CN110087874B - 用于制造可焊接金属-聚合物多层复合材料的方法 - Google Patents
用于制造可焊接金属-聚合物多层复合材料的方法 Download PDFInfo
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Abstract
本发明涉及用于制造夹层板作为半成品的方法,其中将至少一个非金属材料层定位(4)在至少两个金属层(1、2、5)之间。将至少一个所述金属层成形为三维层(2),并且所述金属层(1、2、5)是通过所述金属层(1、2、5)之间的金属接点上的定位焊(3、8)而彼此闭合的材料,以实现所述半成品的电阻焊接性,以便将所述半成品连接到所需的解决方案组合。
Description
技术领域
本发明涉及用于制造可焊接金属-聚合物多层复合材料作为半成品的方法,其中使用电阻加热工艺以在不同金属层之间具有物质与物质的结合并且因此最终具有对于整个复合材料而言的连续材料抗性。然后在后续的部件制造步骤期间,复合材料与其他金属部件、片材或复合材料可异种焊接。然后,后续加工工业可以直接使用该半成品多层复合材料用于进一步的电阻焊接工艺。
复合材料结构可以由不同结构的各种金属、聚合物、陶瓷或有机材料及组合制成。Stamm K.,Witte H.,Sandwichkonstruktionen.Springer-Verlag,Wien,New York,1974显示了用于这样的复合材料构造的不同设计变化。根据该文献,复合材料结构可以区分为渗透的复合材料、微粒化合物、纤维复合材料或多层复合材料。层复合材料在宏观上是不均匀的。一种层复合材料是夹层构造,其被定义为具有分别具有特定材料性质的多个层的结构。另一个特征是不同的层为平坦有序的并且彼此平行取向。夹层结构的典型配置是两个金属外层与聚合物芯材料从两侧粘合。芯层可就其支撑效果进一步区分:
芯材料具有如下支撑效果
·均匀性
·选择性
·部分性和局部性
·单向性
·多向性
使用夹层设计的优点是具有高的轻质潜力,同时具有高刚度和强度水平。夹层的设计可以取决于部件而被调整至部件负载的水平和方向进行。另外,与单块材料相比,可以实现显著更高的机械能和声能吸收。航空航天以及汽车工程、商用车辆、摩托车、农用车辆以及轨道车辆工程、船舶和建筑结构、外壳或可再生能源工业仅是使用夹层结构的所述优点的一些加工工业。
另一方面,夹层结构通常需要复杂的制造工艺。此外,不能使用对于诸如钢的单块材料而言的明确确立且成本有效的生产方法。这尤其适用于焊接工艺,例如电阻焊。
对于采用子工艺电焊、滚缝焊或凸焊的电阻焊,采用电阻加热的焦耳物理定律。这意味着将电能转换为欧姆电阻,然后进一步转换为热能。在点焊过程中,电流在电路中流动。机器部件由铜制成以具有良好的电流传输,带有低电阻和低热损耗。在从铜到金属片材、在片材之间以及从第二片材到铜的过渡点处,电流能量变为欧姆电阻。这些电阻称为过渡电阻或接触电阻。在均匀的单块材料中,电阻被称为材料电阻,并且远低于过渡电阻,导致显著更低的热量。由于这种效果,两个片材之间的过渡电阻是迄今为止最高的,因此此点处的热能也是最高的。最后,此点处的热能达到片材的熔化温度,并产生焊点或称为焊接熔核。对于具有多于两个片材的多层片材组合,可以在材料的不同转变点处达到该效果,这取决于所用金属材料的物理性质。因此,该效果可如期望地(如汽车车体工程中的三片材组合)或非期望地发生,例如:当对原始隔离的电气工程部件产生不希望的金属接点时。
热能的公式是:
Q=Is2*t*RG (1)
其中Is为焊接电流,t=焊接时间,且RG=所有前述电阻的总和。进一步对RG可以表示为:
RG=RM+RT (2)
其中RM是所有材料电阻的总和,且RT是所有过渡电阻的总和。进一步详细的RM可由下式定义:
RM=(ρEL *L)/A (3)
其中ρEL是材料的比电阻,L是导体长度,且A是导体横截面积。
如果金属是以表面处理例如镀锌层制造,则RT可进一步指定为:
RT=RC+RB+RI (4)
其中RC是集中电阻(constriction resistance),RB是体电阻,且RI是由下式定义的杂质层
RI=(ρH *2*s)/(π*r2) (5)
其中ρH是比主电阻,s是杂质层厚度,π是数目Pi,且r是最大接触半径。
使用现有技术的夹层结构时的一个缺点是当夹层结构应与加工工业中的其他部件或片材焊接在一起时,不可通过电阻焊接工艺焊接。在现有技术中,在夹层结构中至少有一个隔离的非金属材料层,例如聚合物或粘合材料。因此,在电阻焊接期间电路不会闭合,因此不能产生将夹层结构熔化到另一个部件或片材的热能。
在WO公开2014009114A1、2014001152A9、2012048844A1和2013156167A1中以及在Tata钢数据表“-A unique and durable composite solution thatdelivers light-weight products and design innovation”中提到了具有不同层的平坦顺序的典型夹层板(互联网地址:http://www.tatasteeleurope.com/static_files/Downloads/Construction/Coretinium/Coretinium%20gen%20app%20data%20sheet.pdf)。
此外,WO公开2008125228A1和2004002646A1描述了一种用于制造金属夹层结构的方法,其中不同的层粘合在一起。所有这些WO公开具有相同的缺点,即在金属外层之间具有隔离材料,这导致不可电阻焊接性。
JP公开H01-127125描述了一种用于制造夹层板的方法,该夹层板包含两个金属片层和一个波纹元件。使用点焊将第一金属片层安装到波纹带的一个表面。然后进行粘合带工艺。使用一对压辊机通过加压和粘合将第二金属片层安装到波纹带的第二表面。所得的半成品的缺点在于,后续加工工业例如车体制造商不能将这些类型的夹层产品用于进一步的电阻焊接工艺以将这种夹层板与其他车体片材、板材或成形部件接合在一起。原因是所提到的粘合带在电阻焊接过程中用作电路的隔离体。没有焊接熔核,因此无法建立连接。
JP专利公开H02-78541A描述了一种如何制造夹层结构的方法,其中在通过***树脂形成的层合体中的一个金属片材的外表面上产生凹陷部分。计算出凸起部分的尖端与另一金属片材的内表面之间的距离由距离指定。这意味着,尽管使用异形的外层钢片材,最终将在两个金属片材之间形成限定的隔离间隙,这导致不可电阻焊接的构造。
EP专利公开1059160A2描述了一种复合材料,其中芯层与两个外层牢固地连接。但是层材料的特征在于非金属(织物图案)并且接点不是材料闭合的。尽管该EP公开是第一个引用的公开,其描述了在整个复合材料厚度上的连续接触,因此不存在可电阻焊接性。
此外,WO专利公开03082573A1和美国专利公开2005126676A1描述了用于制备复合材料的装置和方法。除了金属外层之外,芯层还含有短切纤维类的金属元素。但是在夹层结构的整个高度上的连续材料闭合是不可能的,因为在两个外层上在第一制造步骤期间施加了粘合剂。还从EP专利公开1059160A2(其中不可焊接的间隔织物用于芯材料)或WO专利公开9801295A1和EP专利公开0333685A2(其中通过静电沉降或静电沉积来施加作为芯材料的纤维)已知相关的设计变化。
WO专利公开2016097186A1描述了一种如何制造夹层板作为半成品的方法,其中使用至少一个三维金属层来实现所有金属层之间的直接机械接触,因而使得在电阻焊接期间由于如此闭合的电路而实现电流流动。该公开将该夹层板接合到其它金属片材或部件的一个缺点是没有所有金属层的材料闭合,作为除了夹层板与另一金属片材或部件之间原始的过渡电阻之外,只有在点焊期间起作用的直接机械接触作为另外的过渡电阻。因此,取决于材料组合、材料厚度和材料的物理性质如热传导或热容量,焊接熔核可能导致不同夹层的过渡区域而不导致夹层板和另一个片材的过渡区域。
由于夹层结构在初始状态下(其意味着处于交付状态)通过电阻焊接不可焊接的情况,存在许多精细的工艺以在一定程度上产生可电阻焊接性。一个例子是美国专利申请2013273387,其涉及夹层金属片材的高频焊接。因此,包括至少两个金属片材和布置在两个金属片材之间的片材(由具有与两个金属片材不同组成的材料组成)的第一复合金属片材部件被焊接到第二金属片材部件,其由金属材料或另外的复合材料构成,所述复合材料具有至少两个金属片材和设置在金属片材之间的由具有与该两个金属片材不同组成的材料组成的片材。
在WO公开2011082128A1中提到了一种如何用电阻点焊来焊接夹层板的方法,其中夹层板的复合芯材料层叠有两个金属外层。通过在芯层中具有多个钢纤维来解决产生特定可电阻焊接性的目标,所述多个钢纤维布置成与外层钢片材电连通。一个缺点是焊接结果的可再现性和可重复性。当后续制造商想要使用焊接参数时,无法保证有正确和足够数量的钢纤维接触。在钢纤维与钢外层的接触区域中产生焊接飞溅并燃烧其周围的非金属部件存在很大的危险。除了非金属中间层的软化和移位之外,在以下公开中还详细描述了作为解决目标的一种方式。
为了克服不可电阻焊接的夹层结构的缺点,有不同的专利描述了如何使夹层结构在特定的进一步工艺中可焊接的工艺和方法,其在初始的半成品交付状态配置下为不可焊接的。一个例子是JP公开2006305591A,其中两个金属外层在两个表面上与热塑性树脂绝缘板重叠。通过软化树脂绝缘板并将板向外推离焊接位置,解决了使两个金属层直接接触的目标。两个焊接电极必须处于加热状态,这是成本密集的,对于制造商而言需要特殊设备,并且在后续加工工业中没有确立。
如何制造在部件制造期间通过附加工艺步骤可焊接的特定配置的不可电阻焊接的夹层产品的另一具体方式在DE公开102011054362A1中。通过在第一工艺步骤中加热塑料芯层然后在第二工艺步骤中用至少一个电极向夹层表面施加力来解决该任务。非金属的软化中间层将从受力位置移位,并且两个金属外层都接触。这两个步骤都是在部件制造期间的额外工艺步骤,需要额外的生产时间,增加制造成本并缩短时钟周期。此外,提到该解决方案仅对部件的特定边界区域有效。DE公开102011109708A1制定了相同的附加工艺步骤,其还描述了使夹层结构可焊接的后续工艺,其中两个金属外层在初始状态下不直接接触。FR公开2709083A1描述了一种典型的夹层板,其具有两个金属外层片材和隔离两个外层的非金属芯材料。为了达到特定的可焊接性,使用与DE公开102011054362A1中相同的方法:在片材的边界区域处使非金属芯材料软化和移位。
在WO专利公开2012150144A1中描述了另一种用于为不可电阻焊接的夹层板形成电路的广泛且复杂的方法。其任务是建造带有额外机器部件的电桥,以绕过隔离聚合物材料并达到夹层与其他片材的可焊接性。限制片材可接近性的非常广泛的硬件需要额外的时间来安装和在正确的位置定位。这增加了生产成本。特别是对于成形且大的部件,产生电接触将是有问题的,且具有未经限定的电流流动问题。
WO专利公开2014121940A1A描述了另一种接合夹层的方法。在这种情况下,夹层板被限定为具有两个金属面和绝缘芯材料的结构。该限定导致夹层的初始状态下的不可焊接性。只有在进一步的制造步骤以在板的第一侧面实现舌部和在相对的第二侧面实现凹槽部之后,不使用电阻焊接的接头才是可能的,其中相邻板的舌部和凹槽部在组件上彼此接合以在相邻的板之间形成接头。
基于这些公开,没有解决在初始的半成品和交付状态下具有未给定的可电阻焊接性的夹层结构的缺点。后续的部件制造工业不可能使用其现有的成本有效且快速的电阻焊接工艺。该缺点可源自在整个夹层结构厚度上的非连续金属材料闭合。
本发明的目的是防止现有技术的缺点并实现一种用于制造半成品夹层板的改进方法,其中确保连续的金属材料闭合以用于随后的电阻焊接工艺。在电阻焊接工艺中,未硬化且非金属的材料从金属接点被再次加压,并且不同的金属层被焊接在一起作为所谓的定位焊。本发明的基本特征列在所附的权利要求中。
在本发明的方法中,将至少两个金属层(其中通过使用三维金属片材施加至少一个金属层,例如在WO专利公开2014096180A1中指出的)与至少一个非金属层以在金属层之间未固化和未硬化的状态结合在一起。在构建整个夹层结构之后,进行电阻焊接工艺以实现定位焊,这意味着存在完全的金属接触,导致在整个夹层结构上连续的金属材料闭合。
根据本发明,由至少两个金属层和位于凹部空间中的至少一个非金属和未硬化层制造夹层板,该凹部空间在将所述金属层中至少一个成型为三维物体时而形成于两个金属层之间。该非金属和未硬化层完全填充到两个金属层之间形成的凹部空间中。取决于化学基础,使用加热装置确保非金属材料的良好流动性。优选环氧树脂的温度为35至65℃,优选40至65℃,以达到超过500mPas的粘度。可任选地将三维金属层加热至至多80℃,还优选为55至65℃,以增加填充的非金属材料的流动行为。对于接下来的电阻焊接工艺,优选以电阻滚缝焊工艺进行,为了实现定位焊,电极力对于从不同金属层的金属接点对未硬化的非金属材料再次加压但不破坏夹层的结构以及特定层(如变形)是重要的。因此,优选的电极力为1.0kN-3.0kN,更优选为1.8kN-2.5kN。然后,电极力使得能够在一侧上实现用于焊接的金属接触,但是在另一侧上的非金属未硬化层的高填充度仍然保持与所有金属层的粘附接触。
根据本发明使用的定位焊的优点在于,非金属材料不会由于焊接过程中的高焊接电流或液态金属而被损坏。此外,定位焊能够实现后续的成形操作,例如从平坦夹层片材制造成形部件的深拉工艺。定位焊像普通焊接一样产生夹层的有利刚性。另一方面,在使粘合剂硬化之前,定位焊在夹层结构的制造期间能够实现良好的处理稳定性。由一侧上的定位焊与另一侧上的粘合剂粘合的组合所引起的层的接头能够实现高的形状稳定性而在不同的切削或冲压技术(例如激光切削、水喷射切削、等离子体切削或机械切削)期间没有不同层的脱层。当定位焊的粘合性低于非金属粘合剂的粘合性时,本发明的层粘合性表现为有利的实施方案。结果,可以达到超过130度的弯曲角度而没有任何层的脱层。此外,电阻滚缝焊方法是一种成本有效的制造方法,其又容易自动化,具有高于4米/分钟的高焊接速度。
在后续的制造工艺中,如车体工程,利用根据本发明的定位焊,可以在初始的交付状态下直接使用夹层结构用于随后的电阻焊接工艺,即实现夹层结构以形成闭合电路以及将所得焊接引导至夹层结构与另一金属部件的接触区域中。
参考以下附图更详细地解释本发明,其中
图1示出了从侧视图示意性地所见的优选实施方案,
图2示出了当与另一个部件连接时从侧视图示意性地所见的图1中的实施方案。
在图1中,金属层1和三维金属层2彼此定位焊3。金属层1和金属层2之间的凹部空间4填充有聚合物材料。在图1中,还示出了第三金属层5。金属层5与金属层2定位焊8。分别地,金属层2和5之间的凹部空间6填充有聚合物材料。此外,图1示出了两个定位焊8之间的幅值7的示例。
图2示出了对于图1的夹层结构的解决方案,其中夹层结构与外部部件12定位焊11。
在本发明的优选实施方案中,非金属粘合层仅用于非金属芯,与构成大多数现有技术的夹层结构形成对比,在后者中夹层板由两个金属外层累积,并且有两个粘合层来将两个外层与位于中央的芯材料粘合。因此,本发明的夹层结构可以用更简单的生产线和用增加的时钟频率来制成。该夹层结构更便宜,因为与现有技术的夹层板相比节省了两层。
在本发明的优选实施方案中,重复出现的金属接点的幅值小于5.0mm,其中对于每个幅值使用1.0-1.4kA的焊接电流来形成定位焊。
利用本发明的方法,因此可以接合夹层板,以通过电阻焊接将半成品连接到与其它片材、板材、成形零件或其他夹层板部件的所需解决方案组合的构造。
三维层的形式结合所选择的非金属材料和在金属层之间形成的凹部空间中的非金属材料的填充程度,为这些板提供它们的机械、刚性、声音、接合和加工特征。
在根据本发明的夹层板的制造中,第一和第二金属层有利地由相同的材料制成,例如不锈钢、碳钢、铜、铝、镁,但是第一和第二金属层也可以由不同金属材料、不同金属或不同金属组合物制成。然而,当使用不同金属或不同金属组合物时,这些金属的组合可以进一步改变夹层板的表现。例如,具有不同热膨胀系数的金属的组合在本发明的一些解决方案中可为有利的。通过使用具有两种不同热膨胀系数的两种金属可影响夹层板的热膨胀,并且三维片材的表面将避免在夹层板的焊接区域内中断。此外,具有两个不同金属层的本发明的夹层板可用作多材料设计的车体的湿腐蚀区域中的部件桥。例如,b支柱(b-pillar)的底部由不锈钢制成,门槛梁(rocker rail)由铝制成,夹层板可用作两个部件之间的连接。夹层的铝侧被焊接至铝门槛梁,不锈钢夹层与不锈钢b支柱焊接在一起。结果,在不同部件之间没有接触腐蚀并且没有电化学势桥。然后,唯一的电势桥在夹层中,但非金属层隔离大区域,并且与部件尺寸相比,残余金属接触很小(线性或点接触)。
本发明制造的夹层板中的三维金属层是波纹金属块,第二金属层表面上呈钮扣形、结块形的金属块,或者可与基本上平坦的二维第一金属层机械连接的任何其他三维金属块。用于第二金属层的合适形状例如在WO公开2014/096180中找到。第二金属层的形状还决定了夹层板的阻尼、噪音、振动、刚性,尤其是压曲刚性和可焊接性。结块和钮扣异形片材导致不取决于方向的刚性,但由于点状接触,仅适合用电阻定位焊来焊接。波纹异形片材具有取决于方向的刚性,但是由于线性接触,能够实现用所有连续焊接工序(例如电阻滚缝焊)来焊接。在第二金属层的形状是波纹状并且取决于使用夹层板的解决方案的情况下,第二金属层可以具有基本上正弦波的形状,或者第二层可以具有波纹条的形状,其中该条的彼此相邻的两个部分彼此处于基本垂直的位置。在根据本发明制造的夹层板中,其他形状的波纹条也可用于第二层。
本发明的夹层板中的两个金属层之间的非金属层有利地由聚合物材料、树脂材料、密封剂材料、冷或热固性单组分或双组分黏合胶制成,例如用于汽车工业中的抗碰撞的单组分粘合胶,或含有树脂和硬化剂的双组分夹层粘合材料。非金属中间层的基本性质是在夹层的设置期间的非固化和未硬化状态和在施加期间的粘度以及固化和发泡的方式。达到限定的填充度而不破坏金属接触区域的良好粘度为400至10000mPas,更优选大于500mPas。此外,非金属层的更有利的实施方案具有粘塑性或触变性质,并且比重为1.0-1.1g/cm3。如前所指出的,在施加之前预热非金属材料可适合于达到正确的施加粘度,这取决于所选择的聚合物并且优选在40至65℃的温度范围。
本发明的夹层板中的不同金属层通过粘合到粘合剂和金属材料闭合电阻焊接的组合彼此连接,从而为了将半成品连接到所需的解决方案组合的构造,随后的电阻焊接至其他片材、板材或成形部件将集中在第一金属层和第二金属层彼此具有金属材料闭合的点上。夹层内部的不同材料闭合接点之间的距离λ应该很小,以至于在其他部件的后面位置的每种情况下,由于另一个部件和夹层结构的外部层中之一之间的焊接熔核,都能够构建电路。关于根据ISO 5821的用于电阻点焊的标准使用铜电极,对于本发明的合适距离是λ≤5.5mm,优选λ≤2.5mm。
本发明的夹层结构用于后续的制造工艺,例如乘用车辆、商用车辆、农用车辆或轨道车辆的车体工程,尤其用于湿区域部件或诸如车顶、机罩/前壁、槽道、支柱镶嵌(inlayer)、前盖等部件或用于与噪音相关的应用例如外壳。
Claims (17)
1.用于制造夹层板作为半成品的方法,其中将至少一个非金属材料层定位(4)在至少两个金属层(1、2、5)之间,其中将至少一个所述金属层成形为波纹金属条形式的三维层(2),从而提供所述金属层(1、2、5)之间的金属接点,其特征在于所述金属层(1、2、5)通过定位焊(3、8)通过电阻焊接工艺连接,所述电阻焊接工艺通过电阻滚缝焊来完成,所述电阻滚缝焊的电极力在1.0kN-3.0kN之间,并且焊接速度大于4.0米/分钟,以实现所述半成品的电阻焊接性。
2.根据权利要求1所述的方法,其特征在于,采用在1.8kN-2.5kN之间的电极力完成所述定位焊(3、8)。
3.根据权利要求1或2所述的方法,其特征在于,所述三维层(2)的幅值(7)小于5.0mm,由此使用每幅值1.0-1.4kA的焊接电流来产生所述定位焊。
4.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由相同的金属制成。
5.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由不同的金属材料制成。
6.根据权利要求5所述的方法,其特征在于,所述金属层(1、2、5)由具有两种不同热膨胀系数、影响所述夹层板的热膨胀的金属制成。
7.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由不锈钢制成。
8.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由碳钢制成。
9.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由铝制成。
10.根据权利要求1或2所述的方法,其特征在于,所述金属层(1、2、5)由镁制成。
11.根据权利要求1或2所述的方法,其特征在于,所述非金属层由聚合物材料制成。
12.根据权利要求1或2所述的方法,其特征在于,所述非金属层由树脂材料制成。
13.根据权利要求1或2所述的方法,其特征在于,所述非金属层由密封剂材料制成。
14.根据权利要求1或2所述的方法,其特征在于,所述非金属层由冷或热固性的单组分或双组分的黏合胶制成。
15.根据权利要求1或2所述的方法,其特征在于,所述非金属层由包含树脂和硬化剂的双组分的夹层黏合材料制成。
16.根据权利要求1或2所述的方法,其特征在于,通过在随后的制造过程中焊接来接合所述半成品夹层板,以便将所述半成品连接到所需的解决方案组合。
17.根据权利要求1或2所述的方法,其特征在于,通过在随后的制造过程中电阻点焊来接合所述半成品夹层板,以便将所述半成品连接到所需的解决方案组合。
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