Abstract: A pressure regulator is associated with a solenoid-operated valve that is operated by a pulse waveform at a fundamental frequency substantially greater than the frequency response of the valve mechanism. This substantially attenuates solenoid pulsations and applies a predetermined pressure differential across the valve mechanism to accomplish improved flow control accuracy. The invention is especially advantageous for purging fuel vapor to an intake manifold of an internal combustion engine of an automotive vehicle.

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: An apparatus and method for minimizing electromagnetic interference in a unipolar phase motor having a supply current is provided. The motor further has a plurality of motor phases energizable with pulse width modulation (PWM). The method includes calculating the current harmonics on a right edge aligned PWM, calculating the current harmonics on a left edge aligned PWM pulse, determining the supply current by summing the current harmonics for the right edge aligned PWM pulse and the current harmonics for the left edge aligned PWM pulse, energizing a first motor phase with PWM, and staggering the PWM pulses for each successive motor phase by varying the energizing of any two adjacent energized phases based on the amount of supply current in the motor, the staggering of the PWM pulses minimizing electromagnetic interference and current harmonic generation due to an increase in the supply current.

Abstract: A module (22) for an on-board evaporative emission leak detection system that detects leakage from an evaporative emission space of a fuel system of an automotive vehicle. The module has a housing (50) that includes a first port (52) for communicating the housing to the evaporative emission space and a second port (86) for communicating the housing to atmosphere. The housing contains a particulate filter (84) through which the second port communicates with two parallel flow branches that extend within the housing to the first port. One branch contains a vacuum regulator valve (90), and the other, a solenoid-operated vent valve (88). During a leak detection test, the vent valve is operated closed, and a purge valve (20), that selectively communicates the evaporative emission space with the engine intake manifold, is operated open to cause vacuum to be drawn in the evaporative emission space. The vacuum regulator valve regulates evaporative emission space vacuum to a defined vacuum.

Abstract: A diaphragm for an integrated pressure management system manages pressure and detects leaks in a fuel system. The integrated pressure management system also performs a leak diagnostic for the headspace in a fuel tank, a canister that collects volatile fuel vapors from the headspace, a purge valve, and all associated hoses and connections.

Abstract: An internal combustion engine cylinder head (142) has an exterior wall that contains a walled compartment (140). A wall of that compartment is exposed to an internal coolant passage (146) through which liquid coolant circulates. An exhaust gas passageway (160) running through the compartment has an exhaust gas entrance (162) into the compartment and an exhaust gas exit (164) from the compartment. The compartment comprises a receptacle (148) that intersects the exhaust gas passageway between the entrance and the exit. An EGR valve (10) disposed on the exterior wall comprises a base (12) that has an inlet port (30) and an outlet port (32) and that is disposed within the receptacle with the inlet port open to the entrance via the passageway and the outlet port open to the exit via the passageway. As hot exhaust gas is recirculated, coolant that circulates through the coolant passage aids in limiting peak temperatures to which the valve may be subjected.

Abstract: An air induction system for a vehicle engine includes a sensor assembly for monitoring particulate concentration. The sensor assembly is mounted within an air intake housing, which has an inlet and an outlet. An airflow passageway extends between the inlet and the outlet to the vehicle engine. An air filter is mounted within the housing to filter particulates from air flowing through the airflow passageway. The sensor assembly can be mounted to an intake manifold or incorporated into a mass airflow sensor. The particulate sensor generates a particulate signal representative of particulate concentration entering the vehicle engine via the outlet. The signal is sent to an output device monitored by a vehicle operator.

Abstract: A control for controlling an output of a system of an automotive vehicle having an electric-operated control device that controls an output of a system of the automotive vehicle in accordance with an electric control signal comprising a waveform comprising voltage pulses applied to the device. An electric control, including a processor, for developing the electric control signal from a primary control signal and a secondary control signal. The processor causes the secondary control signal to selectively interact with the primary control signal in developing the electric control signal such that at certain times, the electric control signal is developed from the primary control signal alone, and at certain other times, the electric control signal is developed by interaction of the secondary control signal with the primary control signal.

Abstract: An intake manifold includes an upper shell, a lower shell, and a middle shell that interconnects the upper and lower shells. The lower shell has a plurality of longitudinally spaced shell ports. Each shell port is adapted for installation over a corresponding intake port for an engine cylinder head. The upper shell has a plurality of runners that are used to guide air to the shell ports. The middle shell has a plurality of channels that interconnect the runners and the shell ports such that air can flow through the runner to the cylinder intake port. Fuel injector pockets are formed within the upper, middle, and lower shells with each of the pockets having an injector opening in communication with the corresponding shell port. An internal fuel rail, formed between the upper and middle shells, supplies fuel to each of the injector pockets. A fuel injector is installed into each injector pocket such that the injectors are substantially enclosed within the manifold.

Abstract: A polymeric hose assembly including a male hose inserted within a female hose connects an air cleaner to an internal combustion engine. An elastomeric seal including a plurality of bellows is bonded around the circumference of the exterior surfaces of the female hose and the male hose at bonding points. The plurality of bellows expand to allow for the expansion of the hose assembly to accommodate for engine movement and vibrations.

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 on-board evaporative emission leak detection system has a module (22) for detecting leakage from an evaporative emission space of a fuel system of an automotive vehicle. Interior space (103) of the module's enclosure (102) is communicated to atmosphere. A pump (50) is disposed within space (103) and has an inlet (56) communicated to the interior space and a flow passage (70, 72) at its outlet (58) to allow the pump to create pressure in the evaporative emission space suitable for performance of a leak test. A vent valve (52) is disposed within space (103) and is selectively operable to vent and not vent the flow passage to space (103). An electromagnet actuator (104) has a single electric coil (116) that operates both the pump and the vent valve. A driver circuit (1000) to the coil provides a first current component for operating the pump and a second current component for operating the vent valve.

Abstract: An intake manifold assembly and a valve cover is pivotally supported by the intake manifold assembly for rotational movement relative thereto. Preferably, a hinge assembly pivotally supports and connects the valve cover to the intake manifold assembly. During assembly of the engine, the intake manifold assembly is secured to a portion of a base engine assembly such as the cylinder head. Specifically, threaded fasteners may secure a flange of the intake manifold assembly which is adjacent to the hinge assembly to the cylinder head. The valve cover is rotated relative to the intake manifold assembly and into engagement with the cylinder head so that a valve cover gasket sealingly engages the cylinder head. Fasteners on a side of the valve cover opposite the hinge assembly secure the valve cover to the cylinder head.

Abstract: A non-metallic vehicle gas-directing component includes a plurality of ceramic members embedded within an inner surface. The ceramic members extend into a passageway to form a boundary layer between the flow of exhaust gas and exposed portions of the inner surface to provide a highly heat resistant and lightweight passageway for directing a high temperature gas. A method for producing the vehicle gas-directing component includes temporarily attaching a plurality of ceramic members to an inner mold core during a lost core molding process. In one disclosed embodiment, the ceramic members are temporarily attached directly to the inner mold core by an adhesive. In another disclosed embodiment, the plurality of ceramic members are attached to an inner contour of a core casting cavity by an adhesive.

Abstract: An EEGR valve has a solenoid with an armature supported at each end on circular disks. These disks are fixed to the top and bottom having numerous penetrations (e.g., slots, slits or openings) to permit the disks to be deflected upward or downward. The penetrations are arranged such that when a current is applied to the solenoid coil the armature deflects the disks and permits the armature to move up and down within the coil. The penetrations are arranged as concentric rings of penetrations. The disks are fixed at several locations around their edges to the stator of the solenoid. In this manner, the armature moves back and forth along its axis and not laterally, thus permitting the stator to be located quite close to the armature without wearing against the stator, A spring is provided to preload the armature and deflect the disks in a concave shape different from their unloaded and substantially flat configuration. In this manner, the coil can drive the solenoid.

Abstract: An air cleaner housing system with an detachable air cleaner tube and a method of doing same. The air cleaner housing system includes the air cleaner tube, an air cleaner housing including an aperture, an air filter disposed inside the air cleaner housing, an attachment mechanism comprising a first portion disposed on the air cleaner tube and a second portion disposed on the air cleaner housing, and a first seal disposed between the air filter and the air cleaner tube. The attachment mechanism is a radial twist fit connector which moves between a first rotational position to attach the air cleaner tube to the air cleaner housing, and a second rotational position to detach the air cleaner tube from the air cleaner housing. Alternately, the attachment mechanism is an axial twist fit connector.

Abstract: A simple and reliable connection between an air resonator and a throttle valve body is achieved with a resilient vacuum seal. The vacuum seal is positioned in an outer periphery of a boss on the valve body, and provides an interference fit with the resonator. The seal preferably has a seal lip extending away from the resonator such that a vacuum drawn within the resonator pulls the seal body more tightly against an inner periphery of the bore. Moreover, vibration isolator surfaces are positioned on the seal to dampen vibration between the air resonator and the valve body. The present invention thus provides a simple and secure method of connecting the air resonator to the valve body.

Abstract: An EGR valve has two coaxial valve rings that are sequentially opened when the EGR valve is operated. A first, smaller gap is formed by the first valve ring opening and a second larger gap is formed when the first valve ring moves with respect to the second valve ring. In this manner, a nonlinear flow rate is provided through the EGR valve that permits greater accuracy of control at lower exhaust gas flow rates.

Abstract: An integral heat sink for transferring heat from combustion exhaust gas produced by a vehicular internal combustion engine is disclosed. The heat sink includes a body providing an integral base configured for support by a manifold. The heat sink also includes a hollow elongate member providing a first portion contained in the body. The first portion has an exhaust gas intake. The member also includes a second portion extending from the body. The second portion is configured for insertion into the manifold and provides at least one discharge for the exhaust gas. The heat sink also includes a cavity disposed between the body and the member. The cavity is configured for conveying combustion air from the manifold around at least a portion of the member.

Abstract: A field replaceable unitary manifold housing for providing combustion air and combustion fuel to an internal combustion engine is disclosed. The housing includes an air purification cavity having a spaced apart air intake and air discharge. The housing also includes a filter for purifying air disposed in the air purification cavity intermediate the air intake and the air discharge. The housing also includes a hollow elongate member having a first end coupled to the filter and a second end coupled to a plenum chamber for directing the air, the plenum chamber being integral with the air purification cavity. The housing also includes a plurality of channels, each channel integral with the housing and having a first end integral with the plenum chamber and a second end coupled to a cylinder head of the engine.