Abstract: Gear devices and methods for operating gear devices are provided. In one example, a gear device is provided that comprises structures designed to attenuate targeted vibrations occurring during rotation of the gear device. The structures includes radially aligned struts extending between an inner carrier and an outer carrier, a plurality of openings arranged between the struts, and/or resonators extending between sequential struts.

Abstract: Methods and systems are provided for a turbine integrally formed with a cylinder head. In one example, a system includes a cylinder head and a turbine shaped from a single, continuous piece of metal.

Abstract: Gear devices and methods for operating gear devices are provided. In one example, a gear device is provided that comprises structures designed to attenuate targeted vibrations occurring during rotation of the gear device. The structures includes radially aligned struts extending between an inner carrier and an outer carrier, a plurality of openings arranged between the struts, and/or resonators extending between sequential struts.

Abstract: Methods and systems are provided for a turbine integrally formed with a cylinder head. In one example, a system includes a cylinder head and a turbine shaped from a single, continuous piece of metal.

Abstract: An engine component includes stratified metal layers. The stratified metal layers form walls of a cylinder head having internal cavities defining a cooling jacket configured to direct coolant within and through the walls. The stratified metal layers also form a lattice disposed within and spanning between opposing surfaces of the cooling jacket configured to promote heat transfer between the stratified metal layers and coolant.

Abstract: An engine component includes stratified layers that form an integral cylinder head and an internally cooled valve guide located in a cylinder head guide boss. The integral cylinder head further includes a coolant passage within a body of the valve guide that is in fluid communication with a cylinder head cooling jacket.

Abstract: An engine component includes stratified metal layers. The stratified metal layers form walls of a cylinder head having internal cavities defining a cooling jacket configured to direct coolant within and through the walls. The stratified metal layers also form a lattice disposed within and spanning between opposing surfaces of the cooling jacket configured to promote heat transfer between the stratified metal layers and coolant.

Abstract: Systems for defining an internally threaded bore in a composite material component include one or more thread forming tools each defining a thread forming portion and a locating fixture configured to hold the one or more thread forming tools in a predetermined configuration defining a pattern of internally threaded bores to be provided in the composite material component. The thread forming portions include a plurality of thread forming surfaces each defining a pitch, a crest fillet radius, and a root fillet radius, and define internally threaded bores having an interior helical thread defining a plurality of full crest radii and a plurality of full root radii. A component forming fixture is provided for abutting the locating fixture whereby the one or more thread forming tools are held in an interior of the forming fixture. Methods for forming composite material components having internally threaded bores using the described systems are described.

Abstract: An engine cylinder head comprising an internal metal structure formed from a metal material and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: An engine cylinder head includes an internal metal structure formed from a metal material, at least a portion of which includes a thermal coating and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: A system and methods for routing condensate collected in a heat exchanger reservoir to either an air intake system or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, condensate is routed to a first position along the engine air intake system in a first mode of operation, and a second position upstream of the catalyst along the engine exhaust in a second mode of operation, and a third position downstream of the catalyst along the engine exhaust in a third mode of operation. When substantially no contaminates are detected, the condensate may be routed into the engine exhaust upstream of the catalyst in order to cool the catalyst.

Abstract: An engine cylinder head includes an internal metal structure formed from a metal material, at least a portion of which includes a thermal coating and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: A cam carrier assembly includes a body made of a material lighter than aluminum. The body has a first side operably coupled with a cylinder head and a second side having bearing surfaces with bearing inserts. The bearing inserts support the camshaft. A series of apertures extend between the first and second sides of the body. Lobes of the camshaft operably couple with the valves of the cylinder head through the series of apertures extending between the first and second sides of the body.

Abstract: A valve cover module includes a unitary cover and carrier made of a carbon fiber composite. The unitary cover and carrier has a lower side with a peripheral edge for attaching to a cylinder head. The lower side of the unitary cover and carrier also has a series of cavities interconnected with aligned apertures defining bearing surfaces. A plurality of cam lobes is disposed in the series of cavities. Also, the valve cover module includes a camshaft rotatable on the bearing surfaces and extending through the aligned apertures to couple with the cam lobes.

Abstract: Systems for defining an internally threaded bore in a composite material component include one or more thread forming tools each defining a thread forming portion and a locating fixture configured to hold the one or more thread forming tools in a predetermined configuration defining a pattern of internally threaded bores to be provided in the composite material component. The thread forming portions include a plurality of thread forming surfaces each defining a pitch, a crest fillet radius, and a root fillet radius, and define internally threaded bores having an interior helical thread defining a plurality of full crest radii and a plurality of full root radii. A component forming fixture is provided for abutting the locating fixture whereby the one or more thread forming tools are held in an interior of the forming fixture. Methods for forming composite material components having internally threaded bores using the described systems are described.

Abstract: A cam carrier assembly includes a body made of a material lighter than aluminum. The body has a first side operably coupled with a cylinder head and a second side having bearing surfaces with bearing inserts. The bearing inserts support the camshaft. A series of apertures extend between the first and second sides of the body. Lobes of the camshaft operably couple with the valves of the cylinder head through the series of apertures extending between the first and second sides of the body.

Abstract: A cam carrier assembly includes a cylinder head having valves and a camshaft having lobes. A cam carrier has a first side coupled with the cylinder head engaging around the valves and a second side with bearing surfaces supporting the camshaft. A series of apertures extend between the first and second sides for the lobes to interface with the valves. The cam carrier is made of carbon fiber composite insulating the camshaft from the cylinder head and providing substantial weight reduction to an upper section of an associated engine.

Abstract: An engine cylinder head comprising an internal metal structure formed from a metal material and an external polymer composite structure formed from a polymer composite material, wherein the external polymer composite structure at least partially surrounds the internal metal structure.

Abstract: A system and methods for routing condensate collected in a heat exchanger reservoir to either a combustion chamber of an engine or a position in the engine exhaust based on the type of contaminate in the condensate and operating parameters of the engine or the catalyst are described. In one particular example, the method includes accumulating a portion of compressed air in an accumulator, and when an engine output is below a predetermined amount, coupling a part of the accumulated air with the condensate through a passage into the combustion chamber. Thereby, the methods described may be used to distribute condensate formed in the heat exchanger even at low engine loads.

Abstract: A cam carrier assembly includes a cylinder head having valves and a camshaft having lobes. A cam carrier has a first side coupled with the cylinder head engaging around the valves and a second side with bearing surfaces supporting the camshaft. A series of apertures extend between the first and second sides for the lobes to interface with the valves. The cam carrier is made of carbon fiber composite insulating the camshaft from the cylinder head and providing substantial weight reduction to an upper section of an associated engine.