Soft engine cover for intake manifold

• US 9,840,989 B2
• Filed: 11/30/2015
• Issued: 12/12/2017
• Est. Priority Date: 11/30/2015
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Newman, Christopher W., Snow, Christopher T.
• Primary Examiner(s): Amick, Jacob
• Assistant Examiner(s): BRAUCH, CHARLES JOSEPH
• Application Number:
  US14/954,227
• Publication Number:
  US 20170152818A1
• Time in Patent Office: 743 Days
• Field of Search: 123198 E
• CPC Class Codes: F02B 77/11 Thermal or acoustic insulation
• CPC Class Codes: F02B 77/13 Acoustic insulation
• CPC Class Codes: F02M 35/104 Intake manifolds
• CPC Class Codes: F02M 35/1272 using absorbing, damping, insulating or reflecting materials, e.g. porous foams, fibres, rubbers, fabrics, coatings or membranes
• CPC Class Codes: F05C 2225/06 Polyamides, e.g. NYLON
• CPC Class Codes: F05C 2225/08 Thermoplastics

Abstract

A cover for an engine assembly of a motor vehicle is attached at one end by a hinge and at the other end by sockets interlocking with engine projections. The engine assembly has a first hinge portion located at a top, rearward end of the engine assembly, and has first and second structural projections extending upwardly and spaced from the first hinge portion. The cover has a foam body overmolded onto a rigid substrate. The substrate has an integral second hinge portion to engage the first hinge portion. The foam body is formed of polyurethane foam with first and second sockets releasably receiving the first and second projections, respectively, to hold the cover at an installed position. The soft cover provides excellent noise and vibration performance together with a desired visual appearance. Manual installation and removal of the cover is done easily and without any tools or removable fasteners.

Claims

1. Apparatus for a motor vehicle, comprising:

an engine assembly having a first hinge portion located at a top, rearward end of the engine assembly, and having first and second stationary structural projections extending upwardly and spaced from the first hinge portion; and

a decorative cover comprising a rigid substrate and a foam body overmolded onto the substrate, wherein the substrate comprises a frame portion covered by the foam body, an integral second hinge portion outside the foam body, and a tab extension integrally joining the frame portion and the second hinge portion, wherein the integral second hinge portion is slidably captured by the first hinge portion, and wherein the foam body has stretchable first and second sockets releasably receiving the first and second projections, respectively, so that the foam body stretches to admit and then captures the projections to hold the decorative cover at an installed position.

2. The apparatus of claim 1 wherein the first structural projection is comprised of a ball stud extending from a cam cover of the engine assembly, and wherein the first socket is comprised of a grommet pocket formed into an underside of the foam body and adapted to capture the ball stud.

3. The apparatus of claim 1 wherein the second structural projection is comprised of an oil filler neck extending from the engine assembly, and wherein the second socket is comprised of a passageway extending through the foam body and adapted to capture the oil filler neck.

4. The apparatus of claim 1 wherein the frame portion is substantially rectangular, and wherein the second hinge portion is comprised of a molded pin at an end of the tab extension extending from the frame to emerge from the foam body.

5. The apparatus of claim 4 wherein the first hinge portion is comprised of a pair of C-hooks extending from an intake manifold of the engine assembly to receive the molded pin.

6. The apparatus of claim 1 wherein the first and second projections extend from at least one cam cover of the engine assembly.

7. The apparatus of claim 1 wherein the foam body is comprised of polyurethane foam.

8. The apparatus of claim 1 wherein the rigid substrate is comprised of a molded plastic.

9. The apparatus of claim 8 wherein the plastic comprises nylon.