The present disclosure relates to vehicle air induction systems generally, and more particularly, to clean air duct noise silencing.
Reducing noise that may be heard by vehicle occupants is desirable to automotive manufacturers. The reduction in noise emanating from vehicle air induction systems has been accomplished through the application of specific technology to vehicles. One type of technology provides frequency cancellation through the application of components such as resonators, quarter wave tuners, non-reflective inlet ducts, expansion chambers, or diffusers, to the vehicle. These components are applied at various locations throughout the air induction system, for example, with certain limitations. As one example of these limitations, the clean air intake duct must remain sealed between the air cleaner box and the throttle inlet.
Diffusers and non-reflective ducts that have openings to the atmosphere are not available for installation in the clean air intake duct between the air cleaner box and the throttle inlet. Therefore, clean air duct tuning must be accomplished using resonators, expansion chambers, or quarter wave tuners. Each of these components requires additional packaging space in the engine compartment of the vehicle. It is desirable to provide acoustic tuning of the inlet duct without the use of additional components.
An air intake system for reducing air induction noise may have an air duct housing with a lower shell and an upper shell. Each shell may have a first end and a second end and a plurality of tuning holes formed in the shells. The air intake system further includes an air duct that is connected to the air duct housing and includes a circumferential wall having an interior surface and an exterior surface. The circumferential wall defines an aperture between a first end and a second end and exhibits a predetermined thickness that enables sound to pass through the circumferential wall and into the air duct housing. A venturi is formed between the first and second ends and restricts the amount of sound passing from the first end to the second end of the air duct.
A first method of manufacturing an air intake system is presented and includes forming an air duct including a circumferential wall having an outer surface and an inner surface. The circumferential wall defines an aperture formed between a first and second end of the air duct. The circumferential wall has a first length, a first thickness, and a plurality of notches on the outer surface near the first and second end. The air duct is elongated before it cures so that the circumferential wall decreases to a second thickness that is less than the first thickness. Thereafter, one of the first and second ends of the air duct is rotated in a first direction to reduce the diameter of the air duct between the first and second ends. The air duct is positioned in a lower housing. Thereafter, an upper housing is attached to the lower housing.
A second method of manufacturing an air intake system includes forming an air duct having a circumferential wall including an outer surface and an inner surface, the circumferential wall defining an aperture formed between a first and a second end of the air duct, the circumferential wall having a first length and a first thickness. The air duct is elongated while in a semi-fluid state to decrease the thickness of the circumferential wall. The first end of the air duct is rotated in a first rotational direction while the second end of the air duct is rotated in the second rotational direction concurrent to the drawing to form a venturi portion between the first and second end of the air duct.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Referring now to
Continuing with reference to
The circumferential wall 12 may have an outer surface 22. A plurality of notches 24 are formed around the circumferential wall 12 of the air duct 10 near the first and second ends 14, 16. The plurality of notches 24 or teeth prevent the first and second ends 14, 16 of the air duct 10 from rotating when attached to the air duct housing 32, which is depicted in
With reference to
The venturi creates a smaller diameter in the circumferential wall 12 between the first and second ends 14, 16 of the air duct 10. The effect of the smaller diameter is to create a smaller cross-section in the center (midpoint of the length) of the air duct 10. Because of the smaller diameter, the amount of noise energy that can pass through the air duct 10 is reduced than if a larger diameter duct were utilized. The inlet and outlet angles of the venturi can be designed to reduce air pressure losses that occur as air passes through the venturi. The most efficient inlet and outlet angles of a venturi can be determined through testing and simulation. The desired inlet and outlet angles can be achieved by controlling the amount of rotation and the rate of the rotation and the elongation. The venturi can be formed concurrently with the elongation process or performed subsequent to the elongation process, if desired. Forming the venturi concurrently with the elongation process can be shown to reduce the number of steps required to manufacture the air duct 10 as well as the cost and quantity of the tooling required to manufacture the air duct 10.
With reference to
Similarly, the second end 16 of the air duct 10 and the second end 40 of each of the upper shell 34 and lower shell 36 can interlock with each other. The interlock prevents the air duct 10 from moving in either of the first and second rotational directions. Each of the upper and lower shells 34, 36 can include tuning holes 46 that are used to control dispersion of the pressure waves coming from the air duct 10 when the engine is running. The size, location, and number of tuning holes 46 can be predetermined based on the acoustic requirements for the vehicle.
The upper shell 34 may include a plurality of latches 48 that are received by a plurality of hook members 50 formed on the lower shell 36. The plurality of latches 48 may allow the upper shell 34 and lower shell 36 to be disassembled for servicing the air duct 10 or may be designed to prevent such service if so desired. Alternatively, the upper and lower shells 34, 36 may be attached using other mechanical processes such as welding or by using another fastener, such as screws, bolts, etc.
With reference to
Described in a slightly different manner than that disclosed above, and with reference to
An air duct housing, such as shell 34 and shell 36, may encase the air duct 10 and employ a lower shell 36 with a lower shell first end 38 and a lower shell second end 40 and an upper shell 34 with an upper shell first end 38 and an upper shell second end 40. Each end of each shell 34, 36 may have a plurality of notches 44 about an interior periphery that mesh with the plurality of notches 44 about the exterior periphery of the first duct end 14 and the second duct end 16 to prevent rotation of the air duct 10 relative to the lower shell 36 and the upper shell 34. The lower shell 34 and the upper shell 36 further define a plurality of tuning holes 46 for tuning sound. The tuning holes 46 exhibit a plurality of diameters. The lower shell 36 may further employ a plurality of hook members 50 and the upper shell 34 may employ a plurality of latches 48 such that the plurality of hook members 50 pass into the plurality of latches 48. The air duct housing 34, 36 completely covers the outer surface 22 of the air duct 10. A transverse cross-sectional area at the midpoint duct portion 20 is less than a cross-sectional area of the first duct end 14 and the second duct end 16.
In another configuration, the present teachings may also encompass an apparatus for reducing air induction noise of an air intake (e.g. an air filter 6, throttle body 8, and air duct 10) of an engine 4 of a vehicle 2. The apparatus may further employ an air duct housing having a lower shell 36 and an upper shell 34, the lower shell 36 having a lower shell first end 38 and a lower shell second end 40, the upper shell 34 having an upper shell first end 38 and an upper shell second end 40. The upper shell 34 and lower shell 36 may each define a plurality of tuning holes 46, which may be blind holes (counter bored) or through holes. The air duct 10 may only contact the air duct housing only at an air duct first end 38 and an air duct second end 40. The air duct 10 may have an elongated circumferential wall 12 having an interior surface and an exterior surface. The circumferential wall may define an aperture between the air duct first end and the air duct second end to permit the passage of intake air for the engine 4. The circumferential wall may define a venturi between the first end 14 and second end 16 for restricting an amount of sound passing from the first end 14 to the second end 16 of the air duct 10. The circumferential wall 12 may have a predetermined thickness that enables sound to pass through the circumferential wall and into an air gap or space between the circumferential wall and the air duct housing, and then into the air duct housing 34, 36 and its tuning holes 46. The function of the tuning holes 46, in conjunction with the venturi or reduced cross section of the duct 10, is to attenuate or reduce the noise level of the air passing through the fresh air intake of the engine 4. By reducing the level of noise heard by a person standing exterior to the vehicle 2, or within the vehicle cabin, an overall quieter vehicle 2 may be produced.
A first plurality of notches 24 may be formed on the exterior surface 22 of the circumferential wall at the air duct first end 38 and the air duct second end 40. The air duct 10 and the housing 34, 36 define an air gap therebetween. The upper shell 34 may be arcuate, the lower shell may be arcuate, and the upper shell 34 and the lower shell 36 each have a second plurality of notches 44. The first plurality of notches 24 of the circumferential wall 12 interlock with the second plurality of notches 44 of the upper shell 34 and the lower shell 36. The interlock prevents the air duct 10 from rotating relative to the shells 34, 36. The air duct 10 may further employ a first collar 60 connected to the air duct first end 38, and a second collar 60 connected to the air duct second end 40. Connection of the collars 60 may be by over molding, welding or mechanical fastener attachment.
A method of manufacturing an air intake system that reduces air induction noise may entail forming an air duct 10 including a circumferential wall 12 having an outer surface 22 and an inner surface. The circumferential wall may define an aperture formed between a first end 14 and second end 16 of the air duct 10. Manufacturing the air duct may further entail forming a first plurality of notches 24 on the outer surface of the circumferential wall 12 near the first end 14 and second end 16. The manufacturing method may further entail: elongating the air duct 10, which may be plastic, before it is cured so that the circumferential wall 12 decreases, at least in certain parts, to a second thickness that is less than the first thickness; rotating one of the first and second ends 14, 16 of the air duct 10 in a first direction to reduce the diameter of the air duct between the first and second ends 14, 16; positioning the air duct 10 in a lower housing so that the plurality of first notches 24 formed on the circumferential wall 12 interlock with a plurality of second notches 44 formed in the lower housing 36; and attaching an upper housing 34 to the lower housing 36. The other of the first and second ends 14, 16 may be rotated in a second direction to impart a twisted structural feature in the surface of the duct 10. The method may further entail attaching a first collar 60 to the first end 14 of the air duct 10 and attaching a second collar 60 to the second end 16 of the air duct 10. The first and second collars 60 may be attached to the air duct 10 after the upper and lower housings 34, 36 are attached. The first collar is flexible and may connect to a throttle body and the second collar is flexible and may connect to an air filter.
Thus, functionally, noise caused by air induction passes from the hollow chamber of the air duct 10 and through the thin wall 20 of the air duct 10. The thin wall 20 is permitted to flex and move to absorb noise. Noise that escapes the air duct 10 then passes into the air gap between the air duct 10 and the upper and lower shells 34, 36. The noise may continue into the recesses or holes 46 by passing through the wall of the shells 34, 36. Thus, the level of noise heard outside of the shells 34, 36 may be less than what would be heard if another type of duct were used, such as a straight pipe type of air duct. The air duct 10 and shells 34, 36 are sealed units to prevent dust and air from escaping from either.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
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Number | Date | Country | |
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20100170464 A1 | Jul 2010 | US |