DESC:TECHNICAL FIELD
[0001] The present disclosure relates generally to an air intake system for an internal combustion engine, and more specifically to an air filter assembly for the air intake system of the internal combustion engine.
BACKGROUND
[0002] Conventionally, an air intake system of an internal combustion engine comprises a filter system. In such systems, an air filter assembly is employed for eliminating dust and particulate matters from flowing into combustion chamber of the internal combustion engine. Eliminating dust and particulate matters from intake air is absolutely necessary for minimizing abrasion of a cylinder of the internal combustion engine.
[0003] Modern air filter assemblies used in trucks and commercial vehicles employ a main filter for eliminating the dust and particulate matters before the intake air flows to the outlet flow tube directly or via a safety filter. Typically, such main filters and safety filters are annular or cylindrical in shape and the air from pre-cleaners or intake ducts enters laterally or radially inward through filter media. The air then flows outwardly through an outlet flow tube or exit tube. As commercial vehicles require steady and higher flow rates, the design of the main filter and the safety filter combination is of utmost importance. Also, the design requirements for a compact design for enhancing loading spaces where the air intake system is installed behind the cabin are crucial in differentiating between OEM’s products.
[0004] The flow-capacity and efficiency of modern air filter assemblies are affected by various factors, including restrictions arising out of air passages providing intake air as well as restrictions in outlet flow tube, arrangement of safety element and its effectiveness without decrease of filtration performance, effective design of space between the pre-cleaner and the main filter so as to increase the dust holding capacity without affecting the laminar flow to the main filter, and a compact design to occupy less space without affecting the loading capacity of the commercial vehicles. Prior art air filter assemblies have used different configurations to ease the flow restrictions in main and safety filters, and design the air passages or the spaces between pre-cleaner and main filter assemblies for increasing the flow-rate with increased dust accumulation capacities.
[0005] There are also challenges in designing air passages or the spaces between pre-cleaner and main filter assemblies in the cases where compact designs were preferred. The requirement of compact design with ease of cleaning and replacement also affects the normal air flow requirements of such assemblies. Regular removal of dust may ease the resistance to intake air but requires an elaborate design which may defy compact design requirements.
[0006] The present invention deals with the design and assembly of main and safety filters of the air filter assemblys having the above-mentioned shortcomings and provides an improved and alternative embodiment ensuring reduced resistance to intake air, ease of dust removal, fulfillment of air-flow needs, and the compact design requirements.
SUMMARY
[0007] Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems recognized by the inventor in conventional systems.
[0008] In an aspect of the present disclosure, an air filter assembly for an internal combustion engine is provided. The air filter assembly comprises a filter housing and a main filter. The filter housing comprises a first housing and a second housing coupled below the first housing. The second housing comprises a first space situated just below the first housing and a second space beside the first space. The second space is configured to receive intake air from a foregoing pre-cleaner arrangement. The main filter comprises a main filter and a safety filter surrounded by the main filter. In an aspect of the present disclosure, the second space includes a dead space provided after the foregoing pre-cleaner arrangement and before the main filter. In an aspect of the present disclosure, the main filter is positioned inside the first housing and the first space of the second housing. In an aspect of the present disclosure, the main filter and the safety filter are elliptically shaped.
[0009] According to aspects of the present disclosure, the first housing and the second housing are removably attached to each other. In an aspect of the present disclosure, the first housing includes an outlet flow tube situated at the top for enabling flow of filtered air to the internal combustion engine. The outlet flow tube includes a vacuum indicator situated at the top.
[0010] In an aspect of the present disclosure, the second space of the second housing includes a pair mechanism for receiving the foregoing pre-cleaner arrangement. The pair mechanism comprises a nut assembly for receiving a bolt of the foregoing pre-cleaner arrangement. The pair mechanism includes a seal ring for a fluid-tight arrangement when the bolt of the foregoing pre-cleaner arrangement is received. The seal ring includes a pip provided on one side for protecting the seal ring from falling down.
[0011] According to aspects of the present disclosure, the dead space of the second space of the second housing includes a plurality of guide ribs provided to support the main filter. The dead space includes a valve vacuua provided before the plurality of guide ribs for removing any water entered with the intake air.
[0012] In an aspect of the present disclosure, the main filter includes a filter media surrounding a center tube. The center tube has a mesh like structure. In an aspect, the safety filter includes a guide rib provided at the top. The guide rib enables blind entry of the safety filter in the first housing during assembly. In an aspect the center tube has a first open end and the second closed end with a perpendicular meshed platform structure there between. The perpendicular meshed platform structure provide support to the safety filter during operation and aids assembling as well.
[0013] In yet another aspect, an air filter assembly having elliptically shaped main and safety filters with enhanced laminar flow, adequate dust removal and holding capacity, and with compact design is provided.
[0014] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments.
[0015] It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the below mentioned detailed description and drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0016] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, example constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[0017] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Fig. 1 is a perspective view depicting a front perspective view of an air filter assembly and assembly, in accordance with an exemplary embodiment of the present disclosure;
Fig. 2 depicts a front cross-sectional zoom-in view of the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure;
Fig. 3 illustrates a front cross-sectional view of the air filter assembly and assembly of Fig. 1, in accordance with another exemplary embodiment of the present disclosure;
Fig. 4A is a perspective view of a main filter of the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure;
Fig. 4B is a perspective view of a center tube employed in the main filter of the air filter assembly and assembly of Fig. 4A, in accordance with an exemplary embodiment of the present disclosure;
Fig. 5A depicts a perspective view of construction of a safety filter of the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure;
Fig. 5B illustrates assembly of the safety filter with respect to the main filter of the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure;
Fig. 6A is a zoom-in view of assembly mechanism of the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure;
Fig. 6B is a zoom-in view of the assembly mechanism of Fig. 6A depicting the sealing mechanism employed in the air filter assembly and assembly of Fig. 1, in accordance with an exemplary embodiment of the present disclosure.
[0018] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0019] The following detailed description illustrates embodiments of the present disclosure and manners by which they can be implemented. Although some modes of carrying out the present disclosure has been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible. The person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure. It should be understood that this invention is not limited to the particular methodology, protocols, and the like, described herein and as such may vary. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention, which is defined solely by the claims.
[0020] Unless stated otherwise, or implicit from context, the following terms and phrases include the meanings provided below. Unless explicitly stated otherwise, or apparent from context, the terms and phrases below do not exclude the meaning that the term or phrase has acquired in the art to which it pertains. The definitions are provided to aid in describing particular embodiments of the aspects described herein, and are not intended to limit the claimed invention, because the scope of the invention is limited only by the claims. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.
[0021] As used herein, the term “comprising” or “comprises” is used in reference to compositions, methods, and respective component(s) thereof, that are essential to the invention, yet open to the inclusion of unspecified elements, whether essential or not.
[0022] The singular terms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. Similarly, the word “or” is intended to include “and” unless the context clearly indicates otherwise. Thus, for example, references to the “method” includes one or more methods, and/or steps of the type described herein, and/or which will become apparent to those persons skilled in the art upon reading this disclosure and so forth.
[0023] Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of this disclosure, suitable methods and materials are described below. The term “comprises” means “includes”. The abbreviation, “e.g.” is derived from the Latin exempli gratia and is used herein to indicate a non-limiting example. Thus, the abbreviation “e.g.” is synonymous with the term “for example”.
[0024] In an aspect of the present disclosure, an air filter assembly for an internal combustion engine is provided. The air filter assembly comprises a filter housing and a main filter. The filter housing comprises a first housing and a second housing coupled below the first housing. The second housing comprises a first space situated just below the first housing and a second space beside the first space. The second space is configured to receive intake air from a foregoing pre-cleaner arrangement. The main filter comprises a main filter and a safety filter surrounded by the main filter. In an aspect of the present disclosure, the second space includes a dead space provided after the foregoing pre-cleaner arrangement and before the main filter. In an aspect of the present disclosure, the main filter is positioned inside the first housing and the first space of the second housing. In an aspect of the present disclosure, the main filter and the safety filter are elliptically shaped.
[0025] According to aspects of the present disclosure, the first housing and the second housing are removably attached to each other. In an aspect of the present disclosure, the first housing includes an outlet flow tube situated at the top for enabling flow of filtered air to the internal combustion engine. The outlet flow tube includes a vacuum indicator situated at the top.
[0026] In an aspect of the present disclosure, the second space of the second housing includes a pair mechanism for receiving the foregoing pre-cleaner arrangement. The pair mechanism comprises a nut assembly for receiving a bolt of the foregoing pre-cleaner arrangement. The pair mechanism includes a seal ring for a fluid-tight arrangement when the bolt of the foregoing pre-cleaner arrangement is received. The seal ring includes a pip provided on one side for protecting the seal ring from falling down.
[0027] According to aspects of the present disclosure, the dead space of the second space of the second housing includes a plurality of guide ribs provided to support the main filter. The dead space includes a vacuum valve provided before the plurality of guide ribs for removing any water entered with the intake air.
[0028] In an aspect of the present disclosure, the main filter includes a filter media surrounding a center tube. The center tube has a mesh like structure. In an aspect, the safety filter includes a guide rib provided at the top. The guide rib enables blind entry of the safety filter in the first housing during assembly. In an aspect, the safety filter includes an inner wall and a filter media encompassing the inner wall. In an aspect, the safety filter comprises a safety felt filter provided at the bottom. The inner wall includes a perpendicular meshed platform to prevent the safety felt filter from falling down.
[0029] Embodiments of the present disclosure substantially eliminate, or at least partially address, problems in the prior art, and assist the vehicle manufacturers, air filter manufacturers, internal combustion engine manufacturers, consumers, and suppliers.
[0030] Referring now to the drawings, particularly by their reference numbers, Fig. 1 illustrates an air filter assembly 100 depicted in a front perspective view, in accordance with an embodiment of the present disclosure. The air filter assembly 100 includes a filter housing 102. The filter housing 102 comprises a first housing 104 and a second housing 106 coupled below the first housing 104. In an embodiment of the present disclosure, the first housing 104 and the second housing 106 are removably attached to each other at a first attachment point 108. In another embodiment of the present disclosure, the first housing 104 and the second housing 106 are integrally formed together.
[0031] As may be seen, the first housing 104 includes an outlet flow tube 110 situated at the top, according to embodiments of the present disclosure. In various embodiments, the outlet flow tube 110 enables flow of the filtered air to the internal combustion engine (not shown). In an embodiment, the outlet flow tube 110 includes a receiving mechanism (not shown) for coupling a pipe assembly (not shown) enabling transfer of filtered air to the internal combustion engine (not shown). In embodiments of the present disclosure, the outlet flow tube 110 includes a vacuum indicator 112 situated at the top. Further, a metal bracket 114 is coupled to the first housing 104 for enabling fastening arrangement of the filter housing 102 to a vehicle’s cabin (not shown), according to various embodiments of the present disclosure.
[0032] Again referring to Fig. 1, the second housing 106 comprises a first space 116 and a second space 118, according to various embodiments of the present disclosure. The first space 116 is situated just below the first housing 104. The second space 118 is an open space configured to receive intake air from a foregoing pre-cleaner arrangement (not shown), according to various aspects of the present disclosure. The second space 118 includes a pair mechanism 120 provided at a second attachment point 122 for receiving the foregoing pre-cleaner arrangement (not shown), in various embodiments of the present disclosure. The pair mechanism 120 is described in detail with the description of Fig. 6A & 6B, later on in the description.
[0033] Fig. 1 is merely an example. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0034] Fig. 2 depicts a cross-sectional zoom-in view of the air filter assembly 100 depicted in Fig. 1. As illustrated in the view, the second space 118 includes a dead space 200 provided after the foregoing pre-cleaner arrangement (not shown) and before a main filter 202. According to various embodiments of the present disclosure, this huge dead space 200 provides better dust holding capacity and promotes laminar flow of the intake air entering the following main filter 202. The main filter 202 is discussed further in the Fig. 3 of the present disclosure.
[0035] As may be seen, the dead space 200 includes a plurality of guide ribs 204. The plurality of guide ribs 204 provide support to the main filter 202 and adds to structural rigidity to the overall arrangement, according to various embodiments of the present disclosure. The dead space 200 includes a vacuum valve 206 for removing any water entered with the intake air from the foregoing pre-cleaner arrangement (not shown). In an embodiment, the vacuum valve 206 is provided before the plurality of guide ribs 204. The vacuum valve 206 may include a mechanical/pneumatic/solenoid/hydraulically actuated valve, according to various aspects of the present disclosure.
[0036] Fig. 2 is merely an example. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0037] Moving on to Fig. 3, a front cross-sectional view of the filter housing 102 of the air filter assembly 100 of Fig. 1 is depicted. As may be seen, Fig. 3 illustrates various embodiments of the main filter 202 shown in Fig. 2.
[0038] In this view, The main filter 202 comprises a main filter 300 and a safety filter 302, according to various embodiments of the present disclosure. As may be seen, the safety filter 302 is positioned in the center of the main filter 300. In other words, the main filter 300 encompasses/surrounds the safety filter 302, in various aspects of the present disclosure. In an embodiment, the main filter 300 may be seen positioned inside the first housing 104 and the first space 116 of the second housing 106 and supported by the plurality of guide ribs 204.
[0039] Fig. 3 is merely an example. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0040] Now referring to Fig. 4A, a perspective view of the main filter 300 of the Fig. 3 is illustrated. The view clearly shows the design aspects of the structure of the main filter 300.
[0041] As may be seen, the main filter 300 is elliptically shaped, according to various aspects of the present disclosure. The main filter 300 is elliptically shaped as for the same length of axis, the elliptical cross-section has more perimeter than the round or rectangular shape. With more perimeter comes larger surface area 400 facing the intake air, which supports a continuous high flow-rate configuration required for the internal combustion engines requiring air-flow in the high-configuration side.
[0042] In various embodiments of the present disclosure, the main filter 300 comprises a filter media 402. The filter media 402 is made of generally known filter materials, in aspects of the present disclosure. Further, the main filter 300 comprises a top end cap 404 provided at the top of the filter media 402 and a bottom end cap 406 provided at the bottom of the filter media 402. In an embodiment, the top end cap 404 and the bottom end cap 406 may be made of a soft resilient compressible material such as foam potted urethane, or of a resilient material like polyurethane.
[0043] Now referring to Fig. 4B, the inner structure of the main filter 300 is illustrated, according to various aspects of the present disclosure. As may be seen, the main filter 300 comprises a center tube 408. In embodiments of the present disclosure, the center tube 408 is elliptically shaped and forms an inner wall of the main filter 300. In an embodiment, the center tube 408 is a mesh like structure made of steel, alloy, or any other suitable material capable of overcoming warp issues of the filter media 402 and enabling prolonged use without affecting the efficiency of the main filter 300. Furthermore, the center tube 408 enables receiving the safety filter 302 without affecting the inner portion of the filter media 402.
[0044] Fig. 4A and 4B are merely examples. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0045] Fig. 5A depicts a perspective view of the construction of the safety filter 302 of Fig. 3 and Fig. 5B illustrates a cross-sectional view of the safety filter 302 assembled with respect to the filter housing 102.
[0046] As may be seen in Fig. 5A, the safety filter 302 comprises a filter media 500. The safety filter 302 and the filter media 500 are elliptically shaped. As may be seen in Fig. 5B, the safety filter 302 comprises an inner wall 502 having a mesh like structure made of steel, alloy, or any other suitable material capable of overcoming warp issues of the filter media 500 and enabling prolonged use without affecting the efficiency of the main filter 300. According to embodiments of the present disclosure, the safety filter 302 comprises a safety felt filter 504 provided at the bottom. In an aspect the center tube has a first open end and the second closed end with a perpendicular meshed platform structure there between. The perpendicular meshed platform structure provide support to the safety filter during operation and aids assembling as well.
[0047] Now referring to Fig. 5A, the safety filter 302 comprises a guide rib 508 provided at the top. In an embodiment, the guide rib 508 is removably attached to the inner wall 502 of the safety filter 302. In another embodiment, the guide rib 508 is integrally formed with the inner wall 502. As may be seen, the guide rib 508 includes a first plurality of members 510 along the major axis of the elliptical shape of the safety filter 302 and a second plurality of members 512 along the minor axis of the elliptical shape of the safety filter 302, according to various embodiments of the present disclosure. The guide rib 508 is provided for easing assembly of the safety filter 302 with respect to the top of the first housing 104. In embodiments of the present disclosure, the guide rib 508 enables blind entry of the safety filter 302 at the top of the first housing 104 during assembly.
[0048] Fig. 5A and 5B are merely examples. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0049] Moving on to Fig. 6A & 6B, the pair mechanism 120 of Fig. 1 is illustrated in a zoom-in view. As discussed above, the pair mechanism is provided at the second attachment point 122 for receiving a foregoing pre-cleaner 600.
[0050] As may be seen in Fig. 6A, the pair mechanism 120 comprises a nut assembly 602 for receiving a bolt 604 of the foregoing pre-cleaner 600. It may be noted that the nut assembly 602 is a standalone modular feature and does not fall down even when the foregoing pre-cleaner 600 is removed. In aspects of the present disclosure, the nut assembly 602 provides a design which may be installed in very compact and unreachable spaces. Further, a seal ring 606 is provided for a fluid-tight arrangement when the foregoing pre-cleaner 600 is received at the attachment point 122 of the second housing 106.
[0051] As may be seen in Fig. 6B, a zoom-in view of the seal ring 606 is illustrated. The seal ring 606 includes a pip 608 for having a tight fit between the foregoing pre-cleaner 600 and the second housing 106, according to various embodiments of the present disclosure. The pip 608 provides protection to the seal ring 606 from falling down, in aspects of the present disclosure.
[0052] Fig. 6A and 6B are merely examples. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.
[0053] Embodiments of the present disclosure can be used for various purposes, including, though not limited to, manufacturing and servicing of the internal combustion engines.
[0054] Modifications to various embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”. “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural
,CLAIMS:What is claimed is:

1. An air filter assembly for an internal combustion engine, the air filter assembly comprising:
a filter housing, the filter housing comprising:
a first housing; and
a second housing coupled below the first housing, the second housing comprising:
a first space situated just below the first housing; and
a second space beside the first space, the second space configured to receive intake air from a foregoing pre-cleaner arrangement; and
a main filter, the main filter comprising:
a main filter; and
a safety filter surrounded by the main filter;
characterized in that:
the second space includes a dead space provided after a foregoing pre-cleaner arrangement and before the main filter;
the main filter is positioned inside the first housing and the first space of the second housing; and
the main filter and the safety filter are elliptically shaped.

2. The air filter assembly of claim 1, wherein the first housing and the second housing are removably attached to each other.

3. The air filter assembly of claim 1, wherein the first housing includes an outlet flow tube situated at the top for enabling flow of filtered air to the internal combustion engine.

4. The air filter assembly of claim 1, wherein the second space includes a pair mechanism for receiving the foregoing pre-cleaner arrangement.

5. The air filter assembly of claim 4, wherein the pair mechanism comprises a nut assembly for receiving a bolt of the foregoing pre-cleaner arrangement.

6. The air filter assembly of claim 5, wherein the pair mechanism includes a seal ring for a fluid-tight arrangement when the bolt of the foregoing pre-cleaner arrangement is received.

7. The air filter assembly of claim 1, wherein the dead space includes a plurality of guide ribs provided to support the main filter.

8. The air filter assembly of claim 7, wherein the dead space includes a vacuum valve provided before the plurality of guide ribs for removing any water entered with the intake air.

9. The air filter assembly of claim 1, wherein the main filter includes a filter media surrounding a center tube, the center tube having a mesh like structure.

10. The air filter assembly of claim 1, wherein the safety filter includes a guide rib provided at the top, the guide rib enables blind entry of the safety filter in the first housing during assembly.

11. The air filter assembly of claim 10, wherein the safety filter includes an inner wall and a filter media encompassing the inner wall.

12. The air filter assembly of claim 11, wherein the safety filter comprises a safety felt filter provided at the bottom.

13. The air filter assembly of claim 9, wherein the mesh like structure of the center tube further comprises a perpendicular meshed platform to prevent the safety felt filter from falling down.