Composite Panel for Joining with a Clinch Joint and Method of Forming a Clinch Joint

Abstract

An assembly comprising a first composite fiber reinforced part that is joined to a second part by a clinch joint. The first part includes a first layer of resin that is reinforced with fibers and a second layer of resin that is devoid of fibers and applied to one side of the first layer of fiber reinforced resin. The second part contacts the first layer of the first part. The first part and second part are joined by a clinch joint including a pressed out portion that is pressed into a clinching portion. The second layer of resin contains the fibers in the first part.

What is claimed is: 
     
         1 . An assembly comprising:
 a first part including:
 a first layer of resin reinforced with fibers; 
 a second layer of resin applied to one side of the first layer; and 
   a second part contacting the first layer of the first part, joined by a clinch joint including a pressed-out portion of the first part pressed into a clinching portion of the second part, wherein the second layer of resin retains the fibers within the first part.   
     
     
         2 . The assembly of  claim 1  wherein the first part is formed in a compression molding process with the first layer being formed in a first step and the second layer being applied to the first layer after the first layer is formed. 
     
     
         3 . The assembly of  claim 1  wherein the first part is formed in a compression molding process with the first layer and the second layer being formed in a single step, wherein the second layer is formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer. 
     
     
         4 . The assembly of  claim 1  wherein the second layer is provided to a partial area on the one side of the first layer where the clinch joint joins the first part to the second part. 
     
     
         5 . The assembly of  claim 1  wherein a plurality of clinch joints are formed to join the first part to the second part and the second layer is provided to a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part. 
     
     
         6 . The assembly of  claim 1  wherein the second layer of resin covers the one side of the first layer. 
     
     
         7 . The assembly of  claim 1  wherein the fibers are selected from a group consisting essentially of:
 carbon fibers; 
 glass fibers; 
 talc; and 
 natural fibers. 
 
     
     
         8 . The assembly of  claim 1  wherein the second part is formed of a material selected from a group consisting essentially of:
 steel; 
 aluminum; 
 magnesium; and 
 composite resin. 
 
     
     
         9 . A method of forming a clinch joint for joining a plurality of panels comprising:
 molding a first part that includes a first layer of resin reinforced with fibers;   molding a second layer of resin onto one side of the first layer of resin;   assembling a second part to the first layer of the first part; and   joining the first part to the second part by pressing a pressed-out portion of the first part into a clinching portion of the second part, wherein the second layer of resin inhibits the fibers in the first layer from protruding from the first part proximate the clinch joint.   
     
     
         10 . The method of  claim 9  wherein the molding steps are performed in a compression molding process wherein the first layer is formed in a first step and the second layer is applied to the first layer in a second step after the first layer is formed. 
     
     
         11 . The method of  claim 9  wherein the molding steps are performed in a compression molding process wherein the first layer and the second layer are formed in a single step, and wherein the second layer is formed against a textured surface of a compression molding die that inhibits the fibers from entering the second layer. 
     
     
         12 . The method of  claim 9  wherein the step of molding the second layer further comprises molding the second layer to a partial area on the one side of the first layer where the clinch joint joins the first part to the second part. 
     
     
         13 . The method of  claim 9  wherein a plurality of clinch joints are formed to join the first part to the second part and wherein the step of molding the second layer further comprises molding the second layer to a plurality of partial areas on the one side of the first layer where the clinch joints join the first part to the second part. 
     
     
         14 . The method of  claim 9  wherein the step of molding the second layer further comprises molding the second layer covering one side of the first layer. 
     
     
         15 . The method of  claim 9  wherein the fibers are selected from a group consisting essentially of:
 carbon fibers; 
 glass fibers; 
 talc; and 
 natural fibers. 
 
     
     
         16 . An assembly comprising:
 a first panel including a composite layer of resin and fibers, and a fiber-free layer of resin applied to the composite layer; and   a second panel contacting and joined to the composite layer by a clinch joint, wherein the fiber-free layer prevents the fibers in the composite layer from being exposed due to the clinch joint.   
     
     
         17 . The assembly of  claim 16  wherein the clinch joint further includes a pressed-out portion of the first panel that is disposed within a clinching portion of the second panel. 
     
     
         18 . The assembly of  claim 16  wherein the first panel further includes a first flange and the second panel further includes a second flange that is disposed against the first flange, wherein the clinch joint connects the first flange to the second flange. 
     
     
         19 . The assembly of  claim 18  wherein the clinch joint further includes a pressed-out portion of the first flange that is disposed within a clinching portion of the second flange. 
     
     
         20 . The assembly of  claim 16  wherein the fiber-free layer and the second panel sandwich the composite layer therebetween.