DESC:FIELD OF THE DISCLOSURE

The present disclosure relates to the field of air filters.

BACKGROUND

Vehicles travelling in dusty environment are posed with the problem of air laden with dust particles and other solid impurities, entering engines. Particularly, in the case of tractors, the operational environment involves solid impurities, such as, dust and plant residues. The solid impurities on being mixed with the surrounding air, finds their way into engines of the vehicles when the tractor traverses across the farmland which hamper the operation of the engines.

In order to supply purified intake air to the engines, presently, air filters are located between engines and the entry ducts of the air such that the solid impurities are removed from the intake air before entering the engine. However, in the process of removal of the solid impurities, the air filters are clogged and results in an increase in the pressure drop across the air filter which results in their failure. Hence, the air filters are required to be frequently maintained in order to remove the solid impurities clogged within the air filters to ensure supply of clean air to the engines. Many a times cleaning of filter element is also not adequate due to excessive clogging and the clogged filter element needs to be replaced with new element. This results in frequent shut down of the vehicles for maintenance of the air filters, simultaneously resulting in loss of productive time and increased operating costs.
Hence, there is felt a need for a system which enables overcoming the drawbacks of the presently available system for purifying the intake air.

OBJECTS
Some of the objects of the system of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide an air –filtration system for enabling continuous supply of purified intake air into an engine of a vehicle.
Another object of the present disclosure is to provide an air –filtration system that minimizes frequency of clogging of an air filter associated with a vehicle.
Still another object of the present disclosure is to provide an air –filtration system that increases the operational life of an air filter of a vehicle.
Yet another object of the present disclosure is to provide an air –filtration system that minimizes the maintenance cost of an air filter of a vehicle.
An added object of the present disclosure is to provide an air filtartion system which enables uninterrupted supply of purified intake air over an extended period of time.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY:

An air-filtration system for supplying clean air to an engine of a vehicle is disclosed in accordance with an embodiment of the present disclosure. The air-filtration system includes a pre-cleaner, a particulate collector and a filter. The pre-cleaner is having a tubular configuration and is functionally coupled to the engine. The pre-cleaner receives particulate laden air therein due to an intermittent suction pressure created during intake stroke of a piston within the engine. The pre-cleaner includes a swirl creating element disposed therein that causes swirling of the particulate laden air to facilitate separation of heavier particulate matter from the particulate laden air to at least partially clean the particulate laden air. The particulate collector co-operates with the pre-cleaner and collects heavier particulate matter separated from the particulate laden air in the pre-cleaner. The particulate collector includes an inlet port, a particulate collecting chamber and a flap. The inlet port is functionally coupled to the pre-cleaner. The particulate collecting chamber configures an enclosure that collects the heavier particulate matter from the pre-cleaner via the inlet port. The particulate collecting chamber has an open end configured on an operative bottom end thereof. The flap is hingeably connected to the particulate collecting chamber and selectively unblocks the open end of the particulate collecting chamber to facilitate evacuation of heavier particulate matter from the particulate collecting chamber. The filter is disposed downstream of and in fluid communication with the pre-cleaner. The filter further removes particulate matter from the at least partially cleaned particulate laden air leaving the pre-cleaner and supplies clean air to the engine.

Typically, the flap is a flat flap.

Alternatively, the flap is a dimpled flap such that dimple configured thereon is disposed within the particulate collection chamber when the flap blocks the open end of the particulate collecting chamber.

Generally, the pre-cleaner is connected to the filter by at least one first duct.

Typically, the filter is connected to the engine by the second duct.

In accordance with an embodiment, the axis of the particulate collecting chamber is inclined with respect to the axis of the pre-cleaner at an angle in the range of 20 degrees to 50 degrees.

Generally, the flap blocks the open end of the particulate collecting chamber to retain heavier particulate matter collected therein under action of suction pressure created during intake stroke of the piston within the engine.

In accordance with an embodiment, the pre-cleaner and swirl creating element disposed therein separates heavier particulate matter by facilitating accumulation of the heavier particulate matter on inner walls of the pre-cleaner due to centrifugal forces acting on the heavier particulate matter.

Typically, the flap unblocks the open end of the particulate collecting chamber during exhaust stroke of the piston within the engine due to weight of the heavier particulate matter and absence of any holding forces, thereby facilitating evacuation of heavier particulate matter from the particulate collecting chamber.

Further, the air filtration system includes a gasket fitted along a rim of the open end of the particulate collection chamber.

Typically, the gasket is of polymeric material.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

The air filtration system of the present disclosure will now be described with the help of accompanying drawings, in which:

Figure 1 illustrates a schematic view of an air intake system in accordance with prior art;

Figure 2 illustrates a schematic view of an air filtration system in accordance with the present disclosure;

Figure 3 illustrates a perspective view of an air filtration system in accordance with the present disclosure;

Figure 4 illustrates a sectional view of a pre-filter of the air filtration system illustrated in Figure 3;

Figure 5 illustrates a dust collection chamber of the air filtration system, shown in Figure 2 and Figure 3, in closed condition;

Figure 6 illustrates a dust collection chamber of the air filtration system, shown in Figure 2 and Figure 3, in open condition;

Figure 7 illustrates a dust collection chamber shown in Figure 5 with a dimpled flap;

Figure 8a-8e illustrates different views of a particulate collector with a flap thereof closing an open end of a particulate collecting chamber thereof;

Figure 9a -9c illustrates different views of the flap of the particulate collector of Figure 8a-8e; and

Figure 10a-10b illustrates different views of a gasket fitted along a rim of the open end of the particulate collection chamber of the particulate collector of Figure 8a-8e.
DETAILED DESCRIPTION

Figure 1 illustrates conventional air intake system (10) for filtration of intake air before inducted into an engine of a vehicle operating in an environment having air laden with solid impurities, such as, dust and plant residues. An air filter (1) is located between the engine (3) and the entry duct (2) of the air intake system (10). The air filter (1) ensures removal of solid impurities, such as, dust and plant residues from the intake air prior to entry into the engine (3). However, the continuous filtration of intake air, laden with solid impurities causes choking of the air filter (1) and results in its failure. This causes an increase in maintenance and operational cost.

An air filtration system of the present disclosure will now be described with reference to the embodiments which do not limit the scope and ambit of the disclosure.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The air filtration system in accordance with the present disclosure will now be described with respect to Figure 2 to Figure 7. The air filtration system includes a pre-cleaner (11), having a hollow defined by an inner cylindrical wall, cooperating with an air inlet duct (12) at one end and a duct (13) at the other end. The inner cylindrical wall of the pre-cleaner (11) defines at least one formation (11a), as shown in Figure 4, which causes turbulence in the intake air entering the pre-cleaner (11).

The duct (13) is fluidly coupled with a filter, particularly, an air filter (14) by a duct (13a). The air filter (14) further fluidly communicates with an engine (15) of a vehicle through a duct (16). Intake air for operation of the engine (15) is allowed to enter the air filtration system through the air inlet duct (12) due to an intermittent suction pressure applied at the duct (13) through the air filter (14) by operation of the piston within the engine.

Further, the pre-cleaner (11) cooperates with a particulate collector, also referred to as a dust collector, shown in Figure 5 and Figure 6. The dust collector is positioned so as to be operatively below the pre-cleaner (11). The dust collector includes an inlet port (17), fluidly communicating with the pre-cleaner (11) at one end and a flap (19) at the other. The dust collector further includes a particulate collecting chamber also referred to as a dust collecting chamber (18), typically, cylindrical in structure, cooperating with the inlet port (17) at one end and open at the end distal from the inlet port (17). The open end of the dust collecting chamber (18) is opened and closed by the flap (19) which is connected to the dust collecting chamber (18) through a hinge (19a). The flap (19) is typically flat, as shown in Figure 5, or dimpled, as shown in Figure 7. The dimpled flap, shown on Figure 7, includes a dimple (19b), shown in Figure 7, formed on the flap (19) such that in the closed configuration of the open end of the dust collecting chamber (18), the dimple (19b) is located within the dust collecting chamber (18). In accordance with another embodiment, the flap (19) has central portion punched inwardly towards the valve body such that the when closed the inwardly punched central portion of the flap (19) is disposed within the dust collection chamber (18). Such a configuration of the flap (19) ensures efficient operation of the valve, ejection of the separated heavy particulate matter from the dust collection chamber (18) and control of the gap between valve body or the body of the dust collection chamber (18) and flap (19). The opening of the dust collector chamber (18) is caused by weight of the heavier particulate matter collected in the dust collector chamber (18) and absence of any holding forces. The closing of the open end of the dust collection chamber (18) by the flap (19) is caused by the intermittent suction pressure acting on the flap (19). The intermittent suction pressure is caused by the displacement of the piston within the engine during an intake stoke and an exhaust/power stroke. The dust collecting chamber (18) is fitted at an angle to the axis of the pre-cleaner (11). The angle of the dust collecting chamber (18) to the axis of the pre-cleaner (11) is typically in the range of 20 degrees to 50 degrees and preferably in the range of 30 degrees to 40 degrees. In the intake stroke of the engine (15), the flap (19) is in a closed position wherein the open end of the dust collecting chamber (18) is closed by the flap (19), as shown in Figure 5. In the exhaust/ power stroke of the engine (15), the flap (19) is in an open position wherein the open end of the dust collection chamber (18) is opened by the flap (19), as shown in Figure 6.

The open end of the dust collection chamber (18) is optionally provided with a gasket (22) fitted along the rim of the open end of the dust collection chamber (18). The gasket (22) is typically of polymeric material. The gasket (22) is made up of elastomeric material with abrasion resistant properties for enhancing service life of the gasket. The outside edge of the gasket (22) is tapered for ensuring proper sealing between metal and rubber parts. The gasket (22) is further provided with a groove. Such configuration of the gasket (22) also takes care of flatness variations on the flap (19). The grooves configured in the gasket (22) facilitate easy fitment of gasket (22) on the particulate collector chamber (18) and helps in better serviceability.
During the intake stroke of the engine (15), the intake air enters the pre-cleaner (11). The intake air on the entering into the pre-cleaner (11) is caused to swirl within the pre-cleaner (11) on account of the suction pressure applied at the duct (13) and the turbulence caused by the formations (11a). The turbulence caused by the formations (11a) results in swirling of the intake air within the pre-cleaner (11) with a pre-determined centrifugal force acting on the intake air. The swirling of the intake air is such that the rate of rotation of the intake air is directly proportional to the applied suction pressure. During swirling of the intake air, the particles of higher density in the intake air tend to collect on the inner wall of the pre-cleaner (11) as a result of the centrifugal force. The solid impurities collected on the inner wall of the pre-cleaner (11) are forced into the inlet port (17) wherein due to the angle of inclination of the inlet port (17), the solid impurities are caused to slide into the dust collecting chamber (18) on account of gravity. The solid impurities are collected within the dust collecting chamber (18) during the intake stroke during which the flap (19) closes the open end of the dust collecting chamber (18), as shown in Figure 5. After the completion of the intake stroke, the exhaust/power stroke initiates and hence there is no suction pressure acting on the flap (19) to close the open end of the dust collecting chamber (18). Meanwhile, the solid impurities collected within the dust collecting chamber (18) and the flap (19) are acted upon by the force of gravity which causes the flap (19) to open the open end of the dust collecting chamber (18), thereby expelling the solid impurities collected within the dust collecting chamber (18) out of the air filtration system through the open end of the dust collecting chamber (18).

Thus, the air filtration system of the present disclosure ensures that the air filter (14) is not clogged and hence enables minimizing the maintenance and operational cost of the air filter (14) along with an increase in the service life of the air filter (14). Figure 8a-8e illustrates different views of a particulate collector with a flap 19 thereof closing an open end of a particulate collecting chamber 18. Figure 9a -9c illustrates different views of the flap 19 of the particulate collector. Figure 10a-10b illustrates different views of a gasket 22 fitted along a rim of the open end of the particulate collection chamber 18 of the particulate collector.

TEST SET-UP

Experiments and tests were conducted to determine effectiveness of the air filtration system of the present disclosure in trapping the particulate matter and preventing the particulate matter from reaching an engine of a vehicle. The air filtration system was tested on a test vehicle. The test vehicle was fitted with an air filtration system of the present disclosure.

Tests were conducted in various test conditions across India to determine the effect of the air filtration system of the present disclosure on the service life of the filters.

The following table depicts the service life of the filter when used with filtration system of the present disclosure vis-à-vis when used with conventional filtration systems under same set of conditions.

The following table depicts the environmental conditions under which the filter with conventional filtration systems and filter with filtration systems of the present disclosure were tested.

The following table depicts other test conditions that were set and under which the filter with conventional filtration systems and filter with filtration systems of the present disclosure were tested.

During this test contaminant (ISO Fine / Coarse Test Dust) is fed to the test
sample till the terminating restriction is reached.

From the above test results it is clear that under same set of conditions the service life of the filter when used with filtration system of the present disclosure is more than the service life of the filter when used with conventional filtration systems. Particularly, the air filter exhibits a service life in the range of 8-10 hours when used with conventional filtration system and the same filter exhibits a service life of more than 100 hours when used with the filtration system of the present disclosure.

TECHNICAL ADVANCEMENTS

The technical advancements offered by the present disclosure include the realization of:
• an air filtration system that reduces shut down of vehicle due to air filter maintenance;
• an air filtration system that ensures continuous supply of purified intake air into an engine;
• an air filtration system that ensures minimal failure of an air filter associated with the vehicle;
• an air filtration system that enhances operational life of the air filter;
• an air filtration system that results in minimal maintenance cost;
• an air filtration system that ensures auto ejection of large husk and dust particles which otherwise choke the conventional rubber boot valve; and
• an air filtration system that ensure un-interrupted supply of purified intake air for an extended period of time.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Wherever a range of values is specified, a value up to 10% below and above the lowest and highest numerical value respectively, of the specified range, is included in the scope of the disclosure.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. ,CLAIMS:1. An air-filtration system for supplying clean air to an engine of a vehicle, said air filtration system comprising:
• a pre-cleaner having a tubular configuration and functionally coupled to the engine, said pre-cleaner adapted to receive particulate laden air therein due to an intermittent suction pressure created during intake strokes of a piston within the engine, said pre-cleaner comprising a swirl creating element disposed therein and adapted to cause swirling of the particulate laden air to facilitate separation of heavier particulate matter from said particulate laden air to at least partially clean said particulate laden air;
• a particulate collector adapted to co-operate with said pre-cleaner and collect heavier particulate matter separated from said particulate laden air in said pre-cleaner, said particulate collector comprising:
o an inlet port functionally coupled to said pre-cleaner;
o a particulate collecting chamber configuring an enclosure adapted to collect said heavier particulate matter from said pre-cleaner via said inlet port, said particulate collecting chamber has an open end configured on an operative bottom end of said particulate collecting chamber; and
o a flap hingeably connected to said particulate collecting chamber and adapted to selectively unblock said open end of said particulate collecting chamber to facilitate evacuation of heavier particulate matter from said particulate collecting chamber; and
• a filter disposed downstream of and in fluid communication with said pre-cleaner, said filter adapted to further remove particulate matter from said at least partially cleaned particulate laden air leaving said pre-cleaner and supply clean air to the engine.

2. The air filtration system as claimed in claim 1, wherein said flap is a flat flap.

3. The air filtration system as claimed in claim 1, wherein said flap is a dimpled flap such that dimple configured thereon is disposed within said particulate collection chamber when said flap blocks said open end of said particulate collecting chamber.

4. The air filtration system as claimed in claim 1, wherein said pre-cleaner is connected to said filter by at least one first duct.

5. The air filtration system as claimed in claim 1, wherein said filter is connected to the engine by said second duct.

6. The air filtration system as claimed in claim 1, wherein axis of said particulate collecting chamber is inclined with respect to said axis of the pre-cleaner at an angle in the range of 20 degrees to 50 degrees.

7. The air filtration system as claimed in claim 1, wherein said flap is adapted to block said open end of said particulate collecting chamber to retain heavier particulate matter collected therein under action of suction pressure created during intake stroke of said piston within the engine.

8. The air filtration system as claimed in claim 1, wherein said pre-cleaner and swirl creating element disposed therein is adapted to separate heavier particulate matter by facilitating accumulation of said heavier particulate matter on inner walls of said pre-cleaner due to centrifugal forces acting on said heavier particulate matter.

9. The air filtration system as claimed in claim 1, wherein said flap is adapted to unblock said open end of said particulate collecting chamber during exhaust stroke of said piston within the engine due to weight of said heavier particulate matter and absence of any holding forces, thereby facilitating evacuation of heavier particulate matter from said particulate collecting chamber.

10. The air filtration system as claimed in claim 1, further comprising a gasket fitted along a rim of said open end of said particulate collection chamber.

11. The air filtration system as claimed in claim 1, wherein said gasket is of polymeric material.