CN100334343C - 胶粘结发动机吸气歧管组件 - Google Patents

胶粘结发动机吸气歧管组件 Download PDF

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CN100334343C
CN100334343C CNB028073746A CN02807374A CN100334343C CN 100334343 C CN100334343 C CN 100334343C CN B028073746 A CNB028073746 A CN B028073746A CN 02807374 A CN02807374 A CN 02807374A CN 100334343 C CN100334343 C CN 100334343C
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assembly according
tackiness agent
assembly
matching surface
elements
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CN1511225A (zh
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B·R·琼斯
D·M·康特尔
K·J·瑞茨玛
M·A·麦克马肯
S·阿斯法
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Dow Global Technologies LLC
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F02M35/10—Air intakes; Induction systems
    • F02M35/104—Intake manifolds
    • F02M35/116—Intake manifolds for engines with cylinders in V-arrangement or arranged oppositely relative to the main shaft
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
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    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
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    • F02B75/16—Engines characterised by number of cylinders, e.g. single-cylinder engines
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    • F02B75/22—Multi-cylinder engines with cylinders in V, fan, or star arrangement
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Abstract

一种发动机吸气歧管组件(10)，包括：一个第一元件(12)，带有一个第一配合表面(14)；和一个第二模压塑料元件(16)，带有一个第二配合表面(18)。第二模压塑料元件(16)用一种粘合剂(20)胶粘粘结到第一元件(12)上。

Description

胶粘结发动机吸气歧管组件
技术领域
本发明涉及胶粘结发动机元件组件，更具体地说，涉及胶粘结吸气歧管组件。本发明也涉及一种采用按要求熟化粘合剂的吸气歧管组件。
背景技术
历史上，构造技术涉及分离金属元件的构造和使用紧固件借助于一个中间布置的垫接合元件。这往往需要多个零件并因此是劳动密集的。
塑料发动机吸气歧管组件(如用于汽车发动机)已经由诸如失芯(lost core)工艺之类的近网状制造工艺构造。尽管这些工艺会导致其形状可以复杂的所需的近网状产品，但这些产品一般较贵。
在另一种常用的工艺中，制造两个或多个塑料吸气歧管元件，每个带有一个平面配合表面。元件在其相应配合表面的每一个处由振动焊接接合。这种工艺也往往是时间、能量和劳动力密集的。而且，有可能在焊接时相应元件的任何翘曲或其它表面凹凸不平导致在配合表面处的有害间隙。因而，必不可少的是，相对配合表面是平面的，这约束了设计灵活性。
因而，需要提供一种制造和产生组件的方法，按照这种方法用粘合剂粘结把发动机吸气歧管组件的多个元件接合在一起。进一步需要相应元件在可选择没有紧固件或垫片或再者的情况下彼此附着。还进一步需要相对是非平面的配合表面达到高度整体接合，由此使复杂的塑料元件形状(带有或不带有另外的一体元件)能够由常规的模压工艺模压。
发明内容
本发明通过提供一种包括一个带有一个第一配合表面的第一元件、和一个带有一个第二配合表面的第二元件的发动机吸气歧管组件，来满足以上需要和其它需要。，所述第一元件由玻璃填充塑料制成，并且以大约10体积百分比至大约50体积百分比的量而被玻璃填充。该第二元件用模压塑料制成，所述第一配合表面和所述第二配合表面通过该粘合剂以及一个机械附件而被接合到一起，并且其中该组件包括介于第一和第二元件之间的一个连接，其中所述连接选自搭接连接或企口接合连接。
附图说明
图1是按照本发明的一种吸气歧管组件的立体图。
图2是按照本发明形成的接合的剖视图。
图3a-3c在本发明组件的元件中集成机械附件的例子的剖视图。
具体实施方式
参照图1、2、3a-3c，表示有本发明的一种吸气歧管组件10，它包括一个带有一个第一配合表面14的第一元件12。用一个粘合剂中间层20把带有一个第二配合表面18的第二元件16粘结到第一元件上。第一或第二配合表面的任一个或两个能包括一个或多个另外的涂层、各层或元件。因而，第一或第二元件的任一个或两个的配合表面可以不必一体地形成在元件上。
可选择的是，第一元件12或第二元件16的任一个或两个带有一个有利于元件相对于彼此或相对于发动机的连接或定位的件。更具体地参照图2和3a-3c(其中类似部分由类似标号指示)，表示有不同件的例子。一般地，与第一元件12相联的一个第一件22将与一个与第二元件16相联的第二相对结构件24接合。这样的接合可以环绕在元件的周缘上、位于一个内部部分(未表示)上或二者之上。可以采用任何适当的相互作用结构。例如，可以使用摩擦配合、静配合或某种其它互锁配合。适当接合的例子包括对头连接、搭接、企口接合等。在图3a中表示的一个实施方案中，咬合连接26由在第一件22上的柄舌28生成，柄舌28接合在第二件24上形成的一个相对壁30。在图3b中的另一个实施方案中，元件之一带有一个法兰32，法兰32带有一个用来增大适用于粘结的表面面积和用来接合其它元件的内壁表面34。图3c是在图2中表示的接合的放大视图，并且表明用来实现咬合的一个棘爪36和伸入到配合表面的至少一部分附近的一个槽40中的肋38，以便增大用来接触粘合剂的表面面积、和有效地形成企口接合、咬合或两者。如将理解的那样，可选择地可以形成一个柄舌或其它类似结构，以便有助于实现咬合或提供一个用于使组装便利的可听定位器。以上类型接合的组合也认为在单个组件中是可能的。另外的例子表明在共同拥有的、共同待决美国申请No.09/825,721(标题为“Adhesively Bonded RadiatorAssembly”)中。而且，为了提供接合配合表面的表面面积量的增大、或在元件的相应配合表面之间的重叠，可以采用其它适当的结构或表面处理。
在要接合的表面的至少一部分上最好提供粘合剂，并且最好足以环绕周缘，从而在第一和第二元件之间不会产生明显的间隙。在一个实施方案中，把一团粘合剂放置(例如，通过泵吸)在元件至少一个的相应配合表面上，并且把相对配合表面带到与它接触。然后熟化组件。在另一个实施方案中，把粘合剂预涂(例如，通过喷洒、浸渍、涂刷、擦抹等)在相应元件的配合表面的一个或两个上，然后接合和熟化元件。可以类似地采用任何其它适当接合技术。采用的粘合剂的量最好足以实现组件的所需的性能特性。这样的量将随涂敷不同而变化。
在一个实施方案中，本发明是一种在其相应元件的配合表面上布置一层连续粘合剂条或膜的发动机吸气歧管。如这里使用的那样，连续粘合剂条或膜是指绕配合表面的周缘布置的粘合剂条或膜，并且粘合剂条或膜的末端与粘合剂条或膜的始端连接。在熟化时连续粘合剂条或膜能够在元件之间形成空气和液体紧密密封。这种作用允许粘合剂条或膜代替作为密封装置的垫片。可以把粘合剂涂敷到吸气歧管元件上，在其中元件彼此接触的位置的最近处，或者可以把它涂敷在离元件接触的地方或时刻较远的位置中。这里所使用的较远是指时间和位置之一或两者。在其中把粘合剂涂敷到离其中把元件接合在一起的地方较远的一个或多个上的实施方案中，使用按要求熟化的粘合剂。
在本发明的一个优选实施方案中，第一或第二元件的任一个或两个由塑料材料构造，即热固材料、热塑材料、或其混合物。其中最佳高性能热塑材料是聚对苯二甲酸丁二酯、聚醚酰亚胺、聚亚苯基醚/聚酰胺树脂、聚醚砜树脂、聚醚醚酮树脂、液晶聚合物、聚芳砜树脂、聚酰胺酰亚胺树脂、聚酞亚胺树脂、尼龙6，6、聚酰胺树脂、间同立构聚苯乙烯、及其混合物。在一个特别优选的实施方案中，材料是从聚酰胺、聚苯乙烯、聚烯烃、聚碳酸酯、或其混合物选择的一种热塑性材料。更优选，材料从聚酰胺(如尼龙6，6)、聚苯乙烯或其混合物选择。在一个优选实施方案中，材料是聚酰胺和聚苯乙烯的混合物，并且更优选是尼龙6，6和间同立构聚苯乙烯的混合物。其中有用的材料是环氧树脂。
用来制备元件的塑料一般也包括其它成分，如加强剂、性能改进剂(例如，冲击改进剂、阻燃剂、UV保护剂等)或其它适当填充剂(例如，碎玻璃、矿物质、滑石粉、碳酸钙等)。例如，在一个实施方案中，塑料以约10至约50体积百分比和更优选是约35体积百分比的量被填充玻璃。最好，选择的材料呈现至少约175MPa并且更优选至少约225MPa的拉伸强度、和约1至约10％并且更优选约3至约5％的延长。材料也是耐热的，并且不退化地承受至少约135℃(约275)并且更优选177℃(350)至少约144小时并且更优选168小时。
当然，元件的一个或多个可以是一种金属(例如，铸铁、钢、镁、铝、钛等)、一种合成物、一种陶瓷(例如，碳化物、氮化物、氮化硼等)、或某种其它材料。元件最好使用常规技术和处理条件注射模压。或者，它们可以以另一种适当方式制备，如通过压缩模塑、热成形、吹喷成型等。
元件之一或二者的材料或粘合剂的任一种或两种可以按所需的适当处理(均匀地或局部地)，以改进耐腐蚀、抗氧化、耐热，或最终产品的另一种特性。例如，它们可以掺杂、浸渍或涂敷有用来达到所需的性能的适当添加剂。在某些情况下，通过进一步把粘合剂与适当底层涂料接触可以增强粘合强度。
本发明的粘合剂是一种结构粘合剂，并且更优选是一种可按要求熟化的材料。能使用在熟化后能承受发动机(例如，用于汽车的)的使用条件的任何粘合剂。优选这样的粘合剂在高达约138℃(280)，更优选高达约143℃(290)，甚至更优选高达约160℃(320)及最优选高达191℃(375)的温度下不会分解或分层。
而且，粘合剂在对其内燃机内部达到的上述温度和压力下，能够承受暴露于烃类材料、氯化钙、制动液、甘醇冷却剂、挡风玻璃喷洗溶剂等。在一个可选择实施方案中，粘合剂能够粘结到可以是金属、陶瓷、合成物、塑料等的其它发动机元件上。使用的粘合剂可以是通过包括热熟化、红外熟化、紫外熟化、化学熟化、射频熟化、溶剂损失、及湿态熟化的各种已知机理来熟化的粘合剂。
在另一个实施方案中，粘合剂是一种要求分离操作以使粘合剂开始熟化的按要求熟化粘合剂。在一个实施方案中，这通过使用在组装期间破裂的封装熟化剂实现。在另一个实施方案中，这通过除去保护涂层以把粘合剂暴露于环境条件实现。熟化能通过把粘合剂暴露于热量、红外或紫外光源、或剪力等开始。
尽管也想到其它粘合剂族(例如，尿烷、丙烯酸、硅烷等)，但所需的粘合剂是高温环氧树脂、聚酰胺、上流聚酰胺/环氧树脂粘合剂或环氧酚酸/腈橡胶粘合剂。最佳粘合剂是高温环氧树脂粘合剂。高温环氧树脂粘合剂是指一种其中主要成分是一种当熟化时能承受对于上述温度的暴露而不分解或从基片分层的环氧树脂。
在一个具体优选实施方案中，粘合剂是一种包括一种或多种常规或改进环氧成分、一种适当熟化剂及一种用来保持室温Brookfield粘度(在未熟化状态下)在约500cps量级上的适当触变剂的矿物质填充催化粘合剂。
应该认识到，这里的术语粘合剂不打算从本发明的范围排除涂料或其它粘结剂。
本发明具有显著的设计灵活性。尽管配合表面能是平面的，但它们不必是平面的。在一个优选实施方案中，配合表面的任一个或两个一般不是平面的(例如，等高的、台阶的、波纹的等)。模压塑料元件的采用也使复杂形状结构的形成成为可能。在这方面，能模压吸气歧管，或在其表面之一中或上面构造诸如托架、连接物、电缆导向装置、软管导向装置、吊带、夹片等之类的一个或多个元件。而且，能把导管、端口或其它类似通道钻入或机加工进入一个模压元件，以使多个元件能够与吸气歧管组件一体地形成。
如由熟悉本专业的技术人员理解的那样，其中本发明的多个优点是能形成基本上没有密封垫片、机械紧固件或两者的组件。然而，本发明的范围不排除垫片或紧固件的使用。的确，想到垫片可以由粘合剂(例如，通过模具切削)形成，或者作为其一个元件(例如，作为浸渍剂或涂层)包括本发明的粘合剂。生成结构更像垫片那样密封，但也呈现结构粘合剂的所需的机械特性。
特别参照图3a-3c，能看到接合在接合处有一个横截面厚度(t)。尽管可以使用较大的截面厚度并且保持在本发明的范围内，但在某些高度优选的实施方案中，截面厚度小于约7mm，并且甚至更优选小于约5mm(例如，约3至约4mm)。这进一步使本发明变得比一般采用较大截面厚度的先前组件更为便利。
本发明相对于振动焊接组件的另一个优点在于，与粘合剂接触的第一和第二配合表面的整体基本上能够跨过接合点连续地粘结到粘合剂上，并且由此增强接合强度。相反，在振动焊接填充或增强塑料的场合，在焊接界面处没有焊接填充剂或增强剂(例如，玻璃)。因而，跨过界面，有阻止高焊接强度实现的间断。
尽管在汽车发动机吸气歧管的上下文中已经描述了本发明，但本发明的使用不打算由此限制。采用经受比由汽车发动机经历的那些温和或与之可比较的操作条件的吸气歧管的任何机动物体可以采用本技术。
在制备本组件时，通过以常规方式把粘合剂与一个或多个配合表面接触涂敷粘合剂，以形成一个连续条或膜。可以把粘合剂通过涂敷、挤压涂刷等涂到表面上。在接合元件之前能立即涂敷粘合剂，或者它能从远离其中把元件粘结在一起的位置、或发动机涂敷。把最佳按要求熟化的粘合剂暴露于各种条件，从而它熟化并且由此把元件粘结在一起和在它们之间形成密封。这样的条件能在为了接合把元件带到一起之前或之后施加。熟悉本技术的平均水平的技术人员可以很好地确定可以使用哪种操作熟化粘合剂和何时应该进行该操作。在一个实施方案中，操作可以是一种在组件中固有的操作或汽车的操作。
在另一个实施方案中，吸气歧管组件可以包括一个设计成防止在内燃机的操作中固有的噪声逃逸发动机腔的集成声学管理系统。在一个实施方案中，组件可以包括一个外壳和一个内壳，内壳适于布置在外壳内，并且在两者之间有一个间隙。间隙可以简单地包含能衰减某些声波的空气，由此减小在发动机外部能听到的噪声。或者，间隙能填充有一种消音材料，如弹性材料或泡沫材料。在另一个实施方案中，吸气歧管可以向其内表面上粘结一种消声材料，如弹性体或泡沫。
在另一个实施方案中，本发明的吸气歧管组件能包括一个在外部或内部上起改进吸气歧管对烯烃的绝缘性能作用的涂层或薄膜。这样一种涂层或薄膜能减少来自汽车的逃逸烃类排出。可以使用防止烃类穿过组件传输的任何涂层或薄膜。一种最佳涂层是一个碳-硅石基等离子体沉积涂层，如在通过参考包括在这里的美国专利5,298,587；美国专利5,320,875；美国专利5,433,786及美国专利5,494,712中描述的那样。
本发明的组件能够承受约163℃(约325)的温度至少约2500小时，并且更优选约3000小时；及约177℃(约350)至少约75小时并且更优选约100小时。组件在汽车流体，如制动流体、挡风玻璃喷洗流体、动力转向流体、发动机冷却剂(标准和永久的)、机油(标准、合成和含硫的)，汽油、柴油燃料、乙醇、甲醇、启动流体等的存在下呈现基本上没有可探测的退化。组件由于对于诸如氯化钙、氯化钠、废气(egr型)等环境遇到化合物的暴露也呈现没有可探测的退化。在一个具体优选实施方案中，在组件中接合粘合剂的生成拉伸强度至少约4000psi(28MPa)，更优选至少约6500psi(45MPa)，及甚至更优选至少约9000psi(62MPa)。进一步优选接合强度大于各个模压元件的至少一个且更优选多于一个的强度。
本吸气歧管组件能与其它粘合剂粘结发动机元件组合采用，如在结合参考的共有待决申请09/766,792(标题为Adhesively BondedValve Cover Cylinder Head Assembly)中描述、和在结合参考的共有待决申请No.09/825,721(标题为Adhesively Bonded RadiatorAssembly)中公开的那样。

Claims (17)

1.一种发动机吸气歧管组件，包括：
a)一个第一元件，带有一个相联的第一配合表面，所述第一元件由玻璃填充塑料制成，并且以大约10体积百分比至大约50体积百分比的量而被玻璃填充；
b)一个第二元件，该第二元件用模压塑料制成，并带有一个相联的第二配合表面；
c)一层粘合剂，其中所述第一配合表面和所述第二配合表面通过该粘合剂以及一个机械附件而被接合到一起，并且其中该组件包括介于第一和第二元件之间的一个连接，其中所述连接选自搭接连接或企口接合连接。
2.根据权利要求1所述的组件，其中所述第一和第二元件的配合表面包括大致非平面的第一配合表面。
3.根据权利要求1所述的组件，其中所述粘合剂是一种结构粘合剂。
4.根据权利要求1所述的组件，其中所述粘合剂是一种按要求熟化粘合剂。
5.根据权利要求3所述的组件，其中所述粘合剂是一种高温环氧树脂粘合剂。
6.根据权利要求5所述的组件，其中所述粘合剂是一种高温矿物填充催化粘合剂，该粘合剂包括环氧组分、熟化剂以及触变剂，其中按要求熟化粘合剂是通过去除保护涂层从而将该粘合剂暴露于环境条件下而熟化的。
7.根据权利要求1所述的组件，其中所述粘合剂通过化学熟化而被熟化。
8.根据权利要求1所述的组件，其中所述粘合剂通过溶剂损失而被熟化。
9.根据权利要求1所述的组件，其中所述第一元件包括模压塑料。
10.根据权利要求9所述的组件，其中所述第一元件和所述第二元件由选自下列组群的塑料模压而成：填充聚酰胺、以及填充聚酰胺/聚苯乙烯塑料。
11.根据权利要求9所述的组件，其中所述第一元件和所述第二元件是被填充或增强的塑料。
12.根据权利要求1所述的组件，其中所述第一和第二元件中的至少一个被限定为包括一个外壳和一个内壳，从而所述内壳位于所述外壳之内，并且在二者之间形成一个空气间隙，并且其中所述空气间隙适于被填充一种消音材料。
13.根据权利要求1所述的组件，其中所述第一和第二元件中的至少一个具有通道，该通道钻入或者机加工进入模制元件，从而使得多个元件能被一体化进入所述进气歧管组件，例如托架、连接物、电缆导向装置、软管导向装置、吊带、夹片。
14.根据权利要求9所述的组件，其中所述第一和第二元件每一个均包括一个一体成型部件，该部件在所述第一塑料元件和所述第二塑料元件之间形成一个咬合连接。
15.根据权利要求9所述的组件，其中所得到的连接具有的强度大于所述第一和第二模压塑料元件中的至少一个的强度。
16.根据权利要求1所述的组件，其中所得到的连接具有的强度大于第二模压塑料元件的强度。
17.根据权利要求1所述的组件，其中所述元件中的至少一个包括一个法兰，该法兰具有一个内壁表面。
CNB028073746A 2001-04-04 2002-04-02 胶粘结发动机吸气歧管组件 Expired - Fee Related CN100334343C (zh)

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EP1377742A1 (en) 2004-01-07
KR20030085586A (ko) 2003-11-05
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US20020148427A1 (en) 2002-10-17
MXPA03009061A (es) 2004-02-17
US7213560B2 (en) 2007-05-08
RU2003132165A (ru) 2005-04-10
RU2284421C2 (ru) 2006-09-27
CA2443048A1 (en) 2002-10-17
US20030084864A1 (en) 2003-05-08
WO2002081899A1 (en) 2002-10-17
US7475664B2 (en) 2009-01-13
US20070251483A1 (en) 2007-11-01
CN1511225A (zh) 2004-07-07
US6543404B2 (en) 2003-04-08

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