Internal-combustion engines – Charge forming device – Fuel injection system
Reexamination Certificate
2000-10-17
2001-10-30
Moulis, Thomas N. (Department: 3747)
Internal-combustion engines
Charge forming device
Fuel injection system
C123S184210, C123S456000
Reexamination Certificate
active
06308686
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an air intake manifold and method for assembly thereof where the intake manifold includes an internal fuel rail and wire harness that allows fuel injectors to be installed inside the manifold to form a subassembly.
2. Related Art
Internal combustion engines operate by burning a mixture of fuel and air in a cylinder containing a piston. Engine power is provided by a continuous cycle that takes place inside the engine. First, as the piston moves downward, an inlet valve opens and a mixture of fuel and air is sucked into the cylinder chamber. The valve closes and the piston moves up to compress the mixture. An electric spark plug produces a spark that ignites the fuel, forcing the piston back down. Finally, an outlet valve opens and the piston rises back up to release the exhaust gases out of the cylinder. The cycle continually repeats itself until the engine is shut down.
The engines use fuel injectors to control injection of fuel into the engine cylinders. An air intake manifold is fastened to the engine to provide a system of guides or runners that supply air to be combined with the fuel to form a mixture. The fuel injectors are cylindrical members that are typically mounted to a fuel rail. In most applications, the fuel rail is an external member that is fastened to the outside of the air intake manifold. The fuel injectors are received into bores formed along the manifold.
In some applications, the fuel rail is formed inside the manifold to eliminate attachment hardware and assembly cost. One such manifold is shown in U.S. Pat. No. 5,682,859 issued on Nov. 4, 1997 for “Method and Arrangement For Mounting Fuel Rails” and assigned to the assignee of the present invention. In this arrangement the fuel injector is separately installed externally to the manifold by installing one end of the injector for communication with the fuel rail with the other end of the injector installed into the runner for communication with the intake port for the cylinder. This mounting arrangement requires special seals and the assembly process can be difficult and time consuming. Further, since the fuel injectors are mounted outside of the manifold, the injectors are noisy and cause unwanted vibrations.
In some cases, the traditional mechanical linkage between the accelerator pedal and the engine throttle is replaced by electronic throttle control (ETC). In ETC configurations, an electric signal controls the position of the engine throttle and fuel supply therefor. Wiring harnesses are used to connect the fuel injectors to a power supply for the ETC system. Typically, these wiring harnesses are mounted externally to the manifold, thus exposing the harness to potential damage and environmental contaminants.
Thus, it is desirable to have a mounting arrangement for a fuel injector where the injector can be mounted inside a manifold that has an internal fuel rail to eliminate special mounting hardware and unwanted noise. Further it would be desirable to have such a manifold where wiring needed for electronic throttle control could be easily integrated into the manifold.
SUMMARY OF THE INVENTION
In a disclosed embodiment of this invention, an intake manifold for mounting to an internal combustion engine includes a lower shell, an upper shell, and a middle shell sandwiched between the lower and upper shells. The shells are formed to include an internal fuel rail that allows fuel injectors to be easily installed within the manifold to form a subassembly. The lower shell has a plurality of longitudinally spaced shell ports. Each shell ports is adapted for installation over a corresponding intake port on an engine cylinder head. The upper shell has a plurality of runners that guide air to the shell ports. The middle shell has channels that interconnect the runners and the shell ports. Fuel injector pockets are formed within the upper, middle, and lower shells with each of the pockets having an injector opening in communication with the corresponding shell port. An internal fuel rail is formed between the upper and middle shells for supplying fuel to each of the injector pockets.
In a preferred embodiment, a fuel injector is inserted into each one of the injector pockets to form an intake manifold and injector subassembly that can be easily attached to an internal combustion engine. After the upper, middle, and lower shells are sealed together, the fuel injectors are installed into the injector pockets via the shell ports.
In a further preferred embodiment, an internal wire harness rail is formed between the upper and middle shells for supporting a wire harness that electrically connects each of the injectors to a power supply. The electrical connection is required for use in a vehicle having electronic throttle control.
A method for assembling an air intake manifold includes the steps described below. The upper shell is provided with a plurality of upper fuel injector pocket portions, a middle shell is provided with a plurality of middle fuel injector pocket portions, and a lower shell is provided with a plurality of lower fuel injector pocket portions. A wire harness assembly is installed between the upper and middle shells. The upper shell is connected to the middle shell such that the upper fuel injector pocket portions are aligned with the middle fuel injector pocket portions. The lower shell is connected to the middle shell such that the middle fuel injector pocket portions are aligned with the lower fuel injector pocket portions, thus forming a plurality of fuel injector pockets that extend through the upper, middle, and lower shells. A fuel injector is installed into each of the injector pockets to form a manifold and injector subassembly.
The subject intake manifold and method of assembly therefor offer an improved, inexpensive, and more compact manifold where fuel injectors can be pre-assembled into the manifold for simplified mounting of the manifold onto an engine and for noise reduction.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
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Kennedy Gary I.
Mammarella John R.
Marentette John F.
Worrel Christine C.
Moulis Thomas N.
Siemens Canada Limited
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