Internal-combustion engines – Poppet valve operating mechanism – Lubrication
Utility Patent
1999-06-10
2001-01-02
Kamen, Noah P. (Department: 3747)
Internal-combustion engines
Poppet valve operating mechanism
Lubrication
C123S184210, C123S184350, C123S469000
Utility Patent
active
06167855
ABSTRACT:
FIELD OF THE INVENTION
The invention relates in general to internal combustion engines and in particular to an integrated air-fuel module and assembly method for internal combustion engines.
BACKGROUND OF INVENTION
On internal combustion engines used, for example, in motor vehicles, the air and fuel system component parts such as air intake lines, air cleaners, fuel rails, various emission control devices, and other components are individually assembled to the engine. Individually assembling each component to the engine is a time consuming and labor intensive process.
In the present invention, these air-fuel system components are assembled in a unitized or integrated air-fuel module which is then assembled to the engine.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an apparatus and method for incorporating many of the various fuel and emission components generally located on the top or outside of an internal combustion engine into a completed sub-assembly that can be delivered to an engine assembly line and installed as a unit on the engine.
It is another object of the invention to provide an apparatus and method for reducing the number of components that are normally individually installed on the engine during assembly by a magnitude of about ten, i.e. from about thirty-two to three in a particular application.
It is still a further object of the invention to provide an apparatus and method for reducing the amount of raw material used in building an engine by integrating several individual components into a single component, such as combining the valve covers and the intake manifold base into a single part.
It is yet a further object of the invention to provide an air fuel module with a noise suppression system to reduce engine noise transmitted to the vehicle operator.
These and other objects of the invention are achieved by an integrated air-fuel module comprising an intake manifold base; and at least one valve cover integrally molded in a bottom of the intake manifold base. The integrated air-fuel module may further comprise an air filter mounted on a top of the intake manifold base.
Preferably, the integrated air-fuel module further comprises a throttle body mounted on the top of the intake manifold base and an output tube connected between the throttle body and the air filter. The integrated air-fuel module further comprises a positive crankcase ventilation valve mounted on the intake manifold base.
In one embodiment, the integrated air-fuel module further comprises an exhaust gas recirculation valve, a proportional purge solenoid, and at least one fuel rail each respectively mounted on the intake manifold base. At least one injector is mounted to the at least one fuel rail.
In a preferred embodiment, the integrated air-fuel module further comprises intake manifold runners molded in the intake manifold base and a fuel inlet tube connected to the at least one fuel rail.
In another embodiment, the integrated air-fuel module further comprises a second fuel rail mounted to the intake manifold base and a cross-over fuel tube connecting the two fuel rails.
Preferably, the integrated air-fuel module further comprises a manifold absolute pressure sensor and a charge air temperature sensor each mounted on the intake manifold base.
The integrated air-fuel module further comprises a cover mounted to the intake manifold base and covering substantially all of the intake manifold base including the throttle body. The cover is attached to the intake manifold body by, for example, clips.
In yet another embodiment, the integrated air-fuel module further comprises an electronic control unit mounted to the intake manifold base.
The integrated air-fuel module further comprises an electrical wiring harness mounted to the intake manifold base, the electrical wiring harness comprising an electrical connector at one end and comprising electrical wires respectively connected to the at least one injector, the absolute manifold pressure sensor, the proportional purge solenoid, the throttle body, the exhaust gas recirculation valve, the electronic control unit and the charge air temperature sensor.
Another aspect of the invention is a method of assembling an engine comprising assembling an integrated air-fuel module at a first location; and attaching the integrated air-fuel module to the engine at a second location.
The step of assembling the integrated air-fuel module further comprises providing an intake manifold base having at least one valve cover integrally molded in a bottom of the intake manifold base and having integral intake manifold runners; mounting an air filter on a top of the intake manifold base; mounting a throttle body on the top of the intake manifold base and connecting the throttle body to the air filter with an output tube.
Preferably, the step of assembling the integrated air-fuel module further comprises mounting a positive crankcase ventilation valve, an exhaust gas recirculation valve, a proportional purge solenoid, and at least one fuel rail to the intake manifold base. The assembling step may further comprise mounting a second fuel rail to the intake manifold base and connecting the two fuel rails with a cross-over fuel tube.
In one embodiment, the step of assembling further comprises mounting a manifold absolute pressure sensor, a charge air temperature sensor, an electronic control unit, an oil cap and an oil inlet tube to the intake manifold base.
A cover is mounted to the intake manifold base which covers substantially all of the intake manifold base including the throttle body.
The step of assembling further comprises connecting an electrical wiring harness to at least one injector, the absolute manifold pressure sensor, the proportional purge solenoid, the throttle body, the electronic control unit and the charge air temperature sensor.
Most preferably, the step of providing an intake manifold base includes the step of providing an intake manifold base having two valve covers integrally molded in the bottom of the intake manifold base and further includes the step of molding the intake manifold base in two pieces made of a plastic material and welding the two pieces together to form the intake manifold base.
Further objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the drawing.
REFERENCES:
patent: 5713323 (1998-02-01), Walsh et al.
Mammarella John
Vyskocil Frank
Kamen Noah P.
Siemens Canada Limited
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