CN108223517B - 类似和不同材料的自旋连接 - Google Patents

类似和不同材料的自旋连接 Download PDF

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Publication number
CN108223517B
CN108223517B CN201711286444.6A CN201711286444A CN108223517B CN 108223517 B CN108223517 B CN 108223517B CN 201711286444 A CN201711286444 A CN 201711286444A CN 108223517 B CN108223517 B CN 108223517B
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adhesive layer
spin
fastener
contact
liquefied
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CN108223517A (zh
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B·J·布拉斯科
S·西普里亚诺
R·C·詹尼斯
P-C·王
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)
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Abstract

一种自旋紧固系统包括第一构件和施加到第一构件的粘合剂层。第二构件定位成与粘合剂层接触。在第二构件定位成与粘合剂层接触之后固化所述粘合剂层的至少一部分以使得所述粘合剂层的至少一部分基本刚性。至少一个自旋紧固件依次插入到第二构件、粘合剂层的固化部分和第一构件中的每一个。

Description

类似和不同材料的自旋连接
引言
本公开涉及使用高速摩擦紧固件的材料连接。
诸如钢、铝和复合材料的材料可以通过使用产生摩擦热的高速或自旋紧固件而彼此连接或连接到其它中一个，局部软化或熔化材料并提供紧固件穿过的材料流。仅当自旋紧固件在面板或部件的一侧使用时也是有益的。
自旋紧固件通过局部加热通过使用来自高速旋转的摩擦以及局部软化、融化或融合待连接材料的插入压力而待连接的材料来起作用。软化的材料或熔体的一部分通常在自旋紧固件的头部上方和下方流动，而大部分软化的材料或熔体流出出口区域以产生由自旋紧固件的螺纹啮合的附加材料。然而，已经发现，随着材料的厚度增加，并且特别是随着外部材料的厚度增加，当自旋紧固件离开外部材料时，一部分材料流被迫进入并且被截留在材料板或部件之间。当面板构件不能容易地夹紧在需要安装自旋紧固件的位置时，这个问题就更加严重了。被截留的材料冷却或固化，并在两个部件之间产生相隔距离或间隙，并且由于在自旋紧固件材料界面处产生应力集中而削弱了所得到的连接。
因此，尽管当前的自旋紧固件连接实现其预期目的，但仍需要一种用于使用自旋紧固件来连接材料的新的改进的系统和方法。
发明内容
根据若干方面，一种自旋紧固系统包括第一构件。将粘合剂层施加到第一构件。第二构件定位成与粘合剂层接触。在第二构件定位成与粘合剂层接触之后，粘合剂层的至少一部分被固化，以使得粘合剂层的至少一部分基本刚性。至少一个自旋紧固件依次插入到第二构件、粘合剂层的固化部分和第一构件中的每一个。
在本公开的另一方面中，自旋紧固件包括穿透端，所述穿透端在与第二构件的朝外表面直接接触时产生热量和压力，引起第二构件的一部分材料液化或塑化。
在本公开的另一方面中，粘合剂层和第一构件的液化或塑化材料的第一向外流动部分聚集在第二构件的朝外表面和自旋紧固件的头部之间。
在本公开的另一方面中，将多个球体嵌入用作隔片或垫片的粘合剂层中。
在本公开的另一方面中，每个球体具有基本上等于粘合剂层的厚度的期望值的共同直径。
在本公开的另一方面中，每个球体限定聚合物材料。
在本公开的另一方面中，每个球体限定玻璃材料。
在本公开的另一方面中，当第二构件定位成与粘合剂层接触时，球体直接接触第一构件的表面和第二构件的朝向相反的表面。
在本公开的另一方面，球体在安装至少一个自旋紧固件期间基本上不会通过施加在粘合剂层上的力被压缩，使得第二构件与粘合剂层的接触不会将粘合剂层压缩到期望的粘合剂层的厚度以下。
在本公开的另一方面中，当球体的材料不能通过在插入至少一个自旋紧固件期间产生的温度液化时，球体选择性地插入固化部分的预定宽度外的粘合剂层中以避免所述至少一个自旋紧固件与球体接触。
在本公开的另一方面中，在定位第二构件之前，将粘合剂层以基本上粘稠的液体形式施加到第一构件的表面。
在本公开的另一方面中，固化部分的宽度和位置被预先确定以适合所述至少一个自旋紧固件中的一个的期望的安装位置。
在本公开的另一方面中，用于第一构件和第二构件的特定材料的最佳粘合剂层厚度选自多个粘合剂层厚度。
在本公开的另一方面中，固化之后和在安装自旋紧固件之前的粘合剂层的厚度基本上是固定的，并且在自旋紧固件插入期间基本不可压缩。
根据若干方面，用于自旋紧固部件的方法包括：将粘合剂层施加到第一构件；将第二构件定位成与粘合剂层接触；在第二构件定位成与粘合剂层接触之后固化粘合剂层的至少一部分，以使至少部分粘合剂层基本刚性；以及将至少一个自旋紧固件依次插入到第二构件、粘合剂层的固化部分和第一构件中的每一个以机械地连接第一构件、粘合剂层和第二构件。
在本公开的另一方面中，该方法还包括旋转自旋紧固件，使得当所述自旋紧固件的穿透端与第二构件的朝外表面直接接触时，由穿透端在朝外表面产生的热量和压力导致第二构件的一部分材料液化。
在本公开的另一方面，该方法还包括迫使粘合剂层和第一构件的液化材料的第一向外流动部分在第二构件的朝外表面和自旋紧固件的头部之间聚集。以及将粘合剂层和第一构件的固化部分的液化材料的第二向外流动部分从第一构件向外推动以与第一构件的朝外表面接触，固化的粘合剂防止任何第一向外流动部分或第二向外流动部分保持靠近粘合剂层。
在本公开的另一方面，该方法还包括将多个球体嵌入粘合剂层中，每个球体具有与胶粘剂层的期望厚度基本上相等的共同直径。
在本公开的另一方面中，用于粘合剂层的至少一部分的固化步骤包括在第二构件定位成与粘合剂层接触之后完全固化粘合剂层。
根据若干方面，用于自旋紧固部件的方法包括：将粘合剂层施加到第一构件；将第二构件定位成与粘合剂层接触；在第二构件定位成与粘合剂层接触之后固化粘合剂层以使得粘合剂层基本刚性；以及将至少一个自旋紧固件依次插入到第二构件、固化的粘合剂层和第一构件中的每一个以机械地连接第一构件、粘合剂层和第二构件，自旋紧固件迫使第二构件的液化部分积聚在自旋紧固件的头部附近并且迫使包含粘合剂层和第一构件的材料的液化第二部分积聚在自旋紧固件的柄部的暴露部分附近，固化的粘合剂防止任何液化的第一部分或液化的第二部分保持在粘合剂层附近。
根据本文提供的描述，其他应用领域将变得显而易见。应该理解的是，描述和具体示例仅用于说明的目的，而不旨在限制本公开的范围。
附图说明
这里描述的附图仅用于说明的目的，并不旨在以任何方式限制本公开的范围。
图1是根据示例性方面的自旋紧固系统的横截面正视图；
图2是图1的自旋紧固系统的第一构件和粘合剂层的侧视图；
图3是根据图2修改的进一步添加第二构件的侧视图；
图4是进一步添加粘合剂层的固化部分的根据图1修改的侧视图；
图5是类似于图4的侧视图，示出了在安装之前对齐的自旋紧固件；
图6是类似于图6的侧视图，示出了处于部分安装位置的自旋紧固件；
图7是图1的自旋紧固系统的第一构件和粘合剂层的侧视图，进一步示出了位于粘合剂层内的多个球体；
图8是类似于图7的侧视图，进一步示出了连接到粘合剂层的第二构件；以及
图9是展示对于不同厚度的粘合剂层获得的连接强度的图表。
具体实施方式
以下描述在性质上仅仅是举例说明，并不旨在限制本发明的公开内容、应用或用途。
参考图1，自旋紧固系统10包括第一构件12和第二构件14，使用直接位于第一构件12和第二构件14之间的粘合剂层16将第二构件14连接到第一构件12。粘合剂在第二构件14和第一构件12连接到粘合剂层16之后并且在安装自旋紧固件18之前被固化。然后将自旋紧固件18依次插入到第二构件14、粘合剂层16和第一构件12中的每一个。如果整个粘合剂层16未被固化，则在插入自旋紧固件18之前，粘合剂层16的至少一部分20被固化，使得粘合剂层16的厚度22基本上是固定的，并且在自旋紧固件18的插入过程中基本不可压缩。
自旋紧固件18以高转速(大约1000rpm至8000rpm)旋转，使得当自旋紧固件18的穿透端24向下方向28上直接接触第二构件14的朝外表面26时，由朝外表面26处的穿透端24产生的热量和压力导致第二构件14的一部分材料液化。当自旋紧固件18继续沿向下方向28移动时，粘合剂层16的材料至少在部分20处分解，然后与自旋紧固件18接触的第一构件12的材料液化以与第二构件14的材料的液化部分结合。如本文所使用的，该“自旋紧固件”或自旋紧固件(复数个)可以包括但不限于由摩擦运动产生热量的紧固件，其部分地熔化或液化所接触的材料，并且包括流动钻孔螺钉、弹簧铆钉、盲铆钉和自穿铆钉。
首先，来自第二构件14和粘合剂层16的液化材料的第一向外流动部分30向上升起并聚集在朝外表面26与自旋紧固件18的头部32之间。根据若干方面，自旋紧固件18的头部32为凹入形状以接收第一向外流动部分30，从而允许头部32的外周直接接触第二构件14的朝外表面26。
随后，当自旋紧固件18移动通过第一构件12时，粘合剂层16的固化部分20的液化材料的第二向外流动部分34和第一构件12被迫或向下推动(如图1中所示)并且从第一构件12向外并且与第一构件12的向外指向的表面36接触。第二向外流动部分34然后可用于直接接触在自旋紧固件18的柄部40上形成的螺纹38，并因此为螺纹38提供额外的螺纹啮合。由于在安装自旋紧固件18之前，接收自旋紧固件18的所有粘合剂层16或粘合剂层16的至少部分20被固化，并且因此基本刚性，因此粘合剂层16的材料例如在部分20处部分地分解，使得第一构件12和第二构件14的材料为第二向外流动部分34提供材料。当自旋紧固件18穿过粘合剂层16时，粘合剂层16的基本上刚性的状态防止了液体材料在粘合剂层16的区域中的滞留。
本公开的自旋紧固系统10防止材料在粘合剂层16的区域中滞留。固化的粘合剂防止任何液化的第一部分或液化的第二部分保留在粘合剂层附近。材料在粘合剂层16的区域中的滞留是不期望的，因为它增加了粘合剂层16的厚度22，并且随着液化材料随后在第一构件12和第二构件14之间凝固，可以在第一构件12和第二构件14之间形成凹穴。这样的袋或固化的材料会不利地影响第一构件12和第二构件14之间的连接强度。通过将固定且基本上不可压缩的粘合剂层16粘合到第二构件14，粘合剂层16在自旋紧固件18安装期间滞留粘合连接但部分地分解，第一构件12和第二构件14的液化部分继续移位作为第二向外流动部分34的一部分，由此防止第一构件12、粘合剂层16或第二构件14中的任何一个的液化或分解部分被截留在粘合剂层16的区域中。
参考图2至图6再到图1，提供了使用自旋紧固系统10的方法的步骤。更具体地参考图2，粘合剂层16最初施加到第一构件12。第一构件12可以是包括诸如钢或铝的金属、聚合物材料或诸如碳纤维聚酰胺复合材料的复合材料的多种材料中的任何一种。粘合剂层16可以作为板材或液体，通过涂布、喷涂或通过任何合适的安装工艺来施加。用于粘合剂层16的合适的粘合剂材料的一个实例是由美国密歇根的米德兰的Dow Chemical Company制造的Dow 1480粘合剂。
参考图3，在施加粘合剂层16之后，使第二构件14与粘合剂层16接触。类似于第一构件12，第二构件14可以是包括诸如钢或铝的金属、聚合物材料或诸如碳纤维聚酰胺复合材料的材料的多种材料中的任何一种。第一构件12和第二构件14的材料可以是相同的材料，也可以是彼此不同的材料。
参考图4再到图3，在将第二构件14安装到粘合剂层16上之后，固化整个粘合剂层16或者仅固化粘合剂层16的部分20，将要在固化粘合剂层16的部分20处进行自旋紧固件18的每个后续安装。固化操作可以以任何已知的方式包括通过紫外(UV)光、加热、感应加热炉、硬化剂等进行。如果仅要固化粘合剂层16的固化部分20，则预定宽度42和固化部分20的位置以适合每个自旋紧固件18的期望安装位置。根据进一步的方面，可以预料的是，将使用多个自旋紧固件18来将第一构件12连接到第二构件14，因此如上所述可以形成多个固化部分20并且位于预定位置以适合自旋紧固件18的随后安装。如果在安装第二构件14之后整个粘合剂层16被固化，则可以在任何期望的位置处安装多个自旋紧固件18。根据另外的方面，对于较厚的工件，在安装多个自旋紧固件18之后，所需结构的尺寸是固定的，因此不需要在自旋紧固件18的每个位置固化粘合剂层16。对于薄的工件，粘合剂层16可以在自旋紧固件18的每个位置处被固化。
参考图5再到图4，一个示例性自旋紧固件18定位在固化部分20之一的基本上居中的位置处并且沿旋转方向44轴向旋转。例如，通过将位置编程到计算机数字控制(CNC)机器或机器人的计算机存储器中，可以将固化部分20的中心位置预先标记或以其它尺寸定位在第二构件14的朝外表面26上。
参考图6再到图5，自旋紧固件18被示出为高速旋转并且被迫沿方向28穿过第二构件14和粘合剂层16的固化部分20中的每一个，并且被示出为进入第一构件12。在此期间，液化材料的第一向外流动部分30向上升起并聚集在自旋紧固件18的朝外表面26和头部32之间。
参考图7再到图1，根据若干方面，粘合剂层16被施加到第一构件12的表面46。为了预先限定粘合剂层16的厚度22，将例如由诸如聚合物材料或玻璃的材料制成的多个球体48嵌入粘合剂层16的材料中，例如在施加粘合剂层16之前。每个球体48具有基本上等于厚度22的期望值的公共直径。
参考图8再到图1、4和7，第二构件14被定位成与粘合剂层16接触，使得球体48直接接触第一构件12的表面46和第二构件14的朝向相反的表面50。球体48在安装自旋紧固件18期间基本上不会通过施加在粘合剂层16上的力被压缩，使得随后第二构件14与粘合剂层16的接触不会将粘合剂层16压缩到期望厚度22以下。当选择用于球体48的材料不能通过在随后插入自旋紧固件18期间产生的温度液化时，球体48可选择性地插入到固化部分20的预定宽度42之外的粘合剂层16中，以避免在自旋紧固件18和任何球体48之间的接触。球体48在固化后滞留在粘合剂层16中。
参考图9，期望的是预定所使用的每种粘合剂以及第一构件12和第二构件14的每种材料或材料的组合的最佳粘合线或粘合剂层厚度22以使连接强度最大化。这个数据是根据具体情况得出的，在图表52中提供了一个实例。曲线图表52在纵坐标54上提供粘合的2.5mm厚的搭接剪切碳纤维复合材料的测量的连接强度的范围，其定义了破坏重叠为38mm×38mm制造的38mm×125mm的搭接剪切连接的力，以磅为单位，在横坐标56处为多重粘合或粘合剂层厚度，以0.25mm的增量提供。在图表52中提供的示例中，将0.5mm厚的粘合剂层用于第一构件12、粘合剂层16和由30％质量的碳纤维制造的第二构件14的夹层会产生大约2950lb的最大或最佳接合强度。使用图表52，用户因此可以选择具有0.5mm的最佳粘合剂层厚度，用于具有这些材料的后续安装。当为自旋紧固系统10的不同方面选择不同的材料组合时，可以创建多个类似的图表来使用。因此可以将用于不同材料和不同粘合剂的多个不同的最佳粘合剂层厚度22保存在例如计算机系统的存储器中。
本公开的自旋紧固系统10和组装方法提供了若干优点。这些包括使用位于诸如车身面板或车辆的结构构件之类的构件之间的固化粘合剂。将至少一个自旋紧固件插入到第一构件和第二构件以及固化的粘合剂层。固化粘合剂层的作用类似于第一构件和第二构件的材料在安装自旋紧固件期间液化。固化的粘合剂层防止在安装自旋紧固件期间产生的液化材料积聚在第一构件和第二构件之间，这可能削弱第一构件和第二构件之间的连接。防止液化材料积聚的其它方法可以包括在紧固之前例如通过电阻焊接、铆接等预设零件位置。本公开的系统和方法可以至少用于第一构件12和第二构件14的材料组合，包括金属-金属、金属-聚合物复合材料和聚合物复合材料到聚合物复合材料。
本公开的描述本质上仅是示例性的，并且不偏离本公开的主旨的变型意图在本公开的范围内。这样的变型不被认为是脱离本公开的精神和范围。

Claims (5)

1.一种用于自旋紧固部件的方法，包括：
将粘合剂层施加到第一构件；
将第二构件定位成与所述粘合剂层接触；
在所述第二构件定位成与所述粘合剂层接触之后固化所述粘合剂层的至少一部分以使得所述粘合剂层的至少一部分基本刚性，其中所述粘合剂层的固化部分小于整个粘合剂层；以及
将至少一个自旋紧固件依次插入到所述第二构件、所述粘合剂层的固化部分和所述第一构件中的每一个以机械地连接所述第一构件、所述粘合剂层和所述第二构件。
2.根据权利要求1所述的用于自旋紧固部件的方法，还包括旋转所述自旋紧固件，使得当所述自旋紧固件的穿透端与所述第二构件的朝外表面直接接触时，由所述穿透端在所述朝外表面产生的热量和压力导致所述第二构件的一部分材料液化。
3.根据权利要求1所述的用于自旋紧固部件的方法，还包括：
迫使所述粘合剂层和所述第二构件的液化材料的第一向外流动部分在所述第二构件的朝外表面和所述自旋紧固件的头部之间聚集；以及
将所述粘合剂层的所述固化部分和所述第一构件的液化材料的第二向外流动部分从所述第一构件向外推动以与所述第一构件的朝外表面接触，固化的粘合剂防止所述第一向外流动部分或所述第二向外流动部分中的任何一个保持靠近所述粘合剂层。
4.根据权利要求2所述的用于自旋紧固部件的方法，其进一步包括将多个球体嵌入所述粘合剂层中，所述球体中的每一个具有与所述粘合剂层的期望厚度基本上相等的共同直径。
5.一种用于自旋紧固部件的方法，包括：
将粘合剂层施加到第一构件；
将第二构件定位成与所述粘合剂层接触；
在所述第二构件定位成与所述粘合剂层接触之后固化所述粘合剂层的一部分以使所述粘合剂层的固化部分基本刚性，其中所述粘合剂层的固化部分小于整个粘合剂层；以及
将至少一个自旋紧固件依次插入到所述第二构件、所述粘合剂层的固化部分和所述第一构件中的每一个以机械地连接所述第一构件、所述粘合剂层和所述第二构件，所述自旋紧固件迫使所述第二构件的液化第一部分积聚在所述自旋紧固件的头部附近并且迫使包含所述粘合剂层和所述第一构件的材料的液化第二部分积聚在所述自旋紧固件的柄部的暴露部分附近，所述粘合剂层的固化部分防止所述液化的第一部分或所述液化的第二部分中的任何一个保持在所述粘合剂层附近。
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