Siemens Canada Limited

Christine C Worrel

Debora E Nally

John Francis Marentette

John R Mammarella

Gary I Kennedy

Karl Robert Schwarzpech

An intake manifold includes an upper shell, a lower shell, and a middle shell that interconnects the upper and lower shells. The lower shell has a plurality of longitudinally spaced shell ports. Each shell port is adapted for installation over a corresponding intake port for an engine cylinder head. The upper shell has a plurality of runners that are used to guide air to the shell ports. The middle shell has a plurality of channels that interconnect the runners and the shell ports such that air can flow through the runner to the cylinder intake port. 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, formed between the upper and middle shells, supplies fuel to each of the injector pockets. A fuel injector is installed into each injector pocket such that the injectors are substantially enclosed within the manifold. An internal wire harness rail, formed between the upper and middle shells, supports a wire harness that electrically connects each of the injectors to a power supply.

Intake manifold with internal fuel rail and injectors

A method of making air assist passageways and injector pockets in a manifold or air assist rail includes providing a mold that can open and close with several bosses extending from an inside surface. These bosses are arranged in a row and define the inside of the injector pockets when the mold is filled. The air assist passageway that couples the fuel injector pockets is provided by inserting a long pin that passes through the row of injector pocket bosses inside the mold cavity. When the cavity is filled with molten material and solidifies, the pin is withdrawn, leaving a long air assist passageway extending between the injector pockets. The mold is then opened, pulling the injector pocket bosses out of the now-formed injector pockets. The resulting structure is a row of injector pockets in a manifold or air assist rail into which injectors can be inserted, that are connected by a long air assist passageway. Since the pins were inserted through the mold and into the injector pocket bosses, when the pin is withdrawn, holes will be left at the end of the air assist passageways. These holes in the part can be later plugged or capped to prevent air from leaking out of the air assist passageways. The air assist passageway pin preferably intersects the injector pocket bosses in the middle, thereby being supported on all sides by each boss it passes through.

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Madison Heights, MI, United States of America

Christine C Worrel