Abstract: A heat exchanger (10) cooling a fluid and a method for manufacturing, the heat exchanger (10) having an outer pipe section (12) in which a plurality of inner pipe sections (36) with channels for the fluid to be cooled are disposed. At least one cooling fluid channel (56) is disposed in the outer pipe section (12). The at least one cooling fluid channel (56) and the at least one channel for the fluid to be cooled are in heat contact and fluidically separated from each other. A plurality of inner pipe sections (36) open on both ends (38, 46) form of a pipe bundle (34) having ends fixed tightly in a corresponding lead-through opening (40) of an upstream end body (42) and fixed tightly with the other end (46) in a corresponding lead-through opening (48) of a downstream end body (50).

Abstract: A charge air duct for an internal combustion engine includes a housing with at least one entrance and at least one exit for charge air. A heat exchanger is arranged inside the housing to cool the charge air, a bypass is arranged on the housing to at least partially circumvent the heat exchanger and an actuator is arranged on the housing to influence the charge air flow. The charge air is guided from the entrance to the heat exchanger in a first position of the actuator and from the entrance to the bypass in a second position of the actuator, and the actuator at least partially reduces a cross-section of the charge air in a third position.

Abstract: A charge air duct for an internal combustion engine includes a housing with at least one entrance and at least one exit for charge air, a first heat exchanger arranged inside the housing to cool the charge air, a bypass arranged on the housing to at least partially circumvent the heat exchanger, and an actuator arranged on the housing to influence the charge air flow. The charge air is guided from the entrance to the first heat exchanger in a first position of the actuator and from the entrance to the bypass in a second position of the actuator, and the bypass leads upstream of a second heat exchanger of the charge air duct.

Abstract: A heat exchanger (10) cooling a fluid and a method for manufacturing, the heat exchanger (10) having an outer pipe section (12) in which a plurality of inner pipe sections (36) with channels for the fluid to be cooled are disposed. At least one cooling fluid channel (56) is disposed in the outer pipe section (12). The at least one cooling fluid channel (56) and the at least one channel for the fluid to be cooled are in heat contact and fluidically separated from each other. A plurality of inner pipe sections (36) open on both ends (38, 46) form of a pipe bundle (34) having ends fixed tightly in a corresponding lead-through opening (40) of an upstream end body (42) and fixed tightly with the other end (46) in a corresponding lead-through opening (48) of a downstream end body (50).

Abstract: A charge air duct for an internal combustion engine includes a housing with at least one entrance and at least one exit for charge air. A heat exchanger is arranged inside the housing to cool the charge air, a bypass is arranged on the housing to at least partially circumvent the heat exchanger and an actuator is arranged on the housing to influence the charge air flow. The charge air is guided from the entrance to the heat exchanger in a first position of the actuator and from the entrance to the bypass in a second position of the actuator, and the actuator at least partially reduces a cross-section of the charge air in a third position.

Abstract: A charge air duct for an internal combustion engine includes a housing with at least one entrance and at least one exit for charge air, a first heat exchanger arranged inside the housing to cool the charge air, a bypass arranged on the housing to at least partially circumvent the heat exchanger, and an actuator arranged on the housing to influence the charge air flow. The charge air is guided from the entrance to the first heat exchanger in a first position of the actuator and from the entrance to the bypass in a second position of the actuator, and the bypass leads upstream of a second heat exchanger of the charge air duct.

Abstract: An intake system for an internal combustion engine having an intake plenum and at least one intake pipe which branches off from the intake plenum and which is composed of at least two intake pipe parts that are divided longitudinally. The intake plenum together with one of the intake pipe parts forms a single integral base part. The second intake pipe part is configured as an interchangeable insert that also forms one wall shell of the intake plenum.

Abstract: An intake system for an internal combustion engine having an intake plenum and at least one intake pipe which branches off from the intake plenum and which is composed of at least two intake pipe parts that are divided longitudinally. The intake plenum together with one of the intake pipe parts forms a single integral base part. The second intake pipe part is configured as an interchangeable insert that also forms one wall shell of the intake plenum.

Abstract: A duct system suitable for use as an intake manifold for an internal combustion engine, including flap valves (13) for selective opening and closing of the ducts. The positions of the valves are continuously adjustable in order to produce a swirl in the flow of combustion air. To achieve this, a high degree of angular precision is required in the positioning of the valves. Intake manifold manufacturing tolerances need to be compensated during assembly of the valves. A valve adjusting mechanism is provided in mechanical couplings (23) of the valve linkage between the position adjusting motor (19) and the flap valves (13).

Abstract: An air routing system includes an air filter for cleaning intake air having a clean air outlet a compressor for compressing aspirated intake air an intermediate line connected between the clean air outlet of the filter and the compressor, and an intake module. The intake module includes a plenum with a clean air inlet for compressed intake air at least one intake pope connected to the plenum and a bypass line for excess compressed filtered air. The bypass line has an inlet to a channel segment of the intake module for uncompressed clean air upstream of the compressor, and the bypass line is at least partly integrated into the intake module such that a volume of the bypass line at least partly surrounds the plenum.

Abstract: A valve (10) which includes a valve flap (13), a flap frame (12) and a unitary housing (11), with the flap (13) rotatably received and arranged in the frame (12) such that when the flap is closed, it allows only minimal leakage which is insignificant to the operation of the valve. The flap frame (12) has a precision region (21) for preventing an abrupt flow changes, and the unitary housing (11) is cast in a mold in which the preassembled valve parts (12, 13) are arranged. Direct casting of the housing (11) around the valve parts (12, 13) enables the production of several housing parts to be avoided, as well as rendering measures to mount and seal the several parts unnecessary. The housing (11) can be connected to adjacent components in a leakproof manner, and connections for engine crankcase ventilation or fuel tank ventilation can be integrated into the housing (11). The valve can be used as a throttle valve for an internal combustion engine.

Abstract: A lost core method for producing a hollow structure which method is characterized by fixing the lost core (11) which is to be used in the mold (12) with at least one insert (14), with the insert becoming part of the workpiece (10) to be produced. This is accomplished by casting the insert (14) in the hollow structure. In this way no openings for positioning the lost core (11), which subsequently would have to be closed with a cover, are created in the hollow structure (10) which is to be produced. The described process is therefore useful to advantageously influence the reliability of the resulting molded articles, as well as to favorably influence the manufacturing costs.

Abstract: An air routing system includes an air filter for cleaning intake air having a clean air outlet a compressor for compressing aspirated intake air an intermediate line connected between the clean air outlet of the filter and the compressor, and an intake module. The intake module includes a plenum with a clean air inlet for compressed intake air at least one intake pope connected to the plenum and a bypass line for excess compressed filtered air. The bypass line has an inlet to a channel segment of the intake module for uncompressed clean air upstream of the compressor, and the bypass line is at least partly integrated into the intake module such that a volume of the bypass line at least partly surrounds the plenum.

Abstract: An air routing system, especially an air intake system of an internal combustion engine, which makes optimal use of available installation space by integrating a bypass channel (25) into an air intake module (10). The volume of the bypass channel also provides an acoustic shield for the collector chamber or plenum (22). The free area (13) behind the mounting flange (11) that is required for screwing in mounting bolts in order to mount the air intake module (10) is used by an air intake hood (14) which can be installed on the filter housing (15) after the air intake module has been mounted. This assures that there is a greater volume available in the filter housing (15), thereby reducing the noise at the inlet opening of the air intake module.

Abstract: A valve (10) which includes a valve flap (13), a flap frame (12) and a unitary housing (11), with the flap (13) rotatably received and arranged in the frame (12) such that when the flap is closed, it allows only minimal leakage which is insignificant to the operation of the valve. The flap frame (12) has a precision region (21) for preventing an abrupt flow changes, and the unitary housing (11) is cast in a mold in which the preassembled valve parts (12, 13) are arranged. Direct casting of the housing (11) around the valve parts (12, 13) enables the production of several housing parts to be avoided, as well as rendering measures to mount and seal the several parts unnecessary. The housing (11) can be connected to adjacent components in a leakproof manner, and connections for engine crankcase ventilation or fuel tank ventilation can be integrated into the housing (11). The valve can be used as a throttle valve for an internal combustion engine.

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: 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.