Metal working – Method of mechanical manufacture – Structural member making
Reexamination Certificate
1996-10-24
2001-10-30
Echols, P. W. (Department: 3726)
Metal working
Method of mechanical manufacture
Structural member making
C029S448000, C029S458000, C029S462000
Reexamination Certificate
active
06308411
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to vehicle sidewalls, and more particularly, a truck cab sidewall and a process for making the same.
BACKGROUND OF THE INVENTION
The process of assembling a vehicle involves numerous components and assembly sequences. For instance, many truck cab sidewalls are comprised of a number of pieces of sheet metal attached together. Obviously, this requires separate manufacture processes of each piece, which undoubtedly increases the overall time and complexity of manufacturing the truck cab. In addition, a truck cab sidewall skin is typically riveted to an underlying structure in order to retain it in place. Obviously, a great number of rivets must be used and individually installed in order to secure the sidewall. Furthermore, there are many problems normally associated with riveting sidewalls or sheet metal to a truck cab structure. In particular, leaks may develop through the rivet holes thereby allowing water to penetrate the interior of the truck cab and damage interior components or the sidewall itself.
Therefore, a need exists for a process and truck cab sidewall directed toward overcoming the above-described and other problems typically associated with assembling a truck cab.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a vehicle sidewall manufacturing process and truck cab sidewall which is easier and less costly to assemble into a truck sidewall.
The sidewall has a skin with top, bottom, front, and rear edges. The skin has a first exterior surface and a second interior surface opposing the first exterior surface. The sidewall skin preferably has a front flange formed along the front edge. The front flange preferably projects in a first or inward direction (in a direction toward the interior of the cab). The front flange is sized and positioned for attachment to a door frame of the sidewall so that the sidewall skin may readily and securely be fastened to the underlying truck cab structure. The sidewall skin also preferably has a flange along the top edge which also most preferably is inwardly directed. The top flange may be utilized in attaching the sidewall skin to the underlying sidewall structure of the truck cab. A rear corner is preferably included in the sidewall skin and is formed in the sheet metal at a location spaced inwardly from the rear edge of the sheet. The portion of the sidewall between the rear edge and the corner comprises a portion of the exterior surface of a rear wall of the truck cab. The rear corner is preferably formed by a roll forming technique, as discussed herein in more detail.
The sidewall assembly preferably has a plurality of upright or vertical frame elements or pillars. The upright frame elements of the sidewall assembly have a first exterior surface and a second interior surface opposite the first exterior surface. An upper reinforcing element is preferably provided and interconnects the upper ends of the upright frame elements. The upper reinforcing element also has a first exterior and a second interior surface opposite the first exterior surface. A door frame is fastened to the sidewall frame assembly to substantially complete the underlying framework for the sidewall of the truck cab.
Adhesive is applied to the exterior surfaces of the upright frame elements and the upper reinforcing element. The sidewall skin is typically coupled to the door frame and is adhesively secured to the sidewall frame elements by applying tension to the sidewall skin in a direction from the front of the skin to the rear of the skin. The top or upper flange portion of the sidewall skin can be mechanically fastened to the upper reinforcing element, preferably in the area near the transition region. Although the adhesive may be ambiently cured, preferably an active curing is accomplished. In keeping with this approach, the sidewall assembly is preferably heated to cure the adhesive. The heat curing may be accomplished in a plurality of steps. For example, to provide handling or “green” strength, the sidewall may be heated to partially cure the adhesive. A second or final heat curing step can be performed, for example, after the sidewall is mounted to the truck cab assembly. Preferably, final curing of the adhesive is accomplished simultaneously with a paint curing step during which paint applied to the cab is also cured.
The present invention is directed toward the above objects and advantages individually as well as collectively. These and other objects, advantages, and features will become apparent with reference to the following description and Figures.
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Hill James Edward
Kalstiantz Edmond
Wright, Jr. Homer Franklin
Echols P. W.
Freightliner LLC
Klarquist & Sparkman, LLP
Nguyen T.
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