CN103965792B - 空气粘接方法 - Google Patents

空气粘接方法 Download PDF

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Publication number
CN103965792B
CN103965792B CN201310109227.5A CN201310109227A CN103965792B CN 103965792 B CN103965792 B CN 103965792B CN 201310109227 A CN201310109227 A CN 201310109227A CN 103965792 B CN103965792 B CN 103965792B
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air
method described
manifold
bonding agent
hole
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CN103965792A (zh
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普罗比尔·库马尔·古哈
布拉德·哈斯克尔
休·C·福伦
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Kang Tingnan Opens Up Structural Plastic Co Ltd
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Kang Tingnan Opens Up Structural Plastic Co Ltd
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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
    • 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
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • 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
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/034—Thermal after-treatments
    • B29C66/0342—Cooling, e.g. transporting through welding and cooling zone
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—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
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/826—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined
    • B29C66/8266—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps without using a separate pressure application tool, e.g. the own weight of the parts to be joined using fluid pressure directly acting on the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/944—Measuring or controlling the joining process by measuring or controlling the time by controlling or regulating the time
    • 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
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • C09J5/06—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
    • B29C35/045—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using gas or flames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
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    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/26—Hot fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B11/006—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding by gluing
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    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
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Abstract

通过歧管输送加压空气经具有0.8至2.5毫米的孔直径并沿所述歧管以10到30毫米的平均距离间隔的多个孔接触第一元件以实现具有大于2200雷诺数在150和315℃之间的温度和超过环境压力每平方英寸（psi）0.5和10磅之间的压力下的紊流气流形式在第一元件和第二元件的外表面上以热固化元件之间的可固化的粘接剂以在60至90秒中实现粘接剂固化而没有正常人裸眼可见的粘接线读出。

Description

空气粘接方法
技术领域
本发明大体涉及一种粘接方法，特别涉及用于将汽车纤维增强塑料（fiberreinforced plastic，FRP）元件粘接在一起的方法。
背景技术
当前采用各种技术用于将纤维增强塑料（FRP）元件粘接在一起用于使用在汽车车身应用如，但不限于，发动机罩、车门、保险杠和类似物中。由于在汽车行业中用塑料组件取代较重的金属部件的增长趋势，在可获得的用于生产粘接的FRP组件的设备和方法的数量上已经具有发展。这些组件通常通过加热放置在两个FRP元件的配合表面之间的粘接剂至超过其固化温度的温度进行粘接。
现有技术图1至图3以简化的方式示出公知的粘接技术的例子，其使用热量粘接由FRP元件10和12以及放置在它们之间的粘接剂14组成的FRP组件。图1示出在电极18和块件20之间产生无线电频率静电场的介质加热设备16。静电场迅速加热粘接剂14至其固化温度以上的温度，从而粘接FRP元件10和12。共同转让给Wilkinson等人的美国专利US4941936和给Iseler等人的美国专利US4941937披露了介质加热技术的例子，其在这里通过参考并入。介质加热技术具有减少循环时间的优点，以及伴随的以很难控制和维持的方式加热FRP组件的缺点。
现有技术图2示出利用筒式加热器28用于加热金属块件24和26的粘接设备22。块件24和26反过来加热流经空气管路30的空气，其中的一部分流经开口32用于加热在FRP元件10和12之间的粘接剂14。这种类型的粘接技术的一个缺点是，它需要大量供应压缩空气以有效运作。
现有技术图3示出利用流经通道40的加热蒸汽和/或热水用于加热金属块件36和38的粘接设备34。块件36和38反过来加热在FRP元件10和12之间的粘接剂14。当与在现有技术图1和2中示出的粘接技术相比时，这种粘接技术具有需要高循环时间的缺点。
当粘接的FRP组件使用在外部汽车车身应用中时，所采用的粘接技术不对外部FRP元件的表面质量产生不利影响，且尽管FRP组件的尺寸，该技术提供均匀粘接，是最重要的。
其它现有技术，如美国专利US5554252，提出了一种改进的方法，但是留下了它自己的几个缺点。例如，传统的方法不能使得片状成形料（sheet molding compound，SMC）基板至足够高的温度，以在粘接夹具中60至90秒后提供足够的操作强度至粘接的组件。为了获得较低的循环时间，将需要比使用当前的热空气粘接技术的粘接夹具更昂贵的粘接夹具。此外，常规的方法具有使循环时间较长的低速传热。这种低传热速率的大部分是使用层流气流的结果，其通过传统的教导，提供比湍流气流系统更好的传热速率。方法如美国专利US5554252可以实现更理想的循环时间，但因为层流气流的使用，所披露的较差的方法不会产生足够的传热速率，导致沿粘接接合面板的粘接线的表面变形（又名粘接线读出）。美国专利US5554252的常规实验和优化不允许成功使用环境气流以提供60-90秒的固化时间。
本领域的目前技术的其它缺点是，使用常规技术，聚氨酯粘合剂不能使用在必须经受电泳涂层（超过205℃的温度）的SMC粘接组件如发动机罩和行李箱盖中。常规热空气粘接技术目的用于使用在环氧粘合剂中，其中快速固化化学（催化剂）是可得的，而对于其它粘接剂如聚氨酯是不可得的。最后，本领域的目前技术没有在加热组件内提供可以调节以促进、协助或优化气流用于期望效果的轮廓表面。
因此，将期望产生粘接设备，其改善所得FRP组件的表面质量，并在短时间例如60至90秒内提供遍及整个组件的均匀粘接和操作强度，而没有粘接线读出。另外，将期望提供一种粘接技术，其迅速粘接第一FRP元件至增强FRP元件而不影响表面质量或粘接强度特性，并具有获得足够高的温度用于SMC基板以支持这些期望的特性的能力。
发明内容
本发明提供了一种用于将第一元件粘接至第二元件的方法，包括将未固化的粘接剂放置在第一元件的第一元件配合表面上。以间隔关系支撑第一元件和第二元件，第二元件的第二元件配合表面接触位于第一元件的第一元件配合表面上的未固化的粘合剂。加压空气通过歧管输送，经具有0.8至2.5毫米的孔直径并沿歧管以10至30毫米的距离间隔的多个孔接触第一元件。加压空气以湍流气流方式在150和315℃之间的温度以及超过环境压力每平方英寸（psi）0.5和10磅之间的空气压力下吹入第一元件和第二元件的外表面周围，用于热固化粘接剂。然后低于该温度的较冷的加压空气吹入配合表面区域的周围，而以间隔关系支撑第一元件和第二元件以在60至90秒内实现粘接剂固化，且无正常人裸眼可见的任何粘接线读出。
附图说明
对于本领域技术人员来说，在阅读以下说明书和参考附图后，本发明的各种优点将变得明显，其中：
图1是一种现有技术粘接设备的简化示意图。
图2是第二现有技术粘接设备的简化示意图。
图3是第三现有技术粘接装置的简化示意图。
图4是在本发明的条件下显示湍流气流从元件和粘接其间的粘接剂形成的组件的立体图。
具体实施方式
本发明具有用处在粘接增强外部汽车车身组件，例如，但不限于，发动机罩、车门和保险杠组件中。本发明提供用于粘接第一，通常外部，纤维增强塑料（FRP）元件至第二增强元件的设备和快速方法，尽管可以使用其它塑料或甚至金属，第二增强元件也优选由FRP材料制造。
应理解，在值的范围提供的情况下，范围旨在不仅涵盖范围的端点值，而且涵盖范围的中间值，如明确包含在该范围内以及通过范围的最后重要数字变化。举例来说，从1至4的引用范围旨在包括1-2、1-3、2-4、3-4、和1-4。
在一个具体实施例中，相关的粘接歧管包括一系列孔，每个孔具有0.8至2.5毫米的直径，沿粘接歧管彼此间隔10至30mm的距离。在该具体实施例中，在高于环境压力0.5至10psi之间的压力下，加压加热空气，含有需要固化的环氧或聚氨酯粘接剂，施加压力至第一元件的外表面。应理解，典型的环境压力为14.7psi，但在封闭环境中环境压力可能会发生变化，因此施加的总压力可能会有所不同，但是，调节以施加高于环境压力0.5至10psi。本具体实施例的另一个方面需要加压歧管空气的空气温度为150和315℃之间，并在另一些具体实施例中至230和290°C之间的空气温度范围。与传统的层流热粘接系统相比，这些特征的组合导致在1.5至3.0mm的粘合线厚度提供令人惊讶的快速固化的湍流气流。此外，提供轮廓表面，其是可调的，以促进或协助所述加热空气的湍流。
如在这里所用的，“湍流气流”限定为来自如在这里详细描述的歧管并处于具有大于2120并在某些情况下大于3000甚至大于5000的雷诺数（Re）的条件下的气流。
本发明提供用于借助于湍流加热粘接区域通过增强热传递快速粘接汽车至增强塑料（FRP）元件的粘接方法，与层状气流最好用于该目的的传统观念相反，实现更快的固化时间以及因此生产量。虽然本发明关于FRP元件的粘接进行描述，将理解，其它塑料、复合材料、玻璃或甚至金属元件容易与可固化的粘接剂接合，以和本发明形成连接。在美国专利US5554252中详述描述的设备是能够高通量空气粘接可固化的粘接剂的示例性设备。
根据本发明的一个具体实施例的教导，提供第一元件，通常汽车外壳元件，至增强元件的粘接。形成汽车外壳元件的示例性材料是SMC。理解到，许多汽车车身SMC部件具有高品质的表面光洁度，在行业中通常称为A级表面光洁度。如在图4中所示的，第一元件10和第二元件12以间隔关系保持，未固化的粘接剂14位于第一元件10的配合表面42上。提供第一和第二嵌套元件用于以间隔关系容纳和支撑第一元件10和第二元件12，如结构增强，以控制通过粘接剂14的固化形成的粘接线厚度。对元件的相对移动进行控制，以便第一元件的配合表面42通过其间的粘接剂14结合第二元件的对应的配合表面44以形成嵌套元件。元件的移动和相对位置的保持由包括真空吸盘的真空组件控制。定位器确保嵌套元件50在粘接之前在适当的位置。
可切换的加热和冷却组件（未示出）首先提供加压加热空气至嵌套元件50，其反过来通过歧管52在第一元件10的外表面54的多个部分周围导向加热空气，气流处于箭头显示的方向。理解到，需要与歧管52类似的在第二元件12下吹动湍流空气至第二元件12的外表面56上的歧管，以在60至90秒内引发环氧树脂或聚氨酯固化，但为了视觉清楚，未画出。将外表面54和56暴露于湍流加热气流以引发固化和粘接后，然后该区域暴露于较冷的湍流空气以加速冷却形成组件的现在结合的元件，与嵌套元件50只不同在粘接剂现在是固化的。加压加热空气加热可固化的粘接剂至超过粘接剂固化温度的温度，然后加压冷却空气促进用于所得到的组件的冷却方法。
本发明很容易使用在汽车组件的制造中，但是，本领域技术人员将理解，本发明，如所附的权利要求所限定的，明确不限于该特定应用。此外，本发明是参照从FRP材料形成的发动机罩组件元件进行描述的，然而，本领域技术人员将理解，其它塑料或金属的使用是在本发明的范围内的。
粘接剂14通常包含树脂，其包括非交联聚合物和单体，以及含有硬化剂或催化剂的第二部分。环氧树脂粘接剂能够进行电泳涂层，对于许多汽车应用是非常期望的，而聚氨酯也非常适合根据本发明的热空气引发粘接。
歧管52容易由钢、铝、金属合金、陶瓷或玻璃形成，并具有基本线性系列的多个孔58，定位用于用湍流气流冲击在外表面54上。理解到，根据随着更复杂排列的孔形成而湍流趋于下降的了解，使用双排或更复杂排列的孔。相邻孔之间的平均间距，d，选择在10和30毫米之间。每个孔58具有0.8和2.5毫米之间的直径。理解到，孔的形状可以不同于圆形，还包括椭圆形、矩形、三角形和锯齿切割以形成细长槽；并仍然具有0.5至5平方毫米的相似的面积，A。
具有在直径、间距和孔向的至少一个属性上通过歧管的非均匀性程度的孔58也促进湍流。孔的孔向最经常从管的中心轴线径向延伸。理解到，沿着圆形横截面歧管的弦的孔向或否则如果突出而不延伸通过歧管中心给予从这样的孔出来的气流不同的矢量流。给定的歧管的流动动力学容易通过有限点分析建模以设计在给定的温带和压力产生湍流气流的歧管，以确保大于2200、大于3000、或甚至大于5000的雷诺值。
该加热空气以高于环境每平方英寸0.5至10磅的范围内的压力和在150和315℃之间的温度供应，在其它具体实施例中在230和290℃之间的空气温度范围。该加热空气供应5至30秒。理解到，进入歧管的气流也可以施以脉冲以引发湍流。采用电磁阀容易获得5至500赫兹的脉冲速率。此后，较冷温度的空气通过歧管52推动以冲击在外表面54上，相似的，提供歧管以推动较冷的空气以高于环境压力每平方英寸0.5至10磅的范围内的压力至表面上0至60秒。当加压加热空气冲击在嵌套元件上时，元件10和12之间的粘接剂加热到固化温度以上的温度，以便形成粘接组件，对本领域技术人员来说应该是明显的。热和冷空气提供采用的压力、温度和时间段是通过举例的方式使用的，其它操作参数在本发明的范围内，对本领域的技术人员来说将是明显的。
前述仅仅披露和描述本发明的示例性的具体实施例。本领域技术人员将容易地从这种讨论以及从附图和权利要求认识到，可以在其中进行各种改变，修改和变化，而不脱离如由下面的权利要求所限定的本发明的精神和范围。前面的描述是本发明的特定实施例的说明，但并不意味着是对其实践的限制。下面的权利要求，包括其所有的等同物，旨在限定本发明的范围。

Claims (13)

1.一种用于粘接第一元件至第二元件的方法，其特征在于，包括：
将未固化的粘接剂放置在第一元件的第一元件配合表面上；
以间隔关系支撑第一元件和第二元件；
将第二元件的第二元件配合表面接触位于第一元件的第一元件配合表面上的未固化的粘接剂；
通过歧管输送加压空气经具有0.8至2.5毫米的孔直径并沿所述歧管以10到30毫米的平均距离间隔的多个孔接触第一元件；
将雷诺数大于2120的处于湍流气流形式的在150和315℃之间的温度和超过环境压力每平方英寸(psi)0.5和10磅之间的空气压力下的加压空气冲击到第一元件的外表面上或加热粘接剂，然后，吹入低于该温度的加压空气，而以间隔关系支撑第一元件和第二元件；
在1.5至3.0mm的粘合线厚度60至90秒内固化未固化的粘接剂，而没有正常人裸眼可见的任何粘接线读出。
2.根据权利要求1所述的方法，其特征在于，其中第一元件和第二元件由每个包括分别对应于第一元件和第二元件的外表面的轮廓的轮廓表面的嵌套结构以间隔关系保持，外表面包括沿第一元件和第二元件的配合表面的长度延伸的第一和第二通道，以便基本相等的空气压力施加至第一元件和第二元件的外表面的多个部分，调节外表面以促进湍流气流形式。
3.根据权利要求1所述的方法，其特征在于，其中间隔关系是1.5至3mm。
4.根据权利要求1所述的方法，其特征在于，加压加热空气以230和290℃之间的温度供应。
5.根据权利要求1所述的方法，其特征在于，进一步包括将湍流加热空气冲击在第二元件外表面上用于增强热传递速率，以引发可固化的粘接剂固化。
6.根据权利要求1所述的方法，其特征在于，其中第一元件是汽车车身面板。
7.根据权利要求1所述的方法，其特征在于，其中第二元件是增强结构元件。
8.根据权利要求1所述的方法，其特征在于，其中第一元件是纤维增强塑料A级表面元件。
9.根据权利要求1所述的方法，其特征在于，进一步包括施加脉冲至加压空气。
10.根据权利要求1所述的方法，其特征在于，其中以5至500赫兹的速率施加脉冲至加压空气。
11.根据权利要求1所述的方法，其特征在于，其中所述多个孔在相邻孔间距、孔形状、孔直径或孔向的至少一个属性上变化。
12.根据权利要求11所述的方法，其特征在于，其中所述多个孔至少之一具有不延伸通过所述歧管的中心轴线的孔向。
13.根据权利要求11所述的方法，其特征在于，其中所述多个孔至少之一是槽。
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US5554252A (en) * 1995-01-27 1996-09-10 The Budd Company Hot and cool air bonding apparatus

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US20150367561A1 (en) 2015-12-24
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CN103965792A (zh) 2014-08-06
US9682511B2 (en) 2017-06-20

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