A positive crankcase ventilation system for an internal combustion engine routes blowby gases into the intake of the engine. Because the blowby gases have about 12% water vapor, during cold-weather operation, the water vapor may freeze in the PCV valve or in the port that couples the PCV duct with the intake manifold. In situations in which the PCV duct is pointing toward the direction of flow of the intake gases, a hood or cap is placed over the end of the tube according to the present disclosure. It can be as simple as a 90-degree elbow or multiple openings in the cap. A centerline of the openings is perpendicular or at an obtuse angle with respect to the direction of flow in the duct so that the intake gases do not directly access the openings and cause freezing in the openings (or ports).

A system for manufacturing a family of intake manifolds includes first and second intake molds. One of the first and second intake molds includes an outlet insert. A first intake manifold includes: a plenum chamber, a plenum chamber air inlet; a first number of intake runner passages; and the first number of outlets. Each of the outlets is fluidly connected to a corresponding one of the first number of intake runner passages. The second intake manifold includes: the plenum chamber; the plenum chamber air inlet; the first number of intake runner passages; and a second number of outlets. Each of the second number of outlets is fluidly connected to a corresponding one of the first number of intake runner passages. At least one of the first number of intake runner passages is not fluidly connected to any one of the second number of outlets of the second intake manifold.

An infrared welding system for joining two parts made of thermoplastic material comprises a pair of infrared heaters for heating the two parts while spaced from each other; and energizing the infrared heaters to emit infrared heat and directing the emitted infrared heat onto selected portions of the opposed surfaces of the parts to melt at least portions of the opposed surfaces, while directing an inert gas onto the selected portions to prevent ignition of the melted thermoplastic material. The two parts are clamped together by moving at least one of the parts toward the other part to press the melted surfaces of the parts into contact with each other. The parts are cooled while they remain clamped together to solidify the molten thermoplastic material and thus weld the two parts together.

A metal mold includes a restraining part that is fitted in a recess provided at a part of surfaces of at least two resin parts that serves as an outer surface of a resin hollow body. A linear space is filled with high-pressure resin fluid injected at a predetermined injection pressure. The resin parts are joined together. The mold receives injection pressure of resin fluid, with which the space is filled, through the resin parts, and applies pressing force, which pushes back the resin parts toward the space, to the resin parts as reaction force against injection pressure. Stress is produced on a hollow wall surface in a direction in which the wall surface projects into a hollow portion due to injection pressure. The restraining part applies pressing force to the resin parts in a direction opposite from the stress projecting the wall surface into the hollow portion.

A positive crankcase ventilation system for an internal combustion engine routes blowby gases into the intake of the engine. Because the blowby gases have about 12% water vapor, during cold-weather operation, the water vapor may freeze in the PCV valve or in the port that couples the PCV duct with the intake manifold. In situations in which the PCV duct is pointing toward the direction of flow of the intake gases, a hood or cap is placed over the end of the tube according to the present disclosure. It can be as simple as a 90-degree elbow or multiple openings in the cap. A centerline of the openings is perpendicular or at an obtuse angle with respect to the direction of flow in the duct so that the intake gases do not directly access the openings and cause freezing in the openings (or ports).

A family of manifolds for a family of engines. A first and second engine respectively have a first and second number of cylinders. The second number is at least one and smaller than the first number. Each manifold has a plenum chamber and an inlet. The first and second manifolds respectively have the first and second number of outlets, each connected to one of a first number of runner passages. The first manifold is manufactured by inserting an outlet insert for forming at least one of the first number of outlets into a first or second mold, forming a first portion thereof using the first mold, forming a second portion thereof using the second mold, and connecting the portions. The second manifold is manufactured by forming a first portion thereof using the first mold, forming a second portion thereof using the second mold, and connecting the portions.

A family of manifolds for a family of engines. A first and second engine respectively have a first and second number of cylinders. The second number is at least one and smaller than the first number. Each manifold has a plenum chamber and an inlet. The first and second manifolds respectively have the first and second number of outlets, each connected to one of a first number of runner passages. The first manifold is manufactured by inserting an outlet insert for forming at least one of the first number of outlets into a first or second mold, forming a first portion thereof using the first mold, forming a second portion thereof using the second mold, and connecting the portions. The second manifold is manufactured by forming a first portion thereof using the first mold, forming a second portion thereof using the second mold, and connecting the portions.

A valve body unit (11) in which a plurality of valve bodies (17) which open and close intake passages (10) are attached on a rotational shaft (16) is inserted into inner sides of housing passages (28) of a housing (12) and, thereafter, a holder (13) is mounted in the housing (12) to rotatably support the valve body unit (11). A flange (14) is fixed onto an upper surface of the housing (12) on the holder (13) by means of a vibration welding and the holder (13) is retained with this flange (14) and the housing (12).

A metal mold includes a restraining part that is fitted in a recess provided at a part of surfaces of at least two resin parts that serves as an outer surface of a resin hollow body. A linear space is filled with high-pressure resin fluid injected at a predetermined injection pressure. The resin parts are joined together. The mold receives injection pressure of resin fluid, with which the space is filled, through the resin parts, and applies pressing force, which pushes back the resin parts toward the space, to the resin parts as reaction force against injection pressure. Stress is produced on a hollow wall surface in a direction in which the wall surface projects into a hollow portion due to injection pressure. The restraining part applies pressing force to the resin parts in a direction opposite from the stress projecting the wall surface into the hollow portion.

An intake apparatus for an engine is provided. The intake apparatus includes an intake manifold configured to draw intake air thereinto, a cylinder head having an intake port through which intake air drawn from the intake manifold is supplied into a cylinder of the engine and a flow control valve disposed in the intake manifold and configured to control a flow direction of intake air to be drawn from the intake manifold into the cylinder head to generate a circular flow in the intake air. A port plate is configured to reinforce the circular flow of intake air that is generated in the flow control valve and a plate support is coupled with the port plate and coupled between the intake manifold and the cylinder head to enable the port plate to be inserted into the intake port.