Abstract: A resonator for an induction system includes an inlet and outlet with a resonator cavity arranged therebetween. A tube is arranged within the resonator cavity and at least partially extends between the inlet and outlet. In one example, at least one supplemental noise attenuation device is in communication with the arcuate tube, such as a quarter wave tube and/or Helmholtz resonator. A large opening is provided in the tube that opens into the resonator cavity. In one example, the large opening is arranged on an outer radius side and faces a large cavity portion of the resonator cavity. Additional supplemental noise attenuation is provided by a collar arranged concentrically relative to the tube providing an annular quarter wave tube that is coaxial with the direction of flow from the outlet.

Abstract: A duct for an induction system is provided that has an effective length between an inlet and outlet. An aperture is provided a wall of the duct at a location corresponding to a pipe resonance for attenuating noise at the pipe resonance frequency. In one example, the aperture is provided using a cluster of holes arranged at the location. Multiple apertures are arranged about a circumference of the duct, for example, at opposing sides of the duct. In one example, an aperture is provided at a distance of approximately one quarter the effective length from both the inlet and the outlet. A porous non-woven structure is arranged over the aperture to minimize pressure losses associated with the aperture.

Abstract: A plastic intercooler assembly includes a plurality of plastic tubes that extend between plastic end plates. The plastic tubes are secured to the end plates to provide the desired seal between the end plates and the ends of the tubes. The plastic tubes are attached utilizing plastic welding methods that reduce assembly time and cost.

Abstract: An intake manifold assembly (10) includes a plenum (14) and a variable volume assembly (20). The variable volume assembly (20) includes a deformable member (22) and a biasing member (24). The biasing member (24) positions the deformable member (22) at a predetermined position in response to a vacuum pressure within the plenum (14) to define a volume within the deformable member (22) to change the operational characteristics of the intake manifold assembly (10).

Abstract: An example induction system for an engine includes a plenum in fluid communication with multiple primary runners. A plenum valve is arranged between first and second chambers of the plenum, which are respectively in fluid communication with first and second sets of the primary runners. The plenum valve is configured to move between open and closed positions and regulate flow between the first and second chambers. A second runner is arranged upstream from and in fluid communication with the plenum. A runner valve is arranged in the secondary runner and configured to vary the amount of flow through the secondary runner. A common actuator is interconnected to both the plenum and runner valves and is configured to move both of the plenum and runner valves between desired positions to achieve desired valve configurations that tune the engine.

Abstract: An induction system is designed for an engine that includes a manifold having a plenum in fluid communication with primary runners. A plenum valve is arranged between first and second chambers of the plenum that are respectively in fluid communication with first and second sets of the primary runners. The plenum valve is configured to move between open and closed positions to regulate flow between the first and second chambers. A secondary runner is arranged upstream from and in fluid communication with the plenum. The secondary runner includes first and second runner portions with the second runner portion being shorter than the first runner portion. A runner valve is arranged in the secondary runner between the first and second runner portions and is configured to selectively direct flow through the first and second runner portions to the plenum to obtain a desired effective tuning length.

Abstract: A method of assembling a plastic article includes laser welding a first laser absorbent part having a first surface finish and a second laser transparent part with a second surface finish that is different than the first surface finish. The first part includes a surface finish that is textured and grained. The second part includes a substantially smooth non-textured surface finish. One of the first and second parts includes a carbon black dye that provides a desired black color. The other of the first and second parts does not include the black dye but instead utilizes another dark colored dye. The carbon black dye provides for the part to be laser absorbent and the other type of dye is utilized to provide a substantially similar appearance in a laser transparent part.

Abstract: An intercooler assembly includes a housing that defines an internal space containing a plurality of tubes. A joint between a tube and a tube plate is created by a laser welding process. A form presses the walls of the tube outwardly to form the flange. The downward force of the form not only creates the desired flange, but also exerts a pressure that holds the flange against the tube plate. The form provides for the transmission of laser energy to that the creation of the flange can be performed concurrently with the welding process.

Abstract: An endcap 26 for a motor 28 includes a first layer 32 of metal material, a second layer 32? of metal material, and a third layer 30 of thermal isolating material constrained between the first and second layers such that the third layer inhibits the transfer of thermal energy from the first layer to the second layer and from the second layer to the first layer. The endcap 26 combines the functions of an endplate and heat shield into a single component for isolating internal motor components from radiant energy sources.

Abstract: A method of connecting stranded wire to a lead-frame body 10 includes the provision of a stranded wire 12. It is ensured that insulation is stripped from an end 14 of the stranded wire. An electrically conductive lead-frame connection structure 16 is associated with the lead-frame body. The end 14 of the stranded wire is inserted into the lead-frame connection structure 16 so that the lead-frame connection structure substantially surrounds the wire end. Solder flux is injected so as to be substantially about a portion of the end of the stranded wire. The lead-frame connection structure is placed in contact with a bottom resistance welding electrode 18 or a top resistance welding electrode 20.

Abstract: A fan shroud structure 10 is constructed and arranged to carry a fan and motor. The fan shroud structure includes a base 12 and an annular rim 24 extending from the base. The rim defines a generally central opening 26 sized to accommodate blades of a fan. Motor mounting structure 28 is coupled with the rim 24 and is disposed generally adjacent to the central opening 26. The motor mounting structure 28 is constructed and arranged to support a motor for driving a fan. The fan shroud structure 10 includes a first pair of opposing sides 14, 16 and a second pair of opposing sides 17, 18 coupled to the base to form a box-like configuration defining a perimeter of the fan shroud structure raised with respect to the base such that the sides are discontinuous with respect to the base 12 to shift resonance of the shroud structure.

Abstract: A blower assembly 10? includes a housing 18? having an inlet 19 and an outlet 20. The housing includes an inlet ring 22? at the inlet. A blower wheel 12? is mounted for rotation in the housing. An electric motor 16 includes a shaft 14 having an axis B. The shaft is coupled to the blower wheel so that rotation of the shaft causes rotation of the blower wheel that causes air to flow from the inlet to the outlet. The inlet ring has an annular extension 24 extending linearly in the same direction as the shaft axis B. An end 26 of the blower wheel 12? is within bounds of the extension 24.

Abstract: A cooling module 67 includes a motor assembly 42 having a motor case 24 having at least one open end and including mounting brackets 30 integral therewith. Each bracket has only a bottom portion 32 connected with the motor case. An armature assembly is disposed in the motor case and includes a rotatable shaft 46. A brush card assembly 56 is associated with the armature assembly, and an end cap 60 is disposed over the brush card assembly and partially covers the open end of the motor case and thereby defining a non end cap covered motor portion 63. A fan 64 is coupled to an end of the shaft and has a hub substantially covering one end of the motor assembly. A shroud 74 has a motor cover 76. Fastening structure 78 is associated with the shroud and engaged with the brackets thereby mounting the motor assembly to the shroud, with the motor cover substantially covering the end cap and the non end cap covered motor portion.

Abstract: A flange seal molded as a single piece from a synthetic material which can withstand the high heat and pressure produced by the engine. The flange seal is shaped to correspond the intake manifold housing. Connecting portions on the flange seal separate the individual port openings. The flange seal is located between the intake manifold housing and the cylinder head to seal the joint. Pressure is applied to the flange seal when the fasteners are tightened to aid in sealing.

Abstract: An intake manifold assembly includes a housing, a shaft assembly, an intake insert, and a flange seal. The shaft is a shaft manufactured from metal, preferably aluminum. Bushings are located at each end of the shaft and spaced along the shaft to absorb vibrations and provide a low friction surface for shaft assembly rotation. In addition, the bushings allow for differences in the thermal expansion of the shaft and the intake manifold housing. A bearing is located adjacent a shaft locator to provide a hard mounting surface for the shaft assembly when assembled with the housing.

Abstract: An air inlet is mounted adjacent to an actuator and an intake manifold. A valve shaft extending from the actuator to the air inlet rotates the inlet valve from an open position to a closed position, or vice versa. The actuator senses revolutions per minute of an engine to control the inlet valve position. When the inlet valve is in the closed position the amount of oxygen reaching the engine is reduced. The restricted airflow through the air inlet helps to reduce engine noise.

Abstract: An intake manifold assembly includes a housing, a shaft assembly, and an intake insert. The shaft assembly has a metal shaft with bearings located at each end to provide hard mounting surfaces for the shaft assembly when assembled in the housing. The bearings support the shaft within the housing and allow the shaft to freely rotate. Bushings are spaced along the shaft to absorb vibrations and assist is providing a low friction surface for shaft assembly rotation. Journal pockets in the housing and in the intake insert surround the bushings. Isolators located within the journal pockets and housing surround the bushings and assist in dampening vibrations.

Abstract: An arrangement for attaching a blade to a shaft for use in intake manifolds, uses fasteners that create a load on the blade. Fasteners are inserted through fastener holes in the blade and through shaft holes in the shaft. Once inserted outward pressure by the fastener on the shaft and the blade places the assembly under a constant load. The load prevents the shaft and the blade from vibrating against each other during engine operation. The same attachment method can also be used to retain and bias a shaft locater to the shaft.

Abstract: An active noise attenuation system includes a speaker housing for a speaker assembly that attenuates noise generated by an air induction system for a vehicle engine. The speaker housing is a generic housing formed from plastic that can be utilized with many different vehicle types. An air cleaner housing is positioned between the speaker housing and the engine for filtering out contaminants from the air before the air is drawn into the engine. Brackets are joined to the air cleaner and speaker housings for mounting the housings to a vehicle structure.

Abstract: A fan shroud structure 10 is constructed and arranged to carry a fan. The fan shroud structure includes a body 12 having a periphery, a main surface, and an annular rim 26 defining a generally central opening 28. The opening 28 is sized to accommodate blades of a fan. Fan mounting structure 30 is coupled with the body and is disposed generally adjacent to the central opening. The fan mounting structure is constructed and arranged to support a motor of a fan. The body includes a plurality of surfaces features 34 constructed and arranged to affect resonance of the shroud structure with each feature having a surface 36 that is discontinuous with respect to the main surface 38 of the body. Each feature 34 also extends from the annular rim to the periphery of the body.