CN107400465A - 用于金属和复合材料组件的混合粘合剂系统 - Google Patents

用于金属和复合材料组件的混合粘合剂系统 Download PDF

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Publication number
CN107400465A
CN107400465A CN201710348755.4A CN201710348755A CN107400465A CN 107400465 A CN107400465 A CN 107400465A CN 201710348755 A CN201710348755 A CN 201710348755A CN 107400465 A CN107400465 A CN 107400465A
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China
Prior art keywords
component
adhesive
strength
metal
intensity
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CN201710348755.4A
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English (en)
Inventor
艾伦·乔治·德里
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Ford Global Technologies LLC
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Ford Global Technologies LLC
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Abstract

一种金属或复合材料部件组件包括第一金属或复合材料部件、第二金属或复合材料部件、以及粘合剂层，粘合剂层设置在第一部件和第二部件的交界面上并且粘合第一部件和第二部件。粘合剂层包括快速固化的低强度粘合剂和高强度结构粘合剂。

Description

用于金属和复合材料组件的混合粘合剂系统
技术领域
本公开涉及施加于金属和/或复合材料部件以形成组件的粘合剂的组合以及制造所述组件的方法。
背景技术
减少制造周期时间一直是汽车行业的长期目标。然而，实现约60秒的快速周期时间对于适于承重应用的结构部件和组件仍然是一个挑战。通常，这种组件是由各种部件焊接而来。用于承重应用的金属部件的替代粘合剂接合需要多条生产线、保持夹具和大型工艺清单。因此，一个部件的生产周期时间从几个小时到几个月。
发明内容
公开一种生产金属或复合材料部件组件的方法。组件包括第一金属或复合材料部件、第二金属或复合材料部件、以及粘合剂层。粘合剂层设置在第一部件和第二部件的交界面上并且粘合第一部件和第二部件。粘合剂层包括快速固化的低强度粘合剂和高强度粘合剂。高强度粘合剂可在比快速固化粘合剂更高的温度下固化。高强度粘合剂可比快速固化粘合剂固化慢。快速固化粘合剂可设置在层内彼此间隔开的多个区域中。至少一个区域的直径可约为10mm。多个区域可表示约10％的粘合剂层表面区域。快速固化粘合剂可在施加于环境温度下约10秒内，以根据ISO 6922测量的约为6.9MPa的拉伸强度粘合第一部件和第二部件。高强度粘合剂可具有大于30MPa的后固化拉伸强度。第一部件和第二部件中的至少一个可包括钢。
在另一个实施例中，公开一种金属或复合材料组件。组件可包括具有结构接触区域和端部的第一构件、以及第二构件。第二构件可通过在第一构件的端部和第二构件之间由快速固化的低强度粘合剂形成的第一粘合部粘合地接合到第一构件。此外，第二构件可通过在第一构件的结构接触区域和第二构件之间由高强度粘合剂形成的第二粘合部粘合地接合到第一构件。组件可是悬挂构件组件。第一构件和第二构件可包括相同的金属。至少第一构件可包括碳纤维复合材料。高强度粘合剂可比快速固化的低强度粘合剂固化慢。
在另一个实施例中，公开一种用于形成金属或复合材料组件的方法。方法可包括将快速固化的低强度粘合剂和高强度粘合剂施加到第一部件、第二部件或两者。方法可进一步包括将第二部件按压到第一部件上以形成组件。此外，方法可包括从嵌套中移除组件，使得快速固化的低强度粘合剂提供足够的粘性以使第一部件和第二部件保持接合，至少直到高强度粘合剂在从嵌套移除组件之后固化。与过程所需的时间相关的周期时间可小于60秒。方法可进一步包括在施加快速固化的低强度粘合剂之后约10秒内从嵌套移除组件。高强度粘合剂可是慢固化或高温固化粘合剂。方法可进一步包括将高强度粘合剂在烘箱中在约160℃的温度下固化约20至60分钟。方法还可包括将快速固化的低强度粘合剂施加到多个目标区域，其足够大以在组件从嵌套中移除之后提供非蠕变、非压裂的粘合。
附图说明
图1A到图1E示意性地描绘根据一个或多个实施例的用于实施不同粘合剂的组合生产示例性金属或复合材料部件组件的一系列制造步骤；
图2A和图2B描绘具有用两种类型粘合剂覆盖的表面的部件的示意性俯视图；
图3A描绘根据一个或多个实施例的具有多个单个构件接合的示例性座椅靠背组件的透视图；
图3B和图3D示出图3A的示意性轮廓截面图；
图3C示出图3B的详细截面图；
图3E示出图3D的详细截面图；
图4描绘具有粘合地接合到座椅结构的多个加强支架的示例性座椅结构的透视图；
图5示出了用于汽车应用的具有粘合地接合的加强板的示例性加强支架的透视图；
图6示出了粘合地接合到下侧加强件的示例性前缘冲压件的透视图。
具体实施方式
在本文中描述本公开的实施例。但是应了解，所公开的实施例仅是示例且可以各种及替换的形式体现。附图不一定按比例；一些特征可能被夸大或最小化以示出特定部件的细节。因此，本文公开的特定结构和功能性细节不应理解为限制，而仅作为用于教导本领域技术人员如何以不同方式采用本公开的代表性基础。如本领域技术人员将了解，参照任何附图所示出和描述的各种特征可与在一个或多个其他附图所示的特征结合以产生未详细示出或描述的实施例。所示的特征的组合为典型应用提供代表性的实施例。然而，对于特定应用或实施方式，可以期望与本发明的教导一致的特征的各种组合和修改。
除非另有明确说明，否则在描述本公开的最广泛范围的本说明书中所有数字量表示尺寸或材料性能应被理解为被修改为“约”。
首字母缩略词或其他缩写的第一个定义适于本文中相同缩写的所有后续用途，并且比照适于初始定义的缩写的正常语法变体。除非另有明确说明，否则属性的测量由与之前或之后相同属性相同的技术确定。
详细参考发明人已知的本发明的组合物、实施例和方法。然而应了解，所公开的实施例仅仅是可以各种和替代形式体现的本发明的示例。因此，本文公开的具体细节不应被解释为限制，而是仅作为教导本领域技术人员各种应用本发明的代表性基础。
适于本发明的一个或多个实施例的给定目的的一组或多类材料的描述意味着该组或类的任何两个或更多个成员的混合物是合适的。化学术语中成分的描述是指在添加到描述中指定的任何组合时的组分，并且不一定排除混合物中混合的组分之间的化学相互作用。首字母缩略词或其他缩写的第一个定义适于本文中相同缩写的所有后续用途，并且比照适于初始定义的缩写的正常语法变体。除非另有明确说明，否则属性的测量由与之前或之后相同属性相同的技术确定。
快速周期时间，定义为部件通过制造阶段所需的时间，其在大多数行业中是合意的，并且汽车行业也不例外。然而，加速周期时间的识别方法对于诸如承重金属组件的某些组件肯能存在挑战。通常，某些金属组件的周期时间可能与每周一个组件或每月一个组件一样缓慢。这样缓慢的周期时间进而需要更大的存储容量、多条生产线、大量的进程内库存，并且限制生产量。
通常，包括结构构件的金属组件通过焊接接合，这为组件提供足够的结构完整性。但焊接存在许多缺点，例如由于焊接应力、工艺的热要求、以及焊接操作的整体高复杂性造成的形状偏差。此外，为焊接组件的铆接或螺纹连接提供可靠的腐蚀保护和维护可能会带来挑战，特别是在潮湿的环境中。因此，已开发接合金属冲压零件的替代方法。替代方案中包括通过粘附接合车辆部件和子组件的方法。然而，大多数粘合剂需要间隙宽度，并且在粘合剂以允许处理、运输、机械加工等的足够强度接合单个构件之前具有长固化时间。结构上适于承重应用的粘合剂的长固化时间因此延长周期时间。另一方面，相对较快固化的粘合剂通常无法提供足够的疲劳强度性能。此外，保持待接合构件的复杂夹紧系统经常设置到位以保持各个构件直到粘合剂固化。
已提出粘合剂的各种组合来接合结构构件。例如，在300℃至400℃的温度下固化的热熔粘合剂和室温固化粘合剂在美国专利3,971,688中公开。热熔粘合剂提供初始粘合，并且室温固化粘合剂提供高强度粘合。然而，组件在室温下经过一段时间缓慢地固化。因此，周期时间长，并且需要夹紧以在组件完全固化之前提供足够的压力。
因此，需要一种产生用于具有小于60秒的周期时间的承重、冲击承载应用的部件组件的方法。此外，期望提供一种不需要复杂固定装置和夹具来保持组件的方法，这将进一步缩短周期时间，因为不必安装夹具以及随后从组件中移除。进一步期望提供一种完全自动化的方法，这将消除对任何手动干预的需要。
根据一个或多个实施例，公开一种解决上述一个或多个问题的方法。该方法呈现具有双重粘合剂系统的混合方法。第一粘合剂是快速固化低强度粘合剂。第二粘合剂是高强度粘合剂。两种粘合剂都施加于一个或多个待接合的部件。快速固化粘合剂在室温下活化并且以足够的粘性/足够的强度接合部件，以允许部件作为生坯组件(green assembly)从组装嵌套(assembly nest)中移除。然后将生坯组件放置在烘箱中，其中高强度粘合剂在几分钟内以足够的强度固化，以使组件适合于承重、冲击承载应用。从嵌套内的第一部件的放置到从嵌套移除生坯组件的操作的周期时间在60秒内。然后在几分钟内生产固化的组件。
第一粘合剂是指快速固化的低强度粘合剂。快速固化、迅速固化或迅速粘合涉及第一粘合剂，其达到足以使生坯组件从嵌套运输、重新定位和以其他方式处理生坯组件的粘合。迅速固化或迅速粘合可能意味着所获得的粘合强度为粘合剂理论上可达到的粘合强度的约10％、20％、30％或更多。例如，快速固化表明快速固化的低强度粘合剂可在施加到表面后约10秒内迅速固化。
在将第一粘合剂施加到表面之后，固化可在1至60秒、2至10秒、20至45秒内完成。或者，固化速率可达240秒或以上。固化速率是依赖于衬底的并且涉及达到0.1N/mm2的剪切强度所需的时间。例如，第一粘合剂可在复合材料衬底上在1秒至2秒内固化，而在第一金属衬底上为2秒至10秒，或在具有与第一金属组分不同的第二金属衬底上为20至45秒。固化速率可进一步取决于粘合间隙、相对湿度等、或条件的组合。为加速固化速率，可将活化剂施加到待粘合的表面。活化剂可是基于丙酮的。
固化可通过各种方法，例如热、压力、UV光、水分等、或其组合引发。第一粘合剂可在约50％的湿度下在约18℃至25℃(68°F至77°F)的环境温度下固化。第一粘合剂可在约1.01325巴(14.7psi)的环境压力下固化。或者，第一粘合剂可在更低或更高的温度、湿度和/或压力下固化，使得发生生产的区域的温度、湿度和/或压力引发和/或能够使第一粘合剂固化。适于将第一粘合剂施加到表面的温度可为环境温度或不同的温度。
低强度粘合剂涉及根据ISO 6922测量的具有约0.5MPa至24MPa或以上、2MPa至10MPa或以上、或5MPa至7MPa或以上的较低拉伸剪切强度的第一粘合剂。还设想小于约0.5MPa的拉伸强度。低强度粘合剂可以在上述范围内(根据ISO 6922测量的约0.5MPa至24MPa或以上、2MPa至10MPa或以上、或5MPa至7MPa或以上)的拉伸强度将第一部件和第二部件接合以提供足够的粘性，使得能够从嵌套中移除接合的第一部件和第二部件。足够的粘性是指这样的拉伸剪切强度：其在施加低强度粘合剂后约10秒内能够处理和/或运输接合的部件。
第二粘合剂可为高强度结构粘合剂，其经设计为在各种衬底之间提供足够强的粘合以承载结构负荷，例如具有大于约24MPa至90MPa或以上、30MPa至80MPa或以上、40MPa至50MPa或以上的后固化拉伸剪切强度以及1400MPa或以上的杨氏模量的结构负荷。与第一粘合剂一样，第二粘合剂可通过各种方法，例如热、压力、UV光、水分等或其组合引发。
在至少一个实施例中，第二粘合剂可为高温固化粘合剂。第二粘合剂因此可在比第一粘合剂更高的温度下固化。然而，第二粘合剂的固化所需的温度低于会导致第一粘合剂破坏的温度。或者，第二粘合剂的固化温度可导致第一粘合剂的至少部分破坏。第二粘合剂可在约100℃至300℃(212°F至572°F)、120℃至250℃(248°F至482°F)、150℃至190℃(302°F至374°F)的温度下固化。可设想更高或更低的固化温度。合适的施加温度可为上述环境温度或约20℃至50℃(68°F至122°F)或以上之间的温度。
第二粘合剂可能需要比第一粘合剂更长的固化时间。例如，第二粘合剂可在约1至60分钟、约5至50分钟、约10至30分钟内固化。或者，第二粘合剂可固化超过60分钟，例如长达约24小时。然而，理想的情况是整个组件在几分钟内固化，使得组件在公开的固化时间内实现足够的强度以便立即处理、运输和进一步制造。
第一粘合剂和第二粘合剂可为单组分或双组分粘合剂。虽然第一粘合剂和第二粘合剂的组分不同，但是第一粘合剂和第二粘合剂可基于相同或不同类别的化学品(例如，环氧树脂、如甲基丙烯酸酯的丙烯酸酯、如氰基丙烯酸乙酯的氰基丙烯酸酯、硅酮等或其组合)。至少一种粘合剂可为溶剂型的或者是无溶剂的。粘合剂可包括添加剂，例如增粘树脂如松香及其衍生物；萜烯和改性萜烯；脂族、脂环族和芳族树脂等或其组合。粘合剂还可包括增塑剂，例如苯甲酸酯，其包括1,4-环己烷二甲醇二苯甲酸酯、三苯甲酸甘油酯或季戊四醇四苯甲酸酯、邻苯二甲酸酯、石蜡油、聚异丁烯、氯化石蜡等、或其组合。粘合剂可包括颜料，其可用作用于质量控制的视觉辅助。对于用于各种粘合剂的不同颜料，在视觉评估粘合剂应用的程度时可能是有帮助的。
可通过本文所述的方法接合的部件可是金属或另一种高强度材料。待接合的示例性金属可是具有或不具有诸如锰、硅、镍、钛、铜、铬、和铝的合金元素的金属。示例性的金属可包括各种类型和等级的钢或铝。方法能够接合不同类型的金属，否则其可能难以接合，例如不同的铝合金或不同的钢种。此外，方法允许聚合物与金属直接接合，其为不同部件的材料选择提供进一步的多功能性。高强度材料可包括纤维加强复合材料或其它精设计用于提供重量减轻同时增加材料的刚度、改善耐疲劳性、耐化学性等的材料。虽然碳纤维是由于高强度与重量比和刚度与重量比而合适的加强材料，但也设想其它类型的纤维。其它合适的纤维可包括芳族聚酰胺纤维、玻璃、玄武岩、天然纤维如棉花等或其组合。复合材料内纤维的体积可达到60％至70％。复合材料可为热塑性的或热固性的。热固性材料可包括聚酯树脂、乙烯基酯环氧树脂、酚醛树脂、聚氨酯、聚酰胺、聚酰亚胺、硅酮、或其它类型的树脂及其组合。设想通过热、照射、或通过化学反应诱导时不可逆地固化的任何其它塑料。示例性材料可包括玻璃加强尼龙或棉纤维加强尼龙。高强度材料可包括具有高达约400KSI(400,000PSI)拉伸强度并且潜在地具有其它有益性能如低重量、低密度、高耐腐蚀性、低成本等或其组合的材料。
部件可包括上述的一层或多层金属片或其他材料。部件可具有各种尺寸、形状和配置。组件的尺寸可在每个部件上不同。本文所述的双重混合粘合剂系统特别适于接合冲压的金属片部件或其他具有足够大的表面积的部件以与其它部件的表面区域接触并重叠，使得整个接触区域具有足够的粘合剂接合尺寸。当单个部件或至少其待粘合地接合的部分彼此直接接触时，这是特别有利的。例如，第一部件可嵌套在第二部件或第一部件的轮廓内，并且第二部件可相对于彼此大致平坦地布置。
待粘合地接合以形成组件的部件可通过各种技术来制备，例如弯曲、卷曲、解卷积、拉伸、液压成型、增量成型、熨烫、激光切割、压制机成型、冲压、辊轧成型、轧制、旋转、冲压、水射流切割、轮式或其组合。
如图1A所描绘，方法包括将快速固化的低强度粘合剂10施加到第一部件12上的步骤。高强度粘合剂14以与第一粘合剂10相同或不同的时间施加。为减少周期时间，同时施加粘合剂10、14可能是有益的。但是，如果施加粘合剂的区域相对较大，则同时施加可导致快速固化粘合剂10的过早固化。因此，在施加快速固化粘合剂10之前，在至少一些实施例中施加高强度粘合剂14可能是有益的。粘合剂10、14可形成层16。层16可为连续的或不连续的。层16可包括间隙。
如图1B所示，方法进一步包括将第二组件18施加于层16上。图1C公开使用多于两个部件的替代实施例。虽然图1C描绘了三个单个部件，但是可设想多达10个或更多部件的多层组件。在这样的实施例中，至少第三部件20经由包括第一粘合剂10和第二粘合剂14的附加层16连接到第一部件12和第二部件18。在将附加的部件放置在粘合剂层16上之后，将压力施加到部件上，以确保与粘合剂10、14接合的部件表面被完全润湿或覆盖。应该以这样的力施加压力并且在这样的角度下施加，以便在粘合剂层16中不存在剪切应力的情况下提供完全密度的粘合线。压力可临时施加，同时部件在嵌套24内并且随后在快速固化粘合剂10固化之后释放，使得不必对部件施加附加的压力。嵌套24涉及开顶区域，其中各个部件相对于彼此定位，使得组件被构建。或者，可在后续处理和固化炉28中施加压力。待施加的压力量取决于多种因素，例如使用的材料、部件的尺寸和形状、压缩长度等或其组合。例如，可施加到部件上的压力可为约0.1MPa至约100MPa。设想较低和较高的压力。在至少一个实施例中，在整个过程中，组件不暴露于比环境压力更高的压力。
例如，为降低与该过程相关联的成本，可在没有任何自动化的情况下执行整个过程或其部分。或者，过程的至少一部分可是自动化的。组件可由一个或多个机械手施加。粘合剂可由一个或多个机械手22机械地施加，其经编程为以各种模式施加粘合剂。机械手22可配备有粘合剂供给装置以及具有能够施加粘合剂的施加器的臂。或者，可手动施加粘合剂。一个或多个粘合剂10、14可施加到每个部件12、18、20。或者，至少一个粘合剂10或14可仅施加到部件12、18、20中的一些。例如，粘合剂10、14二者可施加到第一部件12，并且不将粘合剂施加到第二部件18。在另一实施例中，第一粘合剂10可施加到第一部件12，并且第二粘合剂14可施加到第二部件18。或者，不将粘合剂施加到第一部件12和第三部件20，同时将第一粘合剂10和第二粘合剂14施加到第二部件18的表面，使得要与第一部件12和第三部件20接合的每个表面含有粘合剂10、14。
在对部件施加压力之后，快速固化粘合剂10将准备就绪并开始其固化过程，同时高强度粘合剂14保持其未活化或惰性状态。方法进一步包括一旦快速固化粘合剂10固化，就从嵌套24中移除正在形成生坯组件26的部件12、18、20。由于快速固化粘合剂10提供足够强的粘合以接合用于处理和/或运输的部件12、18、20，所以可将生坯组件26从嵌套24中移除，这可以用于形成下一个组件。因此，方法包括从第一部件12放置在嵌套24内起约30秒、40秒、50秒、60秒、70秒、80秒、90秒、120秒、240秒或更多秒内从嵌套24移除生坯组件26。生坯组件26能够在放置到烘箱28之前经过多个过程而不分离成单个部件12、18、20。
方法包括将生坯组件26放置在烘箱28中，其在图1D中示意性地描绘。烘箱28可为能够固化高强度粘合剂14的任何加工烘箱。例如，烘箱28可为通常在接合部件通过的处理期间常用的油漆烘箱。因此，利用已经存在的生产线步骤完成生坯组件26的固化，而不必提供专门设计用于固化的另一个烘箱。然而，在高强度粘合剂14达到足够的强度以粘合这些部件之前，高强度粘合剂14的固化温度不应该足够高以致消除快速固化粘合剂10的结构完整性。方法包括将生坯组件26保持暴露于期望的升高的固化温度一段时间，其足以为承重应用提供足够强度的粘合。时间段根据所使用的高强度粘合剂14的类型而不同。时间段可为约1、2、3、4、5、6、7、8、9、10、15、20、25、30、35、40、45、50、55、60分钟、2、3、4、5、6、7、8、9、10、15、20小时或以上。一旦高强度粘合剂14固化，生坯组件26变成固化组件26'。在至少一个实施例中，设想将固化的组件26'在烘箱28中保持一段附加时间。生坯组件26可在烘箱28中暴露于升高的压力。然后如图1E所描述，固化组件26'可从烘箱28中移除，并且可立即用于本文所述的承重冲击承载应用。
在至少一个实施例中，生坯组件26在从嵌套24中移除之后不直接放置在烘箱28中。在这样的实施例中，生坯组件26可通过粘合剂或其他方式与其它部件或组件接合，从而产生多层组件。例如，底盘、形成车辆的行李箱和后保险杠的结构部件、形成车辆的前保险杠的结构部件、以及底盘的中央主体可根据本文所公开的方法进行自己的子组件，从相应的嵌套机械性地移除到另一个站点，在那里它们可经粘合地接合在一起以形成大组件。或者，大组件可进一步与顶部结构承重部件如门柱、顶板等相结合。一旦接合，整个组件将转移到油漆车间以在烘箱28中进行涂漆和固化。
粘合点30可通过机械手应用以各种模式来制备。示例性模式在图2A和图2B中描绘。例如，如图2A所描绘，高强度粘合剂14可施加在除了少量目标区域32之外的整个粘合区域30上，在其中机械手将施加快速固化粘合剂10。目标区域32可具有任何形状、大小和配置。目标区域32可为圆形、椭圆形、矩形、正方形、菱形、规则的、不规则的、对称的、不对称的等。目标区域32相对于彼此的间隔可在待接合的整个表面中是规则的、不规则的、随机的、对称的、不对称的等。例如，目标区域32可位于部件的至少两个相对的角中。如图2A所示出，具有快速固化粘合剂10的目标区域32可在所有侧面上被高强度粘合剂14包围。或者，可施加快速固化粘合剂10，使得快速固化粘合剂10在高强度粘合剂14的至少两个部分之间形成分隔物。在图2B中描绘的这种实施例中，目标区域32形成分离多个高强度粘合剂条带的条带。
目标区域32的数量和尺寸可根据具体应用而不同。目标区域32应该足够大，以提供足够强度的粘合，以便在施加快速固化粘合剂10之后在高达10秒、60秒、240秒或以上内处理生坯组件26。目标区域32应该足够大以在正常的处理生坯组件26的过程期间提供非蠕变的、非压裂界面。目标区域32可具有例如约1至50mm、5至25mm、10至15mm的直径d。然而，根据具体应用的要求，直径d可更小或更大。目标区域32可覆盖粘合剂层16表面积的约0.5％、1％、2％、3％、5％、10％、15％、20％或25％。
粘合剂10和14可作为层16施加。层16、快速固化粘合剂10、高强度粘合剂14或其组合可具有均匀或变化的厚度。理想的情况是，最小化目标区域32的量和尺寸，使得大部分粘合区域将与高强度粘合剂14接合。虽然施加到部件表面上的高强度粘合剂14的量可大于快速固化粘合剂10的量，但是必须注意确保高强度粘合剂14不覆盖为施加快速固化粘合剂10而保留的粘合区域。
方法可用于生产各种各样的组件，其用于存在短周期时间制造的需要的包括航空航天、汽车、船舶和其他运输应用的各种行业。示例性组件可包括机身、座椅靠背组件、悬架构件、支柱、侧梁、车顶纵梁以及能够承载几千磅的负载、能够承受如轻微后端碰撞的撞击而没有结构损伤、能够响应于前端碰撞吸收能量的其他承重冲击承载应用等或其组合。可利用通过本文所述方法产生的组件的车辆的非限制性示例性类型包括陆上车辆，例如汽车、公共汽车、货物运输车辆、摩托车、越野车辆、履带车辆、火车、水陆两用车辆、飞机、宇宙飞船、船舶等。
在图3A中描绘了座椅靠背组件50的示例性组件，其示出冲压的钢制座椅靠背组件50，其包括通常焊接在一起的四个离散零件，但是本文公开的混合粘合剂方法允许用粘合剂接头来更换焊缝。图3A示出了座椅靠背组件50的透视图，其包括经由左侧构件56和右侧构件58连接到下横向构件54的顶部横向构件52。
图3B描绘了座椅靠背组件50的包括左侧构件56和右侧构件58与顶部横向构件52之间的粘合剂接头的部分的轮廓。构件52、56、58的形状可经修改以提供侧构件56、58与横向构件52的最佳粘合附接。用图3C中粗线表示修改，其进一步说明用于在侧构件56和横向构件52上施加粘合剂10、14的示例性位置。如图可以看出，构件52、56都具有结构接触区域60。侧构件56具有端部62。顶部横向构件52包括凸片64，侧构件的端部62嵌套在其内。快速固化粘合剂10施加到侧构件56的端部62以及在凸片64附近、和/或邻近结构接触区域60施加到横向构件52。高强度粘合剂14可施加到构件52、56中的一个或两个的结构接触区域60。如上所述，粘合剂10、14二者可施加在两个构件上，仅一个构件，或者每个构件可仅接收粘合剂10、14中的一个。例如，当横向构件52是添加的侧构件56的主要部件时，粘合剂10、14二者可施加到横向构件52。如上所述，在施加两个粘合剂之后，侧构件56放置成与粘合剂层16'接触，施加压力，并且在短时间内固化快速固化粘合剂10。顶部横向构件52以类似的方式粘合地接合到左侧构件58。
图3D描绘了座椅靠背组件50部分的轮廓，其包括左侧构件56和右侧构件58与下部横向构件54之间的粘合剂接头。在图3E中描绘用于提供侧构件56和下部横向构件54的最佳粘合剂附接的修改。粘合剂10、14的施加类似于上面关于顶部横向构件52的施加。粘合剂10、14可在相同或不同的时间施加到一个或多个构件52、54、56和58上的所有期望的区域。在快速固化粘合剂10固化之后，将生坯组件从嵌套中转移到固化炉中，其中执行生坯组件到固化组件的转换。
图4中描绘另一示例，其示出具有支架72的座椅结构70，其经由包括本文公开的快速固化粘合剂10和高强度粘合剂14的混合粘合剂系统接合到座椅结构70。支架72提供座椅结构70的足够的加强，使得标准座椅结构可变得适于赛道应用。
在图5中公开替代支架80，其描绘用于汽车应用的示例性加强支架80。支架包括多个施加到支架的基础结构84上的金属片的示例板82。板82通过快速固化粘合剂10和高强度粘合剂14附接到基础结构84上。粘合接合板82可用于向相对较弱的各种零件添加刚性材料的强化层，并且基础结构的材料厚度的增加将导致添加过大的重量，这可能是不期望的。如上所述，粘合剂系统不仅可加速生产，而且还可有助于减轻零件的重量，从而潜在地提高目标车辆的燃料效率。与通过增加基础结构的材料厚度来满足设定强度要求的零件相比，重量减轻可以高达10％、15％、20％、25％、30％、40％、50％或以上。除了本文所述的支架之外，重量减轻可应用于其它组件。
图6中描绘另一示例部件，其示出用于汽车应用的前缘冲压件90。前缘冲压件90放置在汽车发动机罩外壳(未示出)和发动机罩92的下侧加强件之间。本文描述的双重混合粘合剂系统可用于将前缘冲压件90与发动机罩92的下侧加强件粘合地接合。区域94描绘传统焊接位置，其中可施加快速固化粘合剂10和高强度粘合剂14而不是焊接。快速固化粘合剂10和高强度粘合剂14可作为连续的、半连续的或不连续的层96施加在两个零件之间：前缘冲压件90和发动机罩92的下侧加强件。所描绘的层96仅仅是说明性的非限制性示例。层96的范围、尺寸和位置可能与所描绘的不同。
尽管上面描述了示例实施例，这些实施例并不意图描述本发明的所有可能形式。相反，在说明书中所用的措词是用于说明而不是用于限制，且应理解，在不脱离本发明的精神和范围情况下，可以进行多种改变。此外，多个执行实施例的特征可加以组合以形成本公开进一步的实施例。

Claims (20)

1.一种金属或复合材料部件组件，包括：
第一金属或复合材料部件；
第二金属或复合材料部件；以及
粘合剂层，所述粘合剂层设置在所述第一部件和所述第二部件的交界面上并且粘合所述第一部件和所述第二部件，所述粘合剂层包括快速固化的低强度粘合剂和高强度结构粘合剂。
2.根据权利要求1所述的组件，其中，所述高强度结构粘合剂在高于所述快速固化粘合剂的温度下固化。
3.根据权利要求1所述的组件，其中，所述高强度结构粘合剂比所述快速固化粘合剂固化得更慢。
4.根据权利要求1所述的组件，其中，所述快速固化粘合剂设置在所述层内的彼此间隔开的多个区域中。
5.根据权利要求4所述的组件，其中，所述区域中的至少一个的直径约为10mm。
6.根据权利要求4所述的组件，其中，所述多个区域表示所述粘合剂层表面区域的约10％。
7.根据权利要求1所述的组件，其中，所述快速固化粘合剂在施加于环境温度后约10秒内，以根据ISO 6922测量的约为6.9MPa或更高的拉伸强度粘合所述第一部件和所述第二部件。
8.根据权利要求1所述的组件，其中，所述高强度结构粘合剂具有大于30MPa的后固化拉伸强度。
9.根据权利要求1所述的组件，其中，所述第一部件和所述第二部件中的至少一个包括钢。
10.一种金属或复合材料组件，包括：
第一构件，所述第一构件具有结构接触区域和端部；以及
第二构件，所述第二构件通过位于所述第一构件的所述端部和所述第二构件之间由快速固化的低强度粘合剂形成的第一粘合部、以及位于所述第一构件的所述结构接触区域和所述第二构件之间由高强度粘合剂形成的第二粘合部粘合地接合到所述第一构件。
11.根据权利要求10所述的组件，其中，所述组件是悬挂构件组件。
12.根据权利要求10所述的组件，其中，所述第一构件和所述第二构件包括相同的金属。
13.根据权利要求10所述的组件，其中，至少所述第一构件包括碳纤维复合材料。
14.根据权利要求10所述的组件，其中，所述高强度粘合剂比所述快速固化的低强度粘合剂固化得更慢。
15.一种形成金属或复合材料组件的方法，包括：
将快速固化的低强度粘合剂和高强度粘合剂施加到第一部件、第二部件或两者；
将所述第二部件按压到所述第一部件上以形成组件；以及
从嵌套中移除所述组件，使得所述快速固化的低强度粘合剂提供足够的粘性以保持所述第一部件和所述第二部件接合，至少直到所述高强度粘合剂在从所述嵌套移除所述组件之后固化。
16.根据权利要求15所述的方法，其中，所述方法的周期时间小于60秒。
17.根据权利要求15所述的方法，进一步包括在施加所述快速固化的低强度粘合剂之后约10秒内从所述嵌套移除所述组件。
18.根据权利要求15所述的方法，其中，所述高强度粘合剂是慢固化或高温固化粘合剂。
19.根据权利要求15所述的方法，进一步包括将所述高强度粘合剂在烘箱中在约180℃的温度下固化约15至60分钟。
20.根据权利要求15所述的方法，进一步包括将快速固化的低强度粘合剂施加到多个目标区域，所述多个目标区域足够大以在所述组件从嵌套中移除之后提供非蠕变、非压裂的粘合部。
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