Abstract: A turbocharger system includes a compressor, an intercooler, and a hot-charge duct connecting an outlet of the compressor to an inlet of the intercooler. The hot-charge duct has a first end portion connected to the inlet, a second end portion connected to the outlet, and a central tubular portion extending from the first end portion to the second end portion. The central tubular portion is formed of a plurality of circumferentially interconnected semi-tubular sections that extend longitudinally.

Abstract: An engine system is provided with a crankshaft gear coupled to a crankshaft of an engine for rotation therewith, and a balance gear coupled to a balance shaft for rotation therewith. The balance gear and crankshaft gear are in meshed engagement. The balance gear is formed by a series of sectors connected by a series of resilient blocks, with each sector defining first and second recesses along opposite radial edges sized to receive adjacent blocks, respectively. Each elastomeric block is configured to deform both normally and in shear thereby providing damping for the gear. A gear such as the balance gear, and a method of forming the gear are also provided.

Abstract: An isolator for suspending a vehicle component from a chassis is provided. The isolator has an elastomeric body defining first and second apertures therethrough. The isolator has a first support bracket extending through a first outer region of the body. A second support bracket extends through a second outer region of the body. The isolator has first and second flexible couplings, with each coupling connecting the first support to the second support. A method of forming the isolator is also provided.

Abstract: Methods and systems are provided for a phase control apparatus in a variable cam timing (VCT) system of an engine, the phase control apparatus having a locked configuration where a locking pin coupled to a first vane of the vane rotor is engaged with a locking pin recess in a cover plate of the phase control apparatus. In one example, the phase control apparatus includes a rubber or plastic isolator pad positioned in a recess in a wall adjacent to the first vane such that when the vane rotor is rotated to the locked configuration, the first vane contacts the isolator pad before it can strike the housing. The isolator pad serves to maintain the gap between the first vane and the housing, and also reduces the likelihood of other vanes of the vane rotor from striking the housing.

Abstract: Gears are known to have a whine that can be unpleasant to operators or occupants of vehicles. A gear set is disclosed in which the pressure angle of the teeth varies along the periphery of the gear. A mating gear also has teeth with varying pressure angle. The teeth that mate have an identical pressure angle so that present disclosure is applicable only to 1:1 or integer ratio gears: 2:1, 3:1, etc. Because the teeth meet differently as a function of the pressure angle, the fundamental vibration frequency is not reinforced as would be the case with all teeth having the same pressure angle.

Abstract: Methods and devices are provided for locking and unlocking a phase control apparatus. In one example, a phase control apparatus is provided with a locking plate including a drive wheel, a pin recess, and a ramped channel opening into the pin recess and a housing coupled to the locking plate. The phase control apparatus also includes a vane rotor including a vane and positioned in a hydraulic chamber of the housing and a locking pin positioned within a bore of the vane and movable into a locked position where the locking pin engages with the pin recess.

Abstract: A gear train for an engine is provided with a driving gear and a driven gear. The driving gear is formed by a laminate structure of a plurality of plastic sheets and a plurality of metal sheets, with the plastic and metal sheets alternating with one another. The driven gear is formed by another laminate structure of another plurality of plastic sheets and another plurality of metal sheets, with the plastic and metal sheets alternating with one another. The gear train may be provided for use with an engine crankshaft and an associated balance shaft. A method of forming the gear is also provided.

Abstract: An isolator for suspending a vehicle component from a chassis is provided. The isolator has an elastomeric body defining first and second apertures therethrough. The isolator has a first support bracket extending through a first outer region of the body. A second support bracket extends through a second outer region of the body. The isolator has first and second flexible couplings, with each coupling connecting the first support to the second support. A method of forming the isolator is also provided.

Abstract: Methods and devices are provided for locking and unlocking a phase control apparatus. In one example, a phase control apparatus is provided with a locking plate including a drive wheel, a pin recess, and a ramped channel opening into the pin recess and a housing coupled to the locking plate. The phase control apparatus also includes a vane rotor including a vane and positioned in a hydraulic chamber of the housing and a locking pin positioned within a bore of the vane and movable into a locked position where the locking pin engages with the pin recess.

Abstract: An engine system is provided with a crankshaft gear coupled to a crankshaft of an engine for rotation therewith, and a balance gear coupled to a balance shaft for rotation therewith. The balance gear and crankshaft gear are in meshed engagement. The balance gear is formed by a series of sectors connected by a series of resilient blocks, with each sector defining first and second recesses along opposite radial edges sized to receive adjacent blocks, respectively. Each elastomeric block is configured to deform both normally and in shear thereby providing damping for the gear. A gear such as the balance gear, and a method of forming the gear are also provided.

Abstract: A gear train for an engine is provided with a driving gear and a driven gear. The driving gear is formed by a laminate structure of a plurality of plastic sheets and a plurality of metal sheets, with the plastic and metal sheets alternating with one another. The driven gear is formed by another laminate structure of another plurality of plastic sheets and another plurality of metal sheets, with the plastic and metal sheets alternating with one another. The gear train may be provided for use with an engine crankshaft and an associated balance shaft. A method of forming the gear is also provided.

Abstract: Methods and systems are provided for a phase control apparatus in a variable cam timing (VCT) system of an engine, the phase control apparatus having a locked configuration where a locking pin coupled to a first vane of the vane rotor is engaged with a locking pin recess in a cover plate of the phase control apparatus. In one example, the phase control apparatus includes a rubber or plastic isolator pad positioned in a recess in a wall adjacent to the first vane such that when the vane rotor is rotated to the locked configuration, the first vane contacts the isolator pad before it can strike the housing. The isolator pad serves to maintain the gap between the first vane and the housing, and also reduces the likelihood of other vanes of the vane rotor from striking the housing.

Abstract: A vane fluid pump for a vehicle component is provided with an inner rotor supported within a cam. The inner rotor has an outer wall extending between first and second end faces, the outer wall defining a series of slots spaced apart about the outer wall to provide a series of outer wall sections. One of the wall sections defines a groove. Another of the wall sections is independent of grooves or is ungrooved. The pump has vanes positioned within respective slots of the inner rotor and extending outwardly to contact the continuous inner wall of the cam. The groove on the inner rotor is configured fluidly couple with a notch on the housing to provide fluid flow to the discharge port from an upstream pumping chamber to disrupt harmonics during operation to reduce pressure ripples and associated tonal noise.

Abstract: A gerotor pump is provided with a pump housing defining a chamber and having an inlet and an outlet separated by a planar surface. The planar surface defines a notch connected to the outlet. An inner gear member is rotatably and eccentrically supported within an outer gear member. The inner gear member defines a series of external teeth with a first tooth defining a fluid passage therethrough and a second tooth independent of fluid passages. The fluid passage is defined by an aperture extending axially through the first tooth fluidly connected to a channel extending across the first tooth on an end face of the inner gear member. The passage and the notch cooperate to form a fluid pathway for pressure relief and reduced tonal noise in the pump by disrupting harmonics during operation.

Abstract: A gerotor pump has a pump housing defining a chamber and having a fluid inlet and a fluid outlet. An outer gear member is supported for rotation within the chamber about a first axis, the outer gear member having a series of internal teeth. An inner gear member or inner rotor is rotatably supported within the outer gear member about a second axis spaced apart from the first axis. The inner gear member defining a series of external teeth interposed with a series of external pockets. The inner gear member defines a fluid passage therethrough to fluidly connect two nonadjacent pockets, with another pocket independent of fluid passages. The fluid passage is configured to disrupt harmonics during operation to reduce pressure ripples and associated tonal noise.

Abstract: A vane fluid pump for a vehicle component has a cam defining a continuous inner wall surrounding a cavity, and an inner rotor supported within the cam. The inner rotor has a cylindrical outer wall defining a series of slots equally spaced about the outer wall. A series of vanes is provided with each vane positioned within a respective slot of the inner rotor and extending outwardly to contact the continuous inner wall of the cam. Each vane provides a fluid barrier between adjacent pumping chambers formed between the cam and the inner rotor. A first vane of the series of vanes defines a passageway thereacross to fluidly connect adjacent pumping chambers. The passageway is configured to disrupt harmonics during operation to reduce pressure ripples and associated tonal noise. At least another vane is configured without any fluid passageways.

Abstract: A gerotor pump is provided with a body defining a chamber with cylindrical wall sections and having a fluid inlet and a fluid outlet, and a cover. An internally toothed gear member is supported for rotation within the chamber about a first axis, and has a cylindrical outer wall defining a series of grooves. Each groove has an associated aperture extending through the gear member to an inner surface of the gear member, and is radially positioned between adjacent teeth of the internally toothed gear member. An externally toothed gear member is rotatably supported within the internally toothed gear member about a second axis spaced apart from the first axis, and is coupled for rotation with a drive shaft. The internally toothed gear member and externally toothed gear member cooperate to form a plurality of variable volume pumping chambers therebetween to pump fluid.

Abstract: Gears are known to have a whine that can be unpleasant to operators or occupants of vehicles. A gear set is disclosed in which the pressure angle of the teeth varies along the periphery of the gear. A mating gear also has teeth with varying pressure angle. The teeth that mate have an identical pressure angle so that present disclosure is applicable only to 1:1 or integer ratio gears: 2:1, 3:1, etc. Because the teeth meet differently as a function of the pressure angle, the fundamental vibration frequency is not reinforced as would be the case with all teeth having the same pressure angle.

Abstract: Adding dome-shaped protuberances, or polydomes, to an engine system increases the structural integrity of the engine component to which they are added and allows noise radiated in the engine system to be reduced in certain regions of the frequency spectrum without incurring a significant increase in the mass of the engine part to which they are added, which may result in a longer solidification time during the mold injection process. The size and spatial arrangement of polydomes relative to one another can be further adjusted to reduce noise within the engine system and polydomes may be reinforced with ribs to increase the structural stiffness of plastic engine components. Because plastic engine components are created using an injection mold process during the manufacturing process, added surface features (e.g. polydomes and ribs) are continuous with the underlying planar surface to which they are added.

Abstract: A phase control apparatus in a variable cam timing (VCT) system of an engine is described herein. The phase control apparatus includes a locking pin coupled to a vane, the locking pin extending into a locking pin recess in a cover plate in a locked configuration, the locking pin and locking pin recess having a backlash and a housing at least partially enclosing the vane and spaced away from the vane forming a gap in the locked configuration.