Abstract: A recyclable seal is formed on the surface of a climate control system door by placing the door into a mold having channels for receiving a foammelt, forming the foammelt by melting a solid sealant material and mixing a foaming agent therewith, supplying the foammelt mixture under a predetermined pressure to the mold so as to flow through the channels and through openings in the door to form an interconnected seal on opposite sides thereof, venting the channels along substantially the entire length thereof so as to maintain a relatively low differential pressure across the foammelt mixture to force the foaming agent to a center section of the seal so that a gas pocket is formed therein, and cooling the mold while supplying the foammelt mixture thereto.

Abstract: A heat exchanger assembly for an automotive vehicle is provided. The assembly includes a generally rectangular heat exchanger core defining four generally orthogonal ends and a housing configured to receive the heat exchanger core therein. The housing bas a plurality of walls disposed around the ends of the heat exchanger core. At least two of the walls and at least two of the ends cooperate to define a sealing space therebetween. Each of the at least two walls has an injection port provided therein for receiving a seal precursor material into the sealing space. The assembly also includes a seal formed from the precursor material in the sealing space, the seal substantially filling the space.