Patent Application
20190105731
The present disclosure relates to a method for bonding sheet metal panels. In particular, the present disclosure relates to a hot formed bonding method for sheet metal panels.
The present disclosure describes a method for bonding metal workpieces solely using heat transfer and pressure, thereby minimizing cost, reducing overall system mass and scrap, and reducing floor space required for additional joining operations. The presently disclosed method allows bonding of metallic workpieces without the use of traditional method of bonding such as hemming, chemical adhesives, fasteners, welding, and soldering. The workpieces can come out of the tool ready for the next manufacturing step without having to go through an additional assembly operations.
In certain embodiments, the method includes: (a) heating a plurality of metal workpieces until the metal workpieces are fully annealed; (b) applying pressure to the metal workpieces to compress the metal workpieces together while the metal workpieces are still heated until the metal workpieces fuse together; and (c) actively cooling the metal workpieces while the metal workpieces are compressed together to join the metal workpieces together. As a non-limiting example, the metal workpieces may be actively cooled for five seconds to fifteen seconds. The metal workpieces, however, may be actively cooled for more or less time depending on the materials to be joined and the desired mechanical properties. As a non-limiting example, the metal workpieces are actively cooled until the metal workpieces reach eighty degrees Fahrenheit or less. This temperature, however, depends on the materials to be joined and the desired mechanical properties. The method is characterized by an absence of hemming. The method is characterized by an absence of a use of a chemical adhesive. The method is characterized by an absence of a use of a fastener. The method is characterized by an absence of welding. The method is characterized by an absence of soldering. At least one of the metal workpieces includes steel, and heating the plurality of metal workpieces includes heating the plurality of the workpieces at a temperature that is, for example, between 1400 degrees Fahrenheit and 1600 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. At least one of the metal workpieces includes aluminum, and heating the plurality of metal workpieces includes heating the plurality of workpieces at a temperature that is, for example, between 600 and 800 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. Applying pressure to the metal workpieces includes pressing the metal workpieces in a die to form the metal workpieces into a predetermined shape, and actively cooling the metal workpieces includes quenching the metal workpieces at the same time as the metal workpieces are being compressed together in the die. Applying pressure to the metal workpieces includes roll forming the metal workpieces, and actively cooling the metal workpieces includes quenching the metal workpieces at the same time as the metal workpieces are being rolled formed. At least one of the metal workpieces is a metal structure selected from a group consisting of blanks, rolls, panels, fasteners, and coils. The metal workpieces have different sizes or the same sizes.
In certain embodiments, each of the metal workpieces includes steel. Heating the plurality of metal workpieces until the metal workpieces are fully annealed includes heating the metal workpieces in a die until each of the metal workpieces has a temperature that is, for example, between 1400 degrees Fahrenheit and 1600 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. The method further includes removing the metal workpieces from the furnace. The method further includes placing the metal workpieces in a die while the temperature of each of the metal workpieces is greater than, for example, 1400 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. Applying pressure to the metal workpieces to compress the metal workpieces together while the metal workpieces are still heated until the metal workpieces fuse together includes pressing the metal workpieces in the die to form a one-piece structure metal having a predetermined shape at the same time as the temperature of each of the metal workpieces is greater than, for example, 1400 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. Actively cooling the metal workpieces includes quenching the metal workpieces with a liquid coolant for fifteen seconds at the same time as the metal workpieces are being compressed together in the die. The method solely employs heat transfer and pressure to join the metal workpieces together. The method is characterized by an absence of hemming, the method is characterized by an absence of a chemical adhesive, the method is characterized by an absence of a fastener, the method is characterized by an absence of welding, the method is characterized by an absence of soldering, the metal workpieces are in direct contact with each other when the pressure is applied to compress the metal workpieces together, and each of the metal workpieces is a panel.
In certain embodiments, each of the metal workpieces includes aluminum. Heating the plurality of metal workpieces until the metal workpieces are fully annealed includes heating the metal workpieces in a furnace until each of the metal workpieces has a temperature that is, for example, between 600 degrees Fahrenheit and 800 degrees Fahrenheit. This temperature, however, depends on the materials to be joined and the desired mechanical properties. The method further includes removing the metal workpieces from the furnace, the method further includes placing the metal workpieces in a die while the temperature of each of the metal workpieces is, for example, greater than 600 degrees Fahrenheit. The plurality of metal workpieces includes a first metal workpiece and a second metal workpiece. The first metal workpiece has a first size. The second metal workpiece has a second size. The first size is different from the second size. Applying pressure to the metal workpieces to compress the metal workpieces together while the metal workpieces are still heated until the metal workpieces fuse together includes pressing the metal workpieces in the die to form a one-piece structure having a predetermined shape at the same time as the temperature of each of the metal workpieces is, for example, greater than 600 degrees Fahrenheit. Actively cooling the metal workpieces includes quenching the metal workpieces with a liquid coolant for fifteen seconds at the same time as the metal workpieces are being compressed together in the die. The method solely employs heat transfer and pressure to join the metal workpieces together. The method is characterized by an absence of hemming, the method is characterized by an absence of a chemical adhesive. The method further includes removing the one-piece structure from the die. The method is characterized by an absence of a fastener. The method is characterized by an absence of welding, the method is characterized by an absence of soldering. The metal workpieces are in direct contact with each other when the pressure is applied to compress the metal workpieces together. Each of the metal workpieces is a panel.
In certain embodiments, the method includes (a) heating a plurality of metal workpieces until the metal workpieces are fully annealed; (b) applying pressure to the metal workpieces to compress the metal workpieces together while the metal workpieces are still heated until the metal workpieces fuse together; and (c) actively cooling the metal workpieces while the metal workpieces are compressed together to join the metal workpieces together, wherein actively cooling the metal workpieces includes quenching the metal workpieces with a coolant at the same time as the metal workpieces are compressed together. The metal workpieces are actively cooled for five seconds to fifteen seconds. The metal workpieces are actively cooled until the metal workpieces reach eighty degrees Fahrenheit or less.
The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings.
With reference to
In certain embodiments, the method 100 begins at step 101, in which metal workpieces 10 in the form of blanks are stacked together as shown in
At step 104, the metal workpieces 10 are placed in an apparatus capable of applying pressure P to the metal workpieces 10, such as a die 20 (shown in
At step 106, the metal workpieces 10 are actively cooled at the same time as the metal workpieces 10 are compressed together, by for example the die 20 or the roller assembly 50, in order to join (i.e., fuse) the metal workpieces 10 together, thereby forming a one-piece structure. In some embodiments, the metal workpieces 10 are actively cooled for five to fifteen seconds until the metal workpieces 10 reach a temperature of eighty degrees Fahrenheit or less to facilitate handling during subsequent processes. At step 106, the cooling process may entail quenching the metal workpieces 10, with a liquid or gaseous coolant C, at the same time as the metal workpieces 10 are being compressed together in the die 20 (shown in
At step 108, the one-p structure can be subjected to a subsequent manufacturing process to form a finished or final part. For instance, as shown in
While the best modes for carrying out the disclosure have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the disclosure within the scope of the appended claims.
