U.S. patent application number 11/369147 was filed with the patent office on 2006-07-06 for method of adhering members and an assembly formed thereby.
This patent application is currently assigned to L&L Products, Inc.. Invention is credited to Ronald Bogert, Christopher Hable.
Application Number | 20060144513 11/369147 |
Document ID | / |
Family ID | 32511768 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060144513 |
Kind Code |
A1 |
Bogert; Ronald ; et
al. |
July 6, 2006 |
Method of adhering members and an assembly formed thereby
Abstract
The method of adhering members includes positioning of an
adhesive material between an attachment surface of a first member
(e.g., a door beam) and a second member (e.g., a bracket).
Thereafter, the adhesive material is at least partially cured to
adhere the material to the attachment surface to form an assembly
and the assembly is assembled to an article of manufacture (e.g.,
an automotive vehicle).
Inventors: |
Bogert; Ronald; (Brown City,
MI) ; Hable; Christopher; (Romeo, MI) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST
SUITE 210
PONTIAC
MI
48326
US
|
Assignee: |
L&L Products, Inc.
Romeo
MI
|
Family ID: |
32511768 |
Appl. No.: |
11/369147 |
Filed: |
March 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10685221 |
Oct 14, 2003 |
7041193 |
|
|
11369147 |
Mar 6, 2006 |
|
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|
60470511 |
May 14, 2003 |
|
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Current U.S.
Class: |
156/307.3 ;
29/897.2 |
Current CPC
Class: |
B60J 5/0437 20130101;
C08L 63/00 20130101; C09J 2463/00 20130101; Y10T 29/49622 20150115;
B29C 2035/0822 20130101; F16B 11/008 20130101; C09J 2400/243
20130101; C09J 5/06 20130101 |
Class at
Publication: |
156/307.3 ;
029/897.2 |
International
Class: |
C09J 5/02 20060101
C09J005/02 |
Claims
1-30. (canceled)
31. A method of reinforcing a door of an automotive vehicle, the
method, comprising: providing an elongated reinforcement member;
providing a bracket; and at least partially curing an adhesive
material such that the adhesive material adheres to the
reinforcement member and the bracket, the adhesive material located
substantially entirely between the bracket and the elongated
reinforcement member.
32. A method as in claim 31, further comprising: assembling the
reinforcement member to the door of the automotive vehicle; and
further curing the structural adhesive material to further secure
the bracket to the reinforcement member.
33. A method as in claim 31 wherein the step of at least partially
curing the adhesive material includes exposing the adhesive
material to at least one of heat, pressure, radiation, microwaves,
electricity or a combination thereof.
34. A method as in claim 31, further comprising: at least partially
supporting a foam block with the bracket.
35. A method as in claim 31 wherein the adhesive material is epoxy
based.
36. A method as in claim 31 wherein the adhesive material is a
thermosettable material that includes an amine curing agent.
37. A method as in claim 31 wherein the adhesive material includes
a blowing agent.
38. A method as in claim 31 wherein the step of at least partially
curing the adhesive material leaves the adhesive material between
about 30% and about 97% cured.
39. A method as in claim 31 wherein the step of at least partially
curing the adhesive material includes substantially fully curing
the adhesive material.
40. A method as in claim 31, further comprising: further curing the
adhesive material by exposing the adhesive material to elevated
temperatures in a painting or e-coat process.
41. A method as in claim 31 wherein the step of at least partially
curing the adhesive material includes exposing the adhesive
material to heat for a time period that results in a partial
cure.
42. A method as in claim 31 wherein the time period is between
about 3 minutes and about 10 minutes.
43. A method as in claim 31 further comprising: substantially fully
curing the adhesive material in a painting or e-coat process.
44. A method as in claim 31 wherein the step of at least partially
curing the adhesive material includes placing the door beam,
bracket and adhesive material within a heating structure.
45. A method as in claim 31 wherein the step of at least partially
curing the adhesive material includes only locally exposing the
material to heat without exposing a substantial portion of the door
beam to heat.
46. A method of reinforcing a door of an automotive vehicle, the
method, comprising: providing an elongated reinforcement member,
the reinforcement member being a door reinforcement beam having a
first attachment at a first end of the beam and a second attachment
at the second end of the beam, wherein the first end is opposite
the second end and the first attachment and the second attachment
are configured for attachment to a door of the vehicle adjacent
opposite sides of the door; providing a bracket comprised of a
first member and second member; welding flanges of the first member
to flanges of the second member; and an at least partially heat
curing an adhesive material in an oven such that the adhesive
material adheres to the reinforcement member and the bracket, the
adhesive material located substantially entirely between the
bracket and the elongated reinforcement member.
47. A method as in claim 46, further comprising: at least partially
supporting a foam block with the bracket.
48. A method as in claim 46 wherein the adhesive material is epoxy
based.
49. A method as in claim 46 wherein the step of at least partially
curing the adhesive material includes placing the door beam,
bracket and adhesive material within a heating structure.
50. A method of reinforcing a door of an automotive vehicle, the
method, comprising: providing an elongated reinforcement member,
the reinforcement member being a door reinforcement beam having a
first attachment at a first end of the beam and a second attachment
at the second end of the beam, wherein the first end is opposite
the second end and wherein the beam includes a tubular member
extending between the first end and second end of the beam;
providing a bracket comprised of a first member and second member;
welding flanges of the first member to flanges of the second member
such that the bracket surrounds at least a portion of the tubular
member; and at least partially heat curing adhesive material by
placing the door beam, bracket and adhesive material within a
heating structure to adhere the reinforcement member to the
bracket, the adhesive material located substantially entirely
between the bracket and the elongated reinforcement member wherein
the adhesive material is epoxy based; transporting the
reinforcement after the adhesive material adheres to the bracket
and the reinforcement. attaching a mass of foam attached to the
bracket; attaching the first attachment and the second attachment
to a door of the vehicle adjacent opposite sides of the door; and
further curing the structural adhesive material to further secure
the bracket to the reinforcement member.
Description
CLAIM OF BENEFIT OF FILING DATE
[0001] The present application claims the benefit of the filing
date of U.S. Provisional Application Ser. No. 60/470,511, filed May
14, 2003, hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a method of
adhering a first member to a second member and an assembly formed
thereby. More particularly, the present invention relates to a
method of adhering at least one structural reinforcement member to
another member with a structural adhesive material to form a
reinforcement assembly.
BACKGROUND OF THE INVENTION
[0003] For many years, industry has been adhering members together
for a wide variety of applications. As one example, members may be
adhered together to form a reinforcement assembly for an article of
manufacture such as an automotive vehicle. Current methods of
adhering members together, however, suffer from a variety of
drawbacks.
[0004] As one example, adhesives require significant cure times to
adequately adhere one member to another member such that movement
(e.g., transportation) of the members does not undesirably alter
the orientation of one member relative to another. As a result,
these adhesive curing times can add significant time delays for
assembly of articles of manufacture.
[0005] Therefore, the present invention provides an adhesion
process, which overcome the aforementioned exemplary drawback or
other drawbacks related to the adhering of members together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The features and inventive aspects of the present invention
will become more apparent upon reading the following detailed
description, claims, and drawings, of which the following is a
brief description:
[0007] FIG. 1 is a blown up perspective view of an assembly that
may be formed according to an aspect of the present invention.
[0008] FIG. 2 illustrates a portion of a method of adhering members
together according to an aspect of the present invention.
[0009] FIG. 3 illustrates another portion of a method of adhering
members together according to an aspect of the present
invention.
[0010] FIG. 4 illustrates an assembly formed in accordance with an
aspect of the present invention.
[0011] FIG. 5 illustrates another portion of a method of adhering
members together according to an aspect of the present
invention.
[0012] FIG. 6 illustrates another portion of a method of adhering
members together according to an aspect of the present
invention.
[0013] FIG. 7 illustrates a door of an automotive vehicle in
accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The present invention is predicated upon providing an
improved method of adhering a first member to a second member to
form an assembly for an article of manufacture. The method has
found particular utility for forming a reinforcement assembly for
an automotive vehicle although it is contemplated that the method
may be applied to form a variety of assemblies for a variety of
articles of manufacture such as airplanes, boats, buildings,
furniture or the like.
[0015] Accordingly, the method of the present invention typically
includes one or more of the following steps: [0016] 1) positioning
an adhesive material between a surface of a first member and a
surface of a second member; [0017] 2) at least partially curing the
adhesive material to attach the first member to the second member
thereby forming an assembly; [0018] 3) transporting the assembly
from a first location to a second location; and [0019] 4) further
curing the adhesive material.
[0020] Referring to FIGS. 1 through 7, there is illustrated one
exemplary embodiment of an assembly 10 being formed in accordance
with the present invention. The assembly 10 is provided for
purposes of illustration of the present invention. It is
contemplated that alternative assemblies may be formed in
accordance with the teachings of the present disclosure. Some of
those alternative assemblies are disclosed below, however, the
skilled artisan will appreciate that many other alternatives may
also be employed in the practice of the present invention.
[0021] The assembly 10 includes a first member 14 being attached to
a second member 16 with an adhesive material 12. The first member
14 is shown for illustrative purposes as a reinforcement beam for
reinforcing a component of an automotive vehicle such as a vehicle
door. The second member 16 is illustratively shown as a bracket
that is composed a first structure 20 and a second structure
22.
[0022] The first member 14 includes an elongated member 28 (e.g., a
cylindrical pipe) extending between a first attachment 30 and a
second attachment 32 (e.g., a first and second bracket). Both
structures 20, 22 of the second member 16 include an arcuate
portion 34 with a pair of flanges 36 extending therefrom.
Preferably, both the first member 14 and the second member 16
respectively provide attachment surfaces 38, 40 suitable for
adhesion.
[0023] While the first member 14 and second member 16 are
respectively illustrated as a reinforcement beam and a bracket, it
is contemplated that the first member may be formed in a variety of
configurations depending upon its intended application within an
article of manufacture. Within automotive applications, for
example, the members may be frame members, body members or panels,
reinforcing members, pillars, bumpers, closure panels, combinations
thereof or the like. As another example, the method may be used to
attach a fastener such as a clip to a member such as a beam.
[0024] In the embodiment shown, the first member 14 and the second
member 16 including the first attachment 30 the second attachment
32, and both structures 20, 22 are preferably formed of metal
(e.g., steel, aluminum, magnesium, iron, combinations thereof or
the like). It is contemplated, however, that the members 14, 16 and
their respective components may be formed of polymeric materials,
plastics or other materials.
[0025] The adhesive material 12 is shown as a rectangular strip,
although it is possible to shape the adhesive material 12 into
nearly any desired configuration, which may be continuous or
non-continuous. Moreover, it is possible that the adhesive material
may be pumped into repeated similar configuration or varying
configurations. Preferably, the adhesive material 12 is a
structural material that exhibits high strength to weight under
stress conditions.
[0026] One preferred structural adhesive material suitable for use
in the present invention is disclosed in copending U.S. patent
application Ser. No. 10/386,287, filed Mar. 11, 2003 and titled,
"Activatable Material", and is expressly incorporated herein by
reference for all purposes. Accordingly, this exemplary preferred
structural material includes a mixture of epoxy resin (e.g.,
between about 20% and about 80% by weight) and an
elastomer-containing adduct (e.g., between about 20% and about 80%
by weight). It shall be understood, however, that the skilled
artisan will be able to conceive of various alternative suitable
adhesive materials within the scope of the present invention.
[0027] The adhesive material 12 may be activatable (e.g.,
activatable to expand, cure or both) and may be tacky or non-tacky
prior to partial or full cure. For example, the adhesive material
12 may be heat expandable, but is preferably non-expandable or only
slightly expandable (e.g. expandable to between about 100% and
about 115% it pre-expanded size). Of course, greater amounts of
expansion may be experienced as discussed herein. The adhesive
material 12 may also be heat curable.
[0028] According to one preferred embodiment, the adhesive material
includes a conductive filler that imparts conductivity to the
material. Exemplary conductive fillers include, without limitation,
carbon black, carbon fibers, metal coated fillers (e.g., metal
coated carbon fibers), combinations thereof or the like. Other
examples include metal containing material such as iron phosphides,
oxides such as tin oxide (e.g., which may be antimony doped), metal
coated glass spheres, graphite, combinations thereof or the like.
Preferably, when included, the conductive filler composes about 1%
to about 30% by weight, more preferably 5% to about 20% by weight
and even more preferably 7% to about 13% by weight of the
expandable material.
[0029] Preferably, the adhesive material has flowable or foamable
characteristics, although not required. The material may be
generally dry to the touch or tacky and can be placed intermediate
the members 14, 16 in any form of desired pattern, placement, or
thickness, but is preferably a substantially uniform thickness. One
exemplary material is L-5020 structural tape available through
L&L Products, Inc. of Romeo, Mich.
[0030] Though other materials are certainly possible for the
adhesive material, a preferred adhesive material is an expandable
or non-expandable polymeric material (e.g., a plastic, a thermoset
or the like). A particularly preferred material is an epoxy-based
structural adhesive. For example, without limitation, the
structural adhesive may be an epoxy-based material, including an
ethylene copolymer or terpolymer that may possess an alpha-olefin.
As a copolymer or terpolymer, the polymer is composed of two or
three different monomers, i.e., small molecules with high chemical
reactivity that are capable of linking up with similar
molecules.
[0031] A number of epoxy-based structural materials are known in
the art and may be used for the present invention. A typical foamed
or unfoamed structural material includes a polymeric base material,
such as an epoxy resin or ethylene-based polymer which, when
compounded with appropriate ingredients (typically a curing agent
and optionally a blowing agent), can soften, flow, expand, cure, a
combination thereof or the like in a reliable and predictable
manner upon the application of heat or the occurrence of a
particular ambient condition. From a chemical standpoint, the
structural adhesive material is usually initially processed as a
flowable thermoplastic material before curing. It will cross-link
upon curing, which makes the material incapable of further
flow.
[0032] An example of a preferred formulation for the adhesive
material is an epoxy-based material that is commercially available
from L&L Products of Romeo, Mich., under the designations
L5206, L5207, L5208, L5209, L5224, L5225, L5020, L5001, L8120. One
advantage of the preferred adhesive materials over prior art
materials is that the preferred materials can be processed in
several ways. The preferred materials can be processed by injection
molding, pumping, die-cutting (e.g., rotary die-cutting),
extrusion, compression molding or with a mini-applicator. This
enables the formation and creation of part designs that exceed the
capability of most prior art materials.
[0033] While the preferred materials for fabricating the adhesive
material have been disclosed, the material can be formed of other
materials provided that the material selected is heat-activated or
otherwise activated by an ambient condition (e.g. moisture,
pressure, time or the like) and cures in a predictable and reliable
manner under appropriate conditions for the selected application.
One such material is the epoxy based resin disclosed in U.S. Pat.
No. 6,131,897, the teachings of which are incorporated herein by
reference. Some other possible materials include, but are not
limited to, polyolefin materials, copolymers and terpolymers with
at least one monomer type an alpha-olefin, phenol/formaldehyde
materials, acrylic materials, phenolic materials, urethane
materials, phenoxy materials, and polyurethane materials with high
glass transition temperatures. See also, U.S. Pat. Nos. 5,766,719;
5,755,486; 5,575,526; 5,266,133; 5,575,526; 5,932,680; and WO
00/27920 (PCT/US 99/24795) (all of which are expressly incorporated
by reference). In general, it is desirable for the expandable
material to have good corrosion resistance properties. Preferably,
the material will withstand the processing conditions typically
encountered in the manufacture of a vehicle, such as the e-coat
priming, cleaning and degreasing and other coating processes, as
well as the painting operations encountered in final vehicle
assembly.
[0034] In applications where the adhesive material is a heat
activated material, an important consideration involved with the
selection and formulation of the material comprising the adhesive
is the temperature at which a material reaction or expansion, and
possibly curing, will take place. For instance, in most
applications, it is undesirable for the material to be reactive at
room temperature or otherwise at the ambient temperature in a
production line environment. More typically, the structural
ahdesive becomes reactive at higher processing temperatures, such
as those encountered in an automobile assembly plant, when the
material is processed along with the automobile components at
elevated temperatures or at higher applied energy levels, e.g.,
during painting preparation steps. While temperatures encountered
in an automobile assembly operation may be in the range of about
148.89.degree. C. to 204.44.degree. C. (about 300.degree. F. to
400.degree. F.), body and paint shop applications are commonly
about 93.33.degree. C. (about 200.degree. F.) or slightly higher.
If needed, blowing agent activators can be incorporated into the
composition to cause expansion at different temperatures outside
the above ranges.
[0035] In another embodiment, the adhesive material is provided in
an encapsulated or partially encapsulated form, which may comprise
a pellet, which includes an expandable foamable material,
encapsulated or partially encapsulated in an adhesive shell. An
example of one such system is disclosed in commonly owned,
co-pending U.S. application Ser. No. 09/524,298 ("Expandable
Pre-Formed Plug"), hereby incorporated by reference.
[0036] In addition, as discussed previously, preformed patterns may
also be employed such as those made by extruding a sheet (having a
flat or contoured surface) and then die cutting it according to a
predetermined configuration in accordance with the chosen member or
panel, and applying it thereto.
[0037] Prior to applying the adhesive material 12 to one or both of
the members, it may optionally be desirable to treat one or more
surfaces (e.g., the attachment surfaces 38, 40) of the members for
increasing the suitability of the surfaces to adhesion. Exemplary
treatments include, without limitation, exposure of the surfaces to
radiation (e.g., infrared or UV radiation), a laser, plasma,
combinations thereof or the like. Other exemplary treatments may
include applying a primer or other coating to the surfaces. Still
other treatments can include cleaning of the surfaces with solvents
or other cleaners, wiping of the surfaces, a combination thereof or
the like. It is also contemplated that treatments may participate
(e.g., be chemically active) in bonding the adhesive material to
the members such as by treating the members with a catalyst, a
second adhesive material, a combination thereof or the like.
[0038] The adhesive material 12 may be applied to the first member
14, the second member 16 or both using a variety of techniques,
which may be manual, semi-automatic or automatic, for forming the
assembly 10 in accordance with the present invention. The adhesive
material 12 may be applied to the first member 14 then the second
member 16, the second member 16 then the first member 14 or
simultaneously to both members 14, 16.
[0039] According to one preferred embodiment, and referring to FIG.
2, the adhesive material 12 is extruded in strips 48 onto a release
material shown as a release tape or release liner 50. Preferably,
the release liner 50 is provided as continuous for several strips
of adhesive material, but may be provided as a separate piece or
sheet for each strip. Thereafter, the release liner 50 is advanced
adjacent to the first member 14 such that at least one strip 48 of
the adhesive material 12 is released from the release liner 50 and
applied to (e.g., contacted with) the attachment surface 38 of the
first member 14. In the preferred embodiment, the first member 14
is moved (e.g., rotated) such that the strip 48 is substantially
evenly applied to the attachment surface 38.
[0040] Both the movement of the first member 14 and the advancement
of the liner 50 may be accomplished using various techniques, which
may be manual, semi-automatic or automatic. In one example, the
first member 14 is manually placed upon supports (not shown), which
automatically rotate the first member 14 as the liner 50 is
advanced. Moreover, the release liner 50 may be advanced on rolls
(not shown).
[0041] The adhesive material 12 is also preferably applied to
(e.g., contacted with) the attachment surface(s) 40 of the second
member 16 to form the reinforcement assembly 10. In a preferred
embodiment shown in FIG. 3, the first structure 20 and the second
structure 22 are positioned about the first member 14 such that the
flanges 36 of the structures 20, 22 are in substantially opposing
relation to each other and such that the elongated member 28 of the
first member 14 is received within cavities 56 formed by the
arcuate portions 34 of the structures 20, 22. As shown, the arcuate
portions 34 of the structures 20, 22 substantially surround the
elongated member 28 thereby locating the adhesive material 12
between the attachment surfaces 38, 40 of the first and second
members 14, 16.
[0042] In the preferred embodiment, the first structure 20 of the
second member 16 is attached to the second structure 22 of the
second member 16 during formation of the assembly 10. As shown in
FIG. 3, the opposing flanges 36, are welded (e.g., spot-welded) to
each other with electrodes 70. Preferably, for such welding, the
first member 14, the second member 16 or both are held in place by
supports, although not required.
[0043] While one specific preferred embodiment for applying the
adhesive material 12 to the attachment surfaces 38, 40 of the
members 14, 16 and forming the assembly 10 has been disclosed, it
shall be appreciated that the skilled artisan will be able to
imagine a variety of alternative application techniques within the
scope of the present invention. As one example, the adhesive
material may be extruded onto one or more of the attachment surface
of the members with an extruder (e.g., a mini-applicator). As
another example an individual may manually place the adhesive
material in contact with one or more of the attachment surfaces. As
another example, the adhesive material may be applied to an
attachment surface of one member (e.g., the bracket or the pipe)
with a strip of release material thereon and the release material
may be removed (e.g., manually, mechanically or both) followed by
contacting an attachment surface of the other member with the
adhesive material.
[0044] Additionally, it is contemplated that alternatives to the
discussed welding step may be employed. For example, and without
limitation, the first structure 20 may be mechanically secured or
interference fit to the second structure using mechanical fasteners
such as snap-fits, rivets, screws, toggle locks, combinations
thereof or the like. As other alternative examples, magnets or
additional adhesives may be employed in place of welding. Moreover,
it is contemplated that a multi-station assembly such as turntable
may be employed during welding such that members may be loaded and
unloaded from the multi-station assembly while members or
structures of the members are being welded or otherwise secured
together.
[0045] In other alternative embodiments, it is contemplated that
the adhesive material 12 may be the only attachment of the second
member 16 to the first member 14 such that welding or fastening
mechanisms are unneeded. For example, in one embodiment, it is
contemplated that only one of the structures 20, 22 illustrated or
other structures may comprise the second member 14 and that second
member may be secured to the first member 14 with only the adhesive
material.
[0046] Once the adhesive material 12 has been applied to the
attachment surfaces 38, 40 of the first member 14, the second
member 16 or both, the adhesive material 12 undergoes an initial
cure wherein the material 12 is at least partially cured to assist
in securing the first member 14 to the second member 16.
Preferably, the initial cure is a partial cure although it may be a
full cure. A partial cure, as used herein, typically means between
about 10% and about 99.5% cured, more typically between about 30%
and about 97% cured and even more typically between about 50% and
about 94% cured.
[0047] Depending upon the type of adhesive, various curing
techniques may be used for performing the initial cure such as
exposure to heat, exposure to chemicals (e.g., cross-linking
agents), exposure to moisture, exposure to light or radiation
(e.g., UV radiation), exposure to pressure, exposure to microwaves,
combinations thereof or other techniques. Other possible techniques
include a partial chemical cure followed by curing due to exposure
to heat, employment of an encapsulated curing agent or other
chemical followed by opening of the encapsulation by application of
pressure or heat, employment of blocked curing agents, curing by
heat induced by flowing electrical current through the adhesive
material (e.g., during welding), combinations thereof or the
like.
[0048] In FIG. 5, according to a preferred embodiment, the adhesive
material 12 is exposed to infrared (IR) radiation for elevating a
temperature of the adhesive material 12 to perform the initial
cure. In the particular embodiment shown, the first member 14 of
the assembly 10, the second member 16 of the assembly 10 or both
are positioned upon one or more supports 90 for assisting in
positioning the members 14, 16 relative to each other during
initial cure.
[0049] As shown, at least a portion of the assembly 10 is exposed
to a heat source 94 such that the temperature of the adhesive
material 12 is elevated thereby at least partially curing the
adhesive material 12. In turn, the curing of the adhesive material
assists in securing the first member 14 to the second member 16. In
the particular embodiment illustrated, the assembly 10 is advanced
by a conveyor 100 while maintaining the adhesive material below an
infrared elongated lamp as the heat source 94. As shown, only a
localized portion of the assembly 10 adjacent the adhesive material
12 needs to be exposed.
[0050] Advantageously, heating of a localized portion of the
assembly allows faster cooling of the assembly after exposure to
heat source, particularly since the rest of the assembly can act as
a heat sink to remove heat from the localized portion. However, it
is contemplated within the scope of the present invention, that an
entire assembly or group of entire assemblies may be heated, for
example by placing them within a large oven or other heating
structure.
[0051] Preferably, the heat source 94 is configured to produce a
temperature about the adhesive material 12 of between about
200.degree. F. and about 1000.degree. F., more preferably between
about 350.degree. F. and about 750.degree. F. and even more
preferably between about 500.degree. F. and about 600.degree. F.
Also preferable, the adhesive material 12 is exposed to the
temperature for a time period of between about 1 and about 20
minutes, more preferably between about 3 and about 10 minutes and
even more preferably between about 4 and about 6 minutes. During
the time period, the adhesive is cured at least about 20% more
preferably at least about 50% and even more preferably at least
about 80% during the initial cure. Of course, the temperature for
curing, time of curing and amount of curing can vary depending upon
the cure system of any particular adhesive material used.
[0052] After the initial cure, the assembly 10 is typically
transported from a first location adjacent the heat source 94 to a
second location, which is suitable for attachment of the assembly
10 to an article of manufacture. For example, in the preferred
embodiment, and referring to FIG. 6, the assembly 10 is placed upon
a rack 110 for transportation (e.g., by motor vehicle) from a first
manufacturing facility (e.g., an automotive vehicle parts supplier
facility) suitable for forming the assembly to a second facility
(e.g., an automotive vehicle assembly plant) suitable for
assembling an article of manufacture to which the assembly 10 is
applied.
[0053] As can be seen, the assembly 10 is supported by the rack 110
at the first end attachment 30 of the first member 14 such that the
second end attachment 32 of the first member 14 hangs below the
first end attachment 30. In turn, the structural adhesive material
12 is at least partially required to support the second member 16
by securing the second member 16 to the first member 14. In the
particular embodiment shown, the first and second members 14, 16 do
not contact each other and only the adhesive material 12 contacts
both the first and second member 14, 16. Thus, the adhesive
material 12 provides the only link between the first and second
members 14, 16 and is therefore primarily responsible for
supporting the second member 16 relative to the first member
14.
[0054] Advantageously, the adhesive material 12 is secured to the
first member 14 and the second member 16 with greater integrity due
to the initial cure. As such, the first member 14 and second member
16 are less likely to move relative to each other during
transportation of the assembly 10. Thus, the second member 16 is
well supported by the adhesive material 12.
[0055] After transportation, the assembly 10 is attached to an
article of manufacture, which, in FIG. 7, is illustrated as a door
120 of an automotive vehicle. Of course, as discussed, it is
contemplated that the assembly 10 may be applied to various
portions of an automotive vehicle and may also be attached to
various articles of manufacture. As shown, the first end bracket 30
and the second end bracket 32 are attached (e.g. mechanically
fastened or welded) to the door 120 adjacent opposite sides 122,
124 of the door 120.
[0056] Generally, it is contemplated that various alternatives or
alterations to the initial cure, transportation and assembly steps
may also be employed. For example, and particularly where
transportation to the article of manufacture (e.g., automotive
vehicle) is short, the process may be accomplished without an
initial cure. Moreover, and particularly during transportation, it
is contemplated that various different packing methods may be
employed for moving the assemblies. For example, various different
racks may support the assemblies or the assemblies may be
loose-packed. The skilled artisan will be able to think of various
additional packing methods, which may also be employed according to
the present invention.
[0057] Also after transportation and, optionally, after assembly to
the article of manufacture, the adhesive material 12 is further
cured in a secondary cure operation to further secure the first
member 14 to the second member 16. Like the initial cure, the
secondary cure may be accomplished by exposure to heat, exposure to
chemicals (e.g., cross-linking agents), exposure to moisture,
exposure to light or radiation or other techniques. Preferably, the
secondary cure occurs during a processing step that is traditional
or non-additional for the article of manufacture to which the
assembly 10 is attached.
[0058] In the preferred embodiment, the automotive vehicle along
with its door 120 and the assembly 10 undergo an electrocoat
(e-coat) process for applying a coating to the automotive vehicle
and the assembly 10 and for further curing the adhesive material.
During such an e-coat process, the assembly 10 along with the door
120 and the automotive vehicle are typically immersed in a pool of
coating material. While in the coating material, the adhesive
material 12 is exposed to an elevated temperature for a period of
time, which causes the adhesive material to further cure and
preferably substantially completely cure. Typical temperatures in
an e-coat process and, thus, a typical temperature for the
secondary cure is between about 200.degree. F. and about
500.degree. F. and more preferably between about 300.degree. F. and
about 400.degree. F. Typical time periods for an e-coat process
and, thus, a typical time period for the secondary cure are between
about 15 minutes and about 45 minutes and more preferably between
about 25 minutes and about 35 minutes.
[0059] Advantageously, since the e-coat is a step is a traditional
or non-additional step in processing of the automotive vehicle
processing, the secondary cure does not add any significant time to
the processing of the automotive vehicle. As an added advantage,
when the adhesive material 12 is conductive, the adhesive material
12 can assist the adhered members to accept the e-coat and the
material 12 itself can be susceptible to adhesion of the e-coat
coating.
[0060] According to the preferred embodiment as shown in FIG. 7,
the second member 16 is employed for supporting a foam block 130.
The foam block 130 is intended as an energy absorption mechanism in
the event of a collision. It is contemplated, however, that the
purposes of the first member 14, the second member 14 or both may
be widely varied within the scope of the present invention.
[0061] Advantageously, the method of the present invention may be
used to adhere members together wherein other attachment techniques
(welding, employment of mechanical fasteners or the like) are
undesirable. For example, the adhesion method may replace welding
in situations that welding may be detrimental to one of the member
being fastened together. Thus, according to one embodiment, the
method of the present invention is employed to adhere members
together without welding the members to each other.
[0062] Unless stated otherwise, dimensions and geometries of the
various structures depicted herein are not intended to be
restrictive of the invention, and other dimensions or geometries
are possible. Plural structural components can be provided by a
single integrated structure. Alternatively, a single integrated
structure might be divided into separate plural components. In
addition, while a feature of the present invention may have been
described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0063] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize
however, that certain modifications would come within the teachings
of this invention. Therefore, the following claims should be
studied to determine the true scope and content of the
invention.
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