Joints and a system and method of forming the joints

1. A method of forming a joint of an automotive vehicle, the method comprising:

providing a first member of the automotive vehicle, the first member having a distal end;

providing a second member of the automotive vehicle, the second member having a distal end; and

providing a connector having a base portion, a first portion extending away from the base portion and a second portion extending away from the base portion, the connector also having activatable material including an epoxy resin and a core/shell polymer impact modifier disposed upon the first portion and the second portion and wherein the connector is tubular in shape and defines a plurality of intersecting ribs, one or more ribs having a curved shape to circumscribe the tubular shape of the connector;

locating the first portion adjacent the distal end of the first member and the second portion adjacent the distal end of the second member; and

activating the activatable material to form a structural adhesive foam having a tensile modulus greater than about 200 MPa and a post-activation ductility ratio greater than about 2.0 and adhering the structural adhesive foam to the first portion of the connector and the distal end of the first member and to the second portion of the connector and the distal end of the second member;

wherein the foam provides sufficient strength to the joint whereby the first member is free of direct contact with the second member after activating the activatable material and the first and second members are connected to each another without any welds directly or indirectly connecting the members.

2. A method as in claim 1 wherein the first member and second member are part of a frame of the automotive vehicle.

3. A method as in claim 1 wherein at least one of the first member and the second member is a B-pillar.

4. A method as in claim 1 wherein the step of locating the first portion includes fastening the first portion to the distal end of the first member with a mechanical fastener.

5. A method as in claim 1 wherein the step of providing the first member includes hydroforming a first tubular structure defined by the first member.

6. A method as in claim 1 wherein the connector is formed of a plastic material.

7. A method as in claim 1 wherein the first portion of the connector extends away from the base portion in a first direction and the second portion extends away from the base portion in a second direction and the first direction is at an angle of less than 170° relative to the second direction.

8. A method as in claim 1 wherein the connector includes a third portion extending away from the base portion, the third portion also having activatable material disposed thereon wherein the step of activating the activatable material includes adhering the third portion of the connector to a third member of the automotive vehicle.

9. A method of forming a joint of an automotive vehicle, the method comprising:

providing a first member of the automotive vehicle, the first member having a distal end, wherein the first member is provided by hydroforming a first tubular structure defined by the first member, the first tubular structure having a tunnel extending along its length and including at least one hydroformed contour;

providing a second member of the automotive vehicle, the second member having a distal end wherein the second member is provided by hydroforming a second tubular structure defined by the second member, the first tubular structure having a tunnel extending along its length and including at least one hydroformed contour; and

providing a connector having a base portion, a first portion extending away from the base portion and a second portion extending away from the base portion, the connector also having activatable material including an epoxy resin and a core/shell polymer impact modifier disposed upon the first portion and the second portion and wherein the connector is tubular in shape and defines a plurality of intersecting ribs, one or more ribs having a curved shape to circumscribe the tubular shape of the connector;

locating the first portion within the tunnel of the first tubular structure at the distal end of the first member and the second portion within the tunnel of the second tubular structure adjacent the distal end of the second member; and

activating the activatable material to form a structural adhesive foam having a tensile modulus greater than about 200 MPa and a post-activation ductility ratio greater than about 2.0 and adhering the structural adhesive foam to the first portion of the connector and an interior surface of the first tubular structure at the distal end of the first member and adhering the structural adhesive foam to the second portion of the connector and an interior surface of the second tubular structure at the distal end of the second member, the interior surface of the first tubular structure at least partially defining the tunnel of the first tubular structure and the interior surface of the second tubular structure at least partially defining the tunnel of the second tubular structure;

wherein the foam provides sufficient strength to the joint whereby the first member is free of direct contact with the second member after activating the activatable material and the first and second members are connected to each another without any welds directly or indirectly connecting the members.

10. A method as in claim 9 wherein the first member and second member are part of a frame of the automotive vehicle.

11. A method as in claim 9 wherein at least one of the first member and the second member is a B-pillar.

12. A method as in claim 9 wherein the step of locating the first portion includes fastening the first portion to the distal end of the first member with a mechanical fastener.

13. A method as in claim 9 wherein the connector is formed of a plastic material.

14. A method as in claim 9 wherein the first portion of the connector extends away from the base portion in a first direction and the second portion extends away from the base portion in a second direction and the first direction is at an angle of less than 170° relative to the second direction.

15. A method as in claim 9 wherein the connector includes a third portion extending away from the base portion, the third portion also having activatable material disposed thereon wherein the step of activating the activatable material includes adhering the third portion of the connector to a third member of the automotive vehicle.

16. A method of forming a joint of an automotive vehicle, the method comprising:

providing a first member of the automotive vehicle, the first member having a distal end, wherein the first member is provided by hydroforming a first tubular structure defined by the first member, the first tubular structure having a tunnel extending along its length and including at least one hydroformed contour;

providing a second member of the automotive vehicle, the second member having a distal end wherein the second member is provided by hydroforming a second tubular structure defined by the second member, the first tubular structure having a tunnel extending along its length and including at least one hydroformed contour; and

providing a connector having a base portion, a first portion extending away from the base portion and a second portion extending away from the base portion, the connector also having activatable material including an epoxy resin and a core/shell polymer impact modifier disposed upon the first portion and the second portion and wherein the connector is tubular in shape and defines a plurality of intersecting ribs, one or more ribs having a curved shape to circumscribe the tubular shape of the connector;

locating the first portion within the tunnel of the first tubular structure at the distal end of the first member and the second portion within the tunnel of the second tubular structure adjacent the distal end of the second member; and

activating the activatable material to form a structural adhesive foam having a tensile modulus greater than about 200 MPa and a post-activation ductility ratio greater than about 2.0 and adhering the structural adhesive foam to the first portion of the connector and an interior surface of the first tubular structure at the distal end of the first member and adhering the structural adhesive foam to the second portion of the connector and an interior surface of the second tubular structure at the distal end of the second member, the interior surface of the first tubular structure at least partially defining the tunnel of the first tubular structure and the interior surface of the second tubular structure at least partially defining the tunnel of the second tubular structure;

wherein:

i. the foam provides sufficient strength to the joint whereby the first member is free of direct contact with the second member after activating the activatable material and the first and second members are connected to each another without any welds directly or indirectly connecting the members;

ii. the first member and second member are part of a frame of the automotive vehicle;

iii. at least one of the first member and the second member is a B-pillar;

iv. the step of locating the first portion includes fastening the first portion to the distal end of the first member with a mechanical fastener;

v. the connector is formed of a plastic material;

vi. the connector defines a plurality of intersecting ribs;

vii. the first portion of the connector extends away from the base portion in a first direction and the second portion extends away from the base portion in a second direction and the first direction is at an angle of less than 170° relative to the second direction; and

viii. the connector includes a third portion extending away from the base portion, the third portion also having activatable material disposed thereon wherein the step of activating the activatable material includes adhering the third portion of the connector to a third member of the automotive vehicle.

17. A method as in claim 16 wherein the connector includes a first plurality of ribs extending transversely and intersecting a second plurality of ribs and wherein the activatable material is thermosettable and is activated to expand and thermoset in an e-coat or paint oven.

18. A method as in claim 16 wherein each member includes a plurality of parallel ribs extending lengthwise along the member and a plurality of ribs adjacent the circumference of each member and arranged perpendicular to the plurality of parallel ribs.