# US 10,309,351 B2 · Intake system component of internal combustion engine and method for manufacturing intake system component of internal combustion engine

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- Number: US 10,309,351 B2
- Document ID: US10309351B2
- Status: Granted
- Kind: B2
- Application number: 15/677,730
- Filed: 2017-08-15
- Published: 2018-03-01
- Granted: 2019-06-04
- Earliest claimed: 2016-08-29
- Assignees: Toyota Boshoku Kabushiki Kaisha
- Applicants: Toyota Boshoku Kabushiki Kaisha
- Inventors: Yoshinori Inuzuka; Ryusuke Kimura
- Web page: https://patentgrep.com/patent/US10309351B2

## CPC

- F02M 35/02458: {consisting of multiple layers, e.g. coarse and fine filters; Coatings; Impregnations; Wet or moistened filter elements}
- F02M 35/0201: {Housings; Casings; Frame constructions; Lids; Manufacturing or assembling thereof}
- F02M 35/02408: {Manufacturing filter elements}
- F02M: SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF

## Abstract

An intake system component of an internal combustion engine includes a porous material product and a resin molded portion. The porous material product is formed from a porous material and includes an outer edge and a general portion. The resin molded portion encompasses the outer edge and is formed integrally with the porous material product. The general portion is located outside the resin molded portion. The outer edge has a lower filling density than the general portion.

## Claims

### Claim 1

An intake system component of an internal combustion engine, the intake system component comprising:
a porous material product formed from a porous material and including an outer edge and a general portion; and
a resin molded portion encompassing the outer edge and formed integrally with the porous material product, wherein
the general portion is located outside the resin molded portion, and
the outer edge has a lower filling density than the general portion.

### Claim 2 (depends on 1)

The intake system component according to claim 1, wherein
the porous material product further includes a buffer portion located between the resin molded portion and the general portion, and
the buffer portion has a lower filling density than the general portion.

### Claim 3 (depends on 1)

The intake system component according to claim 1, wherein
the intake system component of the internal combustion engine includes a housing of an air cleaner,
the housing includes a periphery defining an opening, and
the resin molded portion includes a flange located on the periphery of the housing.

### Claim 4

A method for manufacturing an intake system component of an internal combustion engine, wherein the intake system component includes a porous material product formed from a porous material and including an outer edge and a general portion, and a resin molded portion encompassing the outer edge and formed integrally with the porous material product, the method comprising:
forming the porous material product that includes the general portion and a low-density portion by thermally pressing the porous material, wherein the low-density portion has a lower filling density than the general portion; and
molding the resin molded portion by injecting molten resin into a cavity of a mold with at least a distal portion of the low-density portion inserted into the cavity.

### Claim 5 (depends on 4)

The method according to claim 4, wherein
the low-density portion includes the distal portion and a continuous portion that is continuous with the distal portion, and
the method further comprises compressing the continuous portion by the mold with the distal portion of the low-density portion inserted into the cavity of the mold.