CN106969011A - 吸收高能量的接合结构 - Google Patents

吸收高能量的接合结构 Download PDF

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CN106969011A
CN106969011A CN201610997899.8A CN201610997899A CN106969011A CN 106969011 A CN106969011 A CN 106969011A CN 201610997899 A CN201610997899 A CN 201610997899A CN 106969011 A CN106969011 A CN 106969011A
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depression
component
fastener
assembly
connected structure
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CN106969011B (zh
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托马斯·诺顿
阿曼达·凯·弗莱斯
安东尼·J·格里马
加勒特·桑基·赫夫
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Ford Global Technologies LLC
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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    • F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/02—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread
    • F16B5/0241—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread with the possibility for the connection to absorb deformation, e.g. thermal or vibrational
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Abstract

公开了一种吸收高能量的接合结构。公开一种接合结构和形成所述接合结构的方法。所述接合结构可包括：第一组件，包括形成在其中并具有一定宽度的凹陷；第二组件；粘合剂层，设置在第一组件和第二组件之间；以及紧固件，延伸穿过所述凹陷。所述紧固件可连接所述第一组件和所述第二组件并具有其宽度大于所述凹陷的最小宽度的头部。所述方法可包括在第一组件中形成具有一定宽度的凹陷，将粘合剂涂覆到多个组件中的一个组件并将所述组件进行堆叠。所述凹陷可在两个组件之间形成粘结间隙。可将紧固件插入到所述凹陷中以连接所述组件，其中，所述紧固件具有其宽度大于所述凹陷宽度的头部。所述凹陷可将组件间隔开以提供用于粘合剂的较大的粘结间隙。

Description

吸收高能量的接合结构
技术领域
本公开涉及一种能够吸收高能量的接合结构，例如，包括机械紧固件和粘合剂的接合结构。
背景技术
连接或接合两个组件是许多工业中的常见工艺。例如，在汽车工业中，多个组件(诸如面板)可能需要被连接以形成车辆。存在许多用于接合两个或更多个组件的方法(诸如，机械紧固件、粘合剂或焊接/钎焊)。每种类型的接合可具有优点和缺点。例如，粘合剂通常有利于减小应力集中，但会具有低的剥离性能。相比于粘合剂，机械紧固件/固定件可提供增强的抗剥离性能，但是机械紧固件/固定件是离散的。
发明内容
在至少一个实施例中，提供一种接合结构，包括：第一组件，包括形成在其中并具有一定宽度的凹陷(indentation)；第二组件；粘合剂层，位于第一组件和第二组件之间；紧固件，延伸穿过所述凹陷并接合所述第一组件和所述第二组件，所述紧固件具有其宽度大于所述凹陷的最小宽度的头部。
在一个实施例中，多个凹陷形成在所述第一组件和/或所述第二组件中。在一个实施例中，所述凹陷包括圆形轮廓。在另一个实施例中，所述凹陷为长形沟槽。所述第一组件可以是具有一定板厚的板，所述凹陷可具有小于所述板厚的厚度。所述紧固件的头部的至少一部分可在具有所述板厚的区域中接触所述第一组件。所述第一组件和所述第二组件可由铝或铝合金形成。所述紧固件可以是流钻螺钉。
在至少一个实施例中，提供一种形成接合结构的方法。所述方法可包括：在第一组件中形成具有一定宽度的凹陷；将粘合剂涂覆到第一组件或第二组件；将第一组件和第二组件堆叠，所述凹陷在第一组件和第二组件之间形成粘结间隙；以及将紧固件插入到所述凹陷中以接合所述第一组件和所述第二组件，其中，所述紧固件具有其宽度大于所述凹陷宽度的头部。
所述方法可还包括：在所述第一组件和/或第二组件中形成多个凹陷。在一个实施例中，所述凹陷形成为具有圆形轮廓。在另一个实施例中，所述凹陷形成为具有第一侧和第二侧的长形沟槽。所述第一组件和所述第二组件可由铝或铝合金形成。在第一组件中形成具有一定宽度的凹陷的步骤可包括形成具有平坦底表面的凹陷。将紧固件插入到所述凹陷中以接合所述第一组件和所述第二组件的步骤可包括将紧固件插入到平坦底表面中。所述紧固件的轴可具有比平坦底表面的宽度大的直径。在第一组件中形成具有一定宽度的凹陷的步骤可包括形成具有侧壁的凹陷，将紧固件插入到所述凹陷中以接合所述第一组件和所述第二组件的步骤可包括将紧固件插入到凹陷中，使得在插入期间紧固件接触所述侧壁的至少一部分。所述侧壁可被形成为使得侧壁的宽度从凹陷的顶部到凹陷的底部变窄。在一个实施例中，所述第一组件是金属板，所述凹陷在冲压矫形(stamping restrike)工艺期间形成。所述紧固件可以是流钻螺钉。
在至少一个实施例中，提供一种接合结构，包括：第一组件，包括形成在其中并具有一定宽度的凹陷；第二组件；第三组件；粘合剂层，设置在第一组件和第二组件之间；以及紧固件，延伸穿过所述凹陷，并接合第一组件、第二组件和第三组件，所述紧固件具有其宽度大于所述凹陷宽度的头部。
附图说明
图1是根据实施例的紧固件正在插入到包括具有凹陷的组件的堆叠组件中的示意性截面图；
图2是根据另一实施例的紧固件正在插入到包括具有凹陷的组件的堆叠组件中的示意性截面图；
图3是根据另一实施例的紧固件正在插入到包括具有凹陷的组件的堆叠组件中的示意性截面图；
图4是根据实施例的紧固件部分地插入到包括具有凹陷的组件的堆叠组件中的示意性截面图；
图5是根据实施例的紧固件完全地插入到包括具有凹陷的组件的堆叠组件中的示意性截面图；
图6是根据实施例的紧固件插入到包括具有圆形凹陷的组件的堆叠组件中的俯视图；
图7是根据实施例的紧固件插入到包括具有长形凹陷的组件的堆叠组件中的俯视图；
图8是根据另一实施例的紧固件插入到包括具有长形凹陷的组件的堆叠组件中的俯视图；
图9是根据实施例的紧固件插入到包括具有圆形凹陷和长形凹陷的组件的堆叠组件中的俯视图；以及
图10是用于将具有凹陷的组件连接到一个或更多个其它组件的方法的流程图的示例。
具体实施方式
根据需要，在此公开本发明的详细实施例；然而，应理解，所公开的实施例仅为本发明的示例，本发明可以以各种和替代的形式实现。附图不一定按比例绘制；可夸大或最小化一些特征以显示特定组件的细节。因此，在此公开的具体结构和功能细节不应被解释为限制，而仅作为用于教导本领域技术人员以各种方式利用本发明的代表性基础。
如上所述，粘合剂通常可有利于减小应力集中，但会具有低的剥离性能。已经开发了高韧性的柔性粘合剂(例如，玻璃粘合剂)，其可具有高伸长性能。这些粘合剂通常可在粘结间隙(例如，邻接部件之间的距离)增大时获得韧性。相比于粘合剂，机械紧固件/固定件可提供增强的抗剥离性能，但它们是离散不连续的。
机械紧固件通常需要特定水平的夹紧压力以获得足够的接合性能。当将粘合剂和机械紧固件组合时，这个压力会局部地将粘合剂从被接合的组件下方挤出并在接合的组件之间形成小的粘结间隙。因此，在较大的粘结间隙处产生的增强的粘合剂韧性可能无法实现。
存在许多类型和设计的机械紧固件。在本公开的接合结构(joint)中可使用任何适合的机械紧固件。可在本公开的接合结构中使用的一种类型是流钻螺钉(flow drillscrew,FDS)。可使用的另一类型的紧固件是自攻螺钉。然而，可以结合任何类型的单面连接方法。FDS是依靠摩擦钻穿母材(parent material)从而产生所需的孔和螺纹以将母材和螺钉互锁在一起的单面机械紧固件的示例。这个过程可能需要邻接的部件彼此接触，以将足够的热量传递到所有部件。这通过使用应用工具/枪施加的轴向力来实现。在一些情况中，来自粘合剂和/或来自超差部件的背压可能需要较大的力以实现充分接触。
所公开的接合构造和过程可减少或消除在多种材料的堆叠中设置间隙孔的需要、可协助定位FDS(或其它紧固件，诸如可替代的自攻螺纹机械紧固件)、减少周期时间和/或紧固压力和/或控制粘结间隙并增加粘合剂覆盖。所述接合构造可提供具有制造性和使用稳健性增强以及韧性增强的接合结构。所公开的接合构造/过程可用于接合两种或更多种材料(例如，两个或更多个金属组件)的任何应用中。在一个实施例中，所述构造/过程可用于接合车辆组件，诸如车身面板。
参照图1至图3，示出了接合结构系统30的若干实施例。接合结构系统30可包括待接合的两个或更多个组件32，其可包括第一组件或顶部组件34和第二组件或底部组件36。如果有两个以上的组件，诸如三个、四个或更多的组件32，则它们可被称为第一组件、第二组件、第三组件、第四组件等。组件32可以由可通过机械紧固件(诸如FDS)连接的任何材料形成。在一个实施例中，一个或更多个组件32可由诸如铝、钢、铁或钛的金属形成。在另一实施例中，一个或更多个组件32可由诸如热塑性塑料的聚合物形成。在另一实施例中，一个或更多个组件32可以由例如纤维复合材料(诸如，碳纤维、玻璃纤维、片状模塑料(sheetmolding compound,SMC)或其它)的复合材料形成。组件32可以是任何以上材料的混合。在一个实施例中，两个(或所有的)组件32可由铝或铝合金形成。
至少两个组件32可通过粘合剂38接合，粘合剂38可以是组件之间的层。粘合剂38可以是具有高伸长性能并在粘结间隙增大时具有增强的韧性(例如，吸收能量)的任何粘合剂。在最终接合的两个组件32之间的距离可称为粘结间隙40，其还可对应于粘合剂38的厚度。在组件32之间的大部分区域或大多数区域中，此粘结间隙40可称为组件32之间的距离。可能存在粘结间隙减小的局部区域，例如，在紧固件已经将两个组件拉拽在一起或以其它方式连接两个组件的区域。因此，在紧固件之间或者不包括紧固件的区域中，粘结间隙40可称为组件32之间的距离。平均粘结间隙可描述包括间距减小的区域的粘结间隙，但由于紧固件的面积相比于组件32中未紧固的面积相对较小，因此平均粘结间隙会更接近紧固件之间的粘结间隙。在一个实施例中，平均粘结间隙可以是至少0.05mm。在另一个实施例中，平均粘结间隙可以是至少0.1mm或至少0.2mm。
接合结构30还可由机械紧固件42(诸如，流钻螺钉(FDS)或自攻螺钉)进行接合。如上所述，机械紧固件通常需要特定水平的夹紧压力或向下的压力以获得足够的接合性能。当将粘合剂和机械紧固件组合时，这个压力会局部地将粘合剂从待接合的组件下方挤出，并在接合的组件之间形成小的粘结间隙。因此，在较大的粘结间隙处产生的增强的粘合剂韧性可能无法实现。为了保持或形成较大的粘结间隙40，一个或两个/所有组件32可设置有凹部、凹坑或凹陷44，以当插入紧固件42时防止或阻止组件32之间变得更加靠近在一起或接触。
参照图1至图3，示出了具有不同形状和构造的凹陷44的若干示例。在示出的示例中，顶部组件34具有凹陷44而底部组件36没有。然而，如上所述，可以变换所述构造(顶部组件没有凹陷，底部组件有凹陷)，或者两个组件均可具有凹陷44(处于配合/接触位置或非配合/接触位置)。虽然示出了单个凹陷，但是组件中可形成可间隔开或以特定间隔定位的多个凹陷44。在一个实施例中，可存在对应于每个紧固件42的凹陷44。在另一个实施例中，每个紧固件42可具有对应的凹陷44(多个紧固件42可具有同一个凹陷44)。另外，可存在额外的组件32，其可堆叠在所示出的组件之上、之下或之间。这些组件32可包括或可不包括凹陷44。在一个实施例中，一个、两个或更多个额外的组件32可堆叠在所示出的底部组件36的底下或下方。如果存在额外的组件32，它们可具有位于它们之间的粘合剂层或者它们可以彼此接触和/或与底部组件36接触。
凹陷44可以以任何适合的方式形成。例如，如果组件32是金属组件，可通过冲压操作利用适合的模具来形成凹陷44。在一个实施例中，可在矫形操作期间使用矫形工具来形成凹陷44。这可确保在大部分或所有的其它成形工艺已经发生之后形成凹陷44，使得在紧固件42插入到凹陷44中之前凹陷44的形状或位置不会明显改变。还可使用其它方法(诸如冲压、切削或其它机加工工艺或材料去除工艺)形成凹陷44。凹陷44还可以被铸造到组件中。如果组件是聚合物，则可在注射成型工艺期间形成凹陷44。凹陷44的形成会使凹陷44的材料变薄。例如，如果在冲压或矫形操作期间形成凹陷44，则在所述工艺期间材料会被拉伸并变薄。
凹陷44可具有底表面46和侧壁48。底表面46相对于组件表面(例如，没有凹陷的区域)可以是平坦的或大致为平坦的。底表面46可平行于或大致平行于堆叠中的另一组件。例如，在图1至图3中所示出的凹陷中，顶部组件34中的凹陷44中的底表面46平行于底部组件36。
相比于组件(例如，如图所示的顶部组件34)的大部分，底表面46可具有减小的厚度。这个减小的厚度可促进紧固件42更容易和/或更快地插入。如果使用FDS作为紧固件，则较薄的底表面46相比于组件的较厚的大部分可更快地加热和局部熔化。这可允许使用减小的轴向力和/或允许减少插入FDS的周期时间。侧壁48还可具有比组件的主体(bulk)的厚度减小的厚度，然而，侧壁48厚度减少的程度可比底表面46厚度减少的程度小。然而，侧壁48和/或底表面46还可具有与组件的主体的厚度相同的厚度。
底表面46可具有被构造为等于或小于紧固件42的轴50的直径的宽度或直径。例如，如果FDS具有3mm的轴直径，则底表面46可具有小于3mm的宽度/直径(诸如，从0.5mm至2.5mm)。因此，当紧固件42插入到凹陷44中并穿过底表面46时，轴50可完全地去掉或替代底表面46。因此，在完成的接合结构中，包括凹陷44的组件的底部区域中可不存在变薄的区域。此外，紧固件42的头部52可具有比凹陷44的底表面46的宽度或直径宽或大的直径。
在一个实施例中，紧固件42的头部52可具有比凹陷44自身的尺寸(诸如，最小尺寸)宽或者大的直径。该尺寸可垂直于凹陷44的高度或深度，诸如凹陷的直径或宽度(例如，最小直径或宽度)。或者，它可以是平行于头部直径的任何尺寸。可以在凹陷的顶部(例如，一旦紧固件被插入，与头部52直接相邻)处确定最小尺寸。因此，当紧固件42插入到凹陷44中并穿过底表面46时，紧固件的头部52可接触组件的非凹陷44的一部分的至少一部分。这可允许紧固件42与组件的相对厚的主体部分接触，相比于头部52接触底表面46或侧壁48来说提供更强的接合。
尽管在横截面中示出凹陷44的侧壁48具有左侧和右侧，但凹陷44的侧壁48可以是连续的。侧壁48的宽度可从其顶部朝着底表面46变细或变窄。侧壁48相对于形成凹陷44的组件的主体可以是凹形或凸形。例如，在图1和图2中，侧壁48具有凸曲率。在图3中，尽管侧壁48的顶部具有凸曲率，但侧壁48大体上具有凹曲率。图3还包括位于第一组件34和第二组件36下面的额外的组件32。侧壁48还可具有恒定的或基本恒定的斜坡。例如，侧壁48可以以30°、45°、60°的角度或其它角度朝着底表面向下倾斜。在一些实施例中，侧壁48可沿着凹陷44的圆周或周边变化。例如，在诸如图1至图3中的横截面中，侧壁48的左侧部分可具有30°的角度，右侧部分可具有60°的角度。当然，这两部分可具有上述构造(例如，凹形、凸形、恒定斜坡)的任何组合或其它。此外，侧壁48可具有构造不同的两个以上的部分。
侧壁48可被构造为使得当被插入时紧固件42的尖端54和/或轴50接触侧壁48的至少一部分。例如，侧壁48的相对侧之间的距离可小于轴50的直径或沿着凹陷44的高度的至少一部分小于紧固件的尖端54的至少一部分。因此，在插入期间可确保紧固件42和侧壁48之间的接触。侧壁48可被构造使得尖端54和/或轴50仅接触侧壁48的一部分，或者使得尖端54和/或轴50接触全部或基本全部的侧壁48。例如，如图1至图3中所示，侧壁48可被构造为使得当被插入时紧固件42的尖端54和/或轴50不接触侧壁48的全部高度。在另一个实施例中，可插入紧固件42使得沿着侧壁的全部高度或其大部分的高度尖端54和/或轴50不接触侧壁48的一部分。
已经发现，通过将凹陷44构造为使得在插入紧固件期间在侧壁48和紧固件42(例如，尖端54)之间存在接触，FDS和侧壁48之间的接触可使得所产生的摩擦增加，其产生更多的热。所述增加的热可使被连接的组件中的材料加热并更快成形，减少利用给定的轴向力插入FDS所必需的周期时间。或者，可使轴向力减小，而使周期时间减少较小的程度或保持相同。因此，通过增加紧固件和组件之间的摩擦，可以更快地和/或利用更少的劳动来插入紧固件。由于对每个紧固件所节省的时间进行叠加，因此这可显著减少装配时间。
参照图4和图5，示出了紧固件42正在进入(图4)堆叠的组件32和已完全插入(图5)到堆叠的组件32的接合结构系统30。如图4中所示，在插入期间，紧固件42的轴50可接触凹陷44的侧壁48。紧固件42的尖端54可穿透组件32和粘合剂38。如图5中所示，当轴50的螺纹部分与侧壁48和/或底部组件36接触时，它可在侧壁48和/或底部组件36中形成螺纹64。如下面更详细描述的，紧固件的头部52可延伸超过、超出或外伸出粘合剂层38的至少一部分66，所述至少一部分保持在或接近全厚度(例如，凹陷或粘结间隙的高度)。
凹陷44可具有任何适合的形状(例如，在俯视图中)。参照图6至图9，示出了凹陷形状的一些示例。在图6中示出的一个实施例中，从俯视图(和平行于组件顶表面和底表面的横截面)来看，凹陷44可具有圆形形状。在这个实施例中，凹陷44的直径(例如，它的顶部/最宽处)可小于将被插入的紧固件42的头部52的直径。因此，当插入紧固件时，头部52在全厚度材料的环形区域(例如，非凹陷的部分)中接触组件。这可通过在顶部组件的处于全厚度而不是减少厚度的区域中将组件固定在一起来提高接合结构的强度。
在图7至图8示出的其它实施例中，从俯视图(和平行于组件顶表面和底表面的横截面)来看，凹陷44可具有长形的形状。这些凹陷44可被称为沟槽58并且可具有相对的第一长侧60和第二长侧62。长形沟槽58的形状可以是具有主轴线和副轴线的任何适合的形状。例如，沟槽58可具有卵形或椭圆形的形状，诸如图7中所示。在另一个示例中，沟槽58可具有矩形或圆角矩形的形状，诸如图8中所示。沟槽58的副轴线或宽度(例如，它的顶部/最宽处)可以小于将被插入的紧固件42的头部52的直径。因此，当插入紧固件时，头部52接触组件的至少一部分(例如，非凹陷的一部分)，在所述至少一部分处组件处于全厚度。这可通过在顶部组件的处于全厚度而不是减少厚度的区域中将组件固定在一起来提高接合结构的强度。
不同组件之间的或相同组件内的凹陷44的形状可以不同。例如，在图9示出的组件中，存在圆形凹陷和卵形/椭圆形凹陷。可基于紧固件插入的期望改进来选择凹陷44的形状。例如，圆形(或非长形)的凹陷可在紧固件尖端/轴和凹陷之间提供最多接触。这可提供更高的摩擦，从而产生更多的热并允许紧固件更快且更省力的穿过组件。因此，当减少力或周期时间是高优先级时，可以使用圆形(或非长形)的凹陷。长形或沟槽形凹陷也可在紧固件尖端/轴与凹陷之间提供接触，但由于侧壁不是在所有侧都接触紧固件，因此相比于圆形凹陷，长形或沟槽形凹陷可提供较少的接触。然而，通过增加两个组件之间的支撑(stand-off)的尺寸/长度，长形凹陷可对粘结间隙闭合提供更多阻力。因此，对于长形凹陷，紧固件的夹紧或紧固力可能不会引起粘结间隙闭合或减小(或者闭合或减小程度小于圆形凹陷)。
沟槽58的侧60和62可以相同或者它们可以不同。例如，第一侧60可具有凹侧壁，第二侧62可具有凸侧壁(反之亦然)。类似地，如果侧壁具有大致恒定的角，侧部60和62的角度可以不同。例如，第一侧60可具有60°至85°的相对陡峭的角度，第二侧62可具有20°至50°的相对平缓的角度(反之亦然)。所述侧部还可具有相同的角度，其可以是上述范围中的任一个。在一个实施例中，沟槽可被构造为使得当被插入时紧固件的尖端/轴接触沟槽的两侧。在另一个实施例中，沟槽可被构造为使得当被插入时紧固件的尖端/轴接触沟槽的其中一侧，而不接触另一侧。沟槽还可被构造为使得当被插入时紧固件的尖端/轴接触沟槽的其中一侧的程度比接触另一侧的程度大(例如，更大面积的接触)。可调节沟槽的侧部的构造以在凹陷和紧固件之间提供更多或更少的接触，以增加或减少插入紧固件期间的摩擦和产生的热。在一些例子中，如果存在过多接触(从而摩擦/加热)，对于螺纹来说紧固件(例如，FDS)可能加热和插入过快而不能充分形成螺纹。因此，沟槽壁可被构造为提供引起期望的摩擦量的接触面积，以使紧固件可以被快速插入但仍会在组件中形成螺纹。
除了改进周期时间或减小轴向力之外，凹陷44还可协助紧固件定位和/或增加紧固件插入的公差。凹陷44可作为用于定位/感测系统(诸如，光学识别系统)的目标或标识符。此外，长形的凹陷(例如，沟槽)还可通过在紧固件的放置中允许更大的公差来协助紧固件定位。例如，如果机器人被构造为将紧固件插入沟槽的长轴线的中心中，则机器人放置可在任一方向上偏离大约一半的沟槽长度并且仍然进行可接受的插入。在一些紧固系统中，可能难以在一个轴线上准确地控制或定位紧固件。例如，如果x轴被更好地控制或更准确，则可将沟槽定向为其长轴线位于系统的y轴上。因此，当发现紧固件位置并将紧固件插入沟槽中时，系统可以准确地在x轴上发现沟槽的较窄的副轴线并且将在y轴上增加灵活性或宽恕性(forgiveness)。如果y轴被更好地控制也应用同样的举措(例如，在x轴上定向沟槽)。在一个实施例中，可至少部分地基于用于定位紧固件的设备的公差来确定沟槽长度。例如，沟槽长度可以是紧固件轴直径、轴直径的公差和定位设备的公差的总和。因此，如果轴直径是5mm，轴公差是±1mm，定位设备的公差是±6mm，则沟槽可具有大约19mm(5+2+12)的长度。
可至少部分地通过紧固件轴的直径和/或组件的厚度来确定凹陷宽度。在一个实施例中，凹陷宽度可以与紧固件的轴直径相同或大约相同(例如，±1mm)。因此，当插入紧固件时，紧固件可占有或基本占有凹陷的全部宽度。如上所述，这可确保紧固件的头部(比轴宽)接触组件的保持全厚度(例如，产生凹陷之前的组件的厚度)的至少一部分。除了接触组件的保持全厚度的至少一部分之外，头部可超过或超出粘合剂层的保持在全厚度(例如，粘结间隙的尺寸或凹陷的高度)处或全厚度附近的至少一部分。例如，头部可超过或超出粘合剂层的具有粘结间隙或凹陷厚度的至少50％(诸如，粘结间隙或凹陷厚度的至少60％、75％、85％或至少90％)的厚度的至少一部分。这在图4至图9中示出，其中紧固件的头部52完全覆盖并延伸超过凹陷(例如，图6和图9中的圆形凹陷)或延伸超过长形凹陷(例如，图7至图9中的沟槽)的侧边60和62。待连接的每个组件可包括一个或多个凹陷44。如果存在多个凹陷，则它们可间隔开。
参照图10，示出了用于根据所公开的接合构造连接两个或更多个组件的流程图100。在步骤102中，在待连接的一个或更多个组件中形成一个或更多个凹陷。所述方法将描述两个金属组件的连接，然而，如上所述的其它材料、形状和堆叠尺寸也是可行的。可使用任何适合的方法(诸如，冲压或矫形)来形成凹陷。在步骤104中，可将粘合剂涂覆到待连接的一个组件或两个组件(如果是两个组件，则涂覆在待连接的表面上)。粘合剂可以是韧性随厚度(例如，较大的粘结间隙)增加的高能量/韧性的粘合剂。可以涂覆特定厚度的粘合剂，所述特定厚度可以是期望的最终厚度。
在步骤106中，可以将具有已插入到粘合剂层的凹陷的组件进行堆叠。由此，凹陷可通过接触另一组件并将组件在凹陷之间间隔开而在待连接的部件之间产生并保持粘结间隙。所述粘结间隙可以与涂覆状态的粘合剂层厚度相同或者可以更小。虽然步骤106被示出为在步骤104之后，但可颠倒所述顺序使得堆叠组件(从而产生粘结间隙)并将粘合剂插入在组件之间。所述顺序可取决于粘合剂的粘度、金属组件的尺寸或其它因素。
在步骤108中，如果所述过程是自动化的(例如，使用机器人或检测系统)，则可通过紧固设备来定位凹陷。如上所述，凹陷可作为定位点，使紧固设备更容易地找到用于紧固件插入的期望位置。如前所述，凹陷还可允许在一个方向上有较松或更宽松的公差。可使用现有技术中已知的任何适合的方法(诸如，光学识别)来识别凹陷的位置。或者，可以将位置编程到诸如机器人的设备中。
在步骤110中，可将紧固件插入到凹陷中。可在每个凹陷中插入一个紧固件，或将多个紧固件插入到一个凹陷中。紧固件可以是自攻螺钉或流钻螺钉(FDS)，在这种情况下，插入通常可包括放置螺钉、旋转/加热、熔化/成形、形成螺纹并插入/拧紧。可将紧固件放置为使得它们接触并进入凹陷的底部，所述底部可以是平坦的。如上所述，紧固件在插入时可完全替代底表面。可将紧固件插入使得在插入期间紧固件的尖端/轴接触凹陷的侧壁的一部分或全部。如果期望较大的摩擦，则凹陷可被构造为与紧固件有更大的接触面积，反之亦然。在插入期间，凹陷可防止或减少粘合剂从组件之间挤出，从而保持大的粘结间隙。
如上所述，所述方法可用于连接两个或更多个组件。虽然已经示出和描述了两个或三个组件之间的接合结构，但可将一个或更多个额外的组件添加到堆叠组件中(例如，添加到底部组件以下)。每个额外的组件在接合结构的区域中可以是平坦的或可包括凹陷以与上文类似地在它和另一组件之间产生粘结间隙。所述方法可用于连接可包括面板或板的车辆组件。所述组件可以由金属(诸如，铝(例如，纯铝或铝合金)或钢)形成。例如，两个组件均可以是铝。
所公开的包括具有形成在其中的凹陷的组件的接合构造和方法可提高组件之间接合的强度和/或韧性(例如，能量吸收)。如上所述，使用传统的紧固件进行连接导致粘结间隙挤在一起甚至几乎消除。由于通过高伸长率的粘合剂吸收的能量的量可以与它们的厚度成比例，因此粘结间隙厚度的数倍增加可引起接合结构的韧性的百分之几百的增加。在一个实施例中，由本公开的凹陷形成的粘结间隙可以比相同条件下(例如，同样的粘合剂、同样的紧固件等)没有凹陷的粘结间隙大至少100％。在另一个实施例中，粘结间隙可以比相同条件下没有凹陷的粘结间隙大至少200％、300％、400％或更多。由于接合结构的韧性可以与粘合剂厚度成比例，因此公开的接合结构的能量吸收可以比没有凹陷的接合结构大如上所述的相同的量。
虽然以上描述了示例性实施例，但并不意味着这些实施例描述了本发明的所有可能的形式。更确切地，说明书中使用的词语是描述性词语而不是限制性词语，并且可以理解，在不脱离本发明的精神和范围的情况下，可以进行各种改变。此外，各个实施的实施例的特征可以组合以形成本发明的进一步的实施例。

Claims (11)

1.一种接合结构，包括：
第一组件，包括形成在第一组件中并具有一定宽度的凹陷；
第二组件；
粘合剂层，位于第一组件和第二组件之间；以及
紧固件，延伸穿过所述凹陷并接合所述第一组件和所述第二组件，所述紧固件具有头部，所述头部的宽度大于所述凹陷的最小宽度。
2.根据权利要求1所述的接合结构，其中，在所述第一组件和/或所述第二组件中形成多个凹陷。
3.根据权利要求1所述的接合结构，其中，所述凹陷包括圆形轮廓。
4.根据权利要求1所述的接合结构，其中，所述凹陷为长形沟槽。
5.根据权利要求1所述的接合结构，其中，所述第一组件是具有一定板厚的板，所述凹陷具有小于所述板厚的厚度。
6.根据权利要求5所述的接合结构，其中，所述紧固件的头部的至少一部分在具有所述板厚的区域中接触所述第一组件。
7.根据权利要求1所述的接合结构，其中，所述第一组件和所述第二组件由铝或铝合金形成。
8.根据权利要求1所述的接合结构，其中，所述紧固件是流钻螺钉。
9.一种形成接合结构的方法，包括：
在第一组件中形成具有一定宽度的凹陷；
将粘合剂涂覆到第一组件或第二组件；
将第一组件和第二组件堆叠，所述凹陷在第一组件和第二组件之间形成粘结间隙；以及
将紧固件插入到所述凹陷中以接合所述第一组件和所述第二组件，其中，所述紧固件具有头部，所述头部的宽度大于所述凹陷的宽度。
10.根据权利要求9所述的方法，还包括：在所述第一组件中形成多个凹陷。
11.一种接合结构，包括：
第一组件，包括形成在第一组件中并具有一定宽度的凹陷；
第二组件；
第三组件；
粘合剂层，设置在第一组件和第二组件之间；和
紧固件，延伸穿过所述凹陷并接合第一组件、第二组件和第三组件，所述紧固件具有头部，所述头部的宽度大于所述凹陷的宽度。
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