Process For Joining Carbon Fiber Composite Materials Using Self-Piercing Rivets

Abstract

A joint and related method. The joint includes bottom and top layers contacted to form first and second contacting portions. The bottom layer is a fiber composite material that is non-ductile at room temperature. A joint member joins the bottom and top layers such that the joint and the top layer are unexposed through the bottom layer.

What is claimed is: 
     
         1 . A joint comprising:
 first and second components contacted to form first and second contacting portions, the second component being a fiber composite material being non-ductile at room temperature; and   a joint member joining the first and second components such that the joint and the first component are unexposed through the second component.   
     
     
         2 . The joint of  claim 1 , wherein the joint member is a self-piercing rivet (“SPR”). 
     
     
         3 . The joint of  claim 2 , wherein the SPR includes a head and a shaft. 
     
     
         4 . The joint of  claim 3 , wherein the SPR shaft contacts and extends into the first component a length. 
     
     
         5 . The joint of  claim 1 , wherein the first component is an aluminum material. 
     
     
         6 . The joint of  claim 1 , wherein the second component is a composite material. 
     
     
         7 . The joint of  claim 1 , wherein the first and second components are first and second panels, respectively. 
     
     
         8 . The joint of  claim 1 , wherein the fiber composite material is a carbon fiber composite material. 
     
     
         9 . The joint of  claim 1 , wherein the fiber composite material exhibits increased ductile behavior at an elevated temperature. 
     
     
         10 . A method comprising:
 contacting bottom and top layers to form a joint between the two layers, the bottom layer being a non-ductile fiber composite material at room temperature;   elevating the temperature of a fastening portion of the bottom layer to make the fastening portion ductile; and   joining the bottom and top layers while the fastening portion is at the elevated temperature.   
     
     
         11 . The method of  claim 10 , wherein the fastening portion is the first contacting portion. 
     
     
         12 . The method of  claim 10 , wherein the joining step includes joining the first and second contacting portions with one or more rivets. 
     
     
         13 . The method of  claim 10 , wherein the elevated temperature is in the range of 100 to 300° C. 
     
     
         14 . The method of  claim 10 , wherein the elevating step is carried out using a radiant, inductive or convective heat. 
     
     
         15 . The method of  claim 10 , wherein the fiber composite material includes a carbon fiber material and a polymeric material. 
     
     
         16 . The method of  claim 10 , wherein the elevated temperature is within +/−30% of the glass transition temperature (in Kelvin) of the fiber composite material. 
     
     
         17 . A method comprising:
 contacting first and second panels to form a joint between the two panels, the second panel being a non-ductile fiber composite material at room temperature;   elevating the temperature of only a fastening portion of the second panel to make the fastening portion ductile; and   joining the first and second panels while the second panel is at an elevated temperature with one or more rivets to form a joined portion.   
     
     
         18 . The method of  claim 17 , wherein the elevated temperature is in the range of 100 to 300° C. 
     
     
         19 . The method of  claim 17 , wherein the fiber composite material includes a carbon fiber material and a polymeric material. 
     
     
         20 . The method of  claim 17 , wherein the elevated temperature is within +/−30% of the glass transition temperature (in Kelvin) of the fiber composite material.