The composite part of  claim 15  wherein the filler material is selected from a group consisting essentially of:
 carbon fiber; 
 glass fiber; 
 mica; and 
 natural fiber.