CN105736536B - 通过直接加热胶合剂胶合机动车辆零件的方法 - Google Patents

通过直接加热胶合剂胶合机动车辆零件的方法 Download PDF

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CN105736536B
CN105736536B CN201410844186.9A CN201410844186A CN105736536B CN 105736536 B CN105736536 B CN 105736536B CN 201410844186 A CN201410844186 A CN 201410844186A CN 105736536 B CN105736536 B CN 105736536B
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adhesive
electromagnetic wave
plastic material
wavelength
wave
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CN105736536A (zh
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弗朗索瓦·维尔雷泽尔
杰罗姆·布里冉
斯蒂芬·格列尔
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All-Resistant Plastics Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种通过直接加热胶合剂胶合机动车辆零件的方法。具体地，提供了一种将塑料材料(MP)的第一零件(1)和第二零件(2)胶合的方法，其中在所述零件(1，2)中的至少一个上面布置至少一个厚度的胶合剂(3)，并且将另一零件(2，1)抵靠在该厚度的胶合剂(3)上，其特征在于：选择至少一种具有给定波长的电磁波，使得所述塑料材料(MP)对该波的透射率不为零，并且使得胶合剂(3)对该波的吸光度不为零；和通过发射穿过所述塑料材料(MP)的所述电磁波，以直接辐射所述胶合剂的方式加热胶合剂(3)的至少一部分，从而激活和/或加速胶合剂(3)交联。

Description

通过直接加热胶合剂胶合机动车辆零件的方法
技术领域
本发明涉及汽车零件的装配领域，尤其是涉及将塑料材料的零件通过胶合装配的领域。
背景技术
在现有技术中已知一种在胶合设备内将两个零件彼此装配的方法。该设备通常包括将两零件之一相对另一零件定位的支撑件，该支撑件包括通常是金属的用于支撑每个零件的两个部分。该设备也包括每个部分的加热装置。通过热传导，每个金属部分加热所支撑的零件。
在将两零件相对彼此定位前，在待装配的两零件之一和/或另一个上应用一个厚度的例如热固性的胶合剂。随后，将两零件拿起并且相对彼此定位。随后，借助加热装置加热零件以激活或加快胶合剂的交联。最后，从该设备中取出装配好的零件。
需要在一定时间内加热零件以激活或加快热固性胶合剂的交联。在这段时间内，所述设备被占用，这构成零件制造过程中的“窝工时间”。现有技术的装配方法因此具有有限的生产能力，该生产能力依赖于所述设备用于装配零件所需的时间周期。
此外，对零件的加热造成较高的能量成本。
另外，所述设备的加热装置使所述设备昂贵并且体积较大。
最后，激活或加快胶合剂的交联是通过加热待胶合的零件而利用传导提供热量来实现的。这样做是由于胶合剂被放在两零件之间因而不可通达。因此不可能直接加热胶合剂。然而，对零件的加热引起：
待胶合的零件的不同膨胀而引起的变形；
外观面的痕迹问题；以及
周期时间大于一分钟，这意味着因需要使用多个胶合装置以保持零件就位所造成的较大产能投资，或者受使用的设备数目限制的产能。
此外，塑料材料不是很好的导热体，如果两个待胶合的零件是塑料材料，该过程会非常的困难。
发明内容
本发明的目的在于提供一种可以改进上述不足的胶合方法。本发明通过使用可以直接加热胶合剂的材料/电磁波组合达到所述目的。
因此，本发明涉及一种将第一零件和第二零件胶合的方法，所述第一零件由塑料材料制成，其中，在所述零件中的至少一个上面布置至少一个厚度的胶合剂，并且将另一零件抵靠在所述厚度的胶合剂上。根据所述方法，选择至少一种具有给定波长的电磁波，使得所述塑料材料对该电磁波的透射率不为零，并且使得所述胶合剂对该电磁波的吸光度不为零；通过发射穿过所述塑料材料的所述电磁波，以直接辐射所述胶合剂的方式加热所述胶合剂的至少一部分，从而激活和/或加速所述胶合剂的交联。
该方法可以通过直接加热胶合剂从而大幅减少周期时间。由此，不需要等待第一个零件被加热并逐渐的将其热量传递到胶合剂。
优选的，选择至少一种电磁波，所述塑料材料对此波的吸光度不为零。
同样优选的，选择至少一种电磁波，胶合剂对此波的透射率不为零。
根据本发明，可以选择具有大于780nm，且/或小于2500nm的波长的电磁波。
根据一实施方式，发射电磁波簇，其中波长在400nm到5000nm之间，优选的在780nm到2500nm之间。
例如可以通过红外线发射器发射电磁波簇。
例如可以通过激光源发射电磁波。
根据一实施方式，将所述电磁波一直发射到这样的程度：在胶合剂的至少一部分交联后，能够在所述两个零件彼此没有相对移动的情况下操作这两个零件构成的整体。
根据本发明，可以在以下材料中选择塑料材料：例如聚烯烃或者热塑性苯乙烯或聚酰胺的热塑性材料，热固性材料，硅酮。
根据本发明，可以在以下胶合剂中选择胶合剂：聚氨酯，环氧树脂，甲基丙烯酸酯，氰基丙烯酸酯。
根据一实施方式，使用包含染料的塑料材料，染料被选择为使其对穿过所述染料的电磁波的透射率不为零。
根据一实施方式，在放置第二个零件前将两零件中的至少一个预热，并且根据被这样预热的第一零件的温度来选择电磁波。
本发明还涉及一种用于胶合第一零件与第二零件的胶合设备，所述第一零件由塑料材料制成，该设备包括：
将所述两个零件中的一个相对另一个定位的支撑件；以及
将至少一种电磁波输送穿过所述塑料材料的至少一个输送装置。
有利的，输送装置可以适于发射波长包括在400nm到5000nm之间的电磁波，优选的波长在780nm到2500nm之间。
最后，输送装置可以包括至少一个红外线发射器和/或红外线灯和/或激光源。
附图说明
参考附图1至3可以更好的理解本发明，所述附图作为实例且不具有任何限制性特征，并且该附图描述了根据本发明的方法。
图1示意性地示出了根据本发明方法的第一步骤。
图2示意性地示出了根据本发明方法的第二步骤。
图3示意性地示出了根据本发明方法的第三步骤。
具体实施方式
现在参考附图1至3，所述附图描述了根据本发明的用于将由塑料材料MP制成的第一零件1与第二零件2胶合的方法。该方法包括以下步骤：
-如图1所示，在所述零件1、2中的至少一个上面布置至少一个厚度的胶合剂3；将两零件1、2装配所需的胶合剂的量称为“厚度”，而不管该量的形状和厚度(条，膜，堆等)；
-如图2所示，将另一个零件2、1抵靠在所述厚度的胶合剂3上；
-挑选至少一个具有给定波长的电磁波，使得所述塑料材料MP对该波的透射率不为零，并且使得胶合剂3对该波的吸光度不为零；以及
-如图3所示，通过发射穿过所述塑料材料MP的所述电磁波，以对其辐射的方式加热胶合剂3的至少一部分，从而激活和/或加快胶合剂3的交联。
将由一组聚合物构成的材料称为“塑料材料”。已知例如热塑性材料(基于苯乙烯、聚酰胺和/或如聚丙烯的聚烯烃等材料)、热固性材料(基于乙烯基树脂、环氧树脂等)又或者硅酮。
根据本发明，塑料材料可以由带有添加物(炭黑，滑石等)的树脂构成且/或通过例如玻璃纤维或碳纤维的增强成分增强。
所述两个零件可以是塑料材料的，可以是相同的塑料材料，或者是不同的塑料材料。
在汽车工业中，已知使用特定的胶合剂用来胶合塑料材料的零件。因此，在本发明范围内，可以使用例如聚氨酯、环氧树脂、甲基丙烯酸酯、和/或氰基丙烯酸酯(cyanoacrylate)胶合剂的胶合剂3。这些胶合剂可以是单一成分的胶合剂(这类胶合剂在例如湿气的外部因子作用下交联)，一成分包括“封装(encapsulé)”的第二成分的胶合剂，两成分混合在一起的胶合剂，和/或可热激活的胶合剂。
在两个零件1、2中的至少一个上面布置至少一个厚度的胶合剂3后，将另一个零件2、1抵靠在该厚度的胶合剂3上，然后激活或加快胶合剂3的交联。
根据本发明，为了激活和/或加快胶合剂3的交联，以对其辐射的方式加热胶合剂3的至少一部分。
借助输送装置4通过发射穿过塑料材料MP的电磁波实现对胶合剂的辐射。
该电磁波被选择为至少部分地直接辐射胶合剂，以便直接加热胶合剂，而不是通过热传导，也就是说不通过以下方式：“加热第一零件，第一零件随后传递其热量”。“直接辐射胶合剂”指的是穿过塑料材料的电磁波的一部分直接到达胶合剂，用来以热的形式带给胶合剂能量。
为此，选择至少一个具有给定波长的波，使得该波在塑料材料MP中的透射率不为零，并且使得胶合剂对该波的吸光度不为零。
介质的吸光度度量了该介质对穿过其的电磁波的吸收能力。介质的透射率(或透射比)被定义为吸光度的逆。因此涉及穿过该介质的通量部分。对于可见光，我们称其为透明度。
通常使用分光光度计来测量这两个性质，该分光光度计提供与穿过介质的通量部分相对应的百分比(透射率)或与被介质吸收的通量部分相对应的百分比(吸光度)。根据所研究的材料的性质的不同，根据分析时所用波长的不同，以及根据在被穿过的介质中该材料厚度(或浓度)的不同，吸光度和透射率是不同的。
因此，无论使用何种测量方法，都将选择具有给定波长的波，该波具有所选的塑料材料MP和所选的胶合剂3、以及第一零件1的厚度和用于胶合的胶合剂厚度所需的吸光度及透射率性质。
当然，在验证了针对胶合操作所需厚度各性质一致的前提下，可以从不同的厚度中进行选择或进行外推(extrapoler)。
在整个说明书中，塑料材料MP的透射率和吸光度的确定与第一零件1的厚度有关，并且胶合剂3的透射率和吸光度的确定与胶合剂条的厚度有关。
优选的，不选择会完全被塑料材料透射的波。实际上，如果选择一种塑料材料MP也可以吸收(吸光度不为零)的波，则可以加热第一零件1，因此通过传导现象也加热了胶合剂(被加热的零件加热了胶合剂)。这一方面利于加快对胶合剂的加热，另一方面利于将胶合剂保持在交联的温度。
此外，优选的，不选择会完全被胶合剂吸收的波。实际上，如果选择一种也能透过胶合剂(透射率不为零)的波，则该波可以到达第二零件2，因此能够加热胶合剂3的整个厚度。从而使胶合剂得到均匀的加热，避免只加热了胶合剂的上层。
针对汽车工业领域内使用的塑料材料和胶合剂，可以轻易的满足这些关于透射率和波长的要求。本领域技术人员因此能够容易的选择一个或多个合适的波长。尤其是，可以参考例如“R.Klein,Laser Welding of Plastic,Wiley-VCH,p.55,64”的著作，在其中对于不同塑料材料，提供了为波长函数的透射率曲线或吸光度曲线。
对于汽车工业中使用的所有塑料材料和所有胶合剂，这样的曲线也可以通过例如分光光度计容易的得到。
此外，本领域技术人员能够进行试验-误差类实验计划，以根据激活和/或加快所述厚度的胶合剂3的交联反应所需的能量来确定最优的波长。
事实上，根据应用所需的塑料材料MP、该材料MP可能有的添加物、零件1的厚度、胶合剂3以及该胶合剂的厚度，本领域技术人员能够选择一个或多个所需波长、待提供的功率、以及照射时间。此外，本领域技术人员挑选适于该应用的输送装置4的类型。
因此，作为非限定的实例，对于400W功率的激光头和40×40cm2的辐射面积，3mm厚的聚丙烯(PP GFL 40％)第一零件1，20cm2的胶合剂面积(长20cm且宽1cm)以及5mm的胶合剂厚度，可以选择这样的电磁波：零件1内的塑料材料MP对该波的透射率大于10％，优选的大于20％，并且胶合剂厚度中的胶合剂3对该波的透射率小于90％，优选的小于50％。根据该实例，可以选择大约940nm的波长。
因此，根据一实施例，使用波长大于780nm的电磁波。这些波非常适合与上述胶合剂组合使用的上述塑料材料。
根据另一实例，使用波长小于2500nm的电磁波。这些波非常适合与上述胶合剂组合使用的上述塑料材料。
因此，根据尤其适于汽车工业中所使用的材料的实施例，使用具有大于780nm且小于2500nm的波长的电磁波。
根据一实施方式，发射电磁波簇(波段)，其中每个波长均符合针对塑料材料和胶合剂的透射率及吸光度所规定的限制。优选的，这些波具有在400nm到5000nm之间(优选的在780nm到2500nm之间)的波长。
这类电磁波特别属于近红外线(或短红外线)区域。可以通过例如红外线灯的红外线发射器发射该电磁波簇。
当更希望使用单一波长时，优选的使用激光源。
根据一实施方式，不一直辐射胶合剂直到胶合剂完全交联。事实上，将电磁波一直发射到这样的程度：在胶合剂3的至少一部分交联后，可以在两零件彼此没有相对移动的情况下操作这两个零件构成的整体。
这允许加快生产的周期时间，胶合剂在窝工时间内(例如在转移到后续工位的时间内或储存的时间内)完成交联。
根据另一实施方式，当希望将第一零件染色时，那么选择染料使其对穿过所述染料的波的透射率不为零，并且使用包含所述染料的塑料材料MP，或将该染料添加到现有的塑料材料中。
根据另一实施方式，在放置第二零件2前预热零件1、2中的至少一个。
本发明还涉及塑料材料MP制成的第一零件1和第二零件2的胶合设备。该设备包括：
-将两零件中的一个相对另一个定位的支撑件；以及
-将至少一种电磁波输送穿过所述塑料材料MP的至少一个输送装置。
输送装置优选的适于发射波长在400nm到5000nm之间(优选的在780nm到2500nm之间)的电磁波。
输送装置包括至少一个红外线发射器和/或红外线灯和/或激光源。
使用红外线灯的一个优势在于，相较光子垂直指向表面的激光，红外线灯可以使所提供的热量更好地分布。

Claims (18)

1.一种将第一零件(1)和第二零件(2)胶合的方法，所述第一零件(1)由塑料材料(MP)制成，其中，在所述零件(1，2)中的至少一个上面布置至少一个厚度的胶合剂(3)，并且将另一零件(2，1)抵靠在所述厚度的胶合剂(3)上，其特征在于：
选择至少一种具有给定波长且波长大于780nm的电磁波，使得所述塑料材料(MP)对该电磁波的透射率不为零，并且使得所述胶合剂(3)对该电磁波的吸光度不为零；和
通过发射穿过所述塑料材料(MP)的所述电磁波，以直接辐射所述胶合剂的方式加热所述胶合剂(3)的至少一部分，从而激活和/或加速所述胶合剂(3)的交联。
2.根据权利要求1所述的方法，其中，选择至少一种电磁波，所述塑料材料(MP)对此波的吸光度不为零。
3.根据上述权利要求中任意一条所述的方法，其中，选择至少一种电磁波，所述胶合剂(3)对此波的透射率不为零。
4.根据权利要求1或2所述的方法，其中，所述电磁波具有小于2500nm的波长。
5.根据权利要求1或2所述的方法，其中，发射电磁波簇，其中电磁波的波长在400nm到5000nm之间。
6.根据权利要求5所述的方法，其中，电磁波的波长在780nm到2500nm之间。
7.根据权利要求1或2所述的方法，其中，通过红外线发射器发射电磁波簇。
8.根据权利要求1或2所述的方法，其中，通过激光源发射所述电磁波。
9.根据权利要求1或2所述的方法，其中，将所述电磁波一直发射到这样的程度：在所述胶合剂(3)的至少一部分交联后，能够在所述两个零件(1，2)彼此没有相对移动的情况下操作这两个零件构成的整体。
10.根据权利要求1或2所述的方法，其中，在以下材料中选择所述塑料材料(MP)：热塑性材料，热固性材料，硅酮。
11.根据权利要求10所述的方法，其中，所述热塑性材料为聚烯烃或热塑性苯乙烯或聚酰胺。
12.根据权利要求11所述的方法，其中，所述聚烯烃是聚丙烯。
13.根据权利要求1或2所述的方法，其中，在以下胶合剂中选择所述胶合剂(3)：聚氨酯，环氧树脂，甲基丙烯酸酯，氰基丙烯酸酯。
14.根据权利要求1或2所述的方法，其中，使用包含染料的塑料材料(MP)，选择染料使其对穿过所述染料的波的透射率不为零。
15.根据权利要求1或2所述的方法，其中，在放置所述第二零件(2)前预热所述零件(1，2)中的至少一个，并且根据被这样预热的第一零件的温度选择电磁波。
16.一种用于胶合第一零件(1)与第二零件(2)的胶合设备，所述第一零件(1)由塑料材料(MP)制成，其特征在于，该设备包括：
将所述两个零件中的一个相对另一个定位的支撑件；以及
将至少一种电磁波输送穿过所述塑料材料(MP)的至少一个输送装置,
所述输送装置适于发射波长在400nm到5000nm之间的电磁波。
17.根据权利要求16所述的设备，其中，所述输送装置适于发射波长在780nm到2500nm之间的电磁波。
18.根据权利要求16所述的设备，其中，所述输送装置包括至少一个红外线发射器和/或红外线灯和/或激光源。
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