DESC:INTEGRATED AIR FILTER HOUSING

Field of the invention:

The present invention generally relates to an air filter systems of internal combustion engines of automobile vehicles and more particularly, to an air filter housing integrated with the driver’s cabin floor.

Background of the invention:

The combustion air entering into an internal combustion engine is always filtered before sending in to filter out dust/particulate matters and prevent engine damage. Need for air filtration especially in India is much high due to rough weather conditions. An air intake system of an automobile mainly comprises of an air filter, few plastic/ metal ducts, its mountings and rubber hoses with its clamps. The conventional method of designing air intake system in commercial vehicle has not changed much since last 20 years in terms of number of parts used and total weight of the system.

The prior art patent DE3333621 discloses an air filter housing for an internal combustion engine. The patent focuses on optimizing the air filter body by end plate elastomer and housing to reduce housing ribbing and to reduce overall space of the air filter. It claims the air filter housing design and states characteristics of filter housing and its optimization in detail. Another prior art patent US20150192044 claims an air filter outlet wherein two outlets are provided for separating the engine inlet air from the compressor inlet air to reduce the pressure drop in engine side during compression in working condition. Still another US patent US7347883B2 discloses an air filter housing having its walls extended to mount battery thereon with the battery tray integrated with the filter housing. However, the cited documents do not provide better space management, reduction of weight and ease of maintenance and serviceability in their designs.
As shown in figure 1, a conventional air filter housing (4) is mounted on a cabin body or chassis through a bracket and strap arrangement (8) in a commercial vehicle (10). Such arrangement is common in all types of commercial vehicles and is popular in entire Cowl range of vehicles. In conventional systems, the conventional air filter systems need additional mounting brackets and straps for mounting filter body. This increases the number of joints which in turn is susceptible to dust entry. Secondly, the overhanging support as shown in figure 1 is prone to failure and the manufacturer has to incur cost for housing and air filter element in totality.

Accordingly, there exists a need to provide an air filter housing unique in terms of layout and integration of parts, which provides better space management, reduction of weight and ease of maintenance and serviceability.

Objects of the invention:

An object of the present invention is to provide an air filter housing integrated with a vehicle cabin floor to provide more space in the driver’s cabin.

Another object of the present invention is to eliminate the need of mounting brackets and straps for mounting the air filter body.

Still another object of the present invention is to reduce the weight and maintenance cost of the air filter system.

Summary of the invention:

Accordingly, the present invention provides an integrated air filter housing for an automobile vehicle. The integrated air filter housing includes a top half and a bottom half. The top half of a predefined shape is made up of a sheet metal of a cabin portion and integrated with a cabin floor. The bottom half is spot welded to the top half from a bottom side of the cabin floor. The bottom half has a shape corresponding to the shape of the top half. The top half and the bottom half are welded to form the housing of a modular size. The shape of the top half and the bottom half is selected from any one of a cylindrical, square, rectangle and hexagon shape based on air filter’s performance requirement.

The integrated housing saves the space for fitting a separate air filter hence more space is available in an engine compartment and below or inside the vehicle cabin. The integrated housing does not require separate mounting arrangement thereby saving the cost for brackets, clamps, fasteners, rubber isolator, tooling and the service cost.

Brief description of the drawings:

The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 shows a perspective view of a conventional air filter system layout of a commercial vehicle, in accordance with the prior art;

Figure 2 shows a perspective view of an air filter housing integrated with a cabin/cowl floor, in accordance with the present invention; and

Figure 3 shows a detailed view of the air filter housing integrated with the cabin/cowl floor, in accordance with the present invention.

Detailed description of the invention:

The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.
The present invention provides a housing made up of sheet metal of a cabin portion and integrated with a cabin floor of the driver’s cabin thereby providing more space therein. All the features of the air filter are fitted inside the integrated air filter housing thereby reducing the number of parts required for separately mounting the air filter in the driver’s cabin.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

Referring to figures 2 and 3, an integrated air filter housing (100) (hereinafter ‘the housing (100)’) for an automobile vehicle (150) in accordance with the present invention is shown. In the vehicle (150), the housing (100) is housed in the driver’s cabin by suitably integrating with a sheet metal components of a cabin floor (120).

As shown in figure 3, the housing (100) includes a top half (40) and a bottom half (80). In an embodiment, the top half (40) of a predefined shape is made up of a sheet metal of a cabin portion and integrated with the cabin floor (120). The bottom half (80) is spot welded to the top half (40) from a bottom side of the cabin floor (120). The bottom half (80) has a shape corresponding to the shape of the top half (40). The top half (40) and the bottom half (80) are welded to form the housing (100) of a modular size. The shape of the top half (40) and the bottom half (80) is selected from any one of a cylindrical, square, rectangle and hexagon shape based on air filter’s performance requirement.

In an embodiment, the housing (100) made up of cabin portion is having features like a dirty air inlet pipe, a clean air outlet pipe, a provision to accommodate primary, secondary filter element and a provision to fit end cover with sealing arrangements.
The housing (100) eliminates the requirement of any separate mounting arrangement. The housing (100) also eliminates the number of joints into the system and reduces the number of parts required for mounting the air filter housing.

Advantages of the invention:
1. The housing (100) eliminates the requirement of a separate housing for the air filter thereby saving the material, tooling and service cost.
2. The housing (100) does not require separate mounting arrangement thereby saving the cost for brackets, clamps, fasteners, rubber isolator, tooling and the service cost.
3. As the space for fitting separate air filter is saved, more space is available in the engine compartment and below or inside the vehicle cabin.
4. The housing (100) has less issues of durability like cracking, leaking, rattling, noise, etc.
5. Separate outside filter is one of NVH source – inside cabin integral filter shall reduce vehicle NVH level
6. Weight saving of approx. 10 Kgs.
7. Being integrated in cabin shall be easy for clean side and dirty side air pipe designs.
8. Generally used material for air filter housing is high grade plastic which is not naturally degradable whereas the integrated housing (100) is mainly made with metals.
9. When separate filters are used, they do not match with vehicle colors whereas the integral filter can have various colors like cabin color.
10. Integration of the housing (100) with the cabin reduces assembly line fitment time and improves roll down jobs per hour time.
11. The integrated housing (100) reduces inventories and improves logistics and bin management at a manufacturing plant.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.
,CLAIMS:We Claim:
1. An integrated air filter housing (100) for an automobile vehicle (150), the housing (100) comprising:
a top half (40) of a predefined shape made up of a sheet metal of a cabin portion and integrated with a cabin floor (120); and
a bottom half (80) spot welded to the top half (40) from a bottom side of the cabin floor (120), the bottom half (80) having a shape corresponding to the shape of the top half (40),
wherein, the top half (40) and the bottom half (80) are welded to form the 10 housing (100) of a modular size.
2. The housing (100) as claimed in claim 1, wherein the shape of the top half (40) and the bottom half (80) is selected from any one of a cylindrical, square, rectangle and hexagon shape based on air filter’s performance requirement.
Dated this 18th day of March, 2019
Prafulla Wange
(Agent for Applicant)
(IN/PA/2058)