Active intake manifold flap cartridge and method

1. An active intake manifold system comprising:

at least one flap cartridge assembly having:

a unitary cartridge housing including

at least one flap valve housing having an airflow aperture therethrough connecting an inlet and outlet; and

a flap valve rotatable in said aperture of said flap valve housing including at least one mounting ear having an aperture, said mounting ears secured to said flap valve, said flap valve rotatable between an open state and a closed state, wherein when in said closed state said flap valve substantially prevents airflow through said flap valve housing aperture, wherein said flap valves share a common axis of rotation;

a shaft extending through said mounting ear apertures, said mounting ears rotationally locking said flap valves to change state in unison; and

a plurality of air intake runners, each having a main runner portion splitting into a plurality of tracts of differing lengths, each tract tuned to a different predetermined engine speed and having a length and volume selected to optimize engine performance at said predetermined speed, each tract in air flow communication with a different flap valve housing outlet;

wherein for said plurality of tracts of any one intake runner only one flap valve at a time is in said open state.

2. The active intake manifold of claim 1 , wherein said inlets of said flap valve housings are secured to and in air flow communication with an air intake duct.

3. The active intake manifold of claim 1 , wherein said flap valve housings of each unitary cartridge housing are arranged linearly side by side in alignment with said common axis of rotation.

4. The active intake manifold of claim 1 , wherein when a portion of said flap valves on said shaft are in said closed state, a different portion of said flap valves are in said open state.

5. The active intake manifold of claim 1 , wherein

each tract of said intake runner is connected to a different flap cartridge assembly;

wherein flap valves in said flap cartridge assemblies are synchronized such that for any given intake runner only one tract has a flap valve in said open state at a time.

6. The active intake manifold of claim 5 , wherein said synchronization between flap cartridge assemblies is provided by a mechanical linkage connecting said shafts of said flap cartridge assemblies such that said shafts rotate in unison.

7. The active intake manifold of claim 1 , wherein said plurality of tracts comprise a long tract and a short tract.

8. The active intake manifold of claim 1 , further comprising:

at least one bearing cartridge sized and configured to be inserted into bearing receptacles provided in said unitary cartridge housing, said bearing cartridge including a bearing aperture sized and configured to permit said shaft to supportively pass through and rotate in said bearing, thereby rotatably supporting said flap valves.

9. The active intake manifold of claim 8 , wherein said bearing cartridge comprises an elastomeric material, said elastomeric material resiliently contacting said bearing receptacle preventing air leakage around said bearing cartridge.

10. The active intake manifold of claim 9 , wherein said bearing receptacles are arch-shaped and said bearing cartridges are shaped and configured to be received into said arch-shaped bearing receptacles.

11. An active intake manifold system comprising:

two flap cartridge assemblies, each having:

a unitary cartridge housing including

a plurality of flap valve housings in a side by side linear arrangement, each having an airflow aperture therethrough connecting an inlet and outlet of each flap valve housing;

a flap valve rotatable in said aperture of said flap valve housing including at least one mounting ear having an aperture, said mounting ears secured to said flap valve, said flap valve rotatable between an open state and a closed state, wherein when in said closed state said flap valve substantially prevents airflow through said flap valve housing aperture, wherein said flap valves share a common axis of rotation;

a shaft extending through said mounting ear apertures, said shaft ears rotationally locking said flap valves to change state in unison; and

a plurality of bearing cartridges sized and configured to be inserted into bearing receptacles in said unitary cartridge housing, each bearing cartridge including a bearing aperture sized and configured to permit said shaft to supportively pass through and rotate in said bearing, rotatably supporting said flap valves;

wherein each bearing cartridge comprises an elastomeric material, said elastomeric material resiliently contacting said bearing receptacle preventing air leakage around said bearing cartridge; and

wherein said bearing receptacles are arch-shaped and said bearing cartridges are shaped and configured to be received into said arch-shaped bearing receptacles;

a plurality of air intake runners having a main runner portion splitting into a short tract and a long tract, each tract tuned to a different predetermined engine speed and having a length and volume selected to optimize engine performance at said predetermined speed; and

a mechanical linkage connecting said shafts of said flap cartridge assemblies such that said shafts rotate in unison;

wherein for each intake runner, each tract is in air flow communication with a flap valve housing outlet on a different one of said flap cartridge assemblies;

wherein said inlet of said flap valve housings are secured in air flow communication to an air intake duct;

wherein said side by side linear arrangement is aligned with said common axis of rotation; and

wherein for each of said flap cartridge assemblies, when a portion of said flap valves are in said closed state, a different portion of said flap valves are in said open state.

12. The active intake manifold system of claim 11 , wherein each of said tracts are ultrasonic welded to a different one of said flap valve housing outlets to provide said air flow communication.

13. The active intake manifold system of claim 11 , wherein said flap valves of each flap valve cartridge assembly are configured to have alternating open-closed states along said common axis of rotation.