Title of Invention	AN INTEGRATED ENGINE CYLINDER HEAD COVER WITH INTEGRATED AIR INTAKE MANIFOLD
Abstract	This invention relates to an engine cylinder head cover for internal combustion engine having plurality of inline cylinders comprising, an integrated air intake manifold, rocker arm chambers for said cylinder heads, a wall separating air intake path of said manifold and said chambers, and said intake manifold and rocker arm chambers formed as a single unit.

Full Text

FORM 2 THE PATENTS ACT 1970 (39 of 1970) & THE PATENTS RULES, 2003 COMPLETE SPECIFICATION (See Section 10; rule 13) TITLE OF INVENTION An Engine Cylinder Head Cover With Integrated Air Intake Manifold APPLICANTS TATA MOTORS LIMITED, an Indian company having its registered office at Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001 Maharashtra, India INVENTORS Jayagopal S and Arunendra Mishra Both Indian Nationals of TATA MOTORS LIMITED, an Indian company having its registered office at Bombay House, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001 Maharashtra, India PREAMBLE TO THE DESCRIPTION The following specification particularly describes the invention and the manner in which it is to be performed. FIELD OF INVENTION This invention relates to an intake manifold and cylinder-head cover preferably for internal combustion engine and more particularly, the invention relates to an intake manifold and cover module to be installed as single unit onto an engine. BACKGROUND OF INVENTION An engine includes an intake manifold for delivering the filtered air from atmosphere to combustion chambers. Intake manifold of an IC engine is generally disposed between the intake port and the air-cleaner and the plenum volume acts as surge-tank to provide air to different cylinders with respect to valve-timing. The intake manifold has many branches (runner pipes) as the number of cylinders to distribute the air into the intake port. Engine also has valve cover, which is secured to the cylinder head by fasteners typically around the entire perimeter of valve cover to enclose the rocker arms and intake and exhaust valves to prevent debris entering the cylinder head and inhibiting its operation. The intake manifold and cylinder-head cover of prior art are manufactured and installed separately on base engine using many fasteners to cover rocker-arm, inlet/ exhaust valves, camshaft. It is desirable to provide intake manifold and cylinder-head cover as a single unit. So that conversion of diesel engine to run on gaseous fuel and adaptations of multi point gas injection system can be possible. It also desired being single unit without compromising the existing functionality and added features as well. The addition features could be able to accommodate fuel injection system, ignition system, Oil separator, Gasket & etc. It is also desirable to use a minimal number of fasteners to speed assembly of the engine. Therefore, what is needed is an intake manifold assembly and valve cover module for installation onto base engine assembly, which may be shipped as single unit and that can provide space for MpSgi (multi point sequential gas injection system) and spark plug and oil separator. OBJECTS OF INVENTION Main object of this invention is to provide an intake manifold apparatus and cylinder head cover as single unit, which uniformly distributes air fuel mixture to all the cylinders. Another object of this invention is to protect rocker arm from debris and dust. Yet another object of invention provide place to accommodate the fuel injection system. Yet another object of this invention is to provide place for High-Tension Coil and Oil separator. SUMMARY OF INVENTION The primary purpose of this invention is to provide a single unit instead of two separate units of intake manifold and cylinder head cover. Casting of this intake manifold cum cylinder head cover is done as single unit from Aluminum. As working pressures and functionality of these two chambers (intake manifold and cylinder head cover) are different, a wall is provided to divide the chambers. So both chambers in single unit can function independently. To prevent blow-by, oil and air-fuel mixture leakage, a gasket is fixed between cylinder head and stated unit. According to this invention an engine cylinder head cover for internal combustion engine having plurality of inline cylinders comprising, an integrated air intake manifold, rocker arm chambers for said cylinder heads, a wall separating air intake path of said manifold and said chambers, and said intake manifold and rocker arm chambers formed as a single unit. BRIEF DESCRIPTION OF DRAWINGS FIG .1 is Schematic diagram of IC Engine, Fuel Storage & Supply System, FIG. 2 is an Isometric view of intake manifold cum cylinder head cover FIG. 3 is a Side view of intake manifold cum cylinder head cover FIG. 4 is Cross section view of arrangement of present invention with the related components fitted on Multi Cylinder Inline Engine DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same. Referring to fig 1, the Internal Combustion Engine comprising multi-cylinder inline arrangement, Pistons, 2 valves per cylinder, Ignition Coils, Cylinder block, Cylinder Head, Cam shaft, Push-Rod, Plenum chamber, Fuel Rail, Gas (fuel) Injectors, Crankshaft, Accessories Drives and etc. Gas (fuel) is stored in Composite cylinders (10). These cylinders have in-built High-Pressure Regulator (11). High pressure line (13) carries gases to electronics Low-Pressure Regulator (14), which converts high pressure to working level pressure. Low-pressure line (15) carries gases to common rail (16). The other end of common rail consist a low pressure sensor (31) to monitor the rail-pressure, injectors (44) are connected to common rail. Intake manifold (19) consists of plenum chamber (30), TMAP Sensor (24) and Electronically Controlled Throttle body (23). In the intake port (22), the Air is delivered to cylinder through intake valves, the valve Opening & Closing controlled by a cam shaft. Slot (25) is provided on intake runner pipe (22) to accommodate injectors and ensuring the optimized angle of injection w.r.t air flow direction. The exhaust port (21) is provided with exhaust valve, the valve Opening & Closing controlled by a cam. FIGURES 2 & 3, show the embodiment according present invention. The integrated unit consist of plenum (30), intake runner (22), Rocker-arm chamber (19), threaded boss (52) for oil separator, slots (50) for spark plug. The intake manifold has an air distribution plenum (30), which is connected through intake runner (22) to each cylinder's intake-port. The combined length of intake runner and intake port is defined for Ram Effect for max torque output. The front side (air-entry) of plenum has flange (59) to accommodate the Electronically Controlled Throttle-body. Next to the ETC, another flange (58) is provided to allow the Exhaust Gas Re-circulation to meet Low-Nox emission by diluting the Intake air at desired ratio. This EGR entry position is decided based on better mixing/distribution of Exhaust with the Intake air to all cylinders. The plenum consists of a boss (60) to accommodate T-MAP sensor. Further it has two identical bosses (51) to accommodate Fuel-Rail. The tapered passages (54) are provided to assemble the said component on cylinder head through fasteners ensuring leak proof (Oil) fitment through the circumference. The next side of this component has curvature (50) and boss projection (61) to allow and hold the Sparkplug respectively to Cylinder head and cover. The ribs (55) are provided to distribute the tightening forces towards the circumference for leak-proof fitment as the fasteners are kept centre line of cylinder head. In an internal combustion engine, the crankcase needs to vent due to the flow of gases (blow-by) from combustion chamber past the piston ring into crankcase. To remove these gases, a threaded hole (52) provided on top on cover to accommodate oil separator. An oil separator for separating and collecting lubrication oil contained in blow-by gas of an internal combustion engine. The separator is formed in the cylinder-head cover of the engine and incorporates a porous filter or filters made of foam metal for absorbing oil constituents in the blow-by gas. The filter is vertically arranged so as to make the absorbed oil to fall to the bottom of the separator and to be collected by the oil reservoir for recycling the separated oil to the cylinder FIGURE 4 shows the cross-section view of arrangement of present invention with the related components fitted on Multi Cylinder Inline Engine. In preferred embodiment of present invention, in-line cylinders are formed in cylinder-block (36). The cylinder head (37) is secured to upper side of cylinder block (36) by set of cylinder-head bolts. Rocker cover and intake manifold unit, which surrounds and protect the engine valve assemblies and rocker arm mechanism. This is fastened to cylinder head (37) by thin & longer bolts. A piston (41) is reciprocally supported in each cylinder (36). Each piston is connected by a connecting rod (not shown in figure) to a crankshaft (44) joumaled in conventional manner in lower portion of cylinder block (36). Fuel is combusted within the cylinders, which reciprocates the pistons. This reciprocating force acts on crankshaft (44), from which power transferred to vehicle. A single integrated intake manifold and cylinder-head cover, generally indicated at (19) is mounted to cylinder head (37). Intake port (38) connects intake runner (22) and cylinder (36). Intake valve (35) is placed in between cylinder and intake port to control the fluid flow and the valve Opening & Closing controlled by cam shaft (43). Camshaft (43) driven by crankshaft (44) through timing gears (not shown in figure). To accommodate injectors (for multi-point sequential gas injection) steel insert (46) is kept during casting. These steel inserts give better surface finish than aluminum surface to ensure leak proof fitment of injectors on intake runner (22). The gaseous fuel is injected into the air, which is channeled from plenum (30) into each intake port of the cylinder (36). A fuel supply plenum (16) supplies fuel to the injectors. Injector (42) is disposed to intake runner through steel insert (46) Injecting fuel into the intake runner makes it possible to introduce a uniform concentrated mixture into the cylinder & form homogenous mixture for proper combustion. The primary purpose of present invention is to provide a single unit instead of two separate units of intake manifold and cylinder head cover further added features to meet the Multi- Point Sequential Gas injection system, Blow-by separation, to hold High-Tension Coil-on-Plug. Casting of this intake manifold cum cylinder head cover is done as single unit from Aluminum. As working pressures and functionality of these two chambers (intake manifold & cylinder head cover) are different, a wall (39) is provided to divide the chambers. So both chambers in single unit can function independently. To prevent blow-by, oil and air-fuel mixture leakage, a gasket (40) is fixed between cylinder head and stated unit. The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof. We claim 1. An engine cylinder head cover for internal combustion engine having plurality of inline cylinders comprising, an integrated air intake manifold, rocker arm chambers for said cylinder heads, a wall separating air intake path of said manifold and said chambers, and said intake manifold and rocker arm chambers formed as a single unit. 2. The engine cylinder head cover as claimed in claim wherein said air intake manifold having an air intake plenum and plurality of air passages connects to cylinder heads. 3. The engine cylinder head cover as claimed in claim 1, wherein said head cover having circular slots for locating injectors. 4. The engine cylinder head cover as claimed in claim 1, wherein said head cover having a threaded boss and an oil separator disposed therein. 5. The engine cylinder head cover as claimed in claim 2, wherein said air intake plenum having an air intake and entry for EGR. 6. The engine cylinder head cover as claimed in claim 1 wherein said air intake plenum having TMAP sensor disposed therein. 7. The engine cylinder head cover as claimed in claim 1 wherein said air intake plenum having outside protrusions to fix the fuel rails. 8. The engine cylinder head cover as claimed in claim 1, wherein said head cover having slots for locating spark plug. 9. The engine cylinder head cover as claimed in claim 1, wherein said head cover having protrusion for assembling the spark plug. 10. The engine cylinder head cover substantially as herein described with reference to accompanying drawings. Dated this 28th day of March 2008 ABSTRACT An Engine Cylinder Head Cover With Integrated Air Intake Manifold This invention relates to an engine cylinder head cover for internal combustion engine having plurality of inline cylinders comprising, an integrated air intake manifold, rocker arm chambers for said cylinder heads, a wall separating air intake path of said manifold and said chambers, and said intake manifold and rocker arm Figure 2 chambers formed as a single unit.

Documents:

685-MUM-2008-ABSTRACT(24-3-2014).pdf

685-mum-2008-abstract.doc

685-mum-2008-abstract.pdf

685-MUM-2008-CLAIMS(AMENDED)-(24-3-2014).pdf

685-MUM-2008-CLAIMS(AMENDED)-(3-10-2012).pdf

685-mum-2008-claims.doc

685-mum-2008-claims.pdf

685-mum-2008-correspondence(24-4-2008).pdf

685-MUM-2008-CORRESPONDENCE(27-2-2014).pdf

685-mum-2008-correspondence-received.pdf

685-mum-2008-description (complete).pdf

685-MUM-2008-DRAWING(24-3-2014).pdf

685-mum-2008-drawings.pdf

685-MUM-2008-FORM 1(24-3-2014).pdf

685-MUM-2008-FORM 13(3-10-2012).pdf

685-mum-2008-form 18(24-4-2008).pdf

685-MUM-2008-FORM 2(TITLE PAGE)-(24-3-2014).pdf

685-mum-2008-form 2(title page)-(28-3-2008).pdf

685-MUM-2008-FORM 26(24-3-2014).pdf

685-MUM-2008-FORM 3(24-3-2014).pdf

685-mum-2008-form 8(24-4-2008).pdf

685-mum-2008-form 9(24-4-2008).pdf

685-mum-2008-form-1.pdf

685-mum-2008-form-2.doc

685-mum-2008-form-2.pdf

685-mum-2008-form-26.pdf

685-mum-2008-form-3.pdf

685-MUM-2008-MARKED COPY(24-3-2014).pdf

685-MUM-2008-REPLY TO EXAMINATION REPORT(3-10-2012).pdf

685-MUM-2008-REPLY TO HEARING(24-3-2014).pdf

685-MUM-2008-SPECIFICATION(AMENDED)-(24-3-2014).pdf

685-MUM-2008-SPECIFICATION(AMENDED)-(3-10-2012).pdf

685-MUM-2008-SPECIFICATION(MARKED COPY)-(3-10-2012).pdf

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