Adhesively bonded engine intake manifold assembly

• US 7,475,664 B2
• Filed: 04/02/2007
• Issued: 01/13/2009
• 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; M.
• Application Number:
  US11/695,332
• Publication Number:
  US 20070251483A1
• Time in Patent Office: 652 Days
• Field of Search: 12318421-18461
• US Class Current: 123/184.21
• 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 making an automotive vehicle engine intake manifold assembly, comprising the steps of:

a) providing a first component having an associated first mating surface for defining a joint;

b) molding a second component having an associated second mating surface for opposing the first mating surface and defining the joint;

c) applying an epoxy structural adhesive to at least one of the first component or the second component;

d) joining the first component together with the second component with the epoxy structural adhesive therebetween for forming a joint section with a thickness less than about 7 mm;

e) snap-fitting the first component together with the second component;

f) curing the structural adhesive for bonding the first component with the second component;

wherein at least one of the first or the second component includes a flange having an inner wall surface adapted for receiving the adhesive on at least one of the first component or the second component.

2. The method of claim 1, wherein the snap-fitting includes audibly locating the first component relative to the second component.

3. The method of claim 2, wherein the epoxy structural adhesive is a high temperature structural adhesive.

4. The method of claim 1, wherein the second component is a plastic that includes a material selected from polyamides, polystyrenes or mixtures thereof.

5. The method of claim 3, further including a step of exposing the adhesive to heat for initiating curing of the epoxy structural adhesive.

6. The method of claim 1, further including a step of contacting the structural adhesive with a primer.

7. The method of claim 1, wherein at least one of the first component or the second component includes a glass filled plastic.

8. A method for making an automotive vehicle engine intake manifold assembly, comprising the steps of:

a) providing a first component having an associated first mating surface for defining a tongue-in-groove joint having a section thickness less than about 5 mm;

b) injection molding a second component having an associated second mating surface for opposing the first mating surface and defining the tongue-in-groove joint;

c) applying a high temperature epoxy structural adhesive to at least one of the first component or the second component;

d) applying a primer to at least one of the first component or the second component;

e) joining the first component together with the second component with the high temperature epoxy structural adhesive therebetween;

f) snap-fitting the first component together with the second component;

g) exposing the adhesive to heat for initiating curing of the structural adhesive; and

h) curing the structural adhesive for bonding the first component with the second component;

wherein at least one of the first or the second component includes a flange having an inner wall surface adapted for receiving the adhesive on at least one of the first component or the second component.

9. The method of claim 8, wherein each of the first component and the second component are plastic.

10. The method of claim 9, further including a step of forming a flange having an inner wall surface adapted for receiving the adhesive on at least one of the first component or the second component.

11. The method of claim 10, wherein the second component is a plastic that includes a material selected from polyamides, polystyrenes or mixtures thereof.