Adhesively bonded engine intake manifold assembly

• US 7,213,560 B2
• Filed: 03/09/2004
• Issued: 05/08/2007
• 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, Mark A., Jones, Bart R., Asfaw, Selamawit
• Primary Examiner(s): MCMAHON, MARGUERITE J
• Application Number:
  US10/796,404
• Publication Number:
  US 20040231628A1
• Time in Patent Office: 1,155 Days
• Field of Search: 12318421-18461, 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. A method for assembling an engine intake manifold comprising the steps of:

providing a first component of an engine intake manifold having an associated first mating surface and a second component having an associated second mating surface, wherein at least one of the first or second components is a plastic material;

placing a cure-on-demand adhesive about the periphery of the first, second or both mating surfaces;

joining the first and second components along the first and second mating surfaces; and

curing the adhesive during a separate and remote curing operation in time, location or both after the placement of the adhesive and the joining of the first and second components.

2. The method of claim 1, wherein the adhesive is encapsulated and the curing step includes rupturing an encapsulated curing agent.

3. The method of claim 1, wherein the adhesive includes a protective coating and the curing step includes removing a protective coating to expose the adhesive to ambient conditions.

4. The method of claim 1, wherein the first, second or both mating surfaces are non-planar.

5. The method of claim 4, wherein upon joining of the first and second component a joint is formed comprising a butt joint, lap joint or tongue in groove joint.

6. The method of claim 5, wherein at least one of the first or second components includes a plastic.

7. The method of claim 1, wherein the plastic material forming at least one of the first or second components include a filled polyamide.

8. The method of claim 1, further comprising the step of mechanically attaching the first and second components with a mechanical attachment feature.

9. The method of claim 8, wherein the mechanical attachment feature comprises a snap fitting.

10. The method of claim 1, wherein the adhesive includes a high temperature epoxy resin adhesive.

11. The method of claim 1, wherein the adhesive includes a high temperature mineral filled catalyzed adhesive.

12. A method for assembling an engine intake manifold comprising the steps of:

providing a first thermoplastic component of an engine intake manifold having an associated first mating surface and a second thermoplastic component having an associated second mating surface, wherein the first and second mating surfaces are non-planar;

placing a continuous bead or film of high temperature epoxy resin cure-on-demand adhesive about the periphery of the first, second or both mating surfaces;

joining the first and second components along the first and second mating surfaces, wherein upon joining the first and second mating surfaces are spatially located at a predetermined distance relative to one another; and

curing the adhesive during a separate and remote operation in time, location or both after the placement of the adhesive, wherein upon curing of the adhesive a joint is formed having a strength greater than the strength of the second thermoplastic component.

13. A method for assembling an engine intake manifold comprising the steps of:

providing a first thermoplastic component having an associated first non-planar mating surface and a second thermoplastic component having an associated second non-planar mating surface, wherein the first, second or both components include an integrally formed mechanical attachment feature configured for engaging the other first or second component;

placing a continuous bead or film of high temperature epoxy resin adhesive about the periphery of the first, second or both mating surfaces; and

joining the first and second components wherein the mechanical attachment feature maintains spatial relationship of the first and second components during curing of the adhesive and the resulting joint has a strength greater than the strength of said second molded plastic component.

14. The method of claim 13, wherein the first, second or both components are filled or other includes a reinforcing material.

15. The method of claim 13, wherein the plastic material forming at least one of the first or second components includes a filled polyamide.

16. The method of claim 15, wherein the adhesive includes a high temperature epoxy resin adhesive.

17. The method of claim 15, wherein the adhesive includes a high temperature mineral filled catalyzed adhesive.

18. The method of claim 13, wherein the mechanical attachment comprises a snap fit configured for providing an audible indicator upon joining of the first and second component.

19. The method of claim 13, wherein upon joining of the first and second component a joint is formed comprising a butt joint, lap joint or tongue in groove joint.

20. The method of claim 13, further comprising the step curing the adhesive during a separate and remote curing operation in time, location or both after the placement of the adhesive and the joining of the first and second thermoplastic components.