Patent Application
20100275862
The present teachings relate generally to reserving under hood space for a vehicle air cleaner. The present teachings relate more specifically to a device and method for integrating a vehicle's air intake chamber, or air cleaner, into the vehicle's radiator fan shroud.
Internal combustion gasoline engines run on a mixture of gasoline and air. Air enters the engine through an air intake chamber, otherwise referred to as an air cleaner or airbox, and proceeds through a series of tubes to the throttle body. The air is then distributed through a series of passages called the intake manifold, where it is circulated to the cylinders. An engine requires air mixed with gasoline (a typical mixture being approximately 14.7 parts of air to one part of gasoline). Accordingly, an engine's horsepower can be limited by the difficulty of getting enough air to the cylinders. It is, therefore, advantageous to limit any air flow restrictions when designing a vehicle's air induction system.
The air cleaner itself is significant not only for air intake, but also as a resonator (e.g., a Helmholtz resonator). A resonance effect occurs when an enclosed volume of a suitable size and shape is connected to the engine's intake manifold, causing the air inside to resonate at a frequency that results in pressure peaks coincident with the cylinders' intake stroke frequency. The system acoustically cancels sound pressure waves to achieve and maintain resonance characteristics. To achieve and maintain these resonance characteristics, it can be advantageous to design an air cleaner of a suitable acoustic volume.
The air cleaner, however, is typically among the last components designed into a vehicle's engine compartment. In order to utilize the minimal remaining space, engineers are typically required to design an air cleaner for each particular vehicle and engine combination. Accordingly, air cleaners are typically engine-mounted or body-mounted where space permits, which generally necessitates a complex piping scheme to route filtered air from the air cleaner into the engine. Turbocharged engines can further complicate air intake placement and piping due to the additional piping required to route filtered air from the air cleaner into the turbochargers and compressed air from the turbochargers to the engine via a charge air cooler. Similar concerns exist for supercharged engines. Such time, space, and design limitations can result in significant setbacks in air flow restriction and air cleaner acoustic volume, as well as additional trade-offs in air charge temperature and air cleaner serviceability.
In accordance with certain embodiments, the present teaching provide an air induction device for a vehicle, the device comprising: an air cleaner integrated into a radiator fan shroud; an air inlet configured to direct air into the air cleaner; and an air outlet configured to receive air from the air cleaner for distribution to an engine of the vehicle.
Certain embodiments of the present teachings also provide an air induction assembly comprising: a radiator fan shroud including first and second air cleaners, the first air cleaner being substantially vertically positioned along a right side of the radiator fan shroud and the second air cleaner being substantially vertically positioned along a left side of the radiator fan shroud.
Certain embodiments of the present teachings further provide a method for minimizing the required piping necessary to accommodate an air induction system of an engine, the method comprising: incorporating an air cleaner into a radiator fan shroud; providing air to the air cleaner; and providing an air outlet configured to receive air from the air cleaner and distribute the air to the engine.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present teachings, as claimed.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and, together with the description, serve to explain the principles of the present teachings.
At least some features and advantages will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:
Although the following detailed description makes reference to illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.
Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. However, these various exemplary embodiments are not intended to limit the disclosure. To the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents.
Integration of a vehicle's air cleaner into the sides of the vehicle's radiator fan shroud can pre-define and reserve an appropriate amount of under-hood space for the air cleaner and serve to minimize the required piping necessary to accommodate an engine's air induction system. Incorporating an air cleaner into a side of a radiator fan shroud can enable the air cleaner to utilize a universally unexploited space to either side of the radiator fan, providing a standard location of suitable size and shape for the air cleaner in the engine compartment. Engineers can further rely on this predefined space for acoustic purposes, because the reserved volume is also suitable for improving Noise, Vibration and Harshness (NVH). Moreover, when positioned adjacent to the radiator fan, the air cleaner is in a favorable location for distributing clean air to turbochargers of a turbocharged engine, or directly to the throttle body of a naturally aspirated engine). This location serves to minimize the piping required to route the filtered air to the engine, thereby reducing air flow restrictions created by complex piping systems. The present teachings also contemplate embodiments that minimize flow restriction for an engine utilizing a supercharger rather than a turbocharger.
Furthermore, this standard location can provide a convenient access point for servicing the air cleaner and routine maintenance, such as air filter replacement.
To integrate an air cleaner into a radiator fan shroud, exemplary embodiments of the present teachings contemplate incorporating at least one air cleaner into a side of the radiator fan shroud so that, when affixed to a radiator, the air cleaner is substantially vertically positioned adjacent to the radiator fan. Substantially vertically positioned, as used herein, includes an elongated air cleaner extending vertically in the engine compartment or at an angle and or shape such that it can accommodate substantially horizontal piping of clean air to a turbocharger in a turbocharged engine, to a supercharger in a supercharged engine, and to a throttle body in a naturally aspirated engine. Substantially horizontal piping, as used herein, includes piping that is horizontal within the engine compartment or at a slight angle to the horizontal such that it limits air flow restrictions.
The radiator fan shroud 1 may be made of a variety of different materials and by a variety of different methods such as, for example, blow molded plastic, injection molded plastic, and/or sheet metal. The material can be fastened in a variety of ways, including via adhesives, fasteners such as screws or rivets, welding, and/or snapping. The radiator fan shroud 1 may include any suitable solid material that can be used to integrate an air cleaner into to the fan shroud, as would be understood by one skilled in the art.
In certain embodiments of the present teachings, the right air cleaner 4 and the left air cleaner 5, respectively, comprise a right filter cavity 10 and a left filter cavity 11. The filter cavities 10 and 11 can each retain a volume that, when combined is suitable for NVH acoustics. Certain embodiments of the present teachings contemplate the right filter cavity 10 having, for example, a 5 liter volume and the left filter cavity 11 having, for example, a 5 liter volume, for a combined volume of 10 liters (to accommodate, for example, a typical V-8 engine). The present teachings contemplate filter cavities of other suitable volume combinations to accommodate V-8 engines and other engine types as would be understood by those skilled in the art. If the vehicle is equipped with a 4-cylinder engine, for example, the pumping pulsations (a source of NVH) are higher, and a more significant resonator may be required. Accordingly, in certain additional embodiments of the present teachings, an air cleaner 4 or 5 may be replaced with a resonator (see
Various other exemplary embodiments of the present teachings contemplate combining air cleaners 4 and 5 into one air cleaner integrated into one side of the radiator fan shroud 1 (see
As illustrated in
Dirty air is circulated through the filter cavities 10 and 11, where it can pass through air filter elements. Certain embodiments of the present teachings contemplate utilizing air filter elements of a conventional shape and design, including flat/panel, oval, and cylindrical air filter elements, whereas various additional embodiments of the present teachings contemplate utilizing air filter elements having varied shapes and sizes that accommodate the shape and size of air cleaners 4 and 5 in which they are to be housed.
Filtered air exits the air cleaners 4 and 5 via clean air outlets 6, and is circulated to turbochargers 12 via low pressure air ducts 13. In certain embodiments of the present teachings, the clean air outlets 6 can be positioned at a base of the air cleaners 4 and 5 to minimize air flow restrictions by decreasing the length and cross section of the ducting to the turbochargers 12 and/or the number of necessary bends in the ducting to the turbochargers 12. The turbochargers 12 compress the clean air, thereby also increasing its temperature. The clean, hot, charged air exits the turbochargers 12 via high pressure air outlets 14, and is circulated to a charge air cooler 16 via high pressure air ducts 15. The charge air cooler 16 does not need to be under or in front of the fan shroud. In various embodiments of the present teachings, the high pressure air outlets 14 can be positioned to minimize a high pressure duct length to the charge air cooler 16. Clean, cool charged air exits the charge air cooler 16 via a cooled air outlet 17, and in the illustrated embodiment is channeled around the radiator fan 8 via a circular duct 18 that can be integrated into the radiator fan shroud by, for example, blow molding, injection molding, or welding. The circular duct 18 serves to allow passage of air to a clean, charged air outlet 19 that sends air to the throttle body. In certain embodiments, the cooled air outlet 17 can be positioned directly below and air cleaner, for example the right air cleaner 4. In the illustrated exemplary embodiment, the clean, charged air outlet 19 can be positioned at the top-center of the radiator fan shroud 1 to minimize a duct length to a throttle body.
In accordance with various embodiments of the present teachings the air cleaner 104 comprises a filter cavity 110 of a volume suitable for NVH acoustics, such as, for example, 10 or 12 liters. Further embodiments of the present teachings contemplate filter cavities of other suitable volumes to accommodate a variety of engine types and sizes. Dirty air inlets 102 and 103 supply dirty air from outside a vehicle to the air cleaner 104 and the resonator 105, respectively. Those skilled in the art will understand that the type, size, number and positioning of the dirty air inlets 102 and 103 depicted in
Dirty air from inlet 102 is circulated through a filter cavity 110, where it can pass through an air filter element. Filtered air can exit the air cleaner 104 to be circulated to a throttle body via low pressure duct connected to a clean air outlet 19. The clean air outlet 19 can be positioned at a position high on the air cleaner 104 to minimize air flow restrictions by decreasing the length and cross section of the ducting to the throttle body and/or the number of necessary bends in the ducting to the throttle body.
The illustrated air cleaner 204 comprises a filter cavity 210 of a volume suitable for NVH acoustics, such as, for example, 10 or 12 liters. Further embodiments of the present teachings contemplate filter cavities of other suitable volumes to accommodate all engine types and sizes. Dirty air inlet 202 supplies dirty air from outside a vehicle to the air cleaner 204. Those skilled in the art will understand that the type, size and positioning of the dirty air inlet 202 depicted in
The dirty air is circulated through a filter cavity 210, where it can pass through an air filter. Filtered air exits the air cleaner 204 via clean air outlet 19, and is circulated to a throttle body via a low pressure air duct (not shown). The clean air outlet 19 can be positioned at a position high on the air cleaner 204 to minimize air flow restrictions by decreasing the length and cross section of the ducting to the throttle body and/or the number of necessary bends in the ducting to the throttle body.
In certain embodiments of the present teachings, the right air cleaner 304 and the left air cleaner 305, respectively, comprise a right filter cavity 310 and a left filter cavity 311. Filter cavities 310 and 311 can each retain a volume that, when combined, is suitable for NVH acoustics.
As illustrated by counterclockwise arrows A in
As further shown by the counterclockwise arrows A, dirty air is circulated through the filter cavity 311, where it can pass through a first air filter. Semi-filtered or coarse-filtered air exits the air cleaner 305 via a clean air outlet, and is channeled under the radiator fan 8 via a circular low pressure duct 313 to the air cleaner 304. The semi-filtered (or coarse-filtered) air is circulated through the filter cavity 310, where it can pass through a second air filter. Filtered air exits the air cleaner 304 via a clean air outlet, and is channeled above the radiator fan shroud 8 via the circular low pressure duct 313 to an air outlet 319 that sends air to a throttle body. In the illustrated exemplary embodiment, the air outlet 319 is positioned at the top-center of the radiator fan shroud 300, but can be positioned otherwise as needed to minimize air flow restrictions by decreasing the length and cross section of the ducting to the throttle body and/or the number of necessary bends in the ducting to the throttle body. Air filter 305 can comprise, for example. a foam filter, paper pleats, or a particle separator.
In certain embodiments of the present teachings, an air cleaner 304 or 305 may be replaced with a resonator (see
In snowy climates, there is also a concern of ingesting snow into the air cleaners via the dirty air inlets, which can plug up the filters, resulting in unacceptable flow restriction in the engine. Accordingly, certain embodiments of the present teachings further contemplate running a coolant line from the radiator through each air cleaner to melt ingested snow to defrost the internal volume of the filters. Due to the unique positioning of the air cleaners, heated liquid may be channeled directly from the radiator tank into each filter cavity while the vehicle is running or just when excess backpressure is detected on the engine. In various embodiments of the present teachings, coolant can be circulated through the air cleaners only upon being triggered by a climate control system, temperature gauge, or other logic.
While the present teachings have been disclosed in terms of exemplary embodiments in order to facilitate better understanding of the present teachings, it should be appreciated that the teachings can be embodied in various ways without departing from the principle of the invention. Accordingly, while the present teachings have been disclosed in terms of a turbocharged engine, a supercharged engine, and a naturally aspirated engine, the teachings as disclosed work equally well for other engine types, and are independent of drive type. Therefore, the present teachings should be understood to include all possible embodiments which can be embodied without departing from the principle of the teachings set forth in the appended claims.
For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the written description and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present teachings. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent. Thus, for example, reference to “an air cleaner” includes two or more different air cleaners. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
It will be apparent to those skilled in the art that various modifications and variations can be made to the system and method of the present disclosure without departing from the scope its teachings. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only.
