Device and method of applying a sealant around a structural adhesive to prevent corrosion

Abstract

A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

1 . A multi-material assembly comprising:
 a first component including a first metal;   a second component comprising a second metal different from the first metal, the first component being joined at an interface to the second component;   a cured adhesive arranged between the first and second components at the interface;   a cured sealant covering at least one edge of the interface, the at least one edge being arranged in an interior defined by the first component and the second component; and   a cured sealer covering at least one other edge of the interface, the at least one other edge of the interface being arranged at an exterior defined by the first component and the second component;   wherein the cured sealant, the cured sealer, the first component, and the second component collectively form a closed volume around the cured adhesive.   
     
     
         2 . The assembly of  claim 1 , wherein the first component and the second component are joined at the interface by at least one mechanical fastener extending through the cured adhesive. 
     
     
         3 . The assembly of  claim 2 , wherein the mechanical fastener is a self-piercing rivet. 
     
     
         4 . The assembly of  claim 1 , wherein the first component and the second component are joined at the interface by at least one spot weld extending through the cured adhesive. 
     
     
         5 . The assembly of  claim 1 , wherein:
 one of the first metal and the second metal comprises aluminum; and   the other of the first metal and the second metal comprises steel.   
     
     
         6 . The assembly of  claim 1 , wherein all edges of the interface are sealed by the cured sealer and the cured sealant. 
     
     
         7 . The assembly of  claim 6 , wherein the cured sealer and the cured sealant form a continuous perimeter around the cured adhesive. 
     
     
         8 . The assembly of  claim 1 , wherein:
 the cured adhesive occupies the entirety of the interface;   a first exposed portion of the cured adhesive and a second exposed portion of the cured adhesive are each arranged outside of the interface;   the cured sealant covers the first exposed portion of the cured adhesive; and   the cured sealer covers the second exposed portion of the cured adhesive.   
     
     
         9 . The assembly of  claim 1 , wherein a joint formed between the first component and the second component is a flange joint, a butt joint, a tee joint, a lap joint, a corner joint, or an edge joint. 
     
     
         10 . A vehicle comprising the assembly of  claim 1 . 
     
     
         11 . A dispensing tool comprising:
 a first delivery pathway connecting to a first reservoir containing an adhesive, the first delivery pathway including a first dispensing nozzle, the first dispensing nozzle being configured to dispense a first bead of the adhesive;   a second delivery pathway separate and distinct from the first delivery pathway, the second delivery pathway connecting to a second reservoir containing a sealant and including a second dispensing nozzle, the second dispensing nozzle being spaced from the first dispensing nozzle by a predetermined distance, and the second dispensing nozzle being configured to dispense a second bead of the sealant, the second bead being separate and distinct from the first bead; and   one or more sensors configured to monitor dispensing of the first and second beads.   
     
     
         12 . The tool of  claim 11 , wherein the one or more sensors monitor whether or not the first bead and the second bead are applied to an associated surface as continuous lines. 
     
     
         13 . The tool of  claim 12 , wherein the one or more sensors generate a signal if the first bead or the second bead is not a continuous line. 
     
     
         14 . The tool of  claim 12 , wherein the one or more sensors include:
 one or more lasers directed at the first and second beads, and   one or more cameras that detect the lasers.   
     
     
         15 . The tool of  claim 14 , wherein the one or more lasers emit light that forms a grid pattern that forms a perimeter around the first nozzle and the second nozzle. 
     
     
         16 . The tool of  claim 15 , wherein:
 the light emitted from each of the one or more lasers generates a line on the associated surface; and   the line forms part of the grid pattern.   
     
     
         17 . The tool of  claim 15 , wherein:
 the light is configured to impinge upon the first bead and the second bead; and   the one or more cameras are configured to detect the light impinging on the first bead and the second bead.   
     
     
         18 . The tool of  claim 11 , wherein:
 the tool further comprises an applicator head; and   the first nozzle, the second nozzle, and the sensors are arranged on the applicator head.   
     
     
         19 . The tool of  claim 11 , wherein the first dispensing nozzle is configured to dispense the first bead at the same time as the second dispensing nozzle is dispensing the second bead. 
     
     
         20 . A robotic arm tooling including the dispensing tool of  claim 11 .