Abstract: A single piece intake manifold having a core and a seal. Material of the seal and material of the core are intermixed to bond the core to the seal. The core is a plastic material such as a polyamide and/or a thermoplastic material. The seal is rubber, plastic or a thermoplastic elastomer. A method for manufacture the intake manifold includes providing a two-piece casting mold, one piece having walls configured to receive a liquefied core material and another piece having walls configured to receive a liquefied seal material. The liquefied seal material is introduced into the mold, and, separately therefrom, the liquefied core material is introduced into the casting mold. When the seal material and the core material are combined in the casting mold, they are both unhardened, or at least partially un-hardened. Heat is applied to the core material and the seal material after such materials are introduced into the mold. Intake manifold made of plastic and method for manufacturing it.

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).

Abstract: A fuel supply device is mounted to a motorcycle engine between two substantially identical air intake connections. The air intake connections each include a body portion with a projection and a flange, each extending radially from the body portion. Fasteners inserted through apertures in the flanges hold the air intake connections to the engine. The protrusion is preferably made of a resilient material, such as rubber. The flange is preferably made of a non-resilient material, such as aluminum. An aperture having an annular recess extends through the projection. The aperture is adapted to receive an internally threaded metal sleeve having an annular protrusion that surrounds the metal sleeve. A threaded fastener preferably extends through the metal sleeve and couples the fuel supply device to the projection. In the event that the fastener is excessively torqued during tightening the metal sleeve can spin in the aperture without damaging the projection.

Abstract: In an intake manifold for a vehicle, including a plurality of branch pipes connected at their one ends to a surge tank, bent at substantially 90 degrees, and horizontally arranged in parallel to one another, and an engine mounting flange connected to the other ends of the branch pipes, particularly in that including a pair of joining members made of a synthetic resin and welded to each other, among welding margins set before welding in at least one joining member along a joining line, the welding margin in a pressing direction for a portion corresponding to an inclined portion is set larger than the welding margin in the pressing direction for the remaining zone excluding the inclined portion of the joining line.

Abstract: The present invention has for its object an intake manifold or distributor with several pipes. Intake manifold or distributor (1), particularly of thermoplastic material, obtained by the assembly of at least two previously produced constituent parts (2 and 3) and comprising several intake pipes (4) formed with said manifold or distributor, characterized in that each intake pipe (4) is at least partially, and preferably totally, constituted by the coaction of at least one wall portion (6, 6′; 7, 7′) of at least one of its constituent parts (2, 3) with the structural insert (8) mounted in one of said parts (2, 3) before their mutual assembly, held in position between them after their assembly and forming at least a portion of the wall of the pipe (4) in question.

Abstract: An insert for reinforcing a flange component and an intake manifold for an internal combustion engine in which such an insert is used. The insert (14a) is open toward a longitudinal side (17) of the cylinder head flange (13), so that a mounting bolt does not have to be pushed through the passageways (16) formed by the insert, but can be inserted from the side. This offers advantages during mounting, since the intake manifold can be pushed onto pre-mounted bolts, which are subsequently tightened to fix the intake manifold. The intake manifold and the described insert are therefore particularly suitable for cost-effective mounting in tight spaces.

Abstract: A mounting arrangement for an intake manifold and a method of making same. The mounting arrangement includes an adapter plate attached to a cylinder head of an engine. The adapter plate has at least one aperture having a smooth inner surface. The intake manifold includes at least one inlet pipe and is mounted to the adapter plate by arranging the at least one inlet pipe in the at least one aperture of the adapter plate. A securing mechanism is arranged between the at least one inlet pipe and the smooth inner surface of the at least one aperture. The mounting arrangement of the present invention substantially isolates the intake manifold from vibrations caused by the operation of the engine, which in the past have been transmitted to the intake manifold by way of mounting flanges.

Abstract: The vehicle engine electrical system comprises a vehicle engine component such as an air intake manifold, at least one conductor, and foam mounting the conductor to the vehicle engine component. The conductor may be connected to a connector and thereby connected to electrical components of the vehicle such as a fuel injector, sensors, or a controller. The conductor is preferably a flex cable while the foam may be plastic.

Abstract: An outboard motor is mounted with a multiple-cylinder engine having cylinders to which intake air is distributed through the intake manifold unit of an intake unit, respectively. The intake manifold unit comprises an intake manifold body formed of a synthetic resin, an idling air control (IAC) valve for regulating a quantity of intake air into the intake manifold unit in an idling operation state, a valve holder to which the IAC valve is operatively connected in a floating manner, and an elastic member through which the IAC valve is mounted to the valve holder. The IAC valve, the elastic member and the valve holder are coupled integrally with each other and mounted to the intake manifold body in the floating state.

Abstract: An intake device for an internal combustion engine, comprising welded shells joined along a partition line, in which the partition line is provided with a region for producing inclined additional surfaces, which generate a transverse force Q2 due to their inclination relative to a pressure force D applied for welding the shells. This transverse force Q2 offsets a transverse force Q1 which is generated as a result of the inclination of partial regions of the partition line relative to the applied pressure force D. In this way, the transverse forces which arise during production of the intake device may be at least partially offset in the component, so that little or no forces are exerted on the molding tools, and the welding results for the intake pipe may thus be improved.

Abstract: In an intake manifold of an internal combustion chamber comprising a surge tank assembly and intake pipe assembly, a seal member is interposed between the end surface of the intake pipe assembly and the mating surface of the surge tank assembly so as to seal off the intake passage and mounting holes individually. Thus, the seal member, combined with the use of the blind threaded holes for the threaded bolts joining the two parts, ensures the sealing of both the intake passages and mounting holes at the interface between the end surface of the intake pipe and the mating surface of the surge tank assembly in a both reliable and simple manner. Preferably, the seal member comprises an O-ring made of elastomeric material, and at least one of the mating surface and end surface is provided with a groove for receiving the seal member.

Abstract: A vehicle fluid directing includes an engine control unit (ECU) mounted directly to the intake manifold to provide engine management and diagnostic functions. A case encloses the ECU to hermetically seal and protect the circuit board and attached components. Sensors preferably extend through the case and into the intake manifold to receives a direct input to the medium passing through the intake manifold. In another embodiment, a sensor such as an accelerometer which does not extend from the case receives vibration input. As the entire circuit board is directly mounted to the intake manifold, the vibrations are received as input to the sensor.

Abstract: A wiring assembly for a plastic intake manifold mounted to an internal combustion engine of a motor vehicle includes a flexible circuit assembly disposed within foam covering the intake manifold. The flexible circuit assembly provides for electrical communication between a controller and a plurality of electrical devices. In one embodiment the electrical devices are integral to the flexible circuit assembly to create a flexible circuit/electrical device assembly forming a single replaceable unit. In another embodiment, multiple flexible circuits are sandwiched between layers of foam, with each flexible circuit separated from the others by layers of foam. Each of the multiple flexible circuits attaches to different types electrical devices or sensors. The invention also provides for a decorative skin disposed over the layers of foam that may include a printed design to eliminate the need for an additional decorative engine cover.

Abstract: An integrated manifold assembly (500) for routing electrical signals in an internal combustion engine is disclosed. The assembly includes an air-intake manifold (506) for drawing fresh air into the internal combustion engine, a main circuit portion (508) fixable to the air-intake manifold (506) of the internal combustion engine, a plurality of circuit runner portions (510) extending from the main circuit portion (508) for interconnecting the main circuit portion (508) with a plurality of engine components (512, 514), and a heat sink (517) affixed to the air-intake manifold (506) and in contact with at least one of the a main circuit portion (508) and the plurality of circuit runner portions (510) for dissipating heat generated in the circuit portions.

Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.

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).

Abstract: A controller is integrated with an engine and provided to an engine cover that is mounted to an opening at an upper portion of the engine and closes the opening. The engine cover includes an engine cover lower portion mounted to the opening and an engine cover upper portion mounted to the engine cover lower portion and covering the obverse of the engine cover lower portion. The engine cover also covers one or more engine control components, and an engine control circuit, a circuit protecting component, and a power distributing board that are mounted to the engine cover lower portion. The one or more engine control components, the engine control circuit, the circuit protecting component, and the power distributing board are covered with the engine cover upper portion.

Abstract: An intake device for an internal combustion engine including a mounting flange (10) for mounting to a cylinder head of an internal combustion engine and a plurality of intake manifolds (11-14) which open into a common collecting chamber. The mounting flange (10) and upper shells (23, 24, 25, 26) form a first component; lower shells (27, 28, 29, 30) form a third component, and a central, second component (31) is provided between the first and third components. The respective components are assembled to each other in such a way that the second component is fixed to the first component by a positive fit, and the third component is fixed to the second component in the same way. The components are preferably secured together by friction welding.

Abstract: The present invention has for its object an intake manifold or distributor with several pipes.

Abstract: A fluid directing assembly includes partitions which define fluid directing runners. The partitions extend from a first portion and include an engagement member extending therefrom. The engagement members extend from the partitions such that an interference fit is formed between the first portion and a second portion of the module. The engagement members assure that fluid communication between runners adjacent the apertures formed by the separate portions is prevented.

Abstract: An intake manifold for a compact internal combustion engine includes a pair of arm having air passageways and coolant passageways formed therethrough. The air passageways couple an air inlet at a carburetor flange to respective air outlets at the ends of the arms. The coolant passageways couple coolant inlets at the ends of arms to a coolant chamber having a first and second coolant outlet, the first coolant outlet providing a first coolant path for connecting the coolant chamber to a radiator assembly, and the second coolant outlet providing a second coolant path for connecting the coolant chamber directly to a coolant pump. A thermostatic valve disposed in the coolant chamber directs the engine coolant along the first and second coolant paths as a function of coolant temperature. The manifold further includes an integral radiator support element.

Abstract: A structure in which an input shaft which is a member for connecting a cylindrical switching valve and a rotary mechanism, and the cylindrical switching valve are brought into contact with each other via a ball-like member. When this structure is employed, the ball-like member serves as a kind of ball joint, so that rotation can be smoothly transmitted even when there is an angle of inclination between the direction of the axis of rotation of the input shaft by which the rotary mechanism for rotating the cylindrical switching valve and the cylindrical switching valve are connected, and the direction of the axis of rotation of this switching valve.

Abstract: An intake manifold with an integrated exhaust gas recirculation system (16, 17a, 17b) which is located primarily within a plenum (12) of the intake manifold and is spaced at a distance (a) from the walls (20) of the intake manifold. This limits the heat transfer to the housing of the intake manifold, so that the housing may be manufactured, for example, of synthetic resin material. Further relief of the synthetic resin housing, particularly of the intake channels (14), from thermal stress is provided in that the intake air within the plenum cools the exhaust gas in the exhaust lines (17a, b), so that the intake-air/exhaust-gas mixture within the intake channels (14) does not exceed the critical temperature for the. synthetic resin walls (20) of the channels even if the exhaust gas recirculation rates are high.

Abstract: Conductors supported integrally with engine structure such as air intake manifolds and the like provide interconnection between engine components without the need for separate conventional wiring harnesses. The conductors take their mechanical strength from the underlying physical object and thus can be lighter than a freestanding harness. Connectors allow traces to continue across points of mechanical interface between structural components and allow wiring of engine components to be accomplished in the same operation as their physical assembly.

Abstract: A compression limiter formed by a roll forming process includes a substantially cylindrical body portion and a plurality of feet. A plurality of notches are stamped along a lower edge of a flat sheet of stock and bent to form the plurality of feet. The flat sheet of stock is then rolled to form the compression limiter. In the preferred embodiment, the compression limiter is formed of a high carbon steel. The plurality of feet of the compression limiter transmit the bolt load of a fastener attaching a plastic intake manifold to a component. In an alternative embodiment, an angled portion attaches each foot to the body of the compression limiter which accommodates for variations in the height of the plastic intake manifold.

Abstract: A resin intake manifold includes a chamber section 12 having an intake air inlet pipe 11, and a plurality of outlet pipes 13 which connect cylinders 32 of an internal combustion engine to the chamber section 12. The resin intake manifold is made by coupling half-parts 21A and 21B of divided halves of the chamber section 12 and the outlet pipes 13 divided along a direction of the pipe axis. The outlet pipes 13 are connected to the chamber section 12 so that the external wall of the outlet pipes 13 on the side of an end 13b is integral with the external wall of the chamber section 12. Further, the outlet pipes 12 extend from the chamber section 12 along a direction of the pipe axis, and are curved to extend in a direction away from the chamber section 12 with a curve angle in a range of not smaller than 90° and not larger than 180°, and continuously extend away from the chamber section 12.

Abstract: In an intake manifold for a vehicle, including a plurality of branch pipes connected at their one ends to a surge tank, bent at substantially 90 degrees, and horizontally arranged in parallel to one another, and an engine mounting flange connected to the other ends of the branch pipes, particularly in that including a pair of joining members made of a synthetic resin and welded to each other, among welding margins set before welding in at least one joining member along a joining line, the welding margin in a pressing direction for a portion corresponding to an inclined portion is set larger than the welding margin in the pressing direction for the remaining zone excluding the inclined portion of the joining line.

Abstract: A resin intake manifold includes a chamber section having an intake port which leads to a throttle body 91, and a plurality of pipe sections 7 which connect interior of the chamber section to cylinders of a multi-cylinder internal combustion engine. The chamber section is made up of a plurality of port members 1 coupled together, each port member 1 including the pipe section 7 and a cylindrical section 6 whose external wall is connected to an end of the pipe section 7.

Abstract: An inertia charge intake manifold is associated with an internal combustion engine having a plurality of cylinders. The intake manifold includes a plurality of elongated separate branch pipes each corresponding to a respective one of the cylinders. The intake manifold also includes a common flange for connecting a first end of each branch pipe to the internal combustion engine. The common flange has a first surface attached to the internal combustion engine. Further, the intake manifold includes a surge tank to which a second end of each branch pipe is connected. The common flange, the surge tank and each branch pipe are made of a hard thermoplastic synthetic resin. The common flange is integrally connected to the surge tank.

Abstract: A fuel supply device is mounted to a motorcycle engine between two substantially identical air intake connections. The air intake connections each include a body portion with a projection and a flange, each extending radially from the body portion. Fasteners inserted through apertures in the flanges hold the air intake connections to the engine. The protrusion is preferably made of a resilient material, such as rubber. The flange is preferably made of a non-resilient material, such as aluminum. An aperture having an annular recess extends through the projection. The aperture is adapted to receive an internally threaded metal sleeve having an annular protrusion that surrounds the metal sleeve. A threaded fastener preferably extends through the metal sleeve and couples the fuel supply device to the projection. In the event that the fastener is excessively torqued during tightening the metal sleeve can spin in the aperture without damaging the projection.

Abstract: A noise insulation structure of a synthetic resin made conduit includes a synthetic resin made chamber and a rubber made noise insulation member. Since the chamber is closely covered around with the noise insulation member through projections and grooves formed on the contact surface of the chamber with the noise insulation member. Further, cylindrical blind-end bores are provided on the inner surface of the noise insulation member so as to form air columns when the noise insulation member is installed on the chamber. The air columns serve as resonators to muffle noise.

Abstract: Inlet manifolds such as intake manifolds, collector tanks, intake pipes, oscillatory intake passages, systems with variable-tract intake manifolds etc., for internal combustion engines operating on the principle of the diesel or Otto engine, where the inlet manifold includes two or more dish-shaped parts that are permanently joined to each other, and the dish-shaped parts are formed sheet parts, castings and/or extruded sections of metal. The permanent joining of the dish-shaped parts may be effected e.g. by adhesive bonding and/or welding.

Abstract: A thermal exchanger to be implemented in the air intake circuit of an internal combustion engine, notably in an intake splitter which includes a hollow plastic body (1) that defines an air intake chamber (2), an entry (3) for air and one or many exits which communicate with the head of the engine. The thermal exchanger constitutes of a chamber (5), at least part of which is in a plastic material, and which features a first opening towards the outside, a second opening (7) that communicates with the intake chamber (2), a third opening (8) that communicates with a canal (9) which supplies coolant fluid, a fourth opening (10) that communicates with a canal (11) which carries the coolant fluid out, a metallic assembly that forms the hot part of the exchanger.

Abstract: The vehicle engine electrical system comprises a vehicle engine component such as an air intake manifold, at least one conductor, and foam mounting the conductor to the vehicle engine component. The conductor may be connected to a connector and thereby connected to electrical components of the vehicle such as a fuel injector, sensors, or a controller. The conductor is preferably a flex cable while the foam may be plastic.

Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.

Abstract: An inertia charge intake manifold is associated with an internal combustion engine having a plurality of cylinders. The intake manifold includes a plurality of elongated separate branch pipes each corresponding to a respective one of the cylinders. The intake manifold also includes a common flange for connecting a first end of each branch pipe to the internal combustion engine. The common flange has a first surface attached to the internal combustion engine. Further, the intake manifold includes a surge tank to which a second end of each branch pipe is connected. The common flange, the surge tank and each branch pipe are made of a hard thermoplastic synthetic resin. The common flange is integrally connected to the surge tank.

Abstract: There is disclosed herein an apparatus for routing electrical signals in an engine having n cylinders and an intake manifold, one embodiment of which comprises: (1) a generally rigid housing generally conforming in shape with and being removably attachable to a top surface of the intake manifold; (2) at least n carrier members attached to the housing and extending outward therefrom, wherein each carrier member is arranged in general proximity with a respective cylinder; (3) a plurality of conductive circuit traces arranged on or within an underside or other surface of the housing and on or within each carrier member; and (4) at least one input/output connector for connection to at least one of an external signal source, an external power source, an external signal destination, and an external power destination, wherein each input/output connector is attached to the housing and is electrically connected to at least one of the circuit traces.

Abstract: A suction apparatus of a multi-cylinder internal combustion engine has a suction manifold disposed in a direction parallel with a row of cylinders at one side of a cylinder head. The suction apparatus includes a plurality of independent suction passages of equal length each extending from an engine main body at right angle, a suction gathering chamber connected to the suction passages and disposed in the direction parallel with the row of cylinders, a throttle body provided at an upper stream end of the suction gathering chamber, and a resonance vessel communicating with the suction gathering chamber. The resonance vessel is supported by a cylinder head cover and a wall of the gathering chamber elastically through rubber members covering above of the independent suction passages with a space, and communicates with an upper part of the suction gathering chamber at a just downstream position of the throttle body.

Abstract: A plastic air intake assembly comprising, for example, upper and lower housing members with the upper member underside and the lower member upper side having a continuous 3-dimensional perimeter mating surface. The upper member mating surface being formed with a chamfered-shape in cross-section and the lower member mating surface being formed with a complementary chamfered-shape in cross-section. The mating surfaces are bonded together in an overlapping flush manner by suitable means, such as heat-cured adhesive, forming a continuous sealed scarf joint parting-line having a low profile with the mating surfaces lying in generally parallel planes with their associated housing wall portions.

Abstract: A power steering fluid reservoir is provided which is formed integrally with an intake manifold. The intake manifold includes an inlet channel for allowing ambient air into the manifold. A plenum is fluidly connected with the inlet channel and the plenum provides a gaseous reservoir. A plurality of runners are fluidly connected with the plenum for distributing air to the cylinders of an engine. Integrally formed with the inlet channel, plenum, and runners is a power steering fluid reservoir. The power steering fluid reservoir is fluidly separated from the intake plenum by a common wall. The common wall allows for continuous cooling of the power steering fluid by an induced flow of ambient air through the plenum.

Abstract: The invention concerns an intake system, in particular an intake pipe of thermoplastic plastics for the intake air of an internal combustion engine with in particular cylinder rows arranged in a V-shape. The intake system comprises at least two elements (10, 14), the first element (10) having a substantially closed shape and simultaneously forming the lower half-shell of the intake pipes. The second element (14) is designed as the upper half-shell of the intake pipes and is connected to the first element (10) by the plastics welding technique.

Abstract: In an intake passage arrangement in an internal combustion engine at least two intake ports located in a cylinder head depart from a common intake flow path. In the area where the flow path branches into the separate intake ports a swirl control device configured as a control flap is positioned, which is rotatable about a rotation axis situated at one end of the control flap. In one position the control flap opens both intake ports, whereas it blocks one intake port in another position. To ensure control of the swirl motion of the intake flow entering the combustion chamber and to permit a most simple and compact design an intermediary part carrying the control flap is essentially configured as a thin, flat frame, and preferably as a die-cast part made of aluminum.

Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer and a lower half shell formed from a polymer and joined to the upper half shell. The upper half shell formed includes an upper perimeter flange having a pair of side flanges and a pair of end flanges, the side flanges having an inner surface and the end flanges having an inner surface. The lower half shell includes a lower perimeter flange having a pair of side flanges and a pair of end flanges, the side flanges having an inner surface and the end flanges having an inner surface. The lower half shell is joined to the upper half shell to define a housing having an internal cavity.

Abstract: An internal combustion engine intake module (10; 60) integrates elements of a PCV system, including a PCV valve (40) and a channel, or conduit, (102) for conveying gaseous fluid.

Abstract: There is disclosed herein an apparatus for routing electrical signals in an engine having n cylinders and an intake manifold, one embodiment of which comprises: (1) a generally rigid housing generally conforming in shape with and being removably attachable to a top surface of the intake manifold; (2) at least n carrier members attached to the housing and extending outward therefrom, wherein each carrier member is arranged in general proximity with a respective cylinder; (3) a plurality of conductive circuit traces arranged on or within an underside or other surface of the housing and on or within each carrier member; and (4) at least one input/output connector for connection to at least one of an external signal source, an external power source, an external signal destination, and an external power destination, wherein each input/output connector is attached to the housing and is electrically connected to at least one of the circuit traces.

Abstract: The invention relates to an admission system for an internal combustion engine, in particular for a motor vehicle engine. Said admission system has a connecting flange (11) for fastening the system to the internal combustion engine, a collection unit (12) which has at least one connection for supplying the intake air, and suction pipe connections the number of which depends on the number of suction pipes. Connection is achieved by suction pipes produced by a plastic blowing process.

Abstract: To protect a plastic intake manifold of an internal combstion engine from heat possessed by exhaust gas recirculation gas, a cooling device is arranged between the plastic intake manifold and an exhaust gas recirculation valve. The cooling device cools the exhaust gas recirculation gas by means of a coolant. A gas discharge part of the cooling device constitutes a pipe portion which penetrates through an exhaust gas inlet hole of the intake manifold keeping a given space between an outer wall of the pipe portion and an inner wall of the exhaust gas inlet hole. The pipe portion may be a leading end portion of an exhaust gas recirculation pipe extending from an exhaust system of the engine.