Patent Publication Number: US-2005132997-A1

Title: Customization cover for engine valve covers

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims the benefit of U.S. Provisional Application No. 60/531,355 filed Dec. 18, 2003. 
    
    
     BACKGROUND OF THE INVENTION  
      A. Field of the Invention  
      The field of the present invention relates generally to valve covers and valve cover systems utilized in internal combustion engines of the type commonly used to power motor vehicles, particularly automobile, truck, boat and motorcycle engines. More specifically, this invention relates to customization covers utilized to modify the visual appearance of the engine valve cover and, generally, the engine compartment. Even more specifically, this invention relates to such customization covers that provide a three dimensional visual effect above the engine valve cover.  
      B. Background  
      As is well known in the vehicle industry, many people like to customize their vehicle, particularly automobiles and trucks, to achieve a desired visual effect that is personal to the vehicle owner. In fact, many people enjoy taking their vehicle to vehicle shows, such as hot rod shows and the like, or attending such vehicle shows where various customized vehicles are displayed. Often the persons showing their vehicles compete to win trophies or other prizes for the best customized vehicle. Efforts to customize a vehicle applies to all aspects of the vehicle, including the engine compartment. For purposes of customizing an engine compartment, it is well known that owners will replace or modify various operational components in the engine compartment to achieve a desired visual effect without necessarily modifying the operational characteristics of the engine. For instance, many vehicle owners will replace standard, factory provided components with like components that are made out of or coated with chrome or other materials or which are painted. It is also well known that many owners replace the standard, factory provided components with components that improve the performance of the vehicle.  
      The replacement or modification of standard factory supplied engine components includes the replacement of the engine valve covers that mount onto the engine block and cover the internal combustion engine valve assembly. As is well known, valve covers are typically made out of metal, such as steel or aluminum, and are either stamped or cast into a trough or trough-type of shape and then bolted to the engine block with a plurality of bolts, usually four to eight bolts. As also well known in the art, the typical valve cover is stamped or cast into the desired shape and provided with various visual features included on the valve cover, including names, symbols, corporate logos, ridges, indents and the like, to achieve the visual effect desired by the manufacturer. Examples of patents for valve covers having unique designs include U.S. Pat. No. Des. 324,867 to Lyndhurst, U.S. Pat. No. Des. 422,551 to Haines, U.S. Pat. No. Des. 305,767 to Tauschke, U.S. Pat. No. 252,878 to Bellino, et al. and U.S. Pat. No. Des. 305,123 to Garrett, et al. These patents, as well as the numerous non-patented valve covers known to exist, all share the common feature that they are the actual valve cover that provides the enclosure function for the operating valves of the engine.  
      As is well known, there are several types of valve covers commonly in use today. What is generally considered the “standard” valve cover is provided in an elongated, upside down trough configuration with a lower lip or flange that extends around the peripheral edge of the valve cover. This lower lip typically has four to eight mounting holes through which bolts are placed to engage the cylinder head portion of the engine block and mount the valve cover thereto with bolts or other connecting members or mechanisms. Typically, a sealing member is disposed between the lower lip portion and the engine block to sealably enclose the operating valves under the valve cover. An example of such an engine valve cover is set forth in U.S. Pat. No. 5,095,860 to Newell, modified for purposes of that invention. A modified valve cover, commonly referred to as a Vortec valve cover and utilized in certain vehicles manufactured by the General Motors Corporation, has a plurality of mounting holes down the center of the trough portion of the valve cover which cooperate with mounting bosses on the cylinder head portion of the engine block, typically placed between adjacent cylinders, in corresponding relationship to the mounting holes on the valve cover. Bolts or studs are used to secure the valve cover to the engine block. Examples of this type of valve cover are shown generally in U.S. Pat. No. 5,884,594 to Wiehle, U.S. Pat. No. 4,593,659 to Wells, et al. and U.S. Pat. No. 5,655,489 to Kammerer, et al. Another modified valve cover for internal combustion engines is configured with ignition coils mounted on top of the valve cover. Yet another modified valve cover for internal combustion engines is shown in U.S. Pat. No. 5,931,131 to Hackett. This patent shows an elongated valve cover assembly having a plurality of bolts or other fastening mechanisms that extend through the top of the valve cover along its peripheral edge. Other types of valve cover arrangements are also likely in use. In general, the standard and modified valve covers are configured to be removed from the engine block to allow access to the engine&#39;s valving mechanisms for repair and/or replacement of the valving components.  
      Customized replacements for both the standard and modified valve cover types of assemblies have been available for some time. For instance, U.S. Pat. No. 4,538,560 to Alden discloses a valve cover that has a clear “window” in the top portion of the valve cover that allows visualization of the valve system under the valve cover. The configuration shown in this patent is the standard type of valve cover, modified for purposes of the invention. It is also well known to manufacture valve covers out of different materials, such as stainless steel or carbon fiber. Manufacturing valve covers out of plastic material, such as polyamide, is discussed in U.S. Pat. No. 5,655,489 to Kammerer, et al. A number of aftermarket suppliers provide valve covers that are stamped or cast with design elements to allow the vehicle owner to obtain a different (compared to that from the original equipment manufacturer or “OEM”) look for his or her vehicle. Other supplies have valve covers that embossed with a design. In order to utilize these replacement valve covers, the user must first remove the existing valve cover and replace it with the new valve cover. In part due to the need for the new valve cover to provide the same functional aspects as the original valve cover, such as sealably enclosing the valve mechanisms, the configuration of the replacement valve cover is basically the same.  
      Due to the desire to improve the visual effect of a vehicle engine compartment, certain vehicle manufactures are providing covers that are configured to entirely or substantially cover the engine compartment. For instance, the Lincoln Navigator® has a cover that is configured to cover the entire engine compartment. The newer model Chevrolet Corvette® and Impala® have covers that cover the intake manifold. U.S. Pat. No. Des. 396,478 to Hubbach discloses an engine cover that is shown as being assigned to Chrysler Corporation. After market suppliers also have covers that are adapted to cover part or all of the engine block, particularly the portion between the valve covers. These covers are configured to generally provide a “clean” look to the engine compartment and are not specifically directed to the valve covers.  
      While the OEM and aftermarket valve covers can achieve certain visual effects, they have the limitation that the design remains very basic, that being a generally rectangular-shaped valve cover. The aforementioned patents and other prior art valve covers are only directed towards the actual valve cover itself. While this generally suffices for covering and protecting the operating valve system, it does not allow much in the way of engine customization. As a result, there is limited ability for the individual vehicle owner to customize his or her vehicle in a way that is personal or particular to him or her. This is particularly true with regard to obtaining a three dimensional effect for the engine valve cover. The presently available OEM and aftermarket valve covers have a very limited or no ability to provide a three-dimensional effect for the engine compartment, which is often desired by those who wish to customize their vehicle.  
      What is needed is a customization cover for engine valve covers that allows vehicle owners or operators to customize their vehicle&#39;s engine compartment without the need to replace the existing valve covers. The preferred customization cover will be relatively easy to install on or over all types of existing engine valve covers and suitable for substantially creating a three dimensional effect for the engine valve cover. The preferred customization cover for engine valve covers should be adaptable to a large variety of different valve cover and/or engine block designs and configurations in order to provide vehicle owners and operators with a choice of different “looks” for their vehicle. The preferred customization cover should also be configured to not interfere with the function of the valve cover and maintain the ability for the owner or his or her repairperson to remove the valve cover to repair or replace components of the operating valve mechanism as needed.  
     SUMMARY OF THE INVENTION  
      The customization cover for engine valve covers of the present invention provides the benefits and solves the problems identified above. That is to say, the present invention discloses a customization cover for engine valve covers that substantially creates a three dimensional effect when utilized with all types of engine valve covers. The customization cover for engine valve covers of the present invention is adaptable for use with the existing standard and modified types of valve covers (including perimeter mount and center mount systems) and can be modified for other types of valve covers, including those not presently available. As the customization cover for engine valve covers does not require removal or replacement of the engine valve cover, although it can be used in conjunction with replacing the valve cover, it is relatively easy to install. The customization cover for engine valve covers can be configured to incorporate a wide variety of different design elements and shapes to allow significant individualization of a person&#39;s vehicle engine compartment. The customization cover for engine valve covers is configured to not interfere with the normal function of the valve cover and to allow the owner/repairperson to remove the valve cover for repair or replacement of the operating valve components.  
      In one general aspect of the present invention, the customization cover for engine valve covers of the present invention includes a main body having a first end, second end, top surface and bottom surface with one or more design elements on the main body generally disposed between the first end and the second end of the main body. The design elements can be a variety of different shapes and configurations. In a preferred configuration, the design elements are cut out of the main body such that they extend through the main body from the top surface to the bottom surface. Preferably, the customization cover includes one or more side component members extending generally downward from the first and/or second side of the main body. In the preferred embodiment, a side component member extends downwardly from each side of the main body to form an elongated channel that is configured generally in an inverted u-shape that is sized to fit over and substantially cover the engine&#39;s valve cover(s). The side components can be integral with the main body, such that they are made by bending the material that makes up the main body, or they can be attached to or near the main body. The side components can be configured with one or more side design elements. The customization cover includes one or more mounting openings that are configured to receive a connector element adapted to place the customization cover generally above the valve cover. In one configuration the mounting openings are disposed generally at or near the center line of the main body so the connector element can cooperatively connect to the valve cover mounting points at or near the centerline of the valve cover. In another configuration the side components each comprise a mounting arm configured with a mounting opening to securely mount the customization cover to the engine block through at the valve cover mounting points generally disposed along the periphery of the valve cover. In another configuration, a bracket is utilized to connect the customization cover to the valve cover mounting points. In yet another configuration, the customization cover mounts to one or more engine components, such as ignition coil mounting points used to mount an ignition coil to the valve cover. In any of the above configurations, the customization cover is preferably configured to be in spaced apart relation to the valve cover to provide a more improved and desired three dimensional effect.  
      Accordingly, the primary objective of the present invention is to provide a customization cover for engine valve covers that provides the advantages discussed above and overcomes the disadvantages and limitations associated with presently available methods and devices of customizing valve covers and vehicle engine compartments.  
      It is also an important objective of the present invention to provide a customization cover for engine valve covers that is easy to install and adaptable for use with all types of engine valve covers.  
      It is also an important objective of the present invention to provide a customization cover for engine valve covers that substantially provides a three-dimensional effect when installed over the engine valve cover.  
      It is also an important objective of the present invention to provide a customization cover for engine valve covers that can incorporate a wide variety of design elements to allow for a variety of personal customization and/or decorative effects according to the user&#39;s own preferences.  
      The above and other objectives of the present invention will be explained in greater detail by reference to the attached figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and/or combination of processes presently described and understood by the claims.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      In the drawings which illustrate the preferred embodiments and the best modes presently contemplated for carrying out the present invention:  
       FIG. 1  is a perspective exploded view of a preferred embodiment of the customization cover for engine valve covers of the present invention shown configured for use with a center mounting type of valve cover;  
       FIG. 2 a  top view of an example design for use with the customization cover of the present invention;  
       FIG. 3  is a top view of another example design for use with the customization cover of the present invention;  
       FIG. 4  is a perspective exploded view of a preferred embodiment of the customization cover of the present invention shown configured for use with a standard or peripheral mounting type valve cover;  
       FIG. 5  is a side view of an alternative bolt and spacer device for use with the customization cover of the present invention;  
       FIG. 6  is a side view of a preferred embodiment of a mounting system for the customization cover of the present invention for use with the center mounting type of valve cover;  
       FIG. 7  is a side view of a preferred embodiment of a mounting system for the customization cover of the present invention for use with a standard or peripheral mounting type of valve cover; and  
       FIG. 8  is a side view, with portions in cross section, illustrating an embodiment of the customization cover of the present invention mounted to the ignition coil above the valve cover on an internal combustion engine utilizing a coil-on-plug ignition system.  
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      With reference to the figures where like elements have been given like numerical designations to facilitate the reader&#39;s understanding of the present invention, and particularly with reference to the embodiments of the customization cover for engine valve covers of the present invention illustrated in the figures, various preferred embodiments of the present invention are set forth below. The enclosed description and drawings are merely illustrative of preferred embodiments and represent several different ways of configuring the present invention. Although specific components, materials, configurations and uses of the present invention are illustrated and set forth in this disclosure, those skilled in the art will understand that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.  
      A customization cover for engine valve covers that is manufactured out of the materials and configured pursuant to the present invention is shown generally as  10  in the figures. As shown in  FIG. 1 , customization cover  10  is used in conjunction with a valve cover, an example of a center mounting valve cover (i.e., the Vortec-type of valve cover) is shown as  12  in  FIG. 1 , that is configured to be mounted on engine block  14 . As known in the art, the center mounting type of valve cover  12  has a plurality of mounting holes  16  that are generally disposed along or near the longitudinal centerline of valve cover  12  and in corresponding relationship with valve cover mounting points  18 , which can be bosses (best shown in  FIG. 6 ) known in the art, located on engine block  14 , generally between adjacent cylinders (not shown). In the prior art configuration, bolts or other types of connectors are inserted through mounting holes  16  and into valve cover mounting points  18  to secure valve cover  12  to engine block  14  over the engine&#39;s valve system (not shown). For the present invention, a new mounting system is provided, as set forth below, that advantageously allows use of customization cover  10  with valve cover  12 .  
      In a preferred embodiment of the present invention, shown in  FIG. 1 , the modified mounting system utilizes a connector element  20 , such as a bolt, having a threaded first end  22  adapted to be threadably received in one of valve cover mounting points (boss)  18  and a threaded second end  24  adapted to threadably receive a upper connector  26 , such as the acorn nut shown. A lower connector  28 , such as the nut shown, affixed to or cooperatively engaged with connector element  20  allows the user to mount valve cover  12  to engine block  14  by inserting first end  22  of connector element  20  through mounting holes  16  into valve cover mounting points  18 . If desired or necessary, washer  30  can be disposed between lower connector  28  and the top surface  32  of valve cover  12 . The lower portion of connector element  20  is configured to securely mount valve cover  12  to engine block  14 . When valve cover  12  is mounted to engine block  14 , by lower connector  28 , the threaded second end  24  of connector element  20  will be extending generally upwardly from lower connector  28  above the top surface  32  of valve cover  12 . Customization cover  10 , which is configured with one or more mounting openings  34  sized to receive second end  24  of connector element  20  and configured to be in corresponding relationship with one or more of mounting holes  16  and valve cover mounting points  18 , is placed over valve cover  12  such that the bottom surface  36  of customizable cover  10  near mounting openings  34  substantially abuts lower connector  28 . Upper connector  26  connected to second end  24  of connector element  20  will secure customization cover  10  in place above, in spaced apart relation when lower connector  28  is utilized, valve cover  12 . As will be understood by those skilled in the art, the use of lower connector  28  and washer  30  will provide a space or gap  37 , best shown in  FIGS. 6 and 7 , between customizable cover  10  and valve cover  12  such that when cover  10  is installed over valve cover  12 . Although customization cover  10  can be used without gap  37 , such that customization cover  10  substantially rests on or abuts top surface  32  of valve cover  12 , use of lower connector  28  or other spacer elements to create gap  37  provides an improved three dimensional effect, heretofore not utilized in conjunction with valve cover  12 . In an alternative embodiment, the spacer element, such as lower connector  28  and/or washer  30 , can be affixed to bottom surface  36  of main body  38  of customization cover  10  to provide the desired gap  37 .  
      As shown in  FIG. 1 , a preferred embodiment of customizable cover  10  has a main body  38 , with a top surface  40 , generally disposed between first end  42  and second end  44 , and one or more side components  46  generally extending downward from first side  48  and/or second side  50  (use at both are shown). In one embodiment of the present invention, customizable cover  10  comprises just the portion between ends  42  and  44  and sides  48  and  50  (i.e., just main body  38  with no side components  46 ). In the preferred embodiment, as shown, customizable cover  10  has side components  46  extending downward from both sides  48  and  50  forming a generally elongated, inverted u-shaped channel  52 . Although top surface  40  of customization cover  10  can be plain or smooth, it is preferred that main body  38  be configured with one or more design elements, shown generally as  54  in  FIG. 1 , and side components  46 . A nearly infinite variety of design elements  54  are suitable for use with customizable cover  10  of the present invention. Design elements  54  can include but are not limited to flames, circles, curves, symbols and various other graphic devices available or desired. Symbols can include corporate logos and trademarks, such as automobile or truck insignia, dollar signs, playing card symbols and the like. Examples of two possible designs are shown in  FIGS. 2 and 3 . As will be readily apparent to those skilled in the art, design elements  54  can be etched, carved or otherwise applied to main body  38 . In the preferred embodiment, however, design elements  54  are cut out of main body  38  such that the design elements  54  go completely through main body  38  from top surface  40  to bottom surface  36 . Also in the preferred embodiment, side components  46  are provided with one or more side design elements  56 . As with design elements  54 , the number of possible configurations for side design elements  56  is virtually infinite and can be cut out of or otherwise applied to side components  46 .  
      Customizable cover  10  can be made out of a variety of different materials, such as stainless steel, anodized aluminum, carbon steel, carbon fiber or various other metals or non-metallic substances, alone or in various combinations. The principal requirement for such material is that it be sufficiently heat resistant to withstand the temperatures associated with valve cover  12  and be adaptable for configuration with the desired design elements. In one embodiment, customizable cover  10  is made from a No. 8 finish stainless steel member sized nine inches in width by eighteen inches in length that is water jet or laser cut to obtain the desired design (such as shown in  FIGS. 2 and 3 ), and then placed in a press break to bend the member so as to form side components  46 , resulting in a cover  10  that is generally configured with channel  52 , as shown in  FIGS. 1, 4 ,  6  and  7 , that is sized to generally fit over valve cover  12 . The dashed lines in  FIGS. 2 and 3  represent possible places to bend the material to obtain main body  38  and side components  46 . Once placed over valve cover  12 , and spaced thereabove by use of connector element  20  with lower connector  28 , a three dimensional effect will be created with the underlying valve cover  12 .  
      In an alternative embodiment of the present invention, shown in  FIG. 4 , customizable cover is adaptable for use with the standard type of valve cover, shown as  58  having mounting holes  16  on the peripheral edge  60  thereof. Customizable cover  10  should be modified or adapted to cooperate with mounting holes  16  on the peripheral edge  60  of valve cover  58  and connect with valve cover mounting points  18  on engine block  14 . One such modification is to utilize one or more brackets  62  having a pair of vertical members  64  interconnected by transverse member  66 . At the lower end of vertical member  64  is a mounting portion  68  having a mounting opening  70  configured to receive bolts  72  for connecting brackets  62  to valve cover mounting points  18  on engine block  14  through mounting holes  16  of valve cover  58 . Transverse member  66  has a threaded mounting opening  74  in cooperation with mounting openings  34  on customizable cover  10 . Bolts  72  fix customizable cover  10  to transverse member  66  of brackets  62 . With brackets  62  in place over valve cover  58 , the user only needs to attach customizable cover  10  to brackets  62 . In an alternative embodiment, bracket  62  can be fixedly attached to customizable cover  10 . For instance, customizable cover  10  can be configured with vertical members  64  extending downward from side portions  46  such that mounting portion  68 , with mounting opening  70 , is placed over mounting holes  16 . Bracket  62  is sized and configured to provide the desired gap  37  between customizable cover  10  and valve cover  58  to create the three dimensional effect of the present invention.  
      Customizable cover  10  can be used in conjunction with the OEM valve covers  12  and  58  or with an aftermarket valve covers  12  and  58 , such as those made out of stainless steel and the like. As known to those skilled in the art, a variety of different devices are available to attach customizable cover  10  to valve cover  12  or valve cover  58 . For instance, various adhesives or magnetic materials may be available for use, depending on the materials utilized. In the preferred embodiment, customization cover  10  is in spaced apart relation to valve cover  12  or valve cover  58 . The desired spacing may be obtained by the lower connector  28  and washer  30  combination discussed above, or it may be obtained by other space providing devices. One such device for use with valve cover  12 , shown in  FIG. 5 , is the use of a rod  78  having threads at the lower end  80  and a spacer  82  affixed (i.e., welding, adhesives, etc.) to the upper end  84 , with spacer  82  having a female threaded opening at top side  86  thereof. A bolt  88  can be used to affix customizable cover  10  over valve cover  12 . Spacer  82  should be sized and configured to provide gap  37  for the desired three dimensional effect. Various other configurations for a spacer element are also possible.  
      A preferred embodiment of utilizing customization cover  10  of the present invention with center mounting valve cover  12  is shown in  FIG. 6 . In this embodiment connector element  20  is “all-thread” bolt in which first end  22  threads into valve cover mounting point (boss)  18 . Lower connector  28  near second end  24  of connector element  20  secures valve cover  12  to engine block  14  (not shown in this figure). Mounting opening  34  of customization cover  10  is placed over second end  24  of connector element  20  and upper connector  26  is installed to secure customization cover  10  in place in spaced apart relation to valve cover  12 . Lower connector  28  abuts both top surface  32  valve cover  12  and bottom surface  36  of customization cover  10  to provide gap  37 . Upper connector  26  abuts the top surface  40  of customization cover  10 .  
      A preferred embodiment of utilizing customization cover  10  of the present invention with peripheral mounting valve cover  58  is shown in  FIG. 7 . In this embodiment, at least a portion of side components  46  extend generally downward to where valve cover  58  mounts to engine block  14  and a generally inwardly extending mounting arm  90  is used to mount customization cover to the valve cover mounting points  18  on engine block  14  with connector element  20 . As shown, connector element  20  is “all-thread” bolt in which first end  22  threads into valve cover mounting point  18 . Lower connector  28  secures valve cover  58  to engine block  14  and upper connector  26  secures customization cover  10  to valve cover  58  and, directly or indirectly, engine block  14 . As shown in  FIG. 7 , the length of side components  46  fix the amount of gap  37  between valve cover  58  and customization cover  10 .  
      An alternative embodiment of the customization cover  10  of the present invention is shown in  FIG. 8 . In this embodiment, customization cover  10  is configured for use with an engine component mounted on the valve cover, such as shown with ignition coil valve cover  92  that is of the type that is adapted for use with ignition coil  94  for coil-on-plug ignition systems. As known in the art, such ignition systems comprise an ignition coil  94  that is mounted to valve cover  92  such that one ignition coil  94  is in operational connection with a spark plug, such that each cylinder of the internal combustion engine has its own ignition coil  94 . Ignition coil  94  mounts to valve cover  92  at ignition coil mounting point  96 . In this embodiment of the present invention, one end of connector element  20  connects to ignition coil mounting point  96  and upper connector  26  connects to the other end of connector element  20  to secure customization cover  10  to ignition coil  94  above valve cover  92  to provide the desired three dimensional effect. If desired, a spacer element, such as lower connector  28  can be utilized to provide additional spacing between ignition coil  94  and customization cover  10 .  
      As will be appreciated by those skilled in the art, the use of customization cover  10  of the present invention does not interfere with the normal functions of valve covers  12 ,  58  or  92  and customization cover  10  is easily installed and can be easily removed if the need arises to replace or repair any of the valving components associated protected by valve covers  12 ,  58  or  92 . In addition, customization cover  10  can be made from a single, integral piece of material or it can be made from separate main body  38  and side component  46  sections that are joined as desired to provide the desired configuration for customization cover  10 . Connector element  20  can be various types of bolts or bolt-like members and upper  26  and lower  28  connectors can be any of a wide variety of different types of nuts or other types of connectors.  
      While there are shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention. One such modification is the use of different materials than those set forth herein and the use of integral versus connected components.