Abstract: An apparatus and method compressibly secure together a plurality of components, wherein some of the components may include plastic or other materials susceptible to creep. The apparatus includes a plurality of stackable compression limiters configured to engage axially end to end in tandem and in some aspects to lockably engage. Each stackable compression limiter includes an elongated sleeve member configured to limit the maximum compressive force applied to its associated component, where different components in the stacked assembly may be configured for different maximum compressive forces.

Abstract: An active intake manifold system includes at least one flap cartridge assembly having a unitary cartridge housing including one or more flap valve housings. A flap valve is rotatable in the aperture of the flap valve housing between an open state and a closed state. A shaft is provided extending through the mounting ear apertures of the flap valves so that the flap valves change state in unison. A plurality of air intake runners provides air flow communication between the outlets of the flap valve housings and the cylinder intake valves of the engine. Each intake runner includes a main runner portion that then splits into a plurality of tracts of differing lengths with each tract tuned to a different predetermined engine speed and having a length and volume selected to optimize engine performance at the predetermined speed. The flap valves may be automatically operated by an actuator under control of an engine control system.

Abstract: Disclosed is a molded plastic intake manifold having an integrated sound barrier configured to reduce noise radiation through the walls of the intake manifold.

Abstract: A lower intake manifold assembly includes a lower housing and a runner insert fitted into the lower housing. The lower housing may be made of metal and the runner insert may advantageously be made of a synthetic resin material. The runner insert provides a sealing surface between the lower housing and the cylinder head of an internal combustion engine. The runner insert also supports a charge motion control valve flap assembly that advantageously may include a shaft and synthetic resin flaps over-molded onto the shaft.

Abstract: An integrated positive crankcase ventilation (PCV) channel is formed along a structural weld line between two shell components that are welded together to form an air intake manifold. The integrated PCV channel can be used to uniformly distribute blow-by gases from the crankcase of an internal combustion engine to a plurality of combustion chambers via the air intake manifold.

Abstract: An apparatus and method are disclosed for compressibly securing together a plurality of components, wherein some of the components may include plastic or other materials susceptible to creep. The apparatus includes a plurality of stackable compression limiters configured to engage axially end to end in tandem and in some aspects to lockably engage. Each stackable compression limiter includes an elongated sleeve member configured to limit the maximum compressive force applied to its associated component, where different components in the stacked assembly may be configured for different maximum compressive forces.

Abstract: An air intake manifold assembly includes an air intake manifold and a insert that is permanently bonded to an inner surface of the air intake manifold. By bonding the insert to the manifold, a dead space is formed between the insert and the manifold, which reduces the plenum volume within the manifold.

Abstract: An active intake manifold system includes at least one flap cartridge assembly having a unitary cartridge housing including one or more flap valve housings. A flap valve is rotatable in the aperture of the flap valve housing between an open state and a closed state. A shaft is provided extending through the mounting ear apertures of the flap valves so that the flap valves change state in unison. A plurality of air intake runners provides air flow communication between the outlets of the flap valve housings and the cylinder intake valves of the engine. Each intake runner includes a main runner portion that then splits into a plurality of tracts of differing lengths with each tract tuned to a different predetermined engine speed and having a length and volume selected to optimize engine performance at the predetermined speed. The flap valves may be automatically operated by an actuator under control of an engine control system.

Abstract: An intake manifold system for an international combustion engine includes an engine intake manifold having a valve; and an actuator connected to the valve to control valve opening. The actuator is connected to a pressurized coolant reservoir of the engine to allow the use of the pressurized fluid of the coolant reservoir to operate the actuator.

Abstract: An air intake manifold assembly for an internal combustion engine composed of a plurality of molded synthetic resin shells assembled to each other so as to define a plenum chamber, a plurality of inlet channels leading from said plenum chamber to cylinder inlets of the internal combustion engine, and a throttle body passageway leading from a throttle body mount into the plenum chamber; with a groove formed in a surface of at least one of the shells facing an adjacent shell and extending from an inlet opening to the throttle body passageway or the plenum chamber so as to form an elongate passage between the assembled shells leading from the inlet to the throttle body passage or plenum chamber, and a method of forming such an intake manifold assembly.

Abstract: A lower intake manifold assembly includes a lower housing and a runner insert fitted into the lower housing. The lower housing may be made of metal and the runner insert may advantageously be made of a synthetic resin material. The runner insert provides a sealing surface between the lower housing and the cylinder head of an internal combustion engine. The runner insert also supports a charge motion control valve flap assembly that advantageously may include a shaft and synthetic resin flaps over-molded onto the shaft.

Abstract: A plastic transmission filter (1) composed of mating upper (2) and lower (3) shells of synthetic resin material with at least one set of registering weld posts (10) extending between inner surfaces of the upper and lower shells; a fluid pervious centertube (4) interposed between the mating shells around the weld posts, and a filter material (5) wrapped around the centertube to form a bag filter. The filter assembly can be welded together in a single vibration welding operation and provides enhanced flow of transmission fluid by avoiding flow restrictions caused by prior art reinforcement poles.

Abstract: An air intake manifold assembly includes an air intake manifold and a insert that is permanently bonded to an inner surface of the air intake manifold. By bonding the insert to the manifold, a dead space is formed between the insert and the manifold, which reduces the plenum volume within the manifold.

Abstract: An integrated positive crankcase ventilation (PCV) channel is formed along a structural weld line between two shell components that are welded together to form an air intake manifold. The integrated PCV channel can be used to uniformly distribute blow-by gases from the crankcase of an internal combustion engine to a plurality of combustion chambers via the air intake manifold.

Abstract: An engine intake manifold includes a casing having a plurality of air intake passages, and a plurality of valve plates, wherein each valve plate is disposed in one of the air intake passages to control airflow through the air intake passage. The valve plates are connected to a common valve shaft for rotation between an open position and a closed position. The engine intake manifold may further include an actuator that is mounted to the casing or to the valve shaft via a snap connection, and is rotationally connected to the valve shaft to allow the actuator to rotate the valve shaft.

Abstract: An intake manifold system for an international combustion engine includes an engine intake manifold having a valve; and an actuator connected to the valve to control valve opening. The actuator is connected to a pressurized coolant reservoir of the engine to allow the use of the pressurized fluid of the coolant reservoir to operate the actuator.

Abstract: A method for making a lower intake manifold of an internal combustion engine includes the steps of (1) forming a main part from a plastic material by injection molding, (2) forming a runner insert for each engine cylinder from a plastic material by injection molding, and (3) individually attaching each runner insert to the main part to ensure the distance between two adjacent runner inserts is within a predetermined limit.

Abstract: A plastic transmission filter (1) composed of mating upper (2) and lower (3) shells of synthetic resin material with at least one set of registering weld posts (10) extending between inner surfaces of the upper and lower shells; a fluid pervious centertube (4) interposed between the mating shells around the weld posts, and a filter material (5) wrapped around the centertube to form a bag filter. The filter assembly can be welded together in a single vibration welding operation and provides enhanced flow of transmission fluid by avoiding flow restrictions caused by prior art reinforcement poles.

Abstract: A component of a reciprocating internal combustion engine system includes first, second, and third layers. The third layer has a honeycomb structure and is disposed between the first and second layers.

Abstract: An engine intake manifold includes a casing having a plurality of air intake passages, and a plurality of valve plates, wherein each valve plate is disposed in one of the air intake passages to control airflow through the air intake passage. The valve plates are connected to a common valve shaft for rotation between an open position and a closed position. The engine intake manifold may further include an actuator that is mounted to the casing or to the valve shaft via a snap connection, and is rotationally connected to the valve shaft to allow the actuator to rotate the valve shaft.