CN1016950B - 粘接纤维增强塑料构件的方法 - Google Patents
粘接纤维增强塑料构件的方法Info
- Publication number
- CN1016950B CN1016950B CN89102969A CN89102969A CN1016950B CN 1016950 B CN1016950 B CN 1016950B CN 89102969 A CN89102969 A CN 89102969A CN 89102969 A CN89102969 A CN 89102969A CN 1016950 B CN1016950 B CN 1016950B
- Authority
- CN
- China
- Prior art keywords
- reinforcement
- assembly
- electrode
- amplitude transformer
- outer component
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
- B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/349—Cooling the welding zone on the welding spot
- B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
- B29C66/73755—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
- B29C66/73755—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
- B29C66/73756—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized the to-be-joined areas of both parts to be joined being fully cured
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
- B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
- B29C66/81811—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
公开了一种粘接方法和设备,在这种方法和设备中用高频加热的方法将汽车的纤维增强塑料壳体构件粘接到增强构件上。
Description
本发明涉及粘接技术,具体涉及将纤维增强塑料的汽车壳体构件粘接在一起的方法和设备。
机动车设计的最新趋势是用塑料部件代替较重的金属部件,采用纤维增强塑料而不用金属板来制作例如车篷、盖板和车门等这种汽车外部壳体组件可以得到很多优点。然而为了使最终的组件具有充分的刚性和机械强度,必须采用增强构件来增强较大的外部纤维增强塑料镶板或构件。
本发明的目的在于这样的快速粘接技术,这种技术采用不会损害外部构件表面质量的方式,将增强构件快速粘接到外部的纤维增强塑料构件上。
按照最佳实施例的说明,粘结剂放在纤维增强塑料构件和有关的增强构件的相粘接的表面之间。将高频信号加在组件两边的电极上,它将粘结剂加热到高于其固化温度,从而可将增强构件粘接到纤维增强塑料构件上。已经意外地发现,这种技术不产生过热,如果产生过热,它将在纤维增强塑料上产生表面缺陷。
因此本发明的主要目的是提供一种能够将增强构件快速粘接到外部的纤维增强塑料壳体构件上的粘接方法和设备。
本发明的另一个目的是提供这样一种粘接方法和设备,这种粘接方法和设备不对外部的纤维增强塑料壳体构件的表面质量产生有害的影响。
本发明的再一个目的是提供这样一种粘接方法和设备,这种粘接方法和设备能够将增强构件平滑地粘接到外部的纤维增强塑料壳体构件上而不管壳体构件和增强构件的大小。
在参照附图研究下面一个最佳实施例的详细说明以后,熟知这种技术的人将会清楚本发明的各种优点。这些附图是:
图1是一个组件的构件分解透视图,该组件包括汽车外部壳体构件和其增强构件。
图2是图1所示组件的部分底部平面图。
图3是图1所示的组件沿图2的3-3线切开的局部切面图。
图4是沿图5的4-4线切开的横切面图,它以简化的形式示出了实现本发明最佳方法的设备。
图5是沿图4的5-5线切开的横切面图。
图6是图4和图5所示设备的前视图。
图7是一个曲线图,它示出了在粘接过程期间时间和所产生的热之间的关系。
本发明具体涉及提供增强的汽车外部壳体组件,例如车篷、车门和挡板组件。本发明提供一种快速粘接方法,用于将第一构件,典型的是外部纤维增强塑料构件,粘接到第二构件即增强构件上,第二增强构件虽然可以用其它的塑料或者甚至是金属来制作,但最好还是用纤维增强塑料来制作。在某些情况下,例如在挡板组件的情况下,将第一构件和第二构件说成是相互增强更合适,因为第二构件实际上形成了汽车组件外部表面的一部分,以便安装汽车零件,如安装信号灯或头灯。
下面参照汽车车篷的制造详细说明本发明,然而,熟知这种技术的人应当意识到,按照后附权利要求书的明确说明,本发明明显地不限于这种特殊的应用。
连篷组件示于附图中,总的用编号10表示。组件10由相当薄的(约0.203至0.305厘米厚)外层构件12和增强构件14组成。外层构件12用纤维增强塑料制作,最好用热固性薄板造型复合材料制造,这种材料是在真空中压铸的。由密执安州Troy城的Budd公司拥有的美国专利No.4488862、4551085和4612149涉及这种技术,因此被作为参考包括在本文中。
当构件12是例如车篷、挡板等这样的汽车外部壳体壁板时,本发明特别实用,这种汽车外部壳体壁板具有相当大的超过大约一平方英尺的表面积并具有至少119.38cm的长度。这种类型的壁板为使其具有足够的机械刚性经常需要进行增强,另外,重要的是,汽车制造厂家特别要求外层外表面要保持光滑,令人喜爱。这种标准在工业上一般被称之为A级表面。
作为不受限制的具体的例子,组件10是Ford Aerostar小型带篷货车的车篷,其外面积约为142.24×55.88cm,其厚度约为0.48cm(增强构件0.23cm加外层厚0.25cm)。
增强构件14最好同样用纤维增强塑料制造。在用图说明的实施例中,构件14的外形在平面图中形成“8”字结构,而在横切面图每个腿是一个“帽子”结构,从图3和图4可以清楚地看到“帽子”结构。帽子形横切面的特点在于升高的拱形部分16和一对反向的法兰18。
为了将增强构件14粘接到外层构件12上,将粘结剂22的片放在法兰18上,然后翻转增强构件14,将其放在外层构件12的内表面上,如图3-6所示。粘结剂22是一种热固性树脂,在固化时其介质特性将发生变化。粘结剂片最好包括由链式聚合物和单体组成的树脂以及由硬化剂或催化剂组成的第二成分。虽然聚氨基甲酸乙脂树脂可能证明是可用的,但环氧树脂粘结剂是目前最好的粘结剂。这些粘结剂不同于胶,如动物胶,这种胶不依赖化学反应来实现其粘接特性。从下面的讨论可以清楚地知道,本发明利用某些粘结剂的这种特性得到了很大的好处。作为具体的但不受限制的例子,粘结剂22是从Lord公司买的Lord320/322型环氧树脂粘结剂。
参照图6,将外层构件-粘结剂-增强构件形成的组件送入高频加热器26的小室27中。这可以用多种方法来实现。在本实施例中,组件是放在许多指状物21上,指状物接触外层构件12下表面的外缘。指状物21跨在滚柱23上从而形成一个滑车,利用活塞装置25该滑车可将组件移向图6
的右方。然后组件被送入高频加热器26的小室27中,送到这样一个位置,在此位置,外层构件12被支承在槽座20的上面。如图4清楚看出的那样,槽座20的上表面被成型为这样的形状,使其它相应于外层构件12的外部表面或A级表面的形状,从而在粘接过程期间给构件12提供均匀的支承。槽座20应当采用具有低介质损耗特性的材料制造。在本例中,槽座20是用铝制造的,但也可以采用其它的材料例如黄铜来制造。冷却介质从入口23至出口25流过导管21,使得在整个粘接过程中使外层构件12的外表面保持在4.4-66℃的恒定温度。
槽座20与接通接地极34的电极板30相连接。槽座20与电极板30这一亚组件由液压活塞32驱动。在外层构件-粘结剂-增强构件这一组件定位在槽座20的上面之后,驱动液压活塞32,使槽座向上升并将组件从其支承指状物21上抬起,从而将外层构件12放在槽座20中。活塞32继续将槽座20向上移动到总的用编号36表示的上电极组件。
电极组件36包括一系列分立的或电绝缘的聚能器部件38,该聚能器部件由框架40同时固定在确定的位置(见图4和图5)。每个聚能器部件38有一个大体上为U形的下部分,该下部分有一对垂挂的腿42。如图4清楚示出的那样,腿42被盛开为这样的形状,使得它们大体上与增强构件14的法兰18相吻合。凹槽44为增强构件14的凸起的拱16提供了一个空隙。聚能器部件38的作用是将高频电源46的能量集中到选定的包含粘结剂22的区域。
电极组件36还包括许多电极板48,这些电极板一般放在聚能器部件38的上面。在图4中示出了三个这样的电极板48、50和52。然而,应当了解,在实际中使用了许多这样的电极板,例如见图5。电极板48、50和52也用导电材料例如铝和黄铜来制造,如图所示,它们每一个都通过上电极54连接到高频电源46上。在电极54和电极板48、50和52之间分别存在着空气间隙49、51和53。
配备有调节在电极板48、50和52与上电极54之间的相对空气间隙或间距的装置(因此通过部件38调节了在电极板下面的被加热的区域)。在电极板和上电极之间的间距影响加到待加热材料上的能量。在本实施例中采用调节空气间隙49、51和53的大小的方法,可以细调在下面的粘结剂中实际产生的热量。这就可以进一步保证加热均匀,从而导致均匀的粘接强度。独立调节在每个聚能器部件38下面产生的热量实际上是使大体上均匀的热量穿过组件10而不管其大小和由此产生的不均匀性。这种调节可用多种方法实现。在图4中,利用可伸缩的管56来实现这种功能,该伸缩管连接在每个电极板48去50和52与其相应的聚能器件38之间。根据聚能器部件38的大小和其待加热的水平区域,可以通过多根可伸缩的管56连接一个以上的电极板。
电源46在电极组件36和下电极板30之间产生高频静电场。由电源46施加的均方根电压可以在例如300伏至8000伏之间。电压小于300伏是不利的,因为这个电压不能充分加热粘结剂22。相反,施加的电压超过8000伏也被认为是不利的,因为此时在电极板48、50和52与地之间将出现严重的电绝缘问题。电源46施加的振荡或交变电流频率在25至40兆赫之间。频率小于10兆赫被认为是不利的,因为此时要求加热粘结剂的电压太大了而不能达到同样的加热时间并且还有很大可能产生电弧。频率超过110兆赫也被认为是不利的,因此时需要的单独的电极板48、50和52数量太大,增加了获得均匀加热粘结剂的困难。另外,频率高于110兆赫时,在聚能器部件38之间的耦合交得更加显著,致使个别电极板48、50和52的调节更加相互影响。人们认为,最佳频率是能够提供足够快的加热时间并在电极组件中极少发生电弧的频率。另外,频率太高时还应到注意到,有可以粘结剂22加热太快而使得其中的化学反应不能跟上温度的上升。
本发明特别适合于大批量生产。作为不受限制的例子,在槽座20已经升到如图4所示的位置扣,只要将频率恒定、电压恒定的电场加上经过15至120秒的时间便可达到优良的粘接强度。此外所说的“恒定”一词是指,在加热期不故意改变频率和电压以得到显著的加倍的加热速率。已经意外地发现,此过程还具有内在的“破损安全”机构,这种机构阻止发生可能破坏外层构件12的光滑外表面的过热。参照图7可以看到,为将两种先前已固
化的热固性纤维增强部件粘接在一起采用发生化学反应的热固性粘结剂时,在粘结剂中产生的热量足以使粘结剂相当快地达到稍高于其固化温度。然而一当粘结剂凝固,即使所加的电场不变,其中产生的热也倾向于随时间减小。虽然这种现象还不完全清楚,但人们认为,这可以归因为粘结剂在其凝固态和非凝固态之间介质特性的改变。在本特定的例子中,电源46的频率为34兆赫,电压约为4400伏,通电时间在30秒至40秒之间。这就提供了足够的时间来保证粘结剂均匀地固化,而在同时,这个速度也是很快的,足以保证生产的经济性。然后降下活塞32,将已粘接好的组件从加热器26中移出来。
我们认为,为将增强构件粘接到热固性薄板成型复合外层构件上,上述的方法比其它方法优越得多。常规的辐射加热方法一般太慢,导致不均匀地粘接,或导致粘结剂发生过热,使其可能燃烧并经外层构件显露出来。感应加热一般需要在粘结剂中或在待加热的区域使用金属粒子。对于汽车外部壳体镶板组件,这不是一种可行的方法。最佳实施例的设备也被设计来克服这些问题,在尝试利用高频加热来粘接相当大的部件时,已经发现这些问题是存在的。已经发现,如果利用一个单一的细长电极在34兆赫的频率来粘接超过大约47英寸的部件,则可能意外地发生不均匀加热。虽然这种现象的原因还不完全清楚,但是可以认为,因为在电极的各个区段具有一定的从该处辐射的能量峰(这可以归因于电极的长度接近交变电源46波长的1/15),所以产生了不均匀加热(因此产生的热量变化大于或等于10%)。因此沿着两个相对电极之间的长度产生了不同的电压上升,人而导致部件不均匀地加热。可以认为,本发明的最佳实施例解决了许多这样的问题,并给生产者提供了必需的将设备细调到被粘接的特定部件上的灵活性。在研究本文所提供的附图、说明和权利要求书之后,熟知这种技术的人将会明白本发明的另外一些优点。
虽然在附图中仅示出并在上述的详细说明中仅描述本发明的方法和设备的一个详细的实施例,但是应当清楚,本发明并不局限在本文所述的特定的实施例上,它可以进行许多重新配置、改型和替换而不违背本发明的范围。例如,本方法和设备可以接着用来生产包括三个或更多个构件的组件,如由第一构件(即外部纤维增强塑料构件)、中间构件(即金属构件)和第二构件(即内部纤维增强塑料构件)构成的汽车车门。熟知这种技术的人还会看出另外一些改变。下述的权利要求书是用来包括所有这些改型的。
Claims (8)
1、一种将固化纤维增强塑料外层构件粘接到增强构件上的方法,该方法包括下面的步骤:
将未固化的热固性粘结剂放置在已固化的纤维增强塑料构件和增强构件的相粘接的表面之间,形成组件;
将组件放在两个电极之间,上述电极的一个电极包括许多电绝缘的聚能器部件;
将以300至8000伏之间的电压、频率范围在10至110兆赫之间的高频信号由高频加热器加到电极上,所加时间为15至120秒足以使粘结剂固化,上述聚能器将高频信号能量均匀地集中在选定的粘结剂区域,使得粘结到增强构件上的纤维增强塑料外层,对该纤维增强塑料外层的表面质量无害的影响。
2、如权利要求1所述的方法,其中上述增强部件包括已固化的纤维增强塑料构件。
3、如权利要求1所述的方法,其中粘结剂是含有树脂和硬化剂两种成分的环氧树脂粘结剂。
4、按照权利要求3所述的方法,它还包括下列步骤:
将粘结剂加在增强构件的法兰上;
将增强构件放在外层构件的内侧面上以构成一个组件;
将该组件放入形状同外层构件表面形状相吻合的槽座中;
使槽座升高直到法兰被送到在聚能器部件下面的位置。
5、如权利要求4所述的方法,其中高频信号的频率和电压基本上是恒定的,加上高频信号的时间为15秒至120秒。
6、一种将汽车外部壳体外层构件粘接到增强构件上的方法,上述外层构件和增强构件采用压塑热固性薄板造型复合材料的方法预成型,上述方法包括下列步骤:
将可热固化的粘结剂片放在增强构件上,粘结剂是含有树脂和硬化剂两种成分的环氧树脂粘结剂;
将增强构件放在外层构件的内侧面上形成组件;
将组件放入形状同外层构件的表面形状相吻合的槽座中;
将组件推入介质加热器的小室中;
用接地电极板和上电极组件围着组件,上电极组件包括许多定位的电学上绝缘的聚能器部件;
将频率在10至110MHz之间的,电压在300至8000伏(均方根值)之间的交变电信号加在电极之间,施加时间为15秒至120秒,从而形成粘接的增强镶板组件,在聚能器下面产生的热量用来快速而有效地定点固化粘结剂,以便随后加工组件,使得粘结到增强构件上的纤维增强塑料外层,对该纤维增强塑料外层的表面质量无有害的影响。
7、如权利要求6所述的方法,它还包括下列步骤:
使信号直通聚能器部件上面的许多垂直可调的电极板,调节在电极板和位于其上面的间隔开的电极之间的垂直距离。
8、如权利要求5所述的方法,其特征是还包括:
通过多块在聚能器部件之上垂直可调节的电极板连接高频信号;
通过伸缩电极板,调节电极板和上电极之间的垂直距离即空气间隙。
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-
1988
- 1988-04-28 US US07/187,358 patent/US4941936A/en not_active Expired - Fee Related
-
1989
- 1989-04-14 CA CA000596814A patent/CA1307727C/en not_active Expired - Fee Related
- 1989-04-14 AU AU33039/89A patent/AU614354B2/en not_active Ceased
- 1989-04-20 EP EP19890107149 patent/EP0339494A3/en not_active Withdrawn
- 1989-04-25 MX MX015801A patent/MX171449B/es unknown
- 1989-04-27 BR BR898901992A patent/BR8901992A/pt not_active Application Discontinuation
- 1989-04-28 JP JP1111927A patent/JPH0257324A/ja active Granted
- 1989-04-28 KR KR1019890005538A patent/KR890015928A/ko not_active Application Discontinuation
- 1989-04-29 CN CN89102969A patent/CN1016950B/zh not_active Expired
Also Published As
Publication number | Publication date |
---|---|
KR890015928A (ko) | 1989-11-27 |
CA1307727C (en) | 1992-09-22 |
JPH0554814B2 (zh) | 1993-08-13 |
EP0339494A2 (en) | 1989-11-02 |
CN1037861A (zh) | 1989-12-13 |
US4941936A (en) | 1990-07-17 |
AU3303989A (en) | 1989-11-02 |
EP0339494A3 (en) | 1991-10-16 |
AU614354B2 (en) | 1991-08-29 |
MX171449B (es) | 1993-10-27 |
JPH0257324A (ja) | 1990-02-27 |
BR8901992A (pt) | 1989-12-05 |
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