Abstract:
A system for controlling a vehicle powertrain is disclosed. The system includes a powertrain circuit for receiving a plurality of powertrain operating signals, processing the operating signals, and outputting a plurality of powertrain control signals for controlling the vehicle powertrain, and an air-intake manifold fixable to an engine of the vehicle powertrain and adapted to receive the powertrain control circuit. The present invention provides a self-contained vehicle powertrain that is testable before installation into a motor vehicle.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a filing under 35 U.S.C. 371, which claims priority to International Application Ser. No. PCT/US01/11287, filed Apr. 6, 2001, which claims the benefit of Provisional application Ser. No. 60/195,077, filed Jun. 4, 2000. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to vehicle powertrains having integrated powertrain control systems mounted on the powertrain. 
     BACKGROUND ART 
     Typically engines, such as internal combustion engines, have an air intake manifold for drawing in air from outside the engine and directing the air into each engine cylinder. The outside air flows in through an air intake duct and into a central air chamber, from which it is then directed into individual runners or channels and into each individual engine cylinder where combustion takes place. 
     Generally, combustion is facilitated by activating a spark from a spark plug within the cylinder of a gasoline engine or by activation of a glow plug within the cylinder of a diesel engine. Such activation is generally accomplished by supplying either post or continuous electrical signals or power feeds to the spark plug or glow plug. These signals or power feeds in turn typically come from either a central distributor, or from individual ignition coils at each cylinder. In fuel injected engines, it may also be desirable to have an individual electronic fuel injector (EFI) disposed approximate each cylinder; these EFI&#39;s also require signals or power feeds, typically from a microprocessor-controlled sub-system. 
     The electrical distribution system required to facilitate these various signals and or power feeds conventionally requires a considerable network of wires, cables, harnesses, connectors, fasteners, brackets, standoffs, strain reliefs, and one or more support frames for arranging, routing, and supporting all of these elements. In addition, most engines nowadays also require various other electrical engine subsystems, such as engine control modules, mass air flow sensors, sensor modules, antilock brake control modules, and so forth. Each of these sub-systems also require its associated wires, harnesses, connectors, housings, fasteners, etc. further adding to the electrical distribution and routing system of the engine. All of these various sub-systems are necessary, they may each add to the overall weight, space, complexity and cost of the engine. 
     Therefore, it would be desirable to provide some means of accommodating the various signals and power feed needs of an engine system by reducing the overall weight, space requirements, cost, and complexity of the engine system. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the disadvantages of the prior art approaches by providing an system for controlling the operation of a vehicle powertrain. The system has a powertrain circuit for receiving powertrain a plurality of operating signals, processing the operating signals, and outputting a plurality of powertrain control signals for controlling the vehicle powertrain, and an air-intake manifold fixable to an engine of the vehicle powertrain and adapted to receive the powertrain control circuit. 
     In accordance with an embodiment of the present invention the powertrain circuit is a flatwire flexible circuit. 
     In accordance with another embodiment of the present invention the flatwire flexible circuit includes a flatwire lead for electrically coupling the powertrain circuit to an external device or circuit. 
     In accordance with yet another embodiment of the present invention a housing for securing the powertrain circuit thereto and providing environmental protection thereof is provided. 
     In accordance with yet another embodiment of the present invention the housing is substantially disposed within an interior of the manifold and in an air stream flowing through the manifold for convectively cooling the powertrain circuit. 
     In accordance with yet another embodiment of the present invention the powertrain circuit is adhesively bonded to the housing with a thermally conductive adhesive. 
     In accordance with yet another embodiment of the present invention the air-intake manifold includes a shelf for supporting the housing within an interior of the manifold. 
     In accordance with yet another embodiment of the present invention the air-intake manifold includes at least two rails for supporting the housing within an interior of the manifold. 
     In accordance with yet another embodiment of the present invention the housing includes an electrical connector affixed to the housing for electrically coupling the powertrain circuit to a circuit or device external of the housing. 
     In accordance with yet another embodiment of the present invention the powertrain circuit includes a processor for processing powertrain control logic for controlling powertrain operation. 
     In accordance with yet another embodiment of the present invention the air-intake manifold includes a heat sink fixed to the air-intake manifold for increasing thermal cooling of the powertrain circuit. 
     In accordance with still another embodiment of the present invention. An air-intake manifold fixable to an engine of a vehicle powertrain for directing intake air into the engine is provided. The manifold includes a powertrain circuit for receiving a plurality of powertrain operating signals, processing the operating signals, and outputting a plurality of powertrain control signals for controlling the vehicle powertrain. 
     These and other advantages, features and benefits of the invention will become apparent from the drawings, detailed description and claims which follow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1-2 are top and perspective views, respectively, of an embodiment of the present invention; 
     FIG. 3 is a top view of an arm portion and terminations according to an embodiment of the present invention; 
     FIGS. 4 a-c  are top views of three possible configurations of an embodiment of the present invention; 
     FIGS. 5-7 are top views of another embodiment of the present invention; 
     FIG. 8 is a sectional side view of yet another embodiment of the present invention; 
     FIGS. 9 a-c  are perspective views of an intake manifold having an integrated powertrain control circuitry attached thereto, in accordance with the present invention; 
     FIGS. 10 a-b  are a side and perspective views of an intake manifold having an integrated powertrain control module housed therein, in accordance with an embodiment of the present invention; 
     FIG. 11 a  is a cross-sectional view through the powertrain integrated module circuitry of the intake manifold, in accordance with the present invention; 
     FIG. 11 b  is a magnified view of the cross-sectional view of FIG. 11 a , in accordance with the present invention; 
     FIGS. 12 a-b  are end views the module opening/cavity of the intake manifold, in accordance with the present invention; and 
     FIGS. 13 a-c  are various cross-sectional views through the module opening/cavity of the intake manifold as indicated in FIGS. 12 a-b  and  13   a , in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, FIGS. 1-2 show an embodiment  100  of the present invention, namely a flex circuit for routing electrical signals in an internal combustion engine (not shown) having a plurality of cylinders and an intake manifold  50 . This embodiment includes: (1) a flex circuit substrate  102  having a body portion  104  and at least n arm portions  106  extending outward from the body portion, wherein the body portion generally conforms in shape with a top surface  52  of the intake manifold  50 , and wherein each arm portion is arranged in general proximity with a respective cylinder; (2) a plurality of conductive circuit traces  108  arranged proximate (i.e., on or beneath/within) at least one surface of the body portion  104  and of each arm portion; and (3) at least one input/output connector  110  for connection to at least one of an external signal source, an external power source, an external signal destination, and an external power destination (collectively designated by reference numeral  70 ), wherein each input/output connector  110  is attached to the substrate  102  and is electrically connected to at least one of the circuit traces  108 . In this embodiment, each circuit trace carried by each arm portion  106  terminates in a termination  108   t  capable of electrical connection with at least one electrical engine element  90 , such as an ignition coil, an electronic fuel injector, a spark plug, and/or a glow plug. 
     The substrate  102  is preferably a substantially flexible substrate, such as a film, sheet, or lamination of polyetherimide, polyester, or other materials used to make flex circuits. Alternatively, the substrate  102  may comprise one or more metal foils or sheets with one or more layers of insulative, conductive, and/or dielectric material selectively applied thereto (e.g., by lamination, etching, or other additive or subtractive processes). Although the substrate  102  is preferably generally flexible, the body portion  104  may alternatively include at least one rigid substrate portion  118  (e.g., an FR-4 daughter board) operably connected to the remaining flexible body portion and/or arm portions. Likewise, the entire body portion  104  may comprise a rigid substrate, to which flexible substrate arm portions  106  are operably attached. 
     The substrate  102  may include a plurality of electronic components  114  operably attached to the circuit traces  108  thereon. These components  114  are preferably surface mount components, such as integrated circuit (IC) chips, leadless chip components (LCCs) such as resistors and capacitors, power devices, interconnect devices, microprocessors and the like. It is possible to take components from otherwise separate electronic control modules—including but not limited to engine control modules, mass air flow sensor modules, anti-lock brake control modules, speed control modules, throttle control modules, fuse box modules, exhaust gas return (EGR) valve control modules, engine temperature sensor control modules and integrate the components onto the flex substrate  102  of the present embodiment. This would provide the advantage of eliminating the various housings, wires, cables, harnesses, busses, interconnects, fasteners, etc. that are otherwise needed for each individual module and incorporating only the necessary parts therefrom (i.e., the electronic components) onto the flex substrate  102 , thereby reducing cost, weight, space, and complexity for the overall powertrain system. Thus, the present invention provides a system and method for controlling the operation of a powertrain wherein the powertrain control electronics (PCE) are packaged integral with the powertrain or, more specifically, within the air intake manifold of the engine. 
     The substrate  102  may further include a hole  116  in the body portion  104  thereof, through which a top portion of the intake manifold  50  or an end portion of an air intake duct  56  may extend. The substrate  102  may also be removably attachable to the top surface  52  of the intake manifold  50 . This may be accomplished, for example, by providing holes in the substrate  102  through which fasteners may be inserted for holding the substrate against the manifold, or by providing fasteners integral with the substrate which directly attach to the manifold. 
     Each arm portion  106  may include a rigid substrate member  120  on an end thereof, wherein the termination of each circuit trace  108  on each arm portion  106  is disposed on the rigid substrate member  120 , as illustrated in FIG.  5 . Also, each circuit trace termination  108   t  on each arm portion  106  may comprise a male plug connector  122   m , a female socket connector  122   f , or a generally flat contact pad  122   cp . These plug connectors  122   m / 122   f  may optionally be attached to or made integral with the rigid substrate member  120  on the end of each arm portion  106 . 
     The conductive circuit traces  108  may be similar to those found on conventional rigid PCBs and flex circuits, such as the metallizations or paths of copper or conductive ink applied to one or both planar sides of such substrates. The traces  108  may also comprise wires or other electrical conductors applied to a surface of the substrate  102 , or which are embedded, molded, or otherwise placed beneath a surface of the substrate (i.e., within the substrate). 
     The input/output (i/O) connector  110  is used to connect one or more substrate circuit trace(s)  108  (typically multiple traces) to one or more external electrical elements  70 . From the perspective of current flow within the engine&#39;s electrical system, these external elements  70  may each be an “upstream” source or a “downstream” destination (or both) with respect to the i/O connector  110 . The electrical flow to or from each of these external elements to which the i/O connector is connected may be generally designated as “signal” strength (e.g., milliamps, millivolts) or “power” strength (e.g., 1+amps, 1+volts). Thus, an external “power source” might be a 12-volt battery, a “power destination” might be a solenoid requiring several amps/volts to actuate, a “signal source” might be a 150-millivolt output from a microprocessor, and a “signal destination” might be a 150-millivolt input to the same microprocessor. Furthermore, it should be understood that the electrical flow into and out of the i/O connector  110  may at any time be continuous, intermittent/pulsed, or both. The i/O connector  110  itself may assume any of the multitude of different i/O connector configurations known in the art which can be operably connected to a flexible, semi-rigid/rigiflex, or rigid substrate  102 . 
     The present embodiment may also include a cover  112  capable of covering substantially all of the body portion  104  and at least part of each arm portion  106 , as shown in FIG.  2 . This cover  112  may be made out of plastic, metal, fiberglass, and the like (or combinations thereof), may be removably attachable to the intake manifold  50 , and serves as a protective covering for the underlying substrate, traces, etc. The cover  112  may include a generally sealable hole therein through which the top portion of the manifold or an end portion of the air intake duct may extend. 
     In its most basic form, the present embodiment  100  may be used to replace the wires, cables, harnesses, support frame(s), powertrain control circuits and other related elements used in conventional powertrain control systems for routing and distributing electrical signals to control the engine&#39;s ignition coils, EFIs, spark plugs, glow plugs, and/or other electrical engine elements  90 , as well as, the vehicle&#39;s transmission, thus reducing cost, space, weight, and complexity for the overall engine system. By further including the electronic components from one or more engine control modules as described above, further reductions can be realized. Moreover, the savings and reductions made possible by the present invention relate not only to the initial manufacturing and assembly of the powertrain system, but also to the maintenance and service life of the powertrain system as well. As an example of how the present embodiment might be used, the flex circuit  100  might contain electronic components (including microprocessors and other integral circuits) and interconnections such that the flex circuit  100  may (1) take in signal and power from various external sources via the i/O connector  110 , (2) process and/or re-route the signal/power within the flex circuit itself, and then (3) send out signal/power feeds through both the i/O connector  110  and the arm portion circuit traces to various external signal/power destinations (e.g., solenoid inputs, electric motor contacts, spark plugs, ignition coils, glow plugs, EFIs, etc.) to control the operation of the powertrain. 
     Many possible configurations exist for the present embodiment, as illustrated in FIGS. 4 a-c  for an engine having four cylinders (i.e., n=4). In a first example, as shown in FIG. 4 a , the substrate  102  may have exactly four arm portions  106  (i.e., one for each cylinder) wherein the circuit traces (not shown) on or within each arm portion  106  have terminations capable of electrical connection with an ignition coil, an EFI, a spark plug, and/or a glow plug associated with the respective cylinder of each arm portion  106 . Here, each arm portion  106  may generally conform in shape with a top runner surface  54  associated with the respective cylinder; the arm portions may then be laid atop (and optionally attached to) their respective runners and covered with a cover  112  corresponding in overall shape with the body and arm portions  104 / 106  as laid out atop the manifold  52  and runners  54 . In a second example, as shown in FIG. 4B, the substrate  102  may have exactly four arm portions  106  with each arm dividing further into first and second branches  106 ′/ 106 ″. In this case, circuit traces (not shown) on or within each first branch  106 ′ have terminations (e.g., male plug connectors or female socket connectors) capable of electrical connection with an ignition coil, while circuit traces on or within each second branch  106 ″ have terminations capable of electrical connection with an EFI. In a third example, as shown in FIG. 6 c , the substrate  102  has 2n arm portions  106 , wherein circuit traces proximate each arm portion  106  have terminations electrically connectable with one of an ignition coil, an EFI, a spark plug, and a glow plug. Many other configurations are also possible within the scope of the present invention. In any case, generally, the flex circuit substrate  102  may be draped and optionally attached onto the top surface  52  of the manifold  50 , and a cover  112  as described above may then be placed over the flex circuit  102  and attached to the manifold  50 . 
     Another embodiment of the present invention relates to an intake manifold cover  200  for routing electrical signals for controlling a powertrain, wherein the powertrain has an internal combustion engine  30  having n cylinders and an intake manifold  50 , as shown in FIGS. 5-7. This embodiment includes: (1) a generally rigid housing  230  generally conforming in shape with and being removably attachable to a top surface  52  of the intake manifold  50  (as shown in FIG.  2 ); (2) at least n carrier members  240  attached to the housing  230  and extending outward therefrom, wherein each carrier member is arranged in general proximity with a respective cylinder; (3) a plurality of conductive circuit traces  208  arranged on or beneath a surface  232  of the housing  230  and on or within each carrier member  240 ; and (4) at least one input/output connector  210  for connection to at least one of an external signal source, an external power source, an external signal destination, and an external power destination (designated collectively by reference numeral  70 ), wherein each input/output connector  210  is attached to the housing  230  and is electrically connected to at least one of the circuit traces  208 . In embodiment  200 , each circuit trace  208  carried by each carrier member  240  terminates in a termination  208   t  capable of electrical connection with at least one electrical engine element  90 , such as an ignition coil, an EFI, a spark plug, and/or a glow plug. 
     Embodiment  200  combines many of the features of flex substrate  102  and cover  112  of embodiment  100 , but is not a mere combination of these two elements. For example, whereas the first embodiment  100  includes a flex circuit substrate  102 , the present embodiment  200  does not necessarily include a flex substrate. Instead, the traces  208  (and electronic components  214  such as integrated circuits and microprocessors operably connected thereto) of the present embodiment  200  may be directly connected to a surface  232  (preferably an underside surface) of the housing  230 , thereby eliminating the need for a flex substrate. Of course, a flex substrate (and/or even a rigid substrate or substrate portion) may be included if desired; for example, the traces  208  and electronic components  214  may be attached to a flex circuit substrate, with this substrate then being attached to the underside or other surface  232  of the housing  230 , or a flex circuit substrate may first be attached to the underside or other surface  232  and then the traces/components  208 / 214  attached thereto. 
     The generally rigid housing  230  may be (and preferably is) somewhat flexible. It is described as being “generally” rigid in that it should be able to generally maintain its shape when being handled (e.g., during manufacture and installation), but should have some inherent flexibility, as is the case with most thermoformed plastic parts, for example. 
     Like embodiment  100 , embodiment  200  may assume many different but related configurations. For example, as shown in FIG. 5, each carrier member  240  may be an electrically insulative flexible substrate which carries the one or more circuit traces  208  thereon or therein. The flex substrate material in this case may be a flexible elastomer, such as silicone, or may be made of polyester, polyetherimide, or other suitable materials. These carrier members  240  may be attached to a lateral edge and/or to an underside or other surface of the housing  230  by adhesives, mechanical fasteners, in-molding, etc., and serve to carry signal/power between at least the i/O connector  210  and an electrical engine element  90  such as an ignition coil, EFI, spark plug, and/or glow plug. For example, each carrier member  240  may serve to carry signals/power from the i/O  210  and/or optional electronics  214  to an ignition coil and/or an EFI associated with the carrier member&#39;s respective cylinder. 
     The housing  230  may comprise a body portion  230   b  and at least n arm portions  230   a  extending outward from the body portion, wherein the body portion generally conforms in shape with top surface  52  of manifold  50 , and wherein each arm portion  230   a  is arranged in general proximity with a respective cylinder, as shown on the left-hand side of the cover shown in FIG.  6 . Alternatively, the housing  230  may comprise a body portion  230   b  as just described and at least one shroud portion  230   s  extending outward from the body portion on one or both lateral edges of the body portion, as shown on the right-hand side of the cover shown in FIG.  6 . In either of these two housing configurations, the arm portions/shroud portions  230   a / 230   s  are preferably made integral with the body portion  230   s , thus constituting a single piece which can be easily molded. In these two configurations each carrier member  240  is preferably attached to a corresponding arm portion  230   a  or shroud portion  230   s , but may alternatively be attached to the body portion  230   b.    
     Each carrier member  240  and/or (if provided) each arm portion  230   a  may be constructed so as to generally conform to each respective cylinder thereof. Alternatively, rather than providing separate but geometrically similar arm portions  230   a  and carrier members  240 , the features of both may be combined to comprise a configuration wherein each carrier member  240  is an outwardly extending integral arm portion of the housing  230 . That is, rather than having carrier members which carry circuit traces thereon or therein attached to separate, corresponding arm portions  230   a  or shroud portions  230   s , instead the circuit traces could be carried on or within an underside (or other) surface of each arm or shroud portion  230   a / 230   s -each arm/shroud portion would both extend outward from the body portion  230   b  and serve as a carrier for the circuit traces  208  associated with the arm portion and respective cylinder, as illustrated in FIG.  7 . 
     Yet another embodiment  300  of the present invention, an intake manifold cover  302  is illustrated in FIG. 8, and includes: (1) a generally rigid housing  330  generally conforming in shape with and being removably attachable to top surface  52  of intake manifold  50 , the housing  330  extending generally over each cylinder; (2) a plurality of conductive circuit traces  308  arranged on or within an underside or other surface of the housing and extending in general proximity with each cylinder; (3) at least one input/output connector for connection to at least one of an external signal source, an external power source, an external signal destination, and an external power destination, wherein each input/output connector is attached to housing  330  and is electrically connected to at least one of the circuit traces  308 ; and (4) at least n electrical connectors  350  in-molded in housing  330 , wherein each connector  350  is connected with at least one of the circuit traces  308  and is disposed within housing  330  so as to be directly connectable with an electrical engine element, such as an electronic fuel injector  94 , when housing  330  is attached to intake manifold  50 . The housing portion(s) which extend over each cylinder may comprise integral arm or shroud portions, similar to FIG.  7 . 
     As shown in FIG. 8, intake manifold cover  302  may further comprise at least one fuel rail  360  integral with the housing  330 , wherein each fuel rail is directly and sealably connectable with at least one electronic fuel injector  94  so as to provide sealable fluid communication between the fuel rail and each EFI connectable thereto. Preferably, the cover  330  is made of molded plastic and includes either one fuel rail  360  for slant-type or in-line engines or two fuel rails  360  for V-type engines. The fuel rail(s)  360  may be conventional metal fuel rails that are insert molded into the housing  330 , or (as shown in FIG. 8) may be metallized or non-metallized channels formed within the housing  330  by lost-core or other molding processes. 
     Manifold cover  302  of the present embodiment may include n electrical connectors  350  disposed within the housing  330 . Each connector  350  is directly connectable with a mating electrical connector portion  94   c  of an associated electronic fuel injector  94  when the housing  330  is placed atop and attached to the intake manifold  50 , for example. 
     At least a subset of the circuit traces  308  may be in-molded within the housing  330  and may comprise a metal stamping, a flex circuit, or a network of wires within the housing. Preferably this subset of traces are each operably connected with the at least n electrical connectors  350 . 
     One advantage of the present embodiment is that the cover  300  may be fitted over and attached to the manifold  50  with the aforementioned electrical connectors  350  fitting directly over their respective electrical engine elements  90 . For example, a cover may have connectors  350  in-molded therein which may simultaneously mate directly with the mating electrical connector portions of n ignition coils and n fuel injectors when the cover is lowered onto and attached to the manifold  50 , without requiring additional steps or interconnecting components (e.g., wire harnesses or cables) for connecting the coils and EFIs with their power/signal sources. Adding the fuel rails  360  as described above further reduces complexity and installation effort. 
     Referring now to FIGS. 9 a - 9   c , a preferred embodiment of the present invention is illustrated. A flat wire substrate  400  having a plurality of discrete and integrated circuit components (not shown) mounted thereon for controlling the operation of a powertrain is shown mounted to a portion of an air intake manifold  402 . As is well know in the art, air intake manifold  402  includes an air filter housing  404 , a throttle body  406 , and coils on plugs  408 . In operation, outside air is drawn into intake tube  410  and is filtered by an air filter (not shown) contained within air filter housing  404  and directed into intake manifold  402  via air ducts and passages (not shown) and through throttle body  406  for supplying the engine with the appropriate air fuel mixture. The direction of air flow into and out of the intake manifold  402  and throttle body  406  is generally indicated by arrows i and O. 
     Substrate  400  operatively includes control circuitry for controlling the operation of a vehicle&#39;s powertrain. Control circuitry, by definition, may include discrete electrical components, integrated circuits, microprocessors and logic devices. Further, control logic may be implemented in substrate  400  using the aforementioned discrete components and/or software programming code. 
     Flatwire substrate  400  is bonded to a top surface  403  of manifold  402  using an adhesive or similar attachment means including screws and/or rivets. A plurality of flat wire leads  401  extend from substrate  400  to electrically couple and carry electrical signals to and from electrical devices and/or sensors, such as injectors, coils and mass air-flow sensors. 
     In FIGS. 9 b  and  9   c  another embodiment of an integrated manifold  402 ′ is illustrated. Integrated manifold  402 ′ has a lower manifold portion  462  and upper manifold portion  464  which are joined along a weld-line  440 . Manifold  402 ′ has a flatwire flexible substrate  400 ′ contained within a recess  420 . Recess  420  improves the overall packageability of manifold  402 ′ within a vehicle&#39;s engine compartment. As in previous embodiments, substrate  400 ′ includes a plurality of flatwire leads  401 ′ for operatively interfacing substrate  400 ′ with the electrical devices and sensors for carrying out powertrain control. 
     Preferably, a heatsink  422  is disposed within recess  420  for contacting a bottom surface of substrate  400 ′ for thermally dissipating and cooling substrate  400 ′. Heatsink  422  is preferably made from a highly thermally conductive metal for improved heat dissipation of substrate  400 ′. 
     Referring now to FIG. 10 a , an integrated intake manifold  402 ″ is shown in accordance with still another embodiment present invention, in which a powertrain control module (PCM) or housing  430  is removably attached to manifold  402 . PCM  430  includes a flatwire flexible substrate  484  (shown in FIG. 11 b ) having electronics for processing engine operating signals and outputting powertrain control signals to control the operation of the powertrain. PCM  430  communicates with various sensors and engine sub-systems using flexible takeouts or leads  432  having connectors  434 . As described in previous embodiments, the flexible takeouts or leads  432  may be integral to the flexible substrate  484  or the takeouts may be soldered to the substrate. As shown in FIG. 10 a , PCM  430  is housed within the interior of intake manifold  402 , preferably, in the path of flowing intake air. This configuration provides maximum cooling and environmental protection for PCM  430 . 
     Referring now to FIG. 10 b , a perspective view of air intake manifold  402 ″ is illustrated having an alternate housing cavity  436 , in accordance with the present invention. PCM  430  may be housed in various locations within intake manifold  402 ″. However, housing cavity  436  is provided along weld-line  440  for ease of manufacturing. Of course, the selection of the precise location of housing cavity  436  within air-intake manifold  402 ″ is governed by the specific vehicle application as well as cooling and environmental requirements. 
     FIG. 11 a  is a cross-sectional view an through intake manifold  402 ″, PCM  430  and housing cavity  436  as indicated in FIG. 10 b , in accordance with the present invention. As illustrated cavity  436  is defined by internal support rails  460  which may be integral with lower manifold portion  462  and upper manifold portion  464 . Alternatively, interior support rail  460  may be separate plastic or metal pieces which are affixed to the interior portions of intake manifold  402 ″ for supporting PCM  430 . As will be illustrated in subsequent views, support rails  460  are configured to hold and support PCM  430  while allowing air to flow over and through the rails and around PCM  430  to maximize convective cooling of the electronics housed within module  430 . 
     With reference to FIGS. 11 a  and  11   b , PCM  430  is shown having a connector  470  for electrically coupling the electronics housed within PCM  430  to flexible circuit takeouts  472  which are routed along the exterior of intake manifold  402 ″. Connector  470  includes a water-tight seal or gasket  474  for providing an environmental seal between connector  470  and an exterior surface  476  of intake manifold  402 ″. As further illustrated in the magnified view in FIG. 11 b , connector  470  mounted to PCM module  430  may be attached to and sealingly matted with intake manifold  402 ″ using conventional screws  480  or other known attachment schemes. 
     As shown in FIG. 1 b , connector  470  includes a plurality of connector pins or electrical traces or features  482  for interconnecting flexible substrate  484  contained within PCM  430  with external circuits and systems. For example, interconnect feature  486  may be provided to electrically couple substrate  484  to selected circuits or takeouts  472  which are exterior to PCM  430  and or routed along an exterior of manifold  402 ″. To increase heat conduction through PCM  430 , substrate  484  is preferably bonded to PCM module  430  using a thermal adhesive  490 . Flatwire takeouts  472  may for example, run to connectors on the bottom of manifold  402 ″ and interconnect with an in molded lead frame (not shown) in lower manifold portion  462 . 
     FIG. 12 a  is an end view of integrated intake manifold  402 ″ illustrating an opening  492  of cavity  436 . In an embodiment the support shelves for constraining PCM  430  are an upper shelf  494  and a lower shelf  496 . The support shelves  494  and  496  may be integrally molded with the manifold housing, or can be separate pieces (made from plastic, metal, etc.) that are attached to the housing or in-molded therein. 
     FIG. 12 b  is an end view of integrated intake manifold  402 ″ illustrating an opening  492  of cavity  436 . In this embodiment the support rails  500  for constraining PCM  430  include a pair of upper rails  502  and a pair of lower rails  504 . The support rails  500 , as with the support shelves described above, may be integrally molded with the manifold housing, or can be separate pieces (made from plastic, metal, etc.) that are attached to the housing or in-molded therein. 
     Referring now to FIG. 13 a , a cross-sectional view of manifold  402  as indicated in FIG. 12 b  as view bb is illustrated. In this embodiment, support shelves or rails are attached to an inner manifold wall  510  during manifold assembly. Air flows through and over shelves/rails and PCM  430 , as indicated by arrows c, to provide sufficient cooling of the PCM. 
     Referring now to FIGS. 13 b  and  13   c , detailed views z′ and z″ as indicated in FIGS. 12 a  and  13   a  of support shelves or rails are further illustrated, in accordance with the present invention. FIG. 13 b  shows only an upper shelf  494 , however, lower shelf  496  of the same configuration would be disposed directly below the upper shelf. Upper shelf  494  includes a plurality of apertures  602  for allowing air to flow therethrough. Edge A of upper shelf may optionally extend to and become integral with edge B of manifold  402 ″. Likewise, edges C may optionally extend to and become integral with edges D of manifold  402 ″. 
     Alternatively, as shown in FIG. 13 c , upper rails  502  are provided for supporting PCM  430  and are integrally attached or in-molded in manifold  402 ″. A set of lower rails  504  (not shown) would also be provided below upper rails  502  for further supporting module  430 . Upper and lower rail configurations provide large air passages  610  for allowing air to flow therethrough. 
     Various other modifications to the present invention will, no doubt, occur to those skilled in the art to which the present invention pertains. For example, although only V-type engines are shown in the drawings, the present invention also relates to slant-type engines, in-line engines, rotary engines, etc. It should also be understood that the present invention relates to both gasoline and diesel internal combustion engines, as well as to hybrid electric/internal combustion engines. The present invention applies to engines using spark plugs, glow plugs, or compression-ignition-only; to those having carburetors, EFIs, or other related systems; and to those having central distributors, coil-on-plug, and other related spark activation systems. Furthermore, while the arm portions, shroud portions, and carrier members have been described above as being connected to or integral with a cover, housing, or body portion, it is within the scope of the present invention that the arm portions, shroud portions, and carrier members may be removably connectable with their associated cover, housing, or body portion, such as by using mating male/female electrical connectors. Also, the housing or cover may include louvers, vanes, and the like for directing some amount of air from the air intake duct across the circuit traces and optional electronic components, so as to assist in cooling these elements during operation. Moreover, it should be understood that while the arm portions and carrier members have variously been described as being connected to ignition coils, EFIs, spark plugs, and glow plugs, it is contemplated that other electrical engine elements may be used instead of or in addition to these four highlighted elements, such as engine sensors, climate sensors, solenoids, switches, etc., whether sending or receiving signals to or from the present invention. Additionally, it should be understood that the use of the word “signal” as variously used herein may encompass both relatively low voltage/low amperage triggering signals and relatively high voltage/high amperage power feeds, whether sent/received in intermittent pulses or in continuous non-pulsed form. Finally, the present invention further includes a flex circuit similar to the above described embodiments, but which has no arm portions, or less than n arm portions, and which may not necessarily include any element which is generally proximate to or related with any engine cylinder. It is the following claims, including all equivalents which define the scope of the present invention.