Adhesively bonded engine intake manifold assembly

• US 6,543,404 B2
• Filed: 04/04/2001
• Issued: 04/08/2003
• Est. Priority Date: 04/04/2001
• Status: Expired due to Fees

• Current Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Original Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Inventors: Ritzema, Kenneth J., Courter, David M., McMaken, Marc A., Jones, Bart R., Asfaw, Selamawit
• Primary Examiner(s): Kamen, Noah P.
• Application Number:
  US09/826,477
• Publication Number:
  US 20020148427A1
• Time in Patent Office: 734 Days
• Field of Search: 123/184.61, 428/41.7, 428/41.8
• US Class Current: 123/184.61
• CPC Class Codes: B29C 65/06 using friction, e.g. spin welding non-plastics elements to plastic elements B29C65/645
• CPC Class Codes: B29C 65/1406 Ultraviolet [UV] radiation
• CPC Class Codes: B29C 65/1412 Infrared [IR] radiation
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/565 involving interference fits, e.g. force-fits or press-fits B29C65/66 takes precedence
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/1222 comprising at least a lapped joint-segment
• CPC Class Codes: B29C 66/1224 comprising at least a butt joint-segment
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29K 2025/04 Polymers of styrene
• CPC Class Codes: B29K 2025/06 PS, i.e. polystyrene
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/7492 Intake manifold
• CPC Class Codes: F02B 75/22 with cylinders in V, fan, or star arrangement
• CPC Class Codes: F02M 35/10039 Intake ducts situated partly within or on the plenum chamber housing
• CPC Class Codes: F02M 35/10144 Connections of intake ducts to each other or to another device
• CPC Class Codes: F02M 35/10321 Plastics; Composites; Rubbers
• CPC Class Codes: F02M 35/10327 : Metals; Alloys catalysts F02M27/02
• CPC Class Codes: F02M 35/10347 : Moulding, casting or the like
• CPC Class Codes: F02M 35/1036 : by welding, bonding or the like welding plastic materials together in general B29C65/02
• CPC Class Codes: F02M 35/116 : for engines with cylinders in V-arrangement or arranged oppositely relative to the main shaft
• CPC Class Codes: F02M 35/12 : Intake silencers ; Sound modulation, transmission or amplification intake silencers also used as exhaust silencer F01N13/007; filters for compressors F04B39/16
• CPC Class Codes: F02M 35/1277 : Reinforcement of walls, e.g. with ribs or laminates; Walls having air gaps or additional sound damping layers
• CPC Class Codes: F05C 2225/08 : Thermoplastics
• CPC Class Codes: Y10T 428/1471 : Protective layer

Abstract

An engine intake manifold assembly (10), including a first component (12) having a first mating surface (14) and a second molded plastic component (16) having a second mating surface (18). The second molded plastic component (16) is adhesively bonded to the first component (12) with an adhesive (20). The adhesive bond strength exceeds the strength of the second molded plastic component (16).

Claims

1. An automotive vehicle engine intake manifold assembly, comprising:

a) a first molded thermoplastic component having an associated first mating surface and an integrally formed first member, said first member including a groove;

b) a second molded thermoplastic component having an associated second mating surface and an integrally formed second member, said second member including a detent for engaging said groove of said first member to form a snap fit mechanical joint between said first molded thermoplastic component and said second molded thermoplastic component; and

c) a high temperature epoxy resin adhesive in contact with said first mating surface and said second mating surface for joining said first molded thermoplastic component and said second molded thermoplastic component to define an automotive vehicle engine intake manifold, wherein said resulting joint has a strength greater than the strength of each of said first molded thermoplastic component and said second molded thermoplastic component.

2. The assembly of claim 1 wherein said first mating surface and said second mating surface are generally nonplanar.

3. The assembly of claim 1 wherein said first component and said second component are blends of polyamides and syndiotactic polystyrenes.

4. The assembly of claim 1 wherein said first component and said second component are injection molded filled plastic blends of nylon and syndiotactic polystyrene.

5. The assembly of claim 1 wherein said joint is substantially free of a sealing gasket.

6. The assembly of claim 1 wherein said joint is substantially free of mechanical fasteners.

7. The assembly of claim 1 wherein the transverse cross section thickness at said joint is less than about 7 mm.

8. The assembly of claim 1 wherein the transverse cross section thickness at said joint is less than about 5 mm.

9. The assembly of claim 1 wherein a primer contacts said adhesive.

10. The assembly of claim 1 wherein substantially the entirety of the first and second mating surfaces in contact with said adhesive is capable of bonding thereto.

11. The assembly of claim 1, further comprising an additional mechanical fastener for joining the components.

12. An automotive vehicle engine intake manifold assembly, comprising:

a) a first plastic component molded of a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics, and having an associated first mating surface and an integrally formed first member;

b) a second plastic component molded of a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics, and having an associated second mating surface and an integrally formed second member for coacting with said first member to form a snap-fit joint between said first plastic component and said second plastic component; and

c) an adhesive in contact with said first mating surface and said second mating surface for joining said first molded thermoplastic component and said second molded thermoplastic component to define an automotive vehicle engine intake manifold.

13. The assembly of claim 12 wherein said first mating surface and said second mating surface are generally nonplanar.

14. The assembly of claim 12 wherein said first component and said second component are blends of polyamides and syndiotactic polystyrenes.

15. The assembly of claim 12 wherein said first component and said second component are injection molded filled plastic blends of nylon and syndiotactic polystyrene.

16. The assembly of claim 12 wherein said joint is substantially free of a sealing gasket.

17. The assembly of claim 12 wherein said joint is substantially free of an additional mechanical fastener.

18. The assembly of claim 12 wherein the transverse cross section thickness at said joint is less than about 7 mm.

19. The assembly of claim 12 wherein the transverse cross section thickness at said joint is less than about 5 mm.

20. The assembly of claim 12 wherein a primer contacts said adhesive.

21. The assembly of claim 12 wherein substantially the entirety of the first and second mating surfaces in contact with said adhesive is capable of bonding thereto.

22. The assembly of claim 12, wherein said integrally formed second member coats with said first member to form a mechanical interlock between said first plastic component and said second plastic component;

and said adhesive of said resulting joint has a tensile strength of at least about 6500 psi (45 MPa).

23. The assembly of claim 12, wherein said integrally formed second member coats with said first member to form a mechanical interlock between said first plastic component and said second plastic component;

and said adhesive of said resulting joint has a tensile strength of at least about 9000 psi (62 MPa).

24. The assembly of claim 12, wherein said integrally formed second member coacts with said first member to form a mechanical interlock between said first plastic component and said second plastic component;

said adhesive of said resulting joint has a tensile strength of at least about 9000 psi (62 MPa),

said resulting joint has a transverse cross section thickness less than about 5 mm;

said resulting joint is substantially free of a sealing gasket; and

said joint is substantially free of an additional mechanical fastener.

25. An assembly of claim 12, further comprising an additional mechanical fastener for joining the components.

26. An engine intake manifold assembly, comprising:

a) a first filled or reinforced plastic component having an associated first mating surface;

b) a second filled or reinforced plastic component having an associated second mating surface;

c) an interface between the first component and the second component at which the first component and the second component are joined to define an engine intake manifold; and

d) means for mechanically attaching said first component with said second component,

wherein the space between the first and second mating surfaces at the interface consists essentially of a structural adhesive,

wherein the resulting joint has a strength greater than the strength of at least one of said first or second molded plastic components.

27. The interface of claim 26 wherein the adhesive is a mineral filled catalyzed cure-on-demand adhesive that includes one or more epoxy components.

28. The assembly of claim 26, wherein said adhesive layer includes a surface treatment.

29. The assembly of claim 26 or 28, wherein the adhesive is a cure-on-demand adhesive.

31. The assembly of claim 27 wherein the adhesive is a mineral filled catalyzed adhesive that includes an epoxy component, a curing agent and a thixotropic agent.

30. An engine intake manifold assembly, comprising:

a) a first component having an associated first mating surface;

b) a second molded plastic component having an associated second mating surface; and

c) a high temperature mineral filled catalyzed adhesive that includes an epoxy component, a curing agent and a thixotropic agent, which is in contact with said first mating surface and said second mating surface for joining said first component and said second component to define an engine intake manifold, wherein the resulting joint has a strength greater than the strength of said second molded plastic component, wherein the cure on demand adhesive is cured by removal of a protective coating to expose the adhesive to ambient conditions.

32. An engine intake manifold assembly, comprising:

a) a first component having an associated first mating surface;

b) a second molded plastic component having an associated second mating surface;

c) a mechanical fastener for joining the first and second components; and

d) a high temperature mineral filled catalyzed adhesive that includes an epoxy component, a curing agent and a thixotropic agent, which is in contact with said first mating surface and said second mating surface for joining said first component and said second component to define an engine intake manifold, wherein the resulting joint has a strength greater than the strength of said second molded plastic component.

33. An automotive vehicle engine intake manifold assembly, comprising:

a) a first molded thermoplastic component having an associated first mating surface and an integrally formed first member, said first member including a groove;

b) a second molded thermoplastic component having an associated second mating surface and an integrally formed second member, said second member including a detent for engaging said groove of said first member to form a snap fit mechanical joint between said first molded thermoplastic component and said second molded thermoplastic component;

c) a mechanical fastener for joining the first and second components; and

d) a high temperature epoxy resin adhesive in contact with said first mating surface and said second mating surface for joining said first molded thermoplastic component and said second molded thermoplastic component to define an automotive vehicle engine intake manifold, wherein said resulting joint has a strength greater than the strength of each of said first molded thermoplastic component and said second molded thermoplastic component.

34. An automotive vehicle engine intake manifold assembly, comprising:

a) a first plastic component molded of a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics, and having an associated first mating surface and an integrally formed first member;

b) a second plastic component molded of a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics, and having an associated second mating surface and an integrally formed second member for coacting with said first member to form a snap-fit joint between said first plastic component and said second plastic component;

c) a mechanical fastener for joining the first and second components; and

d) an adhesive in contact with said first mating surface and said second mating surface for joining said first molded thermoplastic component and said second molded thermoplastic component to define an automotive vehicle engine intake manifold.