Adhesively bonded engine intake manifold assembly

• US 6,739,302 B2
• Filed: 12/13/2002
• Issued: 05/25/2004
• 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:
  US10/318,926
• Publication Number:
  US 20030084864A1
• Time in Patent Office: 529 Days
• Field of Search: 123/184.61
• 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 engine intake manifold assembly, comprising:

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

b) a second component that is made from a molded plastic and has an associated second mating surface; and

c) an adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment, and wherein the assembly includes a lap joint between the first and second component.

2. The assembly of claim 1, wherein the adhesive is a structural adhesive.

3. The assembly of claim 1, wherein the adhesive is a cure-on-demand adhesive.

4. The assembly of claim 1, wherein the second component is made from a glass filled plastic and is glass filled in an amount of about 10 to about 50 volume percent.

5. The assembly of claim 1, further comprising a layer of a primer.

6. The assembly of claim 1, further comprising a plasma-deposited coating.

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

a) a first glass filled plastic component having an associated first generally non-planar mating surface and being glass filled in an amount of about 10 to about 50 volume percent;

b) a second molded plastic component having an associated second generally non-planar mating surface, wherein at least one of the plastic components includes a flange having an inner wall surface; and

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

8. The assembly of claim 7, further comprising a layer of a primer.

9. The assembly of claim 7, further comprising a plasma-deposited coating.

10. The assembly of claim 7, wherein the adhesive is cured by a chemical cure.

11. The assembly of claim 7, wherein the adhesive is cured by solvent loss.

12. The assembly of claim 7, wherein the first or second component further comprises a means for facilitating assembly.

13. The assembly of claim 7, wherein the adhesive is a cure-on-demand adhesive.

14. An engine intake manifold assembly, comprising:

a) a first component having an associated first generally non planar mating surface;

b) a second component that is made from a molded plastic and has an associated second generally non planar mating surface; and

c) an adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment.

15. An engine intake manifold assembly, comprising:

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

b) a second component that is made from a molded plastic and has an associated second mating surface; and

c) an adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment, and wherein the assembly includes a tongue in groove joint between the first and second component.

16. An engine intake manifold assembly, comprising:

a) a first component having an associated first generally non-planar mating surface;

b) a second molded plastic component having an associated second generally non-planar mating surface and including a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics; and

c) a structural adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment.

17. 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 including a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics; and

c) a structural adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment, and wherein at least one of the plastic components includes a flange having an inner wall surface for increasing surface area available for bonding and for engaging the other component.

18. 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 including a plastic selected from the group consisting of filled polyamide and filled polyamide/polystyrenic plastics; and

c) a structural adhesive, wherein the first component and the second component are attached to each other by the adhesive and by a mechanical attachment, and wherein at least one of the first or second components is defined to include an outer shell and an inner shell adapted such that the inner shall is located within the outer shell and an air gap is formed between the two.

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

a) a first glass filled plastic component having an associated first mating surface and being glass filled in an amount of about 10 to about 50 volume percent;

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

c) an adhesive in contact with said first mating surface and said second mating surface for joining said first glass filled plastic component and the second molded plastic component to define an automotive vehicle engine intake manifold, wherein at least one of the first or second components is defined to include an outer shell and an inner shell adapted such that the inner shall is located within the outer shell and an air gap is formed between the two, and wherein the air gap adapted to be filled with a sound deadening material.

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

a) a first glass filled plastic component having an associated first mating surface and being glass filled in an amount of about 10 to about 50 volume percent;

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

c) an adhesive in contact with said first mating surface and said second mating surface for joining said first glass filled plastic component and the second molded plastic component to define an automotive vehicle engine intake manifold, wherein at least one of the first or second components has passages cored or machined into a molded component to enable integration of multiple components into the intake manifold assembly such as brackets, connectors, cable guides, hose guides, harnesses, or clips.