Patent Application
20230416576
In the manufacturing and coating of vehicle components, electrical conductivity is an important part for coating components defect-free. For example, performing an electrodeposition process, also called an electrocoating process, can be used, where a component without proper electrical conductivity may cause arc through (i.e., a defect in the appearance of a weld). The electrocoating process functions by applying voltage an electric current between the components and a counter-electrode in electrical contact until the desired coating is deposited on the component. When the vehicle component (e.g., panel) is not connected to a lead wire to provide the appropriate ground, an arc through the component may occur. The severity of the arc through the component may further be based on the materials of the component. For example, an aluminum component (e.g., a panel) near a magnesium panel may lead to more severe defects. That is, when running the poorly grounded vehicle component (e.g., aluminum panel) through the electrocoating process, the component becomes a floating ground, which causes either no coating on the outer component or an arc through the component (i.e., a welding point at the arc location). Consequently, what is needed is an improved way to maintain electrical continuity through a component while undergoing any electrodeposition process.
Accordingly, systems and methods are disclosed herein to provide consistent uniform electrical contact between the various vehicle components during electrocoating. For example, providing an adhesive having certain conductive properties (e.g., zinc particles) between a first member (e.g., magnesium inner panel) and a second member (e.g., aluminum outer panel) provides electrical conductivity between a first member and a second member. In some embodiments, the vehicle components correspond to a door for a vehicle storage compartment.
In some embodiments, the system includes an adhesive dispersal module configured to apply a particle-induced adhesive on at least one of the first member and the second member. The system further joins the first member and the second member via the particle-induced adhesive. The particle-induced adhesive includes conductive metallic particles and provides electrical conductivity between the first member and the second member. In some embodiments, the system further performs electrocoating on the first member and the second member. In some embodiments, the particle-induced adhesive, between the first member and the second member, enhances uniform adhesive for bond consistency without “squeeze out” while also providing electrical continuity through the adhesive joints.
In some embodiments, the particle-induced adhesive contains conductive metallic particles having a size in the range of 200-2000 micrometers. In some embodiments, a concentration of conductive metallic particles within the particle-induced adhesive is in a range of 0.01-30.0 weight percent (wt. %). In some embodiments, the particle-induced adhesive includes one or more of a thermal adhesive, a high strength adhesive, a UV adhesive, or a combination thereof and conductive metallic particles blended therein.
In some embodiments, to create the particle-induced adhesive, the system applies on at least one of the first member and the second member one or more adhesives and then further applies conductive metallic particles on an exterior of the applied one or more adhesives. In some embodiments, the conductive metallic particles dispersed in the particle-induced adhesive are configured to provide electrical conductivity between the first member and the second member.
In some embodiments, the conductive metallic particles dispersed in the particle-induced adhesive are uniformly dispersed within the particle-induced adhesive. In some embodiments, the first member includes a first metal material first galvanic potential, the second member includes second metal material a second galvanic potential, and the system is configured to select a type and concentration of conductive metallic particles in the particle-induced adhesive such that a galvanic potential of the particle-induced adhesive is between the first galvanic potential and the second galvanic potential.
In some embodiments, the system applies conductive metallic particles in the particle-induced adhesive by one or more of chemical vapor deposition, spraying, sprinkling, or blending particles into the particle-induced adhesive.
In some embodiments, the disclosure provides for an apparatus including a first member comprising a first metal material (e.g., magnesium) having a first galvanic potential, a second member comprising a second metal material (e.g., aluminum) having a second galvanic potential, a particle-induced adhesive on at least one of the first member and the second member, wherein the first member and the second member are joined via the particle-induced adhesive, wherein the particle-induced adhesive includes conductive metallic particles (e.g., zinc particles) and provides electrical conductivity between the first member and the second member when joined.
The present disclosure, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments. These drawings are provided to facilitate an understanding of the concepts disclosed herein and should not be considered limiting of the breadth, scope, or applicability of these concepts. It should be noted that for clarity and ease of illustration, these drawings are not necessarily made to scale.
This disclosure provides, inter alia, novel members joined with an adhesive to provide electrical conductivity between the members. In some embodiments, the system includes a storage chamber configured to store a first member and a second member. The system further includes an adhesive dispersal module configured to an adhesive on at least one of the first member and the second member. The system further joins the first member and the second member via the adhesive. The adhesive includes conductive metallic particles (e.g., a particle-induced adhesive) and provides electrical conductivity between the first member and the second member when the first member and the second member are joined. In some embodiments, the system further performs electrocoating on the first member and the second member. The particle-induced adhesive, between the first member and the second member, enhances uniform adhesive for bond consistency without “squeeze out” while also providing electrical continuity through the adhesive joints.
The conductive metallic particles 108 dispersed in the adhesive 106 may include a particle size in the range of 200-2,000 micrometers (μm). A concentration of conductive metallic particles 108 in the particle-induced adhesive may be in a range of 0.01-30.0 weight percent (wt. %). In some embodiments, as shown in
In some embodiments, the conductive metallic particles dispersed in the particle-induced adhesive are uniformly dispersed within the particle-induced adhesive. In some embodiments, the first member includes a first galvanic potential, the second member includes a second galvanic potential, and the system is configured to select a concentration and type of conductive metallic particles in the particle-induced adhesive such that a galvanic potential of the particle-induced adhesive is between the first galvanic potential and the second galvanic potential. In the particle-induced adhesive, the conductive metallic particles are used as a conductive pigment to produce an anodically active coating. For example, when the first member magnesium, the second member is aluminum, and the conductive metallic particles are zinc, the conductive metallic particles (e.g., zinc) provide a transfer of galvanic current through the adhesive from the second member (e.g., aluminum panel) to the first member (e.g., magnesium panel). The aluminum panel remains galvanically protected by the zinc-induced adhesive by providing the electron-conducting pathways in the system, and there is sufficient zinc to act as the anode. Without compromising the strength of the adhesive, additional additives may be added to the particle-induced adhesives to maintain the functionality. For example, as more conductive metallic particles are dispersed in the adhesive, the viscosity of the adhesive increases, thereby making it more difficult to apply on one of first or second members; accordingly, additives may be added to the adhesive (solvents, emulsifiers, etc.) to improve the functionality. In some embodiments, the system includes the pretreatment of the particle-induced adhesives to prepare for application. For example, a heater may be used to heat the adhesive 106, while a mixer or a sonifier may be used to agitate the adhesive to distribute the conductive metallic particles 108 uniformly.
In some embodiments, the diagram of a first member 402 joined with a second member 404 by a particle-induced adhesive 406 comprising zinc particles is an illustrative example of a bond on the gear tunnel door 410 with an aluminum panel (exterior panel) and a magnesium panel (interior panel).
Adhesive dispersal module 510 is responsible for applying adhesive on a surface of one of the first member or the second member. In some embodiments, the adhesive dispersal module 510 applies adhesive to the surface of both the first member and the second member. Adhesive dispersal module 510 includes adhesive 512 and conductive metallic particles 514. In some embodiments, the conductive metallic particles may be colored or transparent. In some embodiments, the conductive metallic particles may contain fluorescent components that may be illuminated by a certain wavelength of light (e.g., UV light). Mixing module 516 is responsible for mixing the adhesive and conductive metallic particles together. In some embodiments, the conductive metallic particles are sprinkled into the adhesive and mixed using a sonifier that transmits sound waves to mix the adhesive. Mixing module 516 may be configured to mix a predetermined portion of adhesive 512 with a fixed quantity of conductive metallic particles 514. In some embodiments, the amount of adhesive 512 and conductive metallic particles 514 to be mixed together, may be programmed by the user using control circuitry 502. In some embodiments, the amount of adhesive 512 and conductive metallic particles 514 to be mixed together, may be modified based on the desired thickness of the adhesive between the first member and the second member. In some embodiments, the shape and size of the conductive metallic particles 514 may be modified based on the desired thickness of the adhesive between the first member and the second member. In some embodiments, the number of conductive metallic particles and adhesive to be mixed, may be based on an adhesive strength of the mixed adhesive 512. In yet another embodiment, the number of conductive metallic particles and adhesive to be mixed, may be based on the galvanic potential. In some embodiments, the adhesive is a two-part adhesive (e.g., a resin and a hardener) and conductive metallic particles 514 are included in one of the two parts. In such embodiments, mixing module 516 mixes the resin and hardener together and, as a result, also mixes conductive metallic particles 514 in the adhesive. In some embodiments, the conductive metallic particles 514 are sprinkled on a contact point on the first member and on the contact point on the second member with the adhesive 512 applied between the two contact points.
Adhesive dispersal module 510 may also include auxiliary sensors. In some embodiments, auxiliary sensors may keep track of a correct positioning of a surface before applying adhesive. For example, auxiliary sensors may include sensors that record a conveyor belt that carries multiple components to be placed under adhesive dispersal module 510 for adhesive to be applied. In this example, auxiliary sensors may include a motion sensor, and only when control circuitry 502 receives an indication from the auxiliary sensors that the conveyor belt carrying the first member has come to a complete halt, will control circuitry 502 instruct adhesive dispersal module 510 to apply the particle-induced adhesive on a surface of a first member or the second member. In some embodiments, auxiliary sensors may include sensors that keep track of quantities of adhesive 512 and conductive metallic particles 514 in adhesive dispersal module 510. In this embodiment, auxiliary sensors may instruct control circuitry 502 to pause the application of adhesive until the adhesive 512 or conductive metallic particles 514 are replenished.
In some embodiments, auxiliary sensors may include sensors that keep track of quantities of first member 520 and second member 530. In this embodiment, auxiliary sensors may instruct control circuitry 502 to pause the application of adhesive until the first member 520 and second member 530 are replenished. Similarly, auxiliary sensors may include a motion sensor, and only when control circuitry 502 receives an indication from the auxiliary sensors that the conveyor belt carrying the first member, the second member and the adhesive has been applied, will control circuitry 502 instructs joining module 540 to join the first member with the second member. For example, one member may be fixed on a work surface or in a clamp and the other member may be positioned using a robotic arm to be joined. As another example, both pieces may be manipulated and joined by respective robotic arms. In addition, a press may be used to fold the edge of one member over or around edge of the other member. In some embodiments, the first member is placed into position on the second member and the edge of the second member is folded over to join the first member in place.
In some embodiments, the holder 610 is configured to hold the joined members in place while electrocoating is performed on the exterior of the first and second members. In some embodiments, members 606 may be electrocoated by itself in the chamber 602. In some embodiments, members 606 may be supported on a portion of a vehicle, for example, on the truck bed and may be electrocoated with the entire body of the vehicle.
In some embodiments, an electrodeposition method and parameters can be employed in carrying out the electrocoating of the joined members. For example, the process of electrocoating can include an electrically conductive substrate (e.g., joined first and second members) submerged into a coating composition bath. Electricity can be applied to the joined members, and the charged particles of the coating can be deposited onto the joined members. As shown, the joined member 606 can enter into the electrocoat bath where a voltage may be applied from a voltage supply 608. Current can be distributed through the joined member 606, and coating may begin to take place. As the deposition continues thickness of the film onto the surface of the joined member 606 increases. Film thickness of the coating can be controlled by manipulating temperature of the bath, amount of voltage applied, or coating deposition time.
The electrocoating process can be used to deposit an adherent film of the electrocoat onto the joined member 606 when a sufficient voltage can be impressed between the electrodes. The applied voltage may be varied and can be, for example, as low as one volt to as high as several thousand volts; typically the voltage can be between 50 and 400 volts. The current density can be between 1.8 ampere and 7.5 amperes per square foot and tends to decrease during electrodeposition, indicating the formation of a coating. The electrocoating process can be used for electro-depositing any number of layers and any kind of layer to the photovoltaic module.
Step 706 includes adhesive dispersal module 510 configured to apply a particle-induced adhesive on at least one of the first member and the second member. In some embodiments, the particle-induced adhesive is applied by the adhesive dispersal module 510 to the edge of the first member. In some embodiments, the particle-induced adhesive corresponds to particle-induced adhesive 106 of
Step 708 includes joining the first member and the second member via the particle-induced adhesive, wherein the particle-induced adhesive includes the conductive metallic particles and provides electrical conductivity between the first member and the second member. For example, the first member and the second member are joined by seating the first member into the second member. In another example, the first member is placed into position on the second member and the edge of the second member is folded over to join the first member in place. In some embodiments, the particle-induced adhesive forms a beaded layer between the first member and the second member. In some embodiments, the adhesive layer is disposed around the perimeter of one of the first member or the second member. In some embodiments, the adhesive layer is disposed partially around the perimeter. In some embodiments, the first member and the second member need to have electrical conductivity, and accordingly, the area around the edge, where the first member and second member join, includes a particle-induced adhesive.
Step 710 includes performing electrocoating on the first member and the second member. For example, applying voltage to the first member and the second member until the desired coating is deposited on the first member and the second member. In some embodiments, chamber 602 of
Process 700 may include mixing and positioning the particle-induced adhesive on any suitable members on the vehicle that need electrical conductivity where the two members being joined include members comprising materials having different galvanic potentials (e.g., a magnesium member on one side and an aluminum member on the other side). In some embodiments, a variety of adhesive types may be used to join the two members while maintaining the electrical conductivity using conductive metallic particles in the adhesive. The example of magnesium and aluminum members with a zinc-induced adhesive is provided for purposes of illustration only and that the disclosure can be used with any two materials that are being joined and that need electrical conductivity. In some embodiments, the first member includes a first galvanic potential, the second member includes a second galvanic potential and the adhesive includes additives with a third galvanic potential that is selected to be between the first galvanic potential and the second galvanic potential.
The foregoing is merely illustrative of the principles of this disclosure, and various modifications may be made by those skilled in the art without departing from the scope of this disclosure. The above-described embodiments are presented for purposes of illustration and not of limitation. The present disclosure also can take many forms other than those explicitly described herein. Accordingly, it is emphasized that this disclosure is not limited to the explicitly disclosed methods, systems, and apparatuses, but is intended to include variations to and modifications thereof, which are within the spirit of the following claims.
