Internal module, members of the module, and electronic controlled throttle device for internal combustion engine

An internal combustion engine intake module, members thereof and electronically controlled throttle apparatus for a car and related products characterized by great strength, and light weight and compact configuration wherein the weight of the electronically controlled throttle apparatus and motor to be connected is reduced. The internal combustion engine intake module of the present invention comprises a collector, an electronically controlled throttle body connected to the collector, and a plurality of intake manifolds connected in parallel integrally with the collector. It is characterized in that the collector is bent upward on the side of the electronically controlled throttle body, and a motor for driving the electronically controlled throttle is provided on the body integrally with the inner side of the bent side. It is further characterized in that the intake manifolds are made of synthetic resin containing a fiber or aluminum group alloy casting.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an internal combustion engine intake module, members thereof and electronically controlled throttle apparatus of a new car or similar products.

2. Description of the Prior Art

To ensure small size and compact configuration and to improve packaging density in the intake system of an internal combustion engine of a car, various techniques have been proposed to use synthetic resins for an intake manifold and a collector (surging tank), to mold them in an integrated form, and hence to incorporate a throttle valve, collector, intake manifold, injector and related parts into one module. The prior arts of internal combustion engine intake module are disclosed, for example, in the Japanese Application Patent Laid-Open Publication No. 03-202670, Japanese Application Patent Laid-Open Publication No. 06-81719, Japanese Application Patent Laid-Open Publication No. 07-301163, Japanese Application Patent Laid-Open Publication No. 07-83132, and Japanese Application Patent Laid-Open Publication No. 10-281026. In the Japanese Application Patent Laid-Open Publication No. 03-202670, it is shown that the collector and intake manifold are composed of synthetic resin, and the engine side of the intake manifold is made of metal. The Japanese Application Patent Laid-Open Publication No. 10-281026, it is revealed that the collector and intake manifold are composed of synthetic resin.

In any of the known examples, however, no reference is made to a specific relationship with an electronically controlled throttle apparatus connected to the collector.

SUMMZRY OF THE INVENTION

The object of the present invention is to provide an internal combustion engine intake module, members thereof and electronically controlled throttle apparatus for a car and related products characterized by great strength, and light weight and compact configuration wherein the weight of the electronically controlled throttle apparatus and motor to be connected is reduced.

The present invention is concerned with an internal combustion engine intake module composed of the specific structure, members thereof and electronically controlled throttle apparatus. In particular, the present invention is concerned with an internal combustion engine intake module comprising an intake manifold made of synthetic resin containing fibers and a collector, wherein the internal combustion engine intake module is integrated with the electronically controlled throttle drive motor, and is arranged on the intake manifold side.

For example, when a blow-by gas passage for leading air from an electronically controlled throttle body flange to the synthetic resin-made collector is arranged outside the intake manifold connected to each cylinder (on the so-called an internal combustion engine intake module side), the mounting flange of the electronically controlled throttle body is located in the direction away from the gravity center of the internal combustion engine intake module. The gravity center of the internal combustion engine intake module with a motor arranged thereon is far removed from the center gravity of the intake manifold. In this case, the passage for leading air from the electronically controlled throttle body flange to the synthetic resin-made collector must be made robust against the engine vibration or the like.

To solve this problem, the motor of the electronically controlled throttle body motor is arranged on the intake manifold side, and the aforementioned passage is tilted or bent 45 degrees or more. This arrangement ensures that the center gravity of the electronically controlled throttle body is brought closer to the gravity center of the intake manifold. It also alleviate the need of reinforcing of the aforementioned passage for leading air from the electronically controlled throttle body flange to the collector, or eliminates the need of reinforcement. Accordingly, it is preferred that the intake manifold flange be arranged in a descending slope as viewed from the intake manifold side, and that the collector, intake manifold and passage connecting them be made of synthetic resin, especially the one containing fiber, or low glass fiber characterized by low thermal expansion. In addition, carbon fiber, ceramic fiber and metallic fiber are preferred.

This configuration ensures that the gravity center of the electronically controlled throttle body with a motor mounted thereon can be brought close to the gravity center of the resin-made intake manifold, and provides the strength of the passage for leading air from the electronically controlled throttle body flange to the synthetic resin-made collector.

To be more specific, the present invention provides an internal combustion engine intake module comprising:a collector,an electronically controlled throttle body connected to this collector, anda plurality of intake manifolds connected in parallel integrally with this collector;the aforementioned internal combustion engine intake module further characterized in thatthe collector is bent upward on the side of the electronically controlled throttle body, and a motor for driving the electronically controlled throttle is provided on the aforementioned body integrally with the inner side of the aforementioned bent side;the aforementioned collector has a slope that is upwardly tilted 45 degrees or more on the electronically controlled throttle body side,the diameter of the slope is smaller than that of the intake manifold and is almost the same on the electronically controlled throttle body side and the intake manifold side, andthe motor for driving the electronically controlled throttle is provided integrally with the inner side of the aforementioned bent side;the collector and intake manifolds are made of synthetic resin containing a fiber and the intake manifolds are partly integrally formed by bondage; orthe aforementioned internal combustion engine intake module is composed of these combinations.

Further, the present invention provides an internal combustion engine intake module where a plurality of intake manifolds arranged in parallel to a collector are connected with an electronically controlled throttle body;the aforementioned internal combustion engine intake module characterized in thatthe aforementioned intake manifolds are divided into at least two groups, i.e. on the engine side and collector side, and the collector and intake manifolds on the collector side are made of synthetic resin containing a fiber;the intake manifolds are divided into at least two groups, i.e. on the engine side and collector side,the collector and intake manifolds on the collector side are made of synthetic resin containing a fiber,the intake manifolds on the engine side is made of aluminum group alloy casting;the collector and intake manifolds are made of synthetic resin, andan air flow meter for detecting the amount of sucked air is arranged on the aforementioned body on the side opposite to the engine; orthe aforementioned internal combustion engine intake module is composed of these combinations.

The present invention further provides an internal combustion engine intake module where a plurality of intake manifolds arranged in parallel to a collector are connected with an electronically controlled throttle body;the aforementioned internal combustion engine intake module characterized in thatthe collector and intake manifolds are made of synthetic resin,the wiring connector of the motor for driving the electronically controlled throttle body and the wiring connector of the rotary angle sensor of the throttle are formed integrally with each other, and the aforementioned integrally formed connector has its terminal inlet arranged on the body opposite to the engine;the collector and intake manifolds are made of synthetic resin,the wiring connector of the motor for driving the electronically controlled throttle and the wiring connector of the rotary angle sensor of the throttle are formed integrally with each other,the aforementioned integrally formed connector has its terminal inlet arranged on the body opposite to the engine, and the direction of the inlet of the terminal to wiring connector of an air flow meter for detecting the amount of sucked air is arranged in the same direction as the terminal inlet to the integrally formed connector,the harness with an integral unit comprising wires is fixed on the top of the intake manifold, the aforementioned wires consisting of;a wire connected to the motor for driving the throttle rotatably installed on the body,a wire leading to the sensor for detecting the rotary angle of the throttle,a wire leading to the air flow meter for detecting the amount of sucked air,a wire leading to the fuel injection valve installed on the intake manifold,a wire leading from the engine control unit, anda wire leading to a spark plug installed on the engine; orthe aforementioned internal combustion engine intake module is composed of these combinations.

Further, the present invention provides an internal combustion engine intake module comprising a plurality of intake manifolds arranged in parallel to a collector and a variable intake valve arranged on each of the intake manifolds between the collector and intake manifold, the aforementioned internal combustion engine intake module characterized in that the collector and intake manifolds are made of synthetic resin containing a fiber and the intake manifolds are integrally formed by bondage;wherein the aforementioned internal combustion engine intake module comprises:a plurality of intake manifolds arranged in parallel to the collector,a variable intake valve arranged on each of the intake manifolds between the collector and intake manifold, anda negative pressure tank as a drive source of the variable intake valve;the aforementioned internal combustion engine intake module further characterized in that the collector, intake manifolds and negative tank are made of synthetic resin containing a fiber, and the intake manifolds and negative tank are integrally formed by bondage; orthe collector, intake manifolds and negative tank are made of synthetic resin containing a fiber, the intake manifolds and negative tank are integrally formed by bondage, and an engine control unit is installed on the engine side of the intake manifold; orthe aforementioned internal combustion engine intake module is composed of these combinations.

Further, the present invention provides members for an internal combustion engine intake module of an internal combustion engine comprising a plurality of intake manifolds arranged in parallel to a collector, wherein;the collector and intake manifolds are made of synthetic resin containing a fiber, each of intake manifolds has a flange for connection with other intake manifold on the side connected to the engine, and the intake manifolds are integrally formed by bondage; orthe intake manifolds are divided into at least two groups, i.e. on the side connected to the engine side and the side connected to the collector, the intake manifolds on the collector side are made of synthetic resin containing a fiber, while those on the engine side are made of aluminum group alloy, with both of these groups connected by a rubber-made connecting pipe, and the outer periphery of the rubber-made connecting pipe is fixed by a metallic band.

The present invention provides intake manifolds for an internal combustion engine intake module of an internal combustion engine comprising:a shell,a flange on one end of this shell for connection with the engine side,a flange on the other end for connection with another intake manifold, anda mount for a fuel injection valve arranged on the engine side; wherein the flange for connection with the intake manifold is thicker than the shell and the entire body consists of an aluminum group alloy.

The present invention further provides an electronically controlled throttle apparatus for an internal combustion engine comprising:a throttle rotatably installed on the body,a motor for driving this slot,a connector for wiring this motora sensor for detecting the rotary angle of this slot, anda connector for wiring this sensor;whereinthe body and motor housing are made of aluminum group alloy casting, the motor is arranged on the intake manifold side, the motor wiring connector and sensor wiring connector consist of one integrated connector, and the terminal inlet of this integrated connector is located on the sided opposite to the engine;an air flow meter for detecting the amount of sucked air is arranged thereon, the body and motor housing are made of an integrated aluminum group alloy casting, the motor is arranged on the intake manifold side, and the motor is installed on the body on the intake manifold side, while the air flow meter is mounted on the body on the side opposite to the engine;air flow meter wiring connectors are arranged thereon, the body and motor housing are made of an integrated aluminum group alloy casting, the air flow meter is arranged on the aforementioned body on the side opposite to the engine, and the terminal inlet of the wiring connector of this air flow meter; orthe aforementioned throttle is composed of these combinations.

In an internal combustion engine intake module of an internal combustion engine according to the present invention, the motor and air flow meter with respect to the electronically controlled throttle body are arranged at a specified position. This arrangement reduces the load on the weight of the electronically controlled throttle body and motor thereof in particular, and allows the intake manifold and collector to be formed with synthetic resin, with the result that a lightweight and compact internal combustion engine intake module can be obtained. Further, when their wiring and collector are arranged at a specified position, the wiring length can be reduced and, at the same time, the wiring production process can be curtailed. Moreover, this arrangement improves the reliability of the wiring and the entire system.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 6is an outline view of an engine system to which an internal combustion engine intake module of automotive internal combustion engine according to the present invention applies.

InFIG. 6, a cylinder110of an engine block100denotes one of multiple cylinders. Numerals201and202are independent intake pipes constituting an intake manifold. The intake manifold is composed of independent intake pipes in the number corresponding to that of the cylinders. This independent intake pipe202comprises a variable intake valve281that is opened or closed by a negative pressure diaphragm280. A three-way solenoid valve282is switched by the signal sent from an engine control unit (hereinafter referred to as “ECU”)260, and negative pressure to the negative pressure diaphragm280is switched, whereby the variable intake valve281is actuated to get the length of the intake pipe appropriate to the engine loaded status. Numeral203denotes a collector (surging tank) positioned upstream from the intake manifold, and300indicates an electronically controlled throttle body equipped with a built-in throttle valve.

The electronically controlled throttle body300incorporates a throttle position sensor (hereinafter referred to as “TPS”)304as a measuring system, and also contains an air flow meter (hereinafter referred to as “FM”)302for detecting the amount of sucked air. The electronically controlled throttle body300is provided with a motor310and a gear311for opening and closing the throttle valve.

The independent intake pipes201and202are connected with the suction port of the cylinder110branched off from the collector203.

Air captured from an air cleaner (not illustrated) is flow-controlled by the throttle valve of the electronically controlled throttle body300, and is then lead to the collector203. It is fed into the cylinder110located in the intake process through the independent intake pipes (intake manifolds)201and202.

An injector (fuel injection valve)250is arranged close to the suction port of the cylinder110, and serves to inject fuel in response to the control signal from the ECU260.

The injector250is supplied with fuel through the fuel gallery (fuel supply pipe).

In this example, an independent ignition type ignition coil104is directly connected to the spark plug mounted on the cylinder head. The independent ignition type ignition coil10is mounted inside the plughole and an igniter unit (ignition drive circuit)101is installed thereon. Ignition signal is sent directly from the ECU to the igniter unit101to provide ignition control.

Numeral111denotes a crank angle sensor,112a knock sensor for detecting engine knocking,113a cam angle sensor,115and116oxygen sensors provided on the exhaust pipe114. The oxygen sensors115and116provide air-fuel ratio control. Since they are placed before and after the catalyst118, they detect the deterioration of the catalyst performance.

Numeral253is a warm water sensor for detecting the engine coolant. Signals detected by these sensors and AFM are sent to the ECU260through the harness. The ECU260provides the function of computing the amount of fuel and ignition timing in conformity to the current engine status based on various measurement signals and sensor signals.

Part of the engine coolant is fed through the passage provided on the throttle valve via the warm water piping, thereby giving heat to the throttle body and preventing the throttle valve from being frozen. Warm water (engine coolant) is fed back to the engine cooler through the reserve tank and feedback pipe.

Numeral119denotes a canister for recovering the evaporated gas of the fuel tank. The evaporated gas recovered by the canister19is sent to the collector203through the canister purge calve317and canister purge pipe.

The canister purge calve317is also controlled through the ECU260.

Further, the electronically controlled throttle body300is provided with a PCV valve322used for the blow-by gas reducer (positive crankcase ventilation; hereinafter referred to as “PCV valve”) and a fresh air outlet. The PCV is provided to ensure that the blow-by gas taken out of the cylinder head cover or crankcase is fed back to the passage of the air intake system. If blow-by gas is placed in the intake mode under reduced load when there is little generation of blow-by gas, the suction force by negative pressure from the manifold becomes excessive to cause an engine trouble. This problem can be avoided by usinga PCV valve designed in such a structure that the PCV ventilation area is controlled by negative pressure. The blow-by gas is fed downstream from the throttle valve in response to the engine load (sucked air flow rate). Further, fresh air is fed into the cylinder head cover or crankcase through the fresh air outlet and hose connected thereto from the air intake system upstream from the throttle valve at that time, whereby ventilation is provided.

The following describes an internal combustion engine intake module of the internal combustion engine according to the present invention with reference to FIGS. through9.

FIG. 1is a perspective view representing an internal combustion engine intake module200mounted on an engine block100.FIG. 2is a front view representing he internal combustion engine intake module200removed from the engine block100and the ECU removed from the internal combustion engine intake module200(ECU260is incorporated as an element of the internal combustion engine intake module inFIG. 1).FIG. 3is a left side view ofFIG. 2.FIG. 4is a right side view ofFIG. 2.FIG. 5is a vertical cross sectional view of intake manifolds201and202, negative tank312and collector203as main units of an internal combustion engine intake module according to the present invention.FIG. 7is a cross sectional view representing bonding structure of synthetic resin.FIGS. 8 and 9are cross sectional views of the collector on the electronically controlled throttle body side. In the internal combustion engine intake module200according to the present embodiment, the parts of the intake system as well as part of the fuel system, ECU260and various harnesses of electric system are each formed into one module (integration, unitization) wherever possible in order to ensure streamlined car assembly and transfer work, compact designing, improved implementation, reduced costs, reduced hardness resistance and minimized resistance. To achieve these goals, attempts have been made to give various considerations as given below.

The intake manifold202and collector203as main units of the internal combustion engine intake module200are molded integrally in one piece using the synthetic resin containing 30 wt %—or preferably 20 through 40 wt %—of glass fiber characterized by excellent heat resistance and mechanical strength. The synthetic resin to be used includes epoxy resin, polyacetal resin, nylon resin, polyethylene terephthalate resin and polybutylene terephthalate resin. Use of thermoplastic resin is preferred. Other types of fiber used include ceramic, metal and carbon fibers.

The intake manifold201connected to the engine side in particular is preferred to be made of the diecast material of aluminum group alloy equivalent to the ADC12 specified in the Japanese Industrial Standards. In terms of weight, the manifold used contains 4.5 through 13.0 wt % of Si. The manifold containing 0.5 wt % of at least one of Cu, Mg, Zn, Fe, Mn and Ni is also used. Further, such a manifold contains 1.0 through 4.0 wt % of the aforementioned Cu. A flange314thicker than the shell portion is provided on the side of the aforementioned synthetic resin-made intake manifold202. The connected portion is connected to a flange315thicker than the shell portion similarly provided on the intake manifold202integrally formed with the connector203, using a rubber-made connecting pipe204. Both ends of the rubber-made connecting pipe204are locked in place by metallic bands318. The rubber-made connecting pipe204has a spacer319between flanges of the two.

As shown inFIGS. 2 and 5, the collector203is connected with intake manifolds201and202that will be independent intake pipes as synthetic resin-made molded products, wherein these intake manifolds are connected in parallel. They are located inside and formed in an oblong shape.

The intake manifolds201and202for four cylinders according to the present embodiment are given as examples. They are composed of independent intake pipes201a,202a,201b,202b,201c,202c,201dand202d, without being restricted thereto. They can correspond to cylinders in various numbers. As shown in a joint313, the collector203and intake manifold202are made integral with each other by thermal compression bonding through pressure vibration, and the joint313has the structure shown by the outer periphery of the intake manifold202before connection inFIG. 2. As shown in the cross sectional view ofFIG. 7, the joint326is connected onto the connecting surfaces of each other by thermal compression bonding through pressure vibration. There is a space327for storing the portion removed by pressure at the time of connection.

As shown inFIG. 5, the negative tank312where negative pressure is produced by engine rotation is mounted on the lower portion of the collector203on the engine side. It is made of the aforementioned synthetic resin containing fiber, and is bonded to collector203and intake manifold202by thermal compression.

Each of the independent intake pipes201athrough201dand201through202dhas a curved shape as shown inFIG. 5. One end of each independent intake pipe (Top side end; opposite to the collector203) constitutes an intake port periphery. The surface201of one end201′ of this independent intake pipe is connected to the periphery of the intake port on the engine block100side through a seal.

The ends201′ of the independent intake pipes are connected with flanges207formed integrally with these ends201′ side by side. The flange207is equipped with a hole208for mounting the internal combustion engine intake module. The mounting hole208is arranged on the periphery of each intake port.

A stud bolt previously mounted on the engine block is passed through this mounting hole208, and is tightened by a nut. When the intake manifolds201and202are connected using a rubber connecting pipe, the internal combustion engine intake module200is fixed onto the engine block100′, as shown inFIG. 1. The surface formed by extending downward the one end201″ of the independent intake pipe201given inFIG. 5(i.e. the surface perpendicular to the paper surface, passing through broken line B) is equivalent to the engine block side wall surface100′ when the internal combustion engine intake module200is mounted onto the engine block side wall100′. Accordingly, as is apparent fromFIG. 5, the collector203is located backward from the one end surface201″ of the independent intake pipe, as viewed with reference to the engine block side wall surface100′, to ensure that it does not contact the engine block side wall surface100′.

On the one ends (the top ends201′) of the independent intake pipes201athrough201d, injector mounting holes252are formed in the direction of an intake port. Injectors are mounted through these holes, as shown inFIGS. 1 and 5. A fuel gallery (fuel supply pipe)251is mounted on the other ends of injectors205, and is fixed on the intake manifold201, constituting part of the internal combustion engine intake module200.

The independent intake pipe202is provided with a variable Intake valve that is opened or closed by a negative diaphragm280. The three-way solenoid282is switched in response to the signal sent from the ECU260, and the negative pressure for negative diaphragm280is switched, whereby the variable intake valve281is actuated and an adequate intake pipe length is obtained in conformity to the engine load condition. In this case, the negative pressure supplied to the negative diaphragm280is supplied from the negative tank built integrally with the resin intake manifold through the three-way solenoid282. The one end203′ of the collector203along the length is protruded from one side of the intake manifold202along the length, as shown inFIG. 2. An air inlet203bis formed integrally with the collector on the top surface of the collector at this protruded position. The air inlet203bis tilted in the direction of going further away from the intake manifold202, as it extends upward.

The opening of the air inlet203bof the collector203faces upward and the flange203c(seeFIG. 2) on the periphery of the opening is tilted to form a falling inclination as viewed from the intake manifold202. Accordingly, the opening of the air inlet203bis also tilted to form a falling inclination, as viewed from the intake manifold202.

The air inlet203bof this collector203is located on the side of the intake manifold202, and the electronically controlled throttle body300is mounted on the opening flange203cof this air inlet203b. The electronically controlled throttle body300is tilted in the same direction as that of the air inlet203bon the collector side. (To be more specific, it is tilted to form a falling inclination as viewed from the intake manifold202).

As described above, when the air inlet203band electronically controlled throttle body300is tilted to have a specified inclination, an upwardly expanding space is provided between the electronically controlled throttle body300and intake manifold202. This space is utilized to install a motor housing309between the electronically controlled throttle body300and intake manifold202.

As described above, the air inlet side of the collector203is protruded from the intake manifold202in a lateral direction, and the air intake203band electronically controlled throttle body300are arranged on the top surface of this projection. This arrangement provides an internal combustion engine intake module wherein the electronically controlled throttle body300with a motor, intake manifolds201and202and collector203are formed in a compact size. Further, this arrangement allows the electronically controlled throttle body300to be mounted close to the intake manifold202, thereby reducing the distance between the collector203and air inlet203c. Thus, a resin-made passage built integrally with the collector203leading from the collector203to the air intake203ccan be kept strong and firm against engine vibration and the like.

If the aforementioned slope is given to the air inlet301of the electronically controlled throttle body300, the curvature (radius) of the duct can be increased minimize the intake resistance of the duct when an intake duct (not illustrated) is mounted on this air inlet301from an upwardly inclined position. InFIG. 2, the outer wall of the intake manifold202is provided with an auxiliary jig272and brackets270and271for holding part of the harness (not illustrated) other than the module element of the internal combustion engine intake module200. The harness other than this module element is designed to be electrically connectable with a connector terminal400installed on the other side of the ECU260given inFIG. 1through the connector (not illustrated) on the harness side. InFIG. 1, a connection terminal similar to the aforementioned connector terminal400is installed on the other side of the ECU260. (This connector is not visible inFIG. 1since a connector261on the harness262side mounted on the internal combustion engine intake module200is connected so as to cover this connector terminal).

The electronically controlled throttle body300is mounted on the collector203through a blow-by gas passage316, and a throttle valve328is installed inside. The outer wall is provided with a circuit board303of the AFM302for detecting the amount of intake air, a TPS (not illustrated) for detecting the opening of the throttle valve, a cover312for protecting the gear (not illustrated) for transmitting the drive power from motor to the throttle valve328, a PCV valve322, a fresh air feeding nipple325, a warm water pipe321and others. The warm water pipe321is mounted on a thermoelectric element324of the electronically controlled throttle body300, and heat is given to the electronically controlled throttle body300through part of the engine coolant (warm water) introduced through the pipe, thereby preventing the throttle valve from being frozen during operation under cold climates. The motor is installed in a motor housing309. The electronically controlled throttle body300is installed in an upward facing direction on the passage of the blow-by gas316installed also in an upward facing direction from the collector203. The motor housing309is installed inside the electronically controlled throttle body300integrally therewith. Further, the electronically controlled throttle body330is made of the diecast material of aluminum group alloy, similarly to the aforementioned case.

The collector203on the side of electronically controlled throttle body300is curved in the upward direction, as shown inFIGS. 2 and 8, and is tilted about 56 degrees on the center axis line of the electronically controlled throttle body300. Upward curvature, as described above, allows the electronically controlled throttle body300itself and the heavy motor to be installed on the side of lower gravity center, thereby reducing their weight and ensuring a lightweight configuration. Further, this arrangement allows these wires and connector to be concentrated in the same direction, thereby ensuring overall compact designing.

These effects are slightly reduced by adopting the inclined structure as shown inFIG. 9, but similar effects can be ensured. Further, the collector203on the side of the electronically controlled throttle body300is designed to have a smaller diameter than that on the side of the intake manifold202. The diameter is almost the same on the side of the electronically controlled throttle body300and on the side of the intake manifold202. Flanges are used for mechanical connection with the electronically controlled throttle body300.

It is preferred that each flange be integrally formed with connection bolts although not illustrated in eitherFIG. 8or9.

The circuit board303for the control of the AFM302is accommodated in a casing, and the AFM302is screwed onto the side wall opposite to the engine side of the electronically controlled throttle body300. Since this side is opposite to the motor side, the influence of vibration can be minimized, and higher precision control can be obtained. The AFM302is a thermal type air flow meter, for example, and a sub-air passage (not illustrated) for air flow rate measurement is installed on the main passage inside the electronically controlled throttle body300.

These mounted parts are laid out with consideration given to integration features in modularization. For example, the motor310mounted on the electronically controlled throttle body300is composed of a housing integrally built with the electronically controlled throttle body300, and is located between intake manifolds201inside the aforementioned curvature or inclination.

As shown inFIG. 1, a connector306for wiring of the motor for driving the electronically controlled throttle and a connector for wiring of the throttle rotary angle sensor are formed integral with each other. The integrally built connector has its terminal inlet arranged on the electronically controlled throttle body300in the direction opposite to the engine side. As shown inFIG. 1, the connector306for wiring of the motor for driving the electronically controlled throttle and the connector for wiring of the throttle rotary angle sensor are formed integral with each other. The integrally built connector has its terminal inlet arranged on the electronically controlled throttle body300in the direction opposite to the engine side. The direction of the terminal inlet to a connector305for wiring of the air flow meter302for detecting the amount of intake air mounted on electronically controlled throttle body30is the same as the terminal inlet to the integrally built connector. Thus, they are oriented to allow integrated wiring at the same wiring position, thereby reducing the length of wiring and hence ensuring compact designing. The connector305for AFM302for detecting the amount of intake air installed on the electronically controlled throttle body300built in the internal combustion engine intake module200as a module element, power supply for motor310, and connector306or the TPS304for detecting the throttle valve rotary angle are arranged at opposite positions, as viewed from the wall surface1000on the engine block where the internal combustion engine intake module200is mounted. This arrangement allows the electronic parts to be installed away from the engine block, thereby ensuring reliability of the electronic parts.

Further, the connector305for AFM mounted on the electronically controlled throttle body300, the TPS and the motor connector306are arranged close to each other to permit integrated wiring.

At the tip of the air inlet203bof the collector203along the length, a blow-by gas passage316is curved in the upward facing position by the resin integral with the collector203as described above, and is formed at an inclination of 56 degrees. The inlet of this blow-by gas passage316communicates with the PCV valve322on the side of the electronically controlled throttle body300. The outlet is located inside the collector203. The blow-by gas fed inside through the PCV valve322is fed into the collector203through this blow-by gas passage316.

A vacuum take-up nipple313for brake booster is arranged on one side of the outer wall of the air inlet203bof the collector203. This nipple31is also incorporated as a module element of the internal combustion engine intake module.

In the present embodiment, the ECU260and its harness262are also incorporated as a module element of the internal combustion engine intake module200, as shown inFIG. 1. the packaging density and number of modules are increased to provide a compact configuration.

To be more specific, ECU260is removably mounted on the wall surface of the main unit of the internal combustion engine intake module200, as shown inFIG. 1. The harness262consisting of wiring unitized through connector260is integrally formed on the ECU260as a module element, and is fixed on the front wall surface of the intake manifold202. In the present embodiment, four intake manifolds arranged in parallel on the collector203are connected with the electronically controlled throttle body300. It has wiring to the motor for driving the throttle installed rotatably on the electronically controlled throttle body300, wiring to a sensor for detecting the rotary angle of the throttle, wiring to an air flow meter for detecting the amount of intake air, wiring to a fuel injection valve installed on the intake manifold, wiring from an engine control unit, and wiring to an ignition plug installed on the engine. A fixing means for fixing them in position is mounted on the top portion of the intake manifold, and is used to secure the harness in position. As described above, each wire is installed in the same direction as the ECU260to be described later, and this arrangement allows the entire parts to be integrated as a harness, thereby reducing the length and ensuring a compact configuration.

To install the ECU260, multiple (e.g. four) stud bolts264are arranged for constituting the module proper. These stud bolts264are engaged into the installation holes formed on the ECU260, and nuts206are tightened to fix the ECU260in position. For example, the ECU260has to be removed or re-installed for maintenance and replacement after the internal combustion engine intake module200has been mounted in the engine room. In such cases, if the ECU260is fixed using the stud bolt264and nut265as described above, the ECU260can be removed or re-installed by loosening or tightening the nut265with a spanner from above the engine room. Even where there are a great number of parts, the ECU can be removed and re-installed without interfering with other parts. The semiconductor element mounted on the ceramic substrate is sealed by resin, and the ceramic substrate is bonded to an aluminum or cupper radiator plate. The ECU260is fixed with a space left in the intake manifold as described above. This arrangement provides easy thermal dissipation free from direction vibration.

Further, a canister purge valve317is installed on the collector203side of the blow-by gas passage316, as shown inFIG. 2, and a reinforcing member329is integrally formed by the aforementioned synthetic resin also to reinforce the blow-by gas passage316. To support the entire load of the an internal combustion engine intake module, two legs332are provided on the lower portion of the reinforcing member for reinforcing the entire intake manifold202provided on the lower portion of the intake manifold202.

According to the embodiment of the reinforcing member for reinforcing the entire intake manifold202described above, compact size and light weight of a car are provided by increasing the number of module elements. At the same time, the harness of the electrical system is integrated to simplify the car assembling work. This arrangement also simplifies the ever-increasing density in the engine room, and ensures a greater space available in the engine room, whereby the packaging density of parts in the narrow engine room is further improved.

Further, the harness length can be reduced by modularization of control equipment such as ECU, controlled parts such as electronically controlled throttle body and various sensors.

The internal combustion engine intake module is mounted on the engine block100, hence the harness can be connected at a position close to the electrical parts (such as ignition coil). This arrangement reduces the harness length, and hence reduces the entire harness resistance and promotes resistance against noise.

According to the aforementioned embodiment, in the internal combustion engine intake module of an internal combustion engine in a car, the load on weight is reduced by optimizing the arrangement position of the motor and air flow meter with respect to the electronically controlled throttle body. This makes it possible to produce the intake manifold and collector using synthetic resin, with the result that a lightweight and compact internal combustion engine intake module can be produced. Moreover, wiring length can be reduced by optimization of the wiring and connector positions, and the production process in wiring work can be cut down by modularization of wiring. Modularization of wiring also improves reliability of the wiring and entire system.

The aforementioned arrangement improves packaging density in an internal combustion engine intake module system, simplifies the step of mounting the system on a car, improves the convenience of transportation, provides compact configuration and light weight, and enhances a storage capacity. Further, modularization of the harness promotes lower resistance due to reduced length of the harness itself and improves noise resistance, thereby ensuring a high degree of reliability.