Abstract: An electric motor structure includes an electric motor having a housing and an endcap coupled to an end of the housing. The endcap includes a bearing pocket constructed and arranged to cover a bearing structure. The motor structure also includes a heat shield coupled directly to the motor so as to surround and cover the bearing pocket, with a portion of the heat shield being spaced from the bearing pocket.

Abstract: Plastic parts are formed to have a relatively high wall stiffness by utilizing a pair of spaced plastic plates. One of the plates may be a simple plate. The other plate has a plurality of ribs extending from a base. The ribs are welded to the other plate. Use of the ribs provides a relatively high degree of stiffness to the final molded plastic part, for a relatively lightweight part.

Abstract: Steel fuel rails are provided with the mechanical components of a plurality of fuel injector valve bodies. The electronics for operating those valves are molded into an injector pack. The valve bodies are inserted into the passages associated with the injector pack such that the electronics are part of a single molded plastic portion. A corrugated seal is sealed to an outer portion of the passage on the injector pack. Thus, the present invention eliminates the number of connections for supplying fuel that needed to be sealed in the prior art. Further, the number of required assembly steps is reduced over the prior art.

Abstract: An intake manifold (10) includes a fuel rail cavity (30) which receives a metallic fuel rail (14) enclosed by a molded fuel rail cavity cover (32). The fuel rail (14) communicates with each of a plurality of engine cylinders (16) through a fuel module (18). An injector cup (28) fits upon each module cylinder to provide an interface between the fuel module and the fuel rail. Another intake manifold (10) includes a fuel rail (14) which directly interfaces with each fuel module (18) through a bellows (38) attached directly thereto.

Abstract: An active noise control system for use onboard a vehicle normally provides noise cancellation of engine sounds. The speaker of the active noise control system also emits a horn sound responsive to appropriate commands from a controller that receives a horn switch signal from a horn switch supported on a steering wheel assembly. The active noise control system controller enters a power saving mode when the vehicle ignition is turned off and the vehicle is not running. A horn switch activation during the power saving mode wakes up the controller so that the controller unmutes an amplifier and drives the speaker to emit the desired horn sound.

Abstract: An engine noise control system (100) controls engine noise in multiple engine operating modes by controlling a size of an air inlet (104) with a movable valve. An actuator (114) moves the valve (112) between an open position and a closed position depending on the engine operating mode, to control the amount of air travelling into an air cleaner. The actuator (114) is coupled to an engine cylinder de-activation unit (200) to link the valve operation to the engine operating mode. When the engine is operating in a low-power mode, which requires less air, the actuator (114) moves a cable drive (204), which rotates an actuation lever (208) that turns the valve (112) into a closed position. When the engine is operating in a high-power mode, the actuator (114) moves the cable drive (204) to move the valve (112) to an open position.

Abstract: A fuel module carrier assembly mounted between an intake manifold and an internal combustion engine includes an electrical lead, coil assemblies, fuel modules, fuel module seals, a molded carrier and runner seals. The fuel module carrier assembly retains and protects the electrical fuel module components. The electrical lead is molded or assembled into the carrier such that the intake manifold is separate from any metallic or wire components which heretofore were molded directly therein. In one carrier assembly, the fuel modules are inserted into the carrier from the lower or engine. Another carrier assembly receives fuel modules which are plugged into fuel module openings. Another carrier assembly includes an electrical lead having a plurality of connectors each of which receives a fuel module assembly having a fuel module and a mating module connector.

Abstract: An intake manifold (10) includes an integral fuel rail (14) at least partially surrounded by a volume (22). The volume (22), being adjacent the fuel rail (14), minimizes the permeation of fuel out of the fuel rail (14). The volume (22) is also utilizable as a sealed storage space to contain an air induction component (24) to more effectively utilize the packaging space of the intake manifold (10).

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 air cleaner and resonator assembly is formed from a lower shell portion and an upper shell portion that are joined together to define an interior cavity having an inlet through which air is drawn. An exit tube, formed within the lower shell portion, directs air from the inlet to the engine. A middle shell portion is positioned within the inter cavity and is joined to both the upper and lower shell portions. A lower portion of a resonator is molded into the lower shell portion and an upper portion of the resonator assembly is molded into the middle shell portion. The upper portion is aligned with the lower portion and the middle and lower shell portions are welded together to form a sealed resonator chamber that attenuates engine noise. The upper and lower shell portions are then welded together to form the air cleaner and resonator assembly. Air filters are installed within the interior cavity and are selectively accessible through movable covers installed in the upper shell portion.

Abstract: An active noise control system includes a speaker located within an enclosure within a vehicle body component. The speaker enclosure is typically located forward of a vehicle wheel well. An elongated transmission member communicates canceling noise from the speaker enclosure over the wheel well to an outlet adjacent the firewall. The elongated transmission member focuses and directs cancellation noise toward the firewall and bypasses the wheel well and any restriction created thereby.

Abstract: An active noise control system (100) and method modifies a noise made when a vehicle closure, such as a door, hood, or trunk, closes by detecting the closure's velocity and selecting a delay time and control noise amplitude appropriate for the velocity. By modifying the noise of a vehicle door closing, the system (100) can reduce the frequency and reverberation of the noise generated by the door, improving user perception of the vehicle itself.

Abstract: A plastic air intake manifold is cleaned by a washer. The manifold is secured in a water tight chamber and immersed in water. Impellers in the chamber create turbulence in the water to remove oil and impurities located near the impellers. Air jets are activated to produce compressed air bubbles in the water which act abrasively to further clean the manifold. The water, impurities and oil are immediately removed from the chamber by a high power suction water outlet pump.

Abstract: An automotive emission control valve, an EGR valve in particular, has a solenoid for operating a valve element. The solenoid has a stator and an armature. A shaft is pressed into a through-hole in the armature. Ends of the shaft that protrude from the armature are guided by bearings that are fit to upper and lower pole pieces of the stator.

Abstract: An active noise control system (100) and method compensates for changes in a microphone output to maintain accurate noise control. A calibration signal reflecting a desired microphone output is generated and stored in an active noise control module (106). During operation, the active noise control module (106) compares an actual microphone output signal with the calibration signal and compensates for any changes in the actual output signal before any noise compensation or cancellation function occurs.

Abstract: A vehicle connector assembly includes a positive lock feature that allows a hose to be quickly and easily attached to a vehicle component such as an intake manifold or air induction component. The component includes a projection that extends outwardly from a main body to a distal end. A locking cap is installed over the projection and cooperates with an alignment feature on the projection such that the cap does not separate from the projection prior to installation of the hose. An end of the hose is slidably installed within the locking cap and over the projection. The locking cap is then rotated from an unlocked position to a locked position to prevent linear movement of the hose relative to the projection. The locking cap is made from a resilient material and provides a serviceable connection.

Abstract: An actively controlled regenerative snubber configuration for use in unipolar brushless direct current motors comprises a first inductor, a first switch and a capacitor, all of which are connected in series to a positive voltage supply and in parallel with a second inductor and a second switch. The regenerative snubber is used to maintain constant voltage across the switches to prevent braking of the motor through conduction of motor back EMF and to return excess energy stored in the motor phase coils to the positive voltage supply. The return of energy to the positive rail is done in a manner so as to minimize conducted electromagnetic interference at the power leads.

Abstract: An intake manifold includes a permanent runner which provides airflow communication between a plenum volume and a plurality of engine cylinders. An active runner assembly retracts into and extends from the permanent runner assembly in response to a drive system which communicates with a controller to selectively change the length of the intake manifold assembly to optimize performance. The permanent runner assembly includes a plurality of fixed length passages and the active runner assembly includes a plurality of active runner passages. Each active runner passage telescopes in and out of a respective fixed length passage to vary the effective length between the plenum and the engine cylinder.

Abstract: A vehicle air supply noise attenuation system utilizes both active and passive methods of noise attenuation. A helmholtz resonator communicates with an air supply duct, and is designed to attenuate a narrow band of noise. An active noise control system, including a speaker and an electronic controller, is mounted within the resonator volume and attenuates noise over a wider band of frequencies. The combination of the active and passive noise control attenuates noise over a wide band of frequencies without requiring an overly large speaker.

Abstract: A fuel injection system for an internal combustion engine is provided that includes a fuel injector having an injector housing with first and second opposing portions. An injector passage extends between the first and second portions. A valve is disposed in the injector passage for selectively permitting fuel to flow from the first portion to the second portion. A fuel rail having a fuel passage includes a first opening receiving the first portion with the injector passage and fluid communication with the fuel passage. An intake manifold has a second opening receiving the second portion. A polymer layer extends from the fuel rail and intake manifold about at least a portion of the fuel injector sealing the first and second portions respectively to the fuel rail and intake manifold for preventing fuel from leaking from the fuel injection system. The injector wiring may also be integrated into the fuel injection system.