The present invention relates to the efficient removal of dirt particles and similarly-sized foreign matter from intake air that is ingested by internal combustion engines, including both normally-aspirated and turbocharged engines and engines of either type that may be used in both off-road and on-road vehicles.
Many currently-used automotive air cleaners filter out dirt by use of a screen or porous media. This is less efficient for removing many types of dirt particles since the filter media becomes clogged over time and needs to be replaced, including those commonly ingested by vehicles off-road or on highways. An alternative air cleaner, which employs technology used with helicopter engines, utilizes particle separation but requires the use of an external fan to separate out the dirt, and also is less efficient at the relatively low flow rates produced by the engines of automotive or off-road vehicles. The present invention is an improvement over both of these other types of air cleaners, in that it never becomes clogged which would degrade performance nor requires expensive replacement of the filter at relatively low intervals while also effectively removing dirt particles at typical automotive/off-road engine air flow rates and having the further advantage of being capable of operating without an expensive noisy external electric fan which requires power to be supplied by the automotive electric system.
The air filtration device of this invention separates out dirt, sand, and other foreign particles to allow clean intake air to flow into an engine.
In a preferred embodiment of this invention, the air filtration assembly is a replacement of the OEM filter and attaches directly to an engine's air intake port, outside air flows into the assembly and is filtered through multiple cyclonic tubes that spin the intake air at high velocity. The filtered-out particles are collected in a chamber of the device and cleaner, filtered air is sent through into the engine.
In another preferred embodiment, the air filtration assembly can be utilized as a “pre-filter” to take in air, filter out dirt and other foreign particles, and send the air into the vehicle's existing filter system, through which the air eventually passes into the vehicle's engine.
As used herein, the following terms include, but are not limited to, the following meanings.
The term “clean air plenum” means the chamber of the air cleaner where clean air flows to the engine.
The term “dirt collection chamber” means the chamber of the air cleaner where dirt after separation from air is deposited.
The term “dirt clean-out tube” means the lowest point in the assembly below the dirt collection chamber used to facilitate removal of deposited dirt. The dirt clean-out tube has a clear sight glass that when full allows the user to uncap and expel the separated dirt.
The term “cyclonic dirt separation tube” means the assembly that is comprised of “cyclonic outer tube” and the “cyclonic inner tube” that intakes dirty air through six intake ports, spins the mixture at high speeds to separate the dirt then expels the dirt down into the dirt collection chamber while sending clean air out the top to the clean air plenum and into the engine.
The term “cyclonic outer tube” means that portion of the “cyclonic dirt separation tube” that resides on the outermost part of the assembly.
The term “cyclonic inner tube” means that portion of the “cyclonic dirt separation tube” that resides on the inside of the assembly.
In one preferred embodiment of this invention, the structure of
Each cyclonic dirt separation tube separates out dirt particles and other foreign particles by spinning the intake air at high speed. These dirt separation tubes are specifically designed to allow proper engine intake flow and remove the specific sizes of dirt particles and other foreign particles ingested by vehicles operating off-road or on highways. This is accomplished by six intake ports on each cyclonic tube versus a single intake port seen in most cyclonic tube applications. In addition to the cyclonic tube an inner tube exists that deflects dirt to the cylindrical wall of the six-port cyclonic tube. The inner tube also creates a venture effect in the six-port cyclonic tube by reducing flow area and increasing particle speed as the dirt progresses down the length of the tube to the dirt collection chamber of the device. A cyclonic tube with a singular intake port can create upwards of 5 times the backpressure as a six-port intake used on these cyclonic tubes. The six port cyclonic tubes reduce the number of tubes required to maintain normal engine intake backpressure. This reduces the overall size of the device to a reasonable size similar to existing automotive filtration systems that utilize screens or porous media.
These particles fall to the bottom of each dirt separation tube, and then into the dirt collection chamber (5) while clean air exits out the top of the tube, as illustrated in
The dirt collection chamber (5) shown in
In another preferred embodiment, the air filtration device of this invention can take the form of
It is important to maintain the integrity of the air filtration device while in operation, including prevention of cracks or leaks, because the proper operation of the device of this invention relies upon keeping the clean air plenum sealed from outside dirty air and relies on keeping the dirt collection chamber sealed from atmospheric pressure.
In the first-mentioned preferred embodiment, the device may be used as a OEM filter replacement and connected directly to the existing engine air intake, and the use of flexible ducting may be required. In the second-mentioned preferred embodiment, the device may be used as a pre-filter and could be connected to the vehicle's air cleaner intake box; again, the use of flexible ducting may be required.
In either preferred embodiment, during rainy conditions the device is designed to shed water through weep holes located at the bottom of the intake plenum. The cyclone tube's six port inlet is located atop the intake plenum to reduce ingestion of water. In rainy conditions, dust and sand are not present, so separation of dirt from air is typically not a concern. If the device is used in a downpour, the dirt collection chamber should be opened to allow water and dirt to drain. This operation should also be followed when the dirt collection chamber becomes full and indicated by the sight glass located at the bottom of the dirt collection chamber. The size of the device fits in usable space behind the cab above the mid-engine on most off-road high-performance vehicles. For automotive vehicles normally licensed for DOT on-road use or military off-road vehicles, the device may be sized to fit where the OEM air filter box is normally located in the engine bay as a replacement; or when used as a pre-filter, the device may be mounted outside the engine bay and routed to the filter box via flexible ducting. In either preferred embodiment described herein, the device may be made from high temperature plastic and service temperatures up to 180 degrees Fahrenheit.
The air filtration device of this invention may be utilized on, and sized for, many different types of motorized vehicles, including but not limited to: Off-road vehicles such as all-terrain vehicles (including quads, quad bikes, three-wheeler ATVs, and four-wheeler ATVs); off-road motorcycles including dirt bikes; vehicles that can be driven both on- and off-road such as pickup trucks, modified trucks, recreational vehicles, passenger cars, delivery trucks, and delivery vans; military motor vehicles used in off-road and/or all-terrain applications; and construction motor vehicles such as bulldozers, tractors, cranes, forklifts, and backhoes. Those skilled in the art will readily understand that for larger-displacement engines, it will be desirable to size the device appropriately to accommodate the particular engine and to include, within the device, a larger number of cyclonic dirt separation tubes than would be utilized in instances when the device is employed with smaller-displacement engines.
It will be apparent to those skilled in the art that various other modifications and changes to the structures, dimensions, and features described herein may be made without departing from the spirit of the invention and the scope of the appended claims.