Cleat for joining metal and carbon fiber panels

Abstract

Described herein are cleats used for joining metal and carbon fiber panels of vehicle bodies. The cleats are configured to extend laterally across a gap between the metal panel and the carbon fiber panel, overlapping the vehicle interior facing sides of the metal panel and the carbon fiber panel. The cleats comprise an intermediate portion with an intermediate channel, an integral metal side flange and an integral carbon fiber side flange extending laterally from the intermediate portion. During installation, the metal side flange and the carbon fiber side flange are fastened respectively to the metal panel and the carbon fiber panel with an adhesive. The metal panel is located laterally from the intermediate channel and a leading edge of the carbon fiber panel extends into the intermediate channel without abutting the cleat or the metal panel.

Description

CLEAT FOR JOINING METAL AND CARBON FIBER PANELSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from United States Provisional Patent Application Number 63 / 613,960 filed on December 22, 2023, the content of which is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates to joints in vehicle bodies and, in particular, joints between a metal body panel and a carbon fiber body panel.BACKGROUND

[0003] In modem automotive vehicles, carbon fiber is increasingly employed in various ways. Structural elements, decorative elements, body components, etc., may be made of carbon fiber. A challenge arises when attempting to use carbon fiber body elements aside metal, typically sheet steel, body elements. The materials of these elements are structurally and chemically quite distinct, each responding differently to stresses during various road driving conditions, and each having distinct thermal expansion coefficients and characteristics. A body panel joint may be subject to stress when the vehicle chassis twists and loads are imparted in various driving situations. Both tension and compression may be encountered along with twisting and loading. Vehicle body panel loads may arise from aerodynamic forces, door or other closure forces, the application of positive or negative pressure, component mass, dynamic G-force loads, and other factors. Stresses may arise owing to variable temperatures or abrupt temperature changes, including thermal shock in conjunction with vehicle chassis and body panel loads. Accordingly, metal body elements and carbon fiber body elements are usually not bonded the way that identical materials are bonded, including by gluing, welding or similar techniques. From an aesthetic standpoint, leaving a gap between metal panels and carbon fiber panels to compensate for these various stresses may be unsightly. Accordingly, it would be advantageous to have a structure and method to join steel panels and carbon fiber panels which is structurally sound and aesthetically pleasing.SUMMARY

[0004] According to some embodiments, there is provided a joint for a metal panel of a vehicular body and a carbon fiber panel of the vehicular body. The joint comprises a cleat extending laterally across a gap between the metal panel and the carbon fiber panel and overlapping vehicle interior facing sides of the metal panel and the carbon fiber panel. The cleat comprises an intermediate portion with an intermediate channel, an integral metal side flange and an integral carbon fiber side flange extending laterally from the intermediate portion. The metal side flange and the carbon fiber side flange are fastened respectively to the metal panel and the carbon fiber panel with an adhesive. The metal panel is located laterally from the intermediate channel and a leading edge of the carbon fiber panel extending into the intermediate channel without abutting the cleat or the metal panel.

[0005] According to some embodiments, the cleat is formed from steel, aluminum or a polymeric compound.

[0006] According to some embodiments, both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal the intermediate portion.

[0007] According to some embodiments, the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards the metal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of the adhesive therebetween.

[0008] According to some embodiments, a forward edge of the metal panel abuts a locating projection formed in a seating portion of the cleat, whereby the metal panel is located laterally in relation to the cleat outside the intermediate channel and is located adjacent the cleat and separated from the metal side flange by the seating portion.

[0009] According to some embodiments, a body filler is applied between a filler dam and the metal panel, wherein the filler dam protrudes from the intermediate portion between the intermediate channel and the metal panel to provide a first smooth joint surface for painting.

[0010] According to some embodiments, a flexible sealant is applied between the leading edge of the carbon fiber panel and the filler dam to provide a second smooth joint surface for painting.

[0011] According to some embodiments, the adhesive is applied as a liquid.

[0012] According to some embodiments, the adhesive comprises one of an epoxy and a urethane.

[0013] According to some embodiments, the adhesive is applied as a double-sided tape.

[0014] According to some embodiments, the metal panel comprises one of sheet steel, sheet aluminum, sheet steel alloy and sheet aluminum alloy.

[0015] According to some embodiments, there is provided a cleat for joining a metal panel of a vehicular body and a carbon fiber panel of the vehicular body. The cleat comprises a pair of lateral ends and an intermediate portion therebetween and an integral metal side flange and an integral carbon fiber side flange extending laterally from the intermediate portion towards the pair of lateral ends. The intermediate portion comprises an intermediate channel configured to receive a leading edge of the carbon fiber panel therein without abutting the cleat or the metal panel.

[0016] According to some embodiments, the cleat is formed from steel, aluminum and a polymeric compound.

[0017] According to some embodiments, both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal the intermediate portion.

[0018] According to some embodiments, the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards the metal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of adhesive therebetween.

[0019] According to some embodiments, the cleat further comprises at least one locating projection formed in a seating portion of the cleat, wherein when installed a leading edge of the metal panel abuts the at least one locating projection.

[0020] According to some embodiments, there is provided a method of creating a joint between a metal panel of a vehicular body and a carbon fiber panel of the vehicular body using a cleat. The method comprises: providing the cleat comprising an intermediate portion with an intermediate channel, a metal side flange and a carbon fiber side flange, the metal side flange and the carbon fiber side flange extending laterally from the intermediate portion;applying an adhesive to one of a vehicle interior facing side of the metal panel and a vehicle exterior facing side of the metal side flange; locating the metal panel adjacent the metal side flange; pressing the metal panel to the metal side flange to create a connection therebetween; applying the adhesive to one of a vehicle interior facing side of the carbon fiber panel and a vehicle exterior facing side of the carbon fiber side flange; locating the carbon fiber panel adjacent the carbon fiber side flange with a leading edge of the carbon fiber panel extending into the intermediate channel but not abutting the cleat or the metal panel; and pressing the carbon fiber panel to the carbon fiber side flange to create a connection therebetween. The joint is configured to provide a gap between the metal panel and the carbon fiber panel.

[0021] According to some embodiments, a forward edge of the metal panel abuts a locating projection formed in a seating portion of the cleat, whereby the metal panel is located laterally in relation to the cleat outside the intermediate channel and is located adjacent the cleat and separated from the metal side flange by the seating portion.

[0022] According to some embodiments, both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal from the intermediate portion.

[0023] According to some embodiments, the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards the metal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of the adhesive therebetween.

[0024] According to some embodiments, the cleat is formed from steel, aluminum or a polymeric compound.

[0025] According to some embodiments, a body filler is applied between a filler dam and the metal panel, wherein the filler dam protrudes from the intermediate portion between the intermediate channel and the metal panel to provide a first smooth joint surface for painting.

[0026] According to some embodiments, a flexible sealant is applied between the leading edge of the carbon fiber panel and the filler dam to provide a second smooth joint surface for painting.

[0027] According to some embodiments, the adhesive is applied as a liquid.

[0028] According to some embodiments, the adhesive comprises one of an epoxy and a urethane.

[0029] According to some embodiments, the metal panel and the metal side flange, and the carbon fiber panel and the carbon fiber side flange, after being pressed together, are respectively clamped for a sufficient time to permit the adhesive to cure.

[0030] According to some embodiments, the adhesive is applied as a double-sided tape.

[0031] According to some embodiments, the carbon fiber panel is located in relation to the cleat using a fixture or jig.

[0032] According to some embodiments, the metal panel comprises one of sheet steel, sheet aluminum, sheet steel alloy and sheet aluminum alloy.

[0033] Further aspects of the invention will be apparent from the following description and explanations.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] For a better understanding of the various embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:

[0035] FIG. 1 depicts a side view of a vehicle body comprising a metal panel, a carbon fiber panel and a cleat, according to non-limiting embodiments;

[0036] FIG. 2 depicts an exploded view of a joint comprising the metal panel, carbon fiber panel and cleat of FIG. 1, according to non-limiting embodiments;

[0037] FIG. 3A depicts a perspective view of a joint for metal and carbon fiber panels comprising a cleat, according to non-limiting embodiments;

[0038] FIG. 3B depicts a rear view of the joint of FIG. 3 A;

[0039] FIG. 3C depicts an exploded view of the joint of FIG. 3 A;

[0040] FIG. 4 depicts a perspective view of a cleat, according to non-limiting embodiments;

[0041] FIG. 5 depicts a rear view of the cleat of FIG. 4;

[0042] FIG. 6 depicts an enlarged view of a front edge of the cleat of FIG. 4;

[0043] FIG. 7 depicts schematic of a cross-sectional view of a cleat installed between a metal panel and a carbon fiber panel, according to non-limiting embodiments;

[0044] FIG. 8 depicts an enlarged view of the cleat of FIG. 7;

[0045] FIG. 9 depicts an enlarged view of the cleat of FIG. 7 having a body filler and a flexible sealant applied thereon, according to non-limiting embodiments;

[0046] FIG. 10 depicts a schematic of a cross-sectional view of a cleat installed between a metal panel and a carbon fiber panel, the cleat having a plurality of locating protrusions, according to non-limiting embodiments;

[0047] FIGS. 11A and 11B depicts a flowchart of a method of creating a joint between a metal panel of a vehicular body and a carbon fiber panel of the vehicular body using a cleat, according to non-limiting embodiments; and

[0048] FIGS. 12A to 14B depict a method of creating a joint between a metal panel of a vehicular body and a carbon fiber panel of the vehicular body using a cleat, according to non-limiting embodiments.

[0049] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.DETAILED DESCRIPTION

[0050] According to at least some embodiments, there is provided a vehicle body having a metal panel and a carbon fiber panel. The metal panel and the carbon fiber panel each have an exterior side which is meant to be visible, and an interior side (facing the vehicle’s interior when assembled) which is not meant to be visible.

[0051] It has been found that by using a cleat with specific structural features to join a metal panel and a carbon fiber panel while leaving a gap between these panels, the problems of joining the disparate materials may be resolved. The cleat is adhesively joined to each panel. A leading edge of the carbon fiber panel lies in an intermediate channel in an intermediate portion of the cleat. This helps to prevent the leading edge of the carbon fiber panel from contacting either the cleat or the metal panel, so that tension, compression andflexion may occur under various thermal and stress conditions without damage to any of the components of the joint. The cleat allows creation of an exposed gap between the body panels which is typically visually acceptable, and which is adapted to permit an acceptable shape and surface finish. This joint typically permits a continuous, paintable, exterior surface of the joined metal and carbon fiber panels without visible gaps.

[0052] The described cleat generally provides a connection between the metal panel and the carbon fiber panel while leaving a gap between the panels to account for relative movement between the panels owing to thermal and physical and / or mechanical effects. The cleat is typically made of steel but may be molded, cast or extruded from aluminum, or other metals or alloys, or even made from a polymeric material or a metal powder using 3-D printing or the like. Any suitable method to create the cleat is contemplated. The metal cleat is preferably made of stainless steel or zinc plated steel, but other forms of steel or other metals may be used. Although a sheet steel panel will typically be used for body panels given cost, strength and weight considerations, other metals, such as aluminum or other alloys, may be employed depending on the application. It is preferable to use a cleat material which will not create a galvanic potential between the cleat and the metal panel. A galvanic potential may lead to rust or other degradation of one or both metal components. Accordingly, for example, use of a bare aluminum cleat with a bare steel panel would generally be avoided. Of course, properly coating one or both of these metals prior to assembly of the joint might avoid a problem with galvanic currents.

[0053] The cleat has an intermediate portion with an intermediate channel and flanges extending laterally from the intermediate portion. According to some embodiments, the intermediate portion is centrally located on the cleat (which then is also referred to herein as “a central portion”). According to some embodiments, the intermediate channel may be located in a central section of the central portion (which then is also referred to herein as “a central channel”). Since one of the flanges will be bonded to the metal panel, it may be referred to herein as a metal side flange. Similarly, the opposing flange will bond with the carbon fiber panel and may be referred to herein as a carbon fiber side flange. According to some embodiments, each flange is tapered from a maximum thickness in the vicinity of the intermediate portion to a lesser thickness at the distal ends of the flanges. This tapered construction tends to allow the respective panels to bond to the cleat without any visualdeformation of the panels in the adhesively bonded regions of the panels. Such visual deformation, known as sink marks or read through, could occur without the tapered flange structures owing to shrinkage of the adhesive lying between the flanges and the panels as the adhesive cures. In addition, according to some embodiments, the distal ends of the flanges are provided with terminal ridges to limit the flow of adhesive beyond the distal ends of the flanges. If the amount of adhesive applied is precisely metered, such terminal ridges may be unnecessary.

[0054] As noted, the metal panel and the carbon fiber panel are bonded to the cleat using an adhesive. Although a single adhesive is typically used, different adhesives which are optimal to bond the cleat to the specific metal or to carbon fiber may be employed. The adhesive may be applied as a liquid using a caulking gun or similar, or other, means of application. Preferred adhesives are epoxy or urethane structural adhesives, although any adhesive suitable for the purpose may be employed. Typically, the metal and carbon fiber panels are clamped to their respective cleat flanges for a sufficient time to permit the adhesive to cure. The clamping time may vary depending on the formulation of the particular adhesive employed, the temperature, etc. As an alternative to applying a liquid either to the panels or to the cleat, the adhesive may be applied as a sheet, such as a form of two-sided tape. For example, a permanent, pressure sensitive adhesive tape may be provided. This type of tape may provide sufficient adhesion from initial contact with the metal and carbon fiber parts and may become even more structural with the passage of time. Such tape has the advantage of limiting the spread of adhesive beyond the boundaries of the cleat, which may be undesirable. On the other hand, since the cleat is adhered to interior faces of the metal panel and the carbon fiber panel, excess adhesive typically will not be visible in any event. The use of a two-sided tape, as noted, may have the advantage that the adhesive may require less curing time than a liquid adhesive, or no curing time. Also, the clamping of the panels to the cleat flanges may be reduced or eliminated since it is generally not necessary to hold the components in place for an extended time to permit the adhesive bonding them to cure.

[0055] The cleat intermediate portion comprises the intermediate channel and may be provided with other features to facilitate location of the body panels in relation to the cleat. For example, each of the flanges may be provided with a plurality of locating protrusions at various locations to maintain a fixed spacing between the generally flat cleat flanges and thegenerally flat panels. These locating protrusions may also be referred to as stand-off features. The adhesive, if liquid, will flow around the locating protrusions as each panel and its respective flange are clamped together while the adhesive cures. This typically allows the adhesive to contact flat surfaces of each of the flanges and their respective panels while maintaining a constant spacing between these elements.

[0056] The metal side flange of the cleat may be provided with a seating portion and at least one locating projection. The locating project! on(s) may be formed between a distal end of the seating portion and a filler protrusion located between the metal side flange and the intermediate channel. The metal panel may lay upon the seating portion and be located laterally by the locating projection against which a forward edge of the metal panel abuts. In the completed joint, body filler may be applied between the locating project! on(s) and the filler protrusion to form a smooth, paintable surface matching the exterior of the metal panel.

[0057] The carbon fiber panel, in contrast, does not abut the cleat at its leading edge. Typically, the leading edge of the carbon fiber panel is curved interiorly into the intermediate channel. Since there is no abutment with the cleat, there is somewhat greater latitude in locating the carbon fiber panel than the metal panel. Typically, a fixture or jig is used to locate the carbon fiber panel in relation to the cleat and the metal panel. The same fixture or jig may be used to locate the carbon fiber panel to other elements such as a side door opening or a trunk lid, for example. The gap between the carbon fiber panel and the metal panel may thus be varied. There may be trade-offs to allow proper fitting with other elements when fitting a particular carbon fiber panel, such as a body panel, with a particular metal panel, such as an adjacent body panel.

[0058] With the leading edge of the carbon fiber panel lying within the intermediate channel, there is room for the carbon fiber panel to move as a result of thermal or stress effects, as outlined above. This movement can occur without contact of the leading edge of the carbon fiber panel with either the metal panel or the cleat. Thus, damage to any of the carbon fiber panel, the metal panel or the cleat is typically avoided. There is a gap between the metal panel and the carbon fiber panel which makes this movement without damage possible. For aesthetics, and to seal the joint from atmospheric elements like precipitation, dust, debris and other undesirable elements, according to some embodiments, a seal between the carbon fiber panel and the cleat is provided. Since flexibility is required to allow movement of the carbonfiber panel in relation to the cleat and the metal fiber panel fixed to the cleat, a flexible sealant may be applied between the carbon fiber panel adjacent its leading edge and the filler protrusion. The flexible sealant can be made smooth and aesthetically pleasing, and suitable for painting along with the metal panel and carbon fiber panel. Typically, most or all of the cleat will not be visible to the exterior following application of the body filler and the flexible sealant.

[0059] It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the exemplary aspects of the present application described herein. However, it will be understood by those of ordinary skill in the art that the exemplary aspects described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the exemplary aspects described herein. Also, the description is not to be considered as limiting the scope of the exemplary aspects described herein. Any systems, method steps, method blocks, components, parts of components, and the like described herein in the singular are to be interpreted as also including a description of such systems, method steps or tasks, components, parts of components, and the like in the plural, and vice versa.

[0060] Attention is directed to FIGS. 1 and 2, which depict a vehicle body 2 having a metal panel 4, a carbon fiber panel 6 and joint 8 therebetween. Between metal panel 4 and carbon fiber panel 6 is gap 10. After installation, there is provided a cleat 100 which extends laterally across gap 10 and overlaps vehicle interior facing sides 12, 14 of the metal panel 4 and carbon fiber panel 6 (FIG. 3B).

[0061] According to some embodiments, metal panel 4 comprises one of sheet steel, sheet aluminum, sheet steel alloy and sheet aluminum alloy.

[0062] As shown in FIGS. 3A to 4, cleat 100 comprises a pair of lateral ends 102 (individually lateral end 102 A and lateral end 102B) and an intermediate portion 104 therebetween. Intermediate portion 104 comprises an intermediate channel 106. Intermediate channel 106 configured to receive a leading edge 16 of carbon fiber panel 6 therein without abutting the cleat 100 or the metal panel 4. For example, according to some embodiments, intermediate channel 106 is sized and / or shaped such that leading edge 16 may be receivedtherein without contacting cleat 100 or metal panel 4. Cleat 100 further comprises an integral metal side flange 108 and an integral carbon fiber side flange 110 which extend laterally from intermediate portion 104 towards the pair of lateral ends 102.

[0063] According to some embodiments, cleat 100 is formed from steel, aluminum or a polymeric compound. However, any suitable material or combination of materials is contemplated.

[0064] To fasten the cleat 100 to the metal panel 4 and carbon fiber panel 6 and form joint 8, an adhesive 18 is applied to the metal side flange 108 and the carbon fiber side flange 110 (FIG. 2). According to some embodiments, adhesive 18 is applied as a liquid. According to some embodiments, adhesive 18 comprises one of an epoxy and a urethane. According to some embodiments, adhesive 18 is applied as a double-sided tape.

[0065] As discussed above, cleat 100 may comprise features which assist in the distribution of adhesive 18 and / or prevent visual deformation of the metal panel 4 and the carbon fiber panel 6. For example, according to some embodiments, both the metal side flange 108 and the carbon fiber side flange 110 taper from a maximum thickness, T, adjacent intermediate portion 104 to a reduced thickness, R, distal intermediate portion 104 (see, for example, FIGS. 6 and 7). As noted above, tapering the sides typically allows the cleat 100 to deform as the adhesive 18 cures and shrinks to help prevent deformation of the exposed metal panel 4 and carbon fiber panel 6. According to some embodiments, integral metal side flange 108 and integral carbon fiber side flange 110 each comprises a plurality of locating protrusions 114 which project towards the metal panel 4 and the carbon fiber panel 6 when cleat 100 is installed. Locating protrusions 114 are configured to separate the flanges 108, 110 from the panels 4, 6 and to predetermine the thickness of the adhesive 18 therebetween (FIG. 10).

[0066] To help position the metal panel 4, according to some embodiments, cleat 100 comprises at least one locating projection 116 formed in a seating portion 118 (see, for example, FIGS. 8 and 10). When cleat 100 is installed a leading edge 20 of metal panel 4 abuts the locating projection 116. According to some embodiments, metal panel 4 is located laterally in relation to the cleat 100 outside the intermediate channel 106 and is located adjacent the cleat 100 and separated from the metal side flange 108 by seating portion 118.

[0067] According to some embodiments, joint 8 further comprises features that are configured to receive body filler and / or sealer, which helps create a generally continuouspaintable surface transition. For example, according to some embodiments, joint 8 further comprises a body filler 22 applied between a filler dam 120 of the cleat 100 and the metal panel 4 (FIG. 9). The filler dam 120 protrudes from the intermediate portion 104 between the intermediate channel 106 and the metal panel 4 to provide a first smooth joint surface 132 for painting. According to some embodiments, joint 8 comprises a flexible sealant 24 applied between the leading edge 16 of carbon fiber panel 6 and the filler dam 120 to provide a second smooth joint surface 134 for painting. According to some embodiments, both body filler 22 and flexible sealant 24 are applied to joint 8. According to some embodiments, one of body filler 22 and flexible sealant 24 are applied to joint 8. Any suitable body filler and flexible sealant are contemplated.

[0068] Attention is directed to FIGS. 11A to 14B, which depict example method 200 of creating a joint between a metal panel and a carbon fiber panel of a vehicle body using a cleat as described herein. In order to assist in the explanation of method 200, it will be assumed that method 200 is performed using the cleat 100 depicted in FIGS. 1 to 10 and the various components as described herein. However, it is understood that method 200 can be varied, and need not work exactly as discussed herein, and that such variations are within the scope of the present application. It is also emphasized, however, that method 200 need not be performed in the exact sequence as shown, unless otherwise indicated; and likewise various blocks may be performed in parallel rather than in sequence. Hence, the elements of method 200 are referred to herein as “blocks” rather than “steps”. Further, more or fewer elements than indicated herein may be performed.

[0069] At block 202, cleat 100 having intermediate portion 104 with intermediate channel 106, metal side flange 108 and carbon fiber side flange 110 is provided. According to some embodiments, the cleat 100 is formed from steel, aluminum or a polymeric compound.

[0070] At block 204, adhesive 18 is applied to one of the vehicle interior facing side 12 of the metal panel 4 and the vehicle exterior facing side 126 of the metal side flange 108 (FIG. 12A). According to some embodiments, adhesive 18 is applied as a liquid. According to some embodiments, adhesive 18 comprises one of an epoxy and a urethane. However, according to some embodiments, adhesive 18 may be applied as a double-sided tape.

[0071] At block 206, the metal panel 4 is located adjacent the metal side flange 108. For example, according to some embodiments, cleat 100 comprises at least one locatingprojection 116 and in locating the metal panel 4 the leading edge 20 abuts against the locating projection 116.

[0072] At block 208, the metal panel 4 is pressed to the metal side flange 108 to create a connection therebetween (FIG. 12B). According to some embodiments, the metal panel 4 and the metal side flange 108 are clamped together until the adhesive 18 cures.

[0073] At block 210, adhesive 18 is applied to one of the vehicle interior facing side 14 of the carbon fiber panel 6 and the vehicle exterior facing side 128 of the carbon fiber side flange 110 (FIG. 13A).

[0074] At block 212, the carbon fiber panel 6 is located adjacent the carbon fiber side flange 110 such that the leading edge 16 of the carbon fiber panel 6 extends into the intermediate channel 106 without abutting the cleat 100 or the metal panel 4. For example, according to some embodiments, the carbon fiber panel 6 is positioned on the carbon fiber side flange 110 such that the leading edge 16 extends into intermediate channel 106 without contacting an interior surface 130 of the intermediate channel 106 (FIG. 13B). According to some embodiments, the carbon fiber panel 6 is located in relation to the cleat 100 using a fixture or ajig. As discussed above, the resulting joint 8 is configured to provide a gap 10 between the metal panel 4 and the carbon fiber panel 6.

[0075] At block 214, the carbon fiber panel 6 is pressed to the carbon fiber side flange 110 to create a connection therebetween (FIG. 13B). For example, according to some embodiments, the carbon fiber panel 6 and the carbon fiber side flange 110 are clamped together until the adhesive 18 cures.

[0076] According to some embodiments, method 200 further comprises applying body filler 22 between filler dam 120 and the metal panel 4 to provide a first smooth joint surface 132 for painting. According to some embodiments, method 200 further comprises applying flexible sealant 24 between leading edge 16 and filler dam 120 to provide a second smooth joint surface 134 for painting (FIGS. 9, 14A and 14B).

[0077] Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the above examples are only illustrations of one or more implementations. The scope, therefore, is only to be limited by the claims appended hereto.

[0078] It will also be understood that for the purposes of this application, "at least one of X, Y, and Z" or "one or more of X, Y, and Z" language can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XYY, YZ, ZZ, XX, XY).

[0079] In the present application, components may be described as being "configured to" or "enabled to" perform one or more functions. Generally, it is understood that a component that is configured to or enabled to perform a function is configured to or enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.

[0080] Additionally, components in the present application may be described as being "operatively connected to", "operatively coupled to", and the like, to other components. It is understood that such components are connected or coupled to each other in a manner to perform a certain function. It is also understood that "connections", "coupling" and the like, as recited in the present application include direct and indirect connections between components.

[0081] References in the application to "one embodiment", "an embodiment", "an implementation", "a variant", etc., indicate that the embodiment, implementation or variant described may include a particular aspect, feature, structure, or characteristic, but not every embodiment, implementation or variant necessarily includes that aspect, feature, structure, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such module, aspect, feature, structure, or characteristic with other embodiments, whether or not explicitly described. In other words, any module, element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility, or it is specifically excluded.

[0082] It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as "solely", "only", and the like, in connection with the recitation of claim elements or use of a "negative" limitation. The terms "preferably", "preferred", "prefer","optionally", "may", and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.

[0083] The singular forms "a", "an", and "the" include the plural reference unless the context clearly dictates otherwise. The term "and / or" means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase "one or more" is readily understood by one of skill in the art, particularly when read in context of its usage.

[0084] The term "about" can refer to a variation of± 5%, ± 10%, ± 20%, or± 25% of the value specified. For example, "about 50" percent can in some embodiments carry a variation from 45 to 55 percent. For integer ranges, the term "about" can include one or two integers greater than and / or less than a recited integer at each end of the range. Unless indicated otherwise herein, the term "about" is intended to include values and ranges proximate to the recited range that are equivalent in terms of the functionality of the composition, or the embodiment.

[0085] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc.

[0086] As will also be understood by one skilled in the art, all language such as "up to", "at least", "greater than", "less than", "more than", "or more", and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into subranges as discussed above. In the same manner, all ratios recited herein also include all subratios falling within the broader ratio.

Claims

CLAIMS1. A joint for a metal panel of a vehicular body and a carbon fiber panel of the vehicular body comprising: a cleat extending laterally across a gap between the metal panel and the carbon fiber panel and overlapping vehicle interior facing sides of the metal panel and the carbon fiber panel; wherein: the cleat comprises an intermediate portion with an intermediate channel, an integral metal side flange and an integral carbon fiber side flange extending laterally from the intermediate portion; the metal side flange and the carbon fiber side flange are fastened respectively to the metal panel and the carbon fiber panel with an adhesive; and the metal panel is located laterally from the intermediate channel and a leading edge of the carbon fiber panel extending into the intermediate channel without abutting the cleat or the metal panel.

2. The joint of claim 1, wherein the cleat is formed from steel, aluminum or a polymeric compound.

3. The joint of either claim 1 or claim 2, wherein both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal the intermediate portion.

4. The joint of any one of claims 1 to 3, wherein the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards the metal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of the adhesive therebetween.

5. The joint of any one of claims 1 to 4, wherein a forward edge of the metal panel abuts a locating projection formed in a seating portion of the cleat, whereby the metal panel is located laterally in relation to the cleat outside the intermediate channel and is located adjacent the cleat and separated from the metal side flange by the seating portion.

6. The joint of any one of claims 1 to 5, wherein a body filler is applied between a filler dam and the metal panel, and wherein the filler dam protrudes from the intermediate portion between the intermediate channel and the metal panel to provide a first smooth joint surface for painting.

7. The joint of claim 6, wherein a flexible sealant is applied between the leading edge of the carbon fiber panel and the filler dam to provide a second smooth joint surface for painting.

8. The joint of any one of claims 1 to 7, wherein the adhesive is applied as a liquid.

9. The joint of claim 8, wherein the adhesive comprises one of an epoxy and a urethane.

10. The joint of any one of claims 1 to 7, wherein the adhesive is applied as a double-sided tape.

11. The joint of any one of claims 1 to 10, wherein the metal panel comprises one of sheet steel, sheet aluminum, sheet steel alloy and sheet aluminum alloy.

12. A cleat for joining a metal panel of a vehicular body and a carbon fiber panel of the vehicular body comprising: a pair of lateral ends and an intermediate portion therebetween; and an integral metal side flange and an integral carbon fiber side flange extending laterally from the intermediate portion towards the pair of lateral ends; wherein the intermediate portion comprises an intermediate channel configured to receive a leading edge of the carbon fiber panel therein without abutting the cleat or the metal panel.

13. The cleat of claim 12, wherein the cleat is formed from steel, aluminum and a polymeric compound.

14. The cleat of either claim 12 or claim 13, wherein both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal the intermediate portion.

15. The cleat of any one of claims 12 to 14, wherein the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards the metal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of adhesive therebetween.

16. The cleat of any one of claims 12 to 15 further comprising at least one locating projection formed in a seating portion of the cleat, wherein when installed a leading edge of the metal panel abuts the at least one locating projection.

17. A method of creating a joint between a metal panel of a vehicular body and a carbon fiber panel of the vehicular body using a cleat, comprising: providing the cleat comprising an intermediate portion with an intermediate channel, a metal side flange and a carbon fiber side flange, the metal side flange and the carbon fiber side flange extending laterally from the intermediate portion; applying an adhesive to one of a vehicle interior facing side of the metal panel and a vehicle exterior facing side of the metal side flange; locating the metal panel adjacent the metal side flange; pressing the metal panel to the metal side flange to create a connection therebetween; applying the adhesive to one of a vehicle interior facing side of the carbon fiber panel and a vehicle exterior facing side of the carbon fiber side flange; locating the carbon fiber panel adjacent the carbon fiber side flange with a leading edge of the carbon fiber panel extending into the intermediate channel but not abutting the cleat or the metal panel; and pressing the carbon fiber panel to the carbon fiber side flange to create a connection therebetween; wherein the joint is configured to provide a gap between the metal panel and the carbon fiber panel.

18. The method of claim 17, wherein a forward edge of the metal panel abuts a locating projection formed in a seating portion of the cleat, whereby the metal panel is located laterally in relation to the cleat outside the intermediate channel and is located adjacent the cleat and separated from the metal side flange by the seating portion.

19. The method of either claim 17 or 18, wherein both the metal side flange and the carbon fiber side flange taper from a maximum thickness adjacent the intermediate portion to a reduced thickness distal from the intermediate portion.

20. The method of any one of claims 17 to 19, wherein the metal side flange and the carbon fiber side flange each comprise a plurality of locating protrusions projecting towards themetal panel and the carbon fiber panel respectively configured to separate said flanges from said panels and to predetermine the thickness of the adhesive therebetween.

21. The method of any one of claims 17 to 20, wherein the cleat is formed from steel, aluminum or a polymeric compound.

22. The method of any one of claims 17 to 21, wherein a body filler is applied between a filler dam and the metal panel, wherein the filler dam protrudes from the intermediate portion between the intermediate channel and the metal panel to provide a first smooth joint surface for painting.

23. The method of claim 22, wherein a flexible sealant is applied between the leading edge of the carbon fiber panel and the filler dam to provide a second smooth joint surface for painting.

24. The method of any one of claims 17 to 23, wherein the adhesive is applied as a liquid.

25. The method of any one of claims 17 to 24, wherein the adhesive comprises one of an epoxy and a urethane.

26. The method of any one of claims 17 to 25, wherein the metal panel and the metal side flange, and the carbon fiber panel and the carbon fiber side flange, after being pressed together, are respectively clamped for a sufficient time to permit the adhesive to cure.

27. The method of any one of claims 17 to 23 or 26, wherein the adhesive is applied as a double-sided tape.

28. The method of any one of claims 17 to 27, wherein the carbon fiber panel is located in relation to the cleat using a fixture or jig.

29. The method of any one of claims 17 to 28, wherein the metal panel comprises one of sheet steel, sheet aluminum, sheet steel alloy and sheet aluminum alloy.

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