Abstract: An engine component includes stratified layers that form an integral cylinder head and an internally cooled valve guide located in a cylinder head guide boss. The integral cylinder head further includes a coolant passage within a body of the valve guide that is in fluid communication with a cylinder head cooling jacket.

Abstract: An engine cylinder block includes a control valve and stratified layers defining a network internal to the cylinder block. The network includes a main feed line in fluid communication with the control valve, and branched and winding arterial channels extending from the main feed line with diameters that taper to define nozzles configured to spray coolant on sides of pistons carried within the cylinder block.

Abstract: An engine system includes a layered cylinder head with a plurality of intake ports and a stratified tubular member integrated into the cylinder head, configured as a condensate port, surrounding each of the plurality of intake ports and forming a plurality of nozzles located on at least one side of the tubular member. Each of the nozzles arranged to have a plurality of openings extending into a cavity of each intake port such that there is no seal between the tubular member and the cylinder head.

Abstract: An engine additive fluid port includes a series of material layers arranged as a first oblong hollow member configured to seamlessly surround at least a portion of an intake port of an integrated cylinder head. The member penetrates into a cavity of the intake port via a plurality of nozzles featuring apertures capable of spraying a first fluid into the cavity.

Abstract: An engine system includes an exhaust manifold, an exhaust flow having a valve configured to release exhaust gas, and stratified layers defining an integrated intake manifold and an exhaust gas recirculator including a tubular inlet on an exterior of the intake manifold. The inlet defines at least one branch extending into an interior of the intake manifold without a seal between the exhaust gas recirculator and manifold. The at least one branch extends into at least one wing to form a duct containing a plurality of nozzles protruding from the duct into the interior.

Abstract: An engine component includes an intake manifold of stratified layers defining a plurality of runners each having a gas outlet leading to a cylinder head, and a plenum including partial walls forming channels radiating from a common gas inlet extending into a gooseneck conduit having an incorporated positive crankcase ventilation (PCV) apparatus. The gooseneck conduit transitions into the channels and runners such that there is no seal between the gooseneck, plenum, and runners.

Abstract: An engine component includes a tubular member, of stratified layers, curved on both ends and comprising outwardly protruded nozzles located on one side. Each of the nozzles comprising an elongated body and a tip defining apertures. The tubular member forms a nitrous oxide delivery apparatus configured to increase an internal combustion engine's power output and is located in a cavity of an intake manifold such that there is no seal between the member and the manifold.

Abstract: An engine additive fluid port includes a series of material layers arranged as a first oblong hollow member configured to seamlessly surround at least a portion of an intake port of an integrated cylinder head. The member penetrates into a cavity of the intake port via a plurality of nozzles featuring apertures capable of spraying a first fluid into the cavity.

Abstract: An engine component includes an intake manifold of stratified layers defining a plurality of runners each having a gas outlet leading to a cylinder head, and a plenum including partial walls that form channels radiating from a common gas inlet and transitioning into the runners such that there is no seal between the plenum and runners. The partial walls form endoskeletal structure configured to support the intake manifold.

Abstract: An engine component includes an intake manifold of stratified layers defining a plurality of runners each having a gas outlet leading to a cylinder head, and a plenum including partial walls forming channels radiating from a common gas inlet extending into a gooseneck conduit having an incorporated throttle body. The gooseneck conduit transitions into the channels and runners such that there is no seal between the gooseneck, plenum, and runners.

Abstract: An engine system includes a layered cylinder head with a plurality of intake ports and a stratified tubular member integrated into the cylinder head, configured as a condensate port, surrounding each of the plurality of intake ports and forming a plurality of nozzles located on at least one side of the tubular member. Each of the nozzles arranged to have a plurality of openings extending into a cavity of each intake port such that there is no seal between the tubular member and the cylinder head.

Abstract: An engine system includes an exhaust manifold, an exhaust flow having a valve configured to release exhaust gas, and stratified layers defining an integrated intake manifold and an exhaust gas recirculator including a tubular inlet on an exterior of the intake manifold. The inlet defines at least one branch extending into an interior of the intake manifold without a seal between the exhaust gas recirculator and manifold. The at least one branch extends into at least one wing to form a duct containing a plurality of nozzles protruding from the duct into the interior.

Abstract: Systems for defining an internally threaded bore in a composite material component include one or more thread forming tools each defining a thread forming portion and a locating fixture configured to hold the one or more thread forming tools in a predetermined configuration defining a pattern of internally threaded bores to be provided in the composite material component. The thread forming portions include a plurality of thread forming surfaces each defining a pitch, a crest fillet radius, and a root fillet radius, and define internally threaded bores having an interior helical thread defining a plurality of full crest radii and a plurality of full root radii. A component forming fixture is provided for abutting the locating fixture whereby the one or more thread forming tools are held in an interior of the forming fixture. Methods for forming composite material components having internally threaded bores using the described systems are described.

Abstract: Methods and systems are provided for selectively re-cooling intake air downstream of a charge air cooler. In one example, a system may include a cylinder head defining a plurality of cylinders, the cylinder head including a plurality of inlet ports each fluidically coupled to a respective cylinder, a refrigerant supply, and a refrigerant passage surrounding each inlet port and fluidically coupled to the refrigerant supply, the refrigerant passage shaped to correspond to an outer profile of each inlet port.

Abstract: A power train system includes a heat exchanger reservoir to collect condensate, a layered intake manifold, and integral tubing leading from the reservoir to an interior of the intake manifold via an intake manifold wall such that there is no seal between the condensate port and the manifold. The tubing splits into at least two branches transitioning into a set of wings containing a plurality of nozzles protruding into the interior.

Abstract: An engine is provided with a cylinder head defining a lubrication gallery intersecting a valve guide bore wall, and a valve guide. The valve guide has inner and outer walls intersecting valve-side and port-side ends. The inner wall defines a channel extending from an intermediate region of the guide to the valve-side end. The guide defines a passage extending outwardly from the channel at the intermediate region to the outer wall, with the passage fluidly connected to the gallery. Pressurized lubricant is provided to a lubrication gallery intersecting a valve guide bore wall of the cylinder head. Lubricant is directed from the gallery into a passage extending through an intermediate region of a valve guide. A moving valve stem positioned within the guide is lubricated by flowing lubricant from the passage into a channel intersecting the inner wall of the guide and to a valve end of the guide.

Abstract: A power train system includes an exhaust manifold having an exhaust flow and a control valve for releasing exhaust gas, and layered material defining an integrated engine cylinder head and an exhaust gas recirculator, connected to the exhaust flow and the valve, including a tubular inlet defining a plurality of branches around the cylinder head and having a plurality of nozzles extending into cavities of intake ports of the cylinder head. Each of the branches surrounding an exterior surface of one of the intake ports such that there is no seal between the recirculator and the cylinder head.

Abstract: Methods and systems are provided for selectively re-cooling intake air downstream of a charge air cooler. In one example, a system may include a cylinder head defining a plurality of cylinders, the cylinder head including a plurality of inlet ports each fluidically coupled to a respective cylinder, a refrigerant supply, and a refrigerant passage surrounding each inlet port and fluidically coupled to the refrigerant supply, the refrigerant passage shaped to correspond to an outer profile of each inlet port.

Abstract: A combustion engine is provided that includes an engine block with a fiber material in a resin. The engine block defines a piston bore and a bore liner positioned within the piston bore and includes a substrate and a coating positioned on an interior surface of the substrate. An exterior surface of the substrate defines a retention feature.

Abstract: An engine cylinder head includes an internal metal structure forming an upper portion of a combustion chamber. The internal metal structure includes a semi-compliant coating configured to absorb thermal expansion of the internal metal structure. The engine cylinder head also includes a polymer composite forming an external structure at least partially surrounding the internal metal structure.