A method for applying a thermal barrier coating (TBC) to a surface of a cast component includes providing a core, applying the TBC to the core to form a coated core, disposing the coated core within a casting mold, casting metal around at least a portion of the coated core to form a casting intermediary, and removing the core from the casting intermediary to form a cast component. The TBC includes hollow microspheres comprising metal, glass, and/or ceramic materials. The hollow microspheres can have an average diameter of about 10 m to about 100 m. The component can be an automotive component, such as an engine intake assembly, an engine exhaust manifold, an engine block, and/or an engine cylinder head. The surface of the cast component can be one or more surfaces which define an engine intake passage, an engine exhaust passage, and an engine combustion chamber.

A method for manufacturing a waterproof felt duct may include (a) laminating a waterproof film on one side of a first nonwoven fabric and laminating a second nonwoven fabric on the waterproof film laminated on the first nonwoven fabric to form a laminated body; (b) forming a waterproof felt base material by thermally adhering the laminated body; (c) cutting the waterproof felt base material into a desired shape; (d) molding a duct while surrounding the waterproof felt base material cut into the desired shape around the external surface of a molding jig having a worm gear shape; (e) heat-treating the molded duct; (f) cooling the heat-treated duct; and (g) ejecting the cooled duct from the molding jig.

Vapors in the fuel tank of a vehicle are collected in a carbon canister. An ejector or aspirator is used to purge the carbon canister in a pressure-charged engine in which a positive pressure exists in the intake. A compact ejector includes a substantially planar flange and a venturi tube coupled to the flange with a central axis of the venturi tube substantially parallel to the flange. By manufacturing the ejector in two pieces, dimensions within the ejector: throat, converging section, and diverging section, is more accurate than prior art manufacturing techniques thereby providing better flow characteristics throughout the boost range. By forming one of the two pieces of the ejector integrally with the air intake component in which it is coupled, decreases part count and the number of manufacturing processes.

The present invention provides a die assembly for molding a resin-made insert having a sleeve that is inserted into an intake port of an internal combustion engine. Each sleeve has one inlet and two outlets. The die assembly includes an inner die and an outer die. The inner die includes an inlet side part and an outlet side part. The inlet side part and the outlet side part mold an inner peripheral surface of the sleeve in an assembled state, and are removed in mutually opposite directions. By means of this assembly, a sleeve having a complicated structure and shape can be molded easily.

An intake duct for an internal combustion engine includes a tubular side wall. The side wall includes a first molded body and a second molded body that are separate from each other in a circumferential direction of the side wall. The first molded body includes first and second joints. The second molded body includes first and second joints. The first and second joints of the first molded body and the first and second joints of the second molded body are joined to each other. The first molded body includes a rib protruding toward the second molded body and extending in an axial direction of the side wall. The rib is located inward from the first and second joints of the first molded body. The second molded body includes an accommodation recess that accommodates the rib. The accommodation recess is located outward from the rib.

Aspects of the present disclosure include branching fluid passages in an apparatus that reduce turbulent flow and generate evenly distributed fluid pressure as the fluids branch off into the different passages. In some embodiments, the branching passages may be subdivided into two sets: the branching passages for the liquid fuel and the branching passages for the liquid oxidizer. In some embodiments, the two sets of passages are carefully designed in an elegant yet extremely intricate manner that is optimized for proper fluid flow and maximal burn efficiency. The ends of all of the passages meet at the injector interface, which dispense the liquids into the combustion chamber for ignition. Generally, these designs are achieved through additive manufacturing, and would be extremely difficult, if not impossible, to be manufactured using traditional techniques.

An air cleaner includes a housing and a filter element located within the housing. The housing includes a housing body and a fiber molding assembly. The housing body is formed by a plastic molding. The housing body has a wall located upstream of the filter element in an air flow direction and a recess, which is an inwardly recessed part of the wall. The fiber molding assembly is fixed to the wall, covers the recess from outside, and forms a part of a side wall of an inlet passage together with the recess. A communication hole for communication between the inlet passage and an interior of the housing body is formed in the recess.

Vehicle Engine Air Intake System and Method (to be accompanied by FIGS. 1 and 3) In a motor vehicle (12), an air filter housing (14) is at least partially defined by a cross-member (28) forming part of a structural front end module of the vehicle body. The cross-member (28) defines a recess (44) for receiving an air filter (90) and at least one air inlet aperture opening into the recess. An air filter enclosure assembly is mounted to the cross-member over an open face of the recess. The air filter enclosure assembly may include an air filter enclosure (42) and an air filter (90).

An air inlet system for an internal combustion engine comprising an air inlet duct which has an upstream end including an opening and a downstream end for connection to an air flow control component and further comprising a mass air flow sensor assembly, the mass air flow sensor being located closer to the downstream end than the upstream end.

An intake manifold for an internal combustion engine, comprising: a at least one air intake opening connected to an inner chamber, and a plurality of outlet pipes connected to the inner chamber, wherein each outlet pipe is provided with an outlet opening adapted for a sealed connection with a cylinder head of an internal combustion engine, wherein the intake manifold is injection moulded in a plastic material, wherein the intake manifold comprises at least one water injection nozzle moulded into the intake manifold. The advantage of the invention is that a cost-efficient water injection system for a combustion engine is provided.