Abstract: A transparent component portion includes a first weld surface and a first taper locking surface formed opposite from the first weld surface. An absorbing component portion includes a second weld surface and a second taper locking surface formed opposite from the second weld surface. The first and second taper locking surfaces cooperate to force and lock the first and second weld surfaces into abutting engagement for laser welding.

Abstract: An intake manifold assembly (100) includes an inner shell (12) that is inserted into an outer shell (14), and a cover (25) that seals the open end (38) of the outer shell (14). The inner shell (12) includes dividers (16) that form air passages (18). A laser device (40) is traversed along the outer surface of the outer shell (14) along a path (44) corresponds with the inner shell (12) to form a laser weld joint (45). The intake manifold assembly (10) of this invention includes features and methods of assembly that improve the laser weld joints utilized to assemble the plastic intake manifold assembly (10). Both design details and clamping detail are described, every known configuration of U type manifolds can be made by this technique. The technique provides high value and low cost. High reliability is a well known feature of laser welding.

Abstract: An intake assembly includes an intake manifold comprising several interfitting sections attached to each other to define a plurality of air passages, and an EGR conduit within the intake manifold including openings in communication with each of the plurality of air passages. The EGR conduit is in communication with a source of exhaust gases and provides for the proximate and decentralized injection of exhaust gases into the intake manifold assembly. The intake manifold assembly also includes a passage that is in communication with a positive crankcase ventilation system (PCV) and a purge gas system. Gases from the PCV system and the gas purge system mix in the passage and then are communicated to the each of the air passages through individual opening passages.

Abstract: An intake manifold assembly (100 includes an inner shell (12) that is inserted into an outer shell (14), and a cover (25) that seals the open end (38) of the outer shell (14). The inner shell (12) includes dividers (16) that form air passages (18). A laser device (40) is traversed along the outer surface of the outer shell (14) along a predetermined path (44) that corresponds with the position of the inner shell (12) such that a desired laser weld joint (45) is formed The intake manifold assembly (10) of this invention includes features and methods of assembly that improve the laser weld joints utilized to assemble the plastic intake manifold assembly (10). Both design details and clamping detail are described, every known configuration of U type manifolds can be made by this technique. The technique provides high value and low cost. High reliability is a well known feature of laser welding.

Abstract: A vehicle fuel intake system (10) includes an intake manifold (14), an injector pack assembly (18) and an air cleaner assembly (16). The injector pack assembly (18) includes an encapsulated lead frame (36) that provides electrical communication to fuel injectors (26). The intake manifold defines a fuel rail (22) and a cavity (24). Fuel vapors permeating from the fuel rail (22) are trapped in the cavity (24) and channeled back into the air intake passages (20). The air cleaner assembly (16) includes a filter (28) for absorbing fuel vapor emissions from unburned fuel escaping a non-operating engine (12). An actuator (30) moves the filter (28) between an open and closed position. Once the engine begins operation, the actuator (30) opens the filter (28) to allow unrestricted airflow through the intake manifold (14).

Abstract: An intake manifold includes a lower manifold assembly that includes fuel injectors, an electrical conductor assembly for the fuel injectors, and a fuel rail retained between the lower manifold and an upper manifold. The lower manifold defines a portion of the air passage to the engine and provides for a desired positioning of the injector nozzle within the air passage. The fuel injector is sealed at a lower portion near the air passage by being integrated into the lower manifold. A support segment on the lower manifold supports the fuel rail over the fuel injectors. The upper manifold includes a retention segment that holds the fuel rail against the lower manifold and on the fuel injectors.

Abstract: An HQ tube arrangement suitable for packaging within a vehicle includes a first passageway having a fluid inlet and a fluid outlet and a second passageway located adjacent the first passageway. The second passageway is fluidly connected to the first passageway at first and second spaced apart junctions with the second passageway being divided by the junctions into first, second and third passages. The second passageway includes first and second opposing terminal ends respectively spaced from the first and second junctions wherein portions of the first, second and third passageways are oriented in a substantially similar direction to that of the first passageway to form a substantially rectangular configuration.

Abstract: Laser welding is used to attach a laser-transparent component portion to an absorbing component portion at a laser weld joint area. The transparent component portion includes a first weld surface and a first taper locking surface formed opposite from the first weld surface. The absorbing component portion includes a second weld surface and a second taper locking surface formed opposite from the second weld surface. Prior to laser welding, the first and second taper locking surfaces cooperate to force and lock the first and second weld surfaces into abutting engagement at a predetermined pressure. A laser beam is then directed toward the first and second weld surfaces to permanently attach the component portions together. The first and second taper locking surfaces maintain the predetermined pressure during the laser welding process.

Abstract: A throttle shaft and butterfly construction is formed by molding both components from composite plastic, the shaft having integral bosses which are received in holes formed in the throttle plate. The bosses are ultrasonically or heat staked to lock the throttle plate onto the throttle shaft. The butterfly has ribs extending across a face of the butterfly substantially to the edge of the valve in a direction parallel to the flow of air across the butterfly to stiffen the butterfly and reinforcing ribs on the butterfly parallel to the throttle shaft to stiffen both the butterfly and the throttle shaft.

Abstract: A throttle shaft assembly includes throttle shaft with a cam and shaft portion the shaft portion configured to be inserted in the throttle body, a throttle return spring that is coiled around the throttle shaft with two ends one end engaged to the cam portion and the other end engaged to a spring support on the throttle body, and a throttle spring cover that substantially surrounds the throttle return spring and is slideably mounted on the throttle shaft. The throttle return spring can be preloaded and restrained at both ends on the throttle shaft assembly thus preventing the preload from being released as the throttle shaft assembly is inserted into the throttle body. One end of the spring can be released to engage a portion of the throttle body thus reducing a portion of the preload. The cover had several flexible fingers that engage a groove in the throttle shaft and prevent the cover from sliding off thus exposing the spring.

Abstract: A throttle valve for throttling the combustion air flow for an internal combustion engine is disclosed, having a body with a throat, a butterfly in the throat to throttle flow, and a shaft connected to the butterfly to operate it. The shaft has an arm that abuts a throttle stop to maintain the butterfly in an almost-closed (or idle) position. The arm has an opening that permits access to the head of the throttle stop to adjust the throttle stop when the throttle valve is in the almost-closed position. The opening is located so that a tool such as a hex wrench can pass through the opening and engage a socket in the head of the throttle stop, pemitting it to be rotated and adjusted. The throttle shaft and arm are preferably integrally molded of plastic, and the throttle stop head is preferably larger than the threaded shaft of the throttle stop.