Abstract: A housing for a supercharger assembly is provided having an inner wall at least partially defining a rotor cavity. A layer is formed from a sacrificial polymeric material and is provided on at least a portion of the inner wall. The layer is operable to provide approximately zero running clearance and improve scuff resistance between the first and second rotors and the inner wall. The sacrificial polymeric material is applied to the inner wall by insert molding to form the layer. A method of forming the housing is also provided.

Abstract: A rotor assembly is provided for a compressor assembly having a housing defining an inlet port, outlet port, and a rotor cavity in communication with the inlet port and outlet port. The rotor assembly includes a rotor body having a plurality of lobes formed thereon and rotatably mountable within the rotor cavity of the housing. The rotor body has a first end, substantially adjacent to the inlet port, and a second end, substantially adjacent to the outlet port, when mounted within the housing. Each of the plurality of lobes has an outer radius that is greater at the first end than at the second end.

Abstract: A gear drive assembly for a supercharger is provided. The gear drive assembly has at least one gear member rotatable about an axis of rotation and includes a cover member operable to substantially enclose the at least one gear member. A tube member extends though the cover member and is generally aligned along the axis of rotation. The tube member is operable to vent the gear drive assembly. A supercharger assembly incorporating the gear drive assembly is also disclosed.

Abstract: An engine air intake system, which may include a supercharger or other air-handling device, includes a resilient coupling connecting an air intake connector, such as a throttle body, and an air inlet duct. The resilient coupling includes a bellows convolution for allowing limited motion between connected components. The coupling is molded with tuning volumes and connecting passages within the convolution with open sides to allow removal from the mold die. An associated connector closes the chambers upon assembly and forms noise reduction tuning for high frequency air pressure waves.

Abstract: An engine air intake system, which may include a supercharger or other air-handling device, includes a resilient coupling connecting an air intake connector, such as a throttle body, and an air inlet duct. The resilient coupling includes a bellows convolution for allowing limited motion between connected components. The coupling is molded with tuning volumes and connecting passages within the convolution with open sides to allow removal from the mold die. An associated connector closes the chambers upon assembly and forms noise reduction tuning for high frequency air pressure waves.

Abstract: A heat exchanger system is provided including a first and second heat exchanger each configured to pass air therethrough. The second heat exchanger is mounted upstream of the first heat exchanger. The second heat exchanger may be selectively movable between a first position and a second position such that an amount of the air is diverted from the second heat exchanger to the first heat exchanger when the second heat exchanger is in the first position. Alternately, the second heat exchanger may be spaced from the first heat exchanger, with at least one selectively openable shutter mounted adjacent to the first and second heat exchangers. The at least one shutter is movable between a first position and a second position such that an amount of the air is diverted from the second heat exchanger to the first heat exchanger when the at least one shutter is in the first position.

Abstract: A positive displacement supercharger includes a housing having a rotor cavity. A pair of positive displacement rotors are oppositely rotatable in the rotor cavity and have interleaved helical lobes forming rotor chambers operative to carry air axially from an inlet end to an outlet end of the cavity. A gear case adjacent the rotor cavity is drivably connected with and supports the rotors, the gear case including a bearing housing having an end surface facing the rotor cavity and the outlet ends of the rotors. A heat insulating material is applied to the end surface of the bearing housing and is effective to reduce heat flow between the rotor cavity and the end surface of the bearing housing to effectively reduce lubricating oil temperatures in the gear case. The insulating material may be a ceramic plate fixed to the bearing housing end surface.

Abstract: An adjustable Helmholtz resonator assembly is provided having an active state and an inactive state. In the active state the Helmholtz resonator assembly is operable to attenuate pressure pulsations within air passing therethrough. In the inactive state the Helmholtz resonator assembly does not attenuate pressure pulsations within air passing therethrough. The Helmholtz resonator assembly is preferably configured to be mounted within an intake system of an internal combustion engine.

Abstract: A rotor assembly for a supercharger is provided having a first rotor section and at least one other rotor section affixed to the first rotor section. The first rotor section and the at least one other rotor section are formed from powdered metal and are substantially similar in shape. Each of the first rotor section and the at least one other rotor section has a plurality of lobes that are substantially hollow. The first rotor section and the at least one other rotor section are affixed through one of brazing, copper infiltration, and welding. A supercharger assembly incorporating the disclosed rotor assembly is also provided. Furthermore, a method of forming the disclosed rotor assembly is provided.

Abstract: An intake assembly, such as a supercharger assembly, is provided for an internal combustion engine. The intake assembly includes a housing having a wall defining an inlet passage through which intake air enters the intake assembly. A plurality of stiffening ribs is provided on the wall opposite the inlet passage and at least partially defines at least one cavity. A plate is mounted to the wall of the housing and further defines the at least one cavity. The wall defines at least one orifice configured to provide communication between the inlet passage and the at least one cavity. The at least one cavity and the at least one orifice cooperate to form at least one resonator. A method of forming the intake assembly having integral resonators is also provided.

Abstract: An intake assembly operable to communicate intake air to an internal combustion engine is provided. The intake assembly includes an inlet adapter defining a flow conduit through which the intake air may pass and an intake manifold. The inlet adapter is removably mounted with respect to the intake manifold. At least one resonance chamber is defined by at least one of the inlet adapter and the intake manifold. A gasket member is operable to substantially seal the inlet adapter with respect to the intake manifold. The gasket member defines at least one tuner neck operable to provide communication between the at least one resonance chamber and the flow conduit to form at least one Helmholtz resonator.

Abstract: A positive displacement supercharger includes a housing having a rotor cavity. A pair of positive displacement rotors carry air from an inlet end to an outlet end of the cavity. A gear case adjacent the rotor cavity drives the rotors. The gear case includes an external surface, and an internal end surface facing the rotor cavity. Heat passing from compressed air in the cavity through the internal surface to the gear case oil is at least partially removed by ambient cooling air blown against the external surface of the gear case by a cooling fan. The fan is driven by a rotor drive member and directs the cooling air against the gear case external surface so that the cooling airflow varies with supercharger rotor speed. The fan may have blades extending radially from the drive member axis and may be mounted on a drive pulley or an associated drive shaft.

Abstract: A positive displacement supercharger includes a housing defining a rotor cavity with a pair of positive displacement rotors operative to carry air axially from an inlet end to an outlet in the cavity wall near an outlet end of the cavity. The outlet communicates with an outlet plenum partially defined by the cavity wall. The cavity wall includes a stiff portion defining a plurality of lightening recesses, such as a waffle pattern, limiting distortion of the wall by pulsations in the plenum. The recesses may be time and cost efficiently converted to Helmholtz tuners by covering the recesses with a cover plate, which may be perforated to include at least one tuning opening (perforation) into each tuning chamber (recess) and forming tuning volumes of the tuning chambers and their associated tuning openings effective to attenuate selected frequencies of pulsations in the plenum and thereby reduce undesired noise emanating from the air system of the supercharger.

Abstract: A Roots supercharger has an extended cavity with 103 mm diameter rotors having chambers defined by interleaved helical lobes with equal angular face offsets exceeding 60 degrees from inlet to outlet end faces angled in directions opposite to directions of rotor rotation. The chambers have angular seal times of less than 67 degrees of rotation. A preferred embodiment has a displacement of 122 cu mm/revolution, rotor length of 208 mm, face offsets of 65.3 degrees and seal time of 58.6 degrees. The rotor lobe helix angle is essentially 0.314 deg/mm, equal to the helix angle of a prior art supercharger with rotors of common diameter, displacement of 112 cubic inch/revolution, rotor length of 191 mm, previously considered maximum, 60 degree face offset, previously considered optimum, and seal time of 67 degrees. Both flow volumes and efficiency of the new configuration are improved from the prior art wherein the 60 degree face offset was considered optimum.

Abstract: A supercharger includes multiple back flow ports which are controlled by valves. The valves regulate the timing and area for back flow of pressurized outlet air into the rotor chambers. The back flow air tends to equalize air pressure in the chambers prior to their exhausting into the outlet and thereby reduces flow back noise. The multiple ports are opened selectively or sequentially to provide noise control with improved efficiency at varying speeds.

Abstract: A Roots supercharger has an extended cavity with 103 mm diameter rotors having chambers defined by interleaved helical lobes with equal angular face offsets exceeding 60 degrees from inlet to outlet end faces angled in directions opposite to directions of rotor rotation. The chambers have angular seal times of less than 67 degrees of rotation. A preferred embodiment has a displacement of 122 cu mm/revolution, rotor length of 208 mm, face offsets of 65.3 degrees and seal time of 58.6 degrees. The rotor lobe helix angle is essentially 0.314 deg/mm, equal to the helix angle of a prior art supercharger with rotors of common diameter, displacement of 112 cubic inch/revolution, rotor length of 191 mm, previously considered maximum, 60 degree face offset, previously considered optimum, and seal time of 67 degrees. Both flow volumes and efficiency of the new configuration are improved from the prior art wherein the 60 degree face offset was considered optimum.

Abstract: A supercharger includes multiple back flow ports which are controlled by valves. The valves regulate the timing and area for back flow of pressurized outlet air into the rotor chambers. The back flow air tends to equalize air pressure in the chambers prior to their exhausting into the outlet and thereby reduces flow back noise. The multiple ports are opened selectively or sequentially to provide noise control with improved efficiency at varying speeds.

Abstract: A seal for the T-joint between upper and lower engine crankcase members and a crankshaft seal member has a longitudinal portion received between and engaging the upper and lower crankcase members, and a generally triangular tip formed by a shorter side and a longer side with the shorter side facing toward the crankshaft seal member as the crankshaft seal member is installed. The tip deforms as the crankshaft member is installed, and thereby seals the T-joint.