Adhesively bonded radiator assembly

Abstract

A radiator assembly ( 10 ), including an end tank ( 12 ) having a first mating surface ( 14 ) and a heat exchanger ( 16 ) having a second mating surface ( 18 ). The heat exchanger ( 16 ) is adhesively bonded to the end tank ( 12 ) with an adhesive (22).

What is claimed is:  
     
         1 . A radiator 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) an adhesive in contact with said first mating surface and said second mating surface for joining said first component and said second component to define a radiator assembly, wherein the resulting joint has a strength greater than the strength of said second molded plastic 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 is a blend of a polyamide and a syndiotactic polystyrene.  
     
     
         4 . The assembly of  claim 1  wherein each of said first component and said second component is an injection molded filled plastic blend of nylon 6,6 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 . An automotive vehicle radiator assembly, comprising: 
 a) a first molded thermoplastic end tank having an associated first mating surface;    b) a second molded thermoplastic end tank having an associated second mating surface;    c) a heat exchanger having a first end and a second end, said ends adapted for opposingly receiving respectively each of said end tank and    c) an epoxy adhesive in contact with said first mating surface and said second mating surface for joining said end tanks to said heat exchanger to define an automotive vehicle radiator.    
     
     
         12 . The assembly of  claim 11  wherein said first mating surface and said second mating surface are generally nonplanar.  
     
     
         13 . The assembly of  claim 11  wherein said first end tank and said second end tank are blends of polyamides and syndiotactic polystyrenes.  
     
     
         14 . The assembly of  claim 11  wherein said first end tank and said second end tank are injection molded filled plastic blends of nylon and syndiotactic polystyrene.  
     
     
         15 . The assembly of  claim 11  wherein said joint is substantially free of a sealing gasket.  
     
     
         16 . The assembly of  claim 11  wherein said joint is substantially free of mechanical fasteners.  
     
     
         17 . The assembly of  claim 11  wherein the transverse cross section thickness at said joint is less than about 7 mm.  
     
     
         18 . The assembly of  claim 11  wherein said heat exchanger is nonrectangular.  
     
     
         19 . The assembly of  claim 18  wherein said heat exchanger includes a rounded shape edge configuration.  
     
     
         20 . The assembly of  claim 11  wherein said heat exchanger is contoured in the fore-aft direction of the vehicle.  
     
     
         21 . An automotive vehicle radiator assembly, comprising: 
 a) a first plastic end tank component molded from the group selected from filled polyamide and filled polyamide/polystyrenic plastics, and having an associated first mating surface and an integrally formed first member;    b) a heat exchanger having a second mating surface and an integrally formed second member for coating with said first member to form a mechanical joint between said end tank and said heat exchanger; and    c) an epoxy 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 radiator, wherein said resulting joint has a lap shear strength of at least about 4000 psi (28 MPa).    
     
     
         22 . The assembly of  claim 21  wherein said first mating surface and said second mating surface are generally nonplanar.  
     
     
         23 . The assembly of  claim 21  wherein said first component and said second component are blends of polyamides and syndiotactic polystyrenes.  
     
     
         24 . The assembly of  claim 21  wherein said first end tank and said second beat exchanger are injection molded filled plastic blends of nylon and syndiotactic polystyrene.  
     
     
         25 . The assembly of  claim 21  wherein said joint is substantially free of a sealing gasket.  
     
     
         26 . The assembly of  claim 21  wherein said joint is substantially free of mechanical fasteners.  
     
     
         27 . The assembly of  claim 21  wherein the transverse cross section thickness at said joint is less than about 7 mm.  
     
     
         28 . The assembly of  claim 21  wherein the transverse cross section thickness at said joint is less than about 5 mm.  
     
     
         29 . The assembly of  claim 21  wherein a primer contacts said adhesive.  
     
     
         30 . The assembly of  claim 21  wherein substantially the entirety of the first and second mating surfaces in contact with said adhesive is capable of bonding thereto.  
     
     
         31 . The assembly of  claim 21 , wherein said adhesive of said resulting joint between said end tank and said heat exchanger has a tensile strength of at least about 6500 psi (45 MPa).  
     
     
         32 . The assembly of  claim 21 , wherein said adhesive of said resulting joint between said end tank and said heat exchanger has a tensile strength of at least about 9000 psi (62 MPa).  
     
     
         33 . The assembly of  claim 21 , wherein said end tank matingly engages said heat exchanger so that 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 folding tangs and mechanical fasteners.    
     
     
         34 . The assembly of  claim 21  wherein said heat exchanger is nonrectangular.  
     
     
         35 . The assembly of  claim 21  wherein said heat exchanger includes a rounded shape edge configuration.  
     
     
         36 . The assembly of  claim 21  wherein said heat exchanger is contoured in the fore-aft direction of the vehicle.  
     
     
         37 . The assembly of  claim 33  wherein said resulting joint includes a flange disposed in a groove.  
     
     
         38 . The assembly of  claim 37 , wherein said groove is defined by a wall having a tang for achieving a snap fit.