Intelligent air management module

An air management module for use in a vehicle pneumatic suspension system, the air management module comprising:

• a plurality of inlets configured to receive compressed air from a vehicle air compressor;
• a plurality of outlets configured to provide the compressed air to a plurality of vehicle air springs;
• a plurality of control valves configured to receive the compressed air form the inlets and selectively provide the compressed air to the plurality of outlets, each control valve of the plurality of control valves including a first portion and a second portion;
• and
• a manifold configured to route the compressed air from the plurality of inlets to the plurality of outlets, the manifold including,
• an outer layer, the plurality of inlets and the plurality of outlets connected to the outer layer,
• an inner layer, the first portion of each control valve of the plurality of control valves seated within the inner layer,
• a medial layer sandwiched between the outer layer and the inner layer, wherein the outer layer, the inner layer, and the medial layer are each injected molded, wherein the medial layer includes a rear surface and a front surface, the rear surface opposing the front surface, and wherein the rear surface of the medial layer is fixed to the inner layer and the front surface of the medial layer is fixed to the outer layer.

A method of manufacturing an air management module, the method comprising:

• forming, by injection molding, an outer manifold layer defining one or more first passages and one or more apertures, the one or more apertures configured to receive an inlet connector and an outlet connector, the inlet and outlet connectors configured to be fluidly connected to the one or more first passages;
• forming, by injection molding, a medial manifold layer defining one or more second passages;
• forming, by injection molding, an inner manifold layer defining one or more third passages, wherein the one or more first passages, the one or more second passages, and the one or more third passages are collectively configured to form one or more flow-control orifices configured to minimize a pressure differential between the inlet connector and the outlet connector and where at least one flow-control orifice is a flow-restrictor orifice purposefully sized to create a prescribed pressure differential between at least two different outlets;
• and
• fixing, by friction welding, the medial manifold layer to the outer manifold layer and the inner manifold layer.