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: The invention relates to a plastic heat exchanger (1), in particular for automotive applications, having an inlet tank (2) which has an inlet (5) for a first fluid and surrounds an inlet chamber (6), having an outlet tank (3) which has an outlet (7) for the first fluid and surrounds an outlet chamber (8), having multiple plastic tubes (4) which are tightly connected to the inlet tank (2) and to the outlet tank (3) and connect the inlet chamber (6) to the outlet chamber (8) so they communicate with one another and around which a second fluid flows during operation. To improve the heat transfer, at least some of the plastic tubes (4) have at least one longitudinal section (9) in which ring-shaped areas (13) having variable cross sections follow one another in the longitudinal direction of the tube.

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 intercooler comprises a plurality of plastic cooling tubes extending between a first end plate and a second end plate and a baffle arranged in the intercooler and extending at least partially between the first end plate and the second end plate. The baffle comprises a plurality of first openings for receiving a respective plastic cooling tube, the baffle further comprising a plurality of second openings arranged between the first openings. The second openings permit air to flow through the intercooler whilst creating turbulence in the air flow which increase the thermal transfer between the air and the tubes increasing the efficiency of the intercooler.

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: The method of noise attenuation comprises the steps of generating a noise canceling signal, sensing for an system condition, and ceasing the generation of the noise canceling based upon the system condition. This method is embodied in a system that includes an air induction body, a speaker in proximity to the air induction body, a sensor for sensing a system condition, and a control unit with a noise cancellation feature. The control unit is in communication with both the speaker and the sensor. Based upon the sensed system condition, the control unit may disable the noise cancellation feature.

Abstract: A modular air induction assembly comprises an air induction body, an air filter operatively attached to the air induction body, and a speaker operatively attached to the air induction body. The modular air induction assembly is then installed into the air induction system of a vehicle during production. The air induction body may also comprise a first portion and a second portion that permits service of the assembly following initial vehicle installation.

Abstract: The air induction system comprises an air induction body with a mouth and a speaker forming an interface with the mouth. A fender portion of a vehicle at least partially covers the interface, protecting the interface from environmental conditions. A control unit controls with the speaker to thereby generate a noise attenuating sound.

Abstract: A Helmholtz resonator includes a chamber at least partially defining a cavity. The chamber has a neck which defines a passage that is in fluid communication with the cavity. The chamber and the neck produce a passive response to a sound wave produced by the internal combustion engine. The sound wave negatively effects engine performance. An active resonator is disposed within the chamber. The active resonator produces a forced response for supplementing the passive response and increasing the band width of the noise attenuating pressure wave. The Helmholtz resonator is in fluid communication with a portion of an air induction system that defines a passageway that carries the sound wave. A driver is connected to the active resonator, which is preferably a loud speaker, to drive the loud speaker and produce the forced response. The driver preferably utilizes a signal source, such as an engine speed signal, to synchronize the forced response with the engine speed.

Abstract: An air induction system with active noise control includes a self-cleaning air filter that is integrated within an air intake housing. The self-cleaning air filter filters out contaminants such as dust and dirt particulates from air flowing through the intake housing. The self-cleaning filter is powered and controlled by the same electronic unit that is used to power the active noise control system.

Abstract: An air induction system comprises an air induction body, a speaker with a first diaphragm disposed about the air induction body, and a second diaphragm spaced from the first diaphragm. A signal is generated from the first diaphragm and transmitted to the second diaphragm. The second diaphragm generates a noise attenuating sound.

Abstract: A modular air induction assembly comprises an air induction body, an air filter operatively attached to the air induction body, and a speaker operatively attached to the air induction body. The modular air induction assembly is then installed into the air induction system of a vehicle during production. The air induction body may also comprise a first portion and a second portion that permits service of the assembly following initial vehicle installation.

Abstract: The air induction system comprises an air induction body with a mouth and a speaker forming an interface with the mouth. A fender portion of a vehicle at least partially covers the interface, protecting the interface from environmental conditions. A control unit controls with the speaker to thereby generate a noise attenuating sound.

Abstract: An air induction system with active noise control includes a self-cleaning air filter that is integrated within an air intake housing. The self-cleaning air filter filters out contaminants such as dust and dirt particulates from air flowing through the intake housing. The self-cleaning filter is powered and controlled by the same electronic unit that is used to power the active noise control system.

Abstract: An air induction system comprises an air induction body, a speaker with a first diaphragm disposed about the air induction body, and a second diaphragm spaced from the first diaphragm. A signal is generated from the first diaphragm and transmitted to the second diaphragm. The second diaphragm generates a noise attenuating sound.

Abstract: The active noise attenuation system comprises a speaker, a control unit in communication with the speaker, and a memory unit in communication with the control unit storing cancellation waveform data. The system uses the stored cancellation waveform data to create a cancellation waveform through a speaker in proximity to an air induction system to thereby attenuate engine noise. Sensors serve to trigger the release of the cancellation waveform as well as to affect the form of the cancellation waveform to ensure noise attenuation.

Abstract: The method of noise attenuation comprises the steps of generating a noise canceling signal based on an environmental assumption, assessing the environmental assumption of the control unit, and altering the noise canceling signal based on the assessment. Assessing may comprise the step of comparing the environmental assumption with actual environmental data, including the step of generating a test sound wave to obtain actual environmental data. The test sound wave is then compared to a model of the sound wave based on the environmental assumption. This method is embodied in a system that includes an air induction body, a speaker in proximity to the air induction body, a microphone in communication with the speaker, a reference sensor, and a control unit with a noise cancellation feature with an environmental assumption. The control unit is in communication with the speaker, reference sensor, and the microphone and assesses the environmental assumption in light of actual environmental data.

Abstract: The method of noise attenuation comprises the steps of generating a noise canceling signal, sensing for an system condition, and ceasing the generation of the noise canceling based upon the system condition. This method is embodied in a system that includes an air induction body, a speaker in proximity to the air induction body, a sensor for sensing a system condition, and a control unit with a noise cancellation feature. The control unit is in communication with both the speaker and the sensor. Based upon the sensed system condition, the control unit may disable the noise cancellation feature.

Abstract: A noise attenuation system for the air induction ducting particularly for an internal combustion engine has an outwardly facing loudspeaker mounted within an air inlet duct so as to lie in the plane of the air intake opening. Signals from an error microphone (and also optionally a detector microphone) are processed in a signal controller, the output driver used to drive the loudspeaker so that a cancellation sound field is produced, which attenuates the noise emanating from the air intake. The speaker is mounted on a fairing body creating an annular flow passage, a filter element ring inserted in the annular space.

Abstract: A system and method of attenuating noise generated in a multicylinder internal combustion engine as a result of opening and closing of the exhaust and intake valves in which cross passages extend between regions of the exhaust and intake manifolds adjacent the exhaust and intake valves of different cylinders in which the exhaust and intake valves open at approximately the same time. The acoustic waves of the noise caused by opening of the exhaust and intake valves respectively are set in mutual opposition to each other to thereby substantially cancel each other. A low mass flexible diaphragm in each cross passage prevents cross flow of exhaust gases while allowing transmission of the acoustic waves. Porous plugs restrict flow to the diaphragm while being sufficiently open to allow free transmission of the noise sound waves to the diaphragm to not impair the mutual cancellation process.