FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPETE SPECIFICATION
(See Section 10 and Rule 13)
WATER SEPARATOR ASSEMBLY FLEETGUARD FILTERS PRIVATE LIMITED
An Indian Company having registered address at: 136, Park Marina Road, Baner, Pune - 411 045, MH, India
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

TECHNICAL FIELD
[0001] The present disclosure relates generally to a water separator assembly, and more specifically to a water separator assembly for intake air of an internal combustion engine.
BACKGROUND
[0002] The operation of internal combustion engines used in vehicles or other mechanical equipment, such as diesel engines, generally require to be equipped with an air filter assembly. The air filter assembly filters air that is directed into the combustion air inlet for the engine. Typically, the air filter assembly comprises a serviceable filter cartridge positioned therein, that is either periodically serviced or replaced. These filter cartridges typically remove dust, debris, and other fine particles from the incoming intake air.
[0003] In internal combustion engines, the incoming intake air must also be cleaned from any water included in it. The water may be included in the intake air from rainwater or water from the road, which is injected into the air. To minimize any damage from occurring to the engine, the turbocharger, or any other component, it is essentially desirable to separate as much of the water as possible from the flow of intake air to the air intake system of the internal combustion engine.
[0004] In existing practices for removing water from the flow of intake air, a variety of systems and methods have been employed, combinely referred

to as water separators. With ever changing stringent emission norms and focus on durability of internal combustion engines, it is desirable to remove as much of water as possible without affecting the overall working efficiency of the engines and the manufacturing cost to produce. Thus, such a water separator is needed which is simple in design, is cheaper to produce, and achieves the maximum water removal efficiency.
[0005] Conventionally, emphasis has been on features of water separators which provide greater efficiency in water separation, less problematic intake air flow restrictions, and ease of assembly and use. Numerous designs have been proposed in which various arrangements of water separators have been propounded over time. Some water separators are made so as to focus on longer maintenance free service life, some are made to focus on increasing water removal efficiency/capacity, some are made to facilitate compact designs, some are only focused on balancing the pressure loss due to air flow restrictions. But none of the prior arts have ever successfully met all the above criteria.
[0006] In light of the above shortcomings and drawbacks of the existing water separators, there exists a need for a water separator without any substantial pressure loss and better water removal efficiency/capacity. Further, there exists a need for a water separator which is simple in design so as to limit the manufacturing cost for achieving desired water removal efficiency and acceptable for providing compact design for the internal combustion engines.
[0007] The present invention deals with a design of an improved water separator providing an improved and alternative embodiment ensuring

simple and efficient design, lower manufacturing cost, and a possibility of meeting durability standards while enhancing overall water removal efficiency. The present invention further provides an efficient and compact water separator.
SUMMARY
[0008] Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems recognized by the inventor(s) in conventional systems.
[0009] In an aspect of the present disclosure, a water separator for separating liquid water from intake air flow to a filter assembly. The water separator comprises an inlet air assembly, an intermediate assembly coupled to the inlet air assembly and receiving inlet air from the inlet air assembly, and an outlet air assembly coupled to the intermediate assembly and receiving inlet air from the intermediate assembly.
[0010] The inlet air assembly comprises a louver arrangement having plurality of louvers for removing water from the inlet air entering the water separator and a water drain opening provided after the louver arrangement and at the bottom of the inlet air assembly for draining water removed by the louver arrangement. The intermediate assembly comprises a first end, a second end, a C-shaped enclosed structure, and a plurality of flow diverters. The top of the C-shaped enclosed structure directing the incoming inlet air downwards and the bottom of the C-shaped enclosed structure directing the incoming inlet air upwards against the gravity

changing the flow direction. The plurality of flow diverters provided near the top of the C-shaped enclosed structure and extending up to the bottom of the C-shaped enclosed structure. The outlet air assembly comprises a long enclosed structure narrow at the top and expanded near the bottom, the top of the long enclosed structure coupled to the second end of the intermediate assembly and the bottom configured to provide outlet to the inlet air.
[0011] The inlet air assembly is placed before the intermediate assembly and the outlet air assembly, the intermediate assembly is placed after the inlet air assembly and before the outlet air assembly, and the outlet air assembly is placed after the inlet air and intermediate assembly. The louver arrangement causes water removal from the inlet air, then the plurality of flow diverters causes water removal from the inlet air, and then the change in flow direction caused by the bottom of the C-shaped enclosed structure causes water removal from the inlet air.
[0012] 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.
[0013] 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 ACCOMPANYING DRAWINGS
[0014] 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.
[0015] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Fig. 1A is a side perspective view depicting a water separator and Fig. 1B is a front perspective view showing the water separator, in accordance with an exemplary embodiment of the present disclosure;
Fig. 2 illustrates a perspective view of a water separator, in accordance with exemplary embodiments of the present disclosure; and
Fig. 3 is a side perspective view of a water separator showing the inlet air flow direction, in accordance with an exemplary embodiment of the present disclosure.
[0016] 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
[0017] 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 have 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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”.
[0022] In an aspect of the present disclosure, a water separator for separating liquid water from intake air flow to a filter assembly. The water separator comprises an inlet air assembly, an intermediate assembly

coupled to the inlet air assembly and receiving inlet air from the inlet air assembly, and an outlet air assembly coupled to the intermediate assembly and receiving inlet air from the intermediate assembly.
[0023] The inlet air assembly comprises a louver arrangement having plurality of louvers for removing water from the inlet air entering the water separator and a water drain opening provided after the louver arrangement and at the bottom of the inlet air assembly for draining water removed by the louver arrangement. The intermediate assembly comprises a first end, a second end, and a plurality of flow diverters. The top of the C-shaped enclosed structure directing the incoming inlet air downwards and the bottom of the C-shaped enclosed structure directing the incoming inlet air upwards against the gravity changing the flow direction. The plurality of flow diverters provided near the top of the C-shaped enclosed structure and extending up to the bottom of the C-shaped enclosed structure. The outlet air assembly comprises a long enclosed structure narrow at the top and expanded near the bottom, the top of the long enclosed structure coupled to the second end of the intermediate assembly and the bottom configured to provide outlet to the inlet air.
[0024] The inlet air assembly is placed before the intermediate assembly and the outlet air assembly, the intermediate assembly is placed after the inlet air assembly and before the outlet air assembly, and the outlet air assembly is placed after the inlet air and intermediate assembly. The louver arrangement causes water removal from the inlet air, then the plurality of flow diverters causes water removal from the inlet air, and then the change in flow direction caused by the bottom of the C-shaped enclosed structure causes water removal from the inlet air.

[0025] Embodiments of the present disclosure substantially eliminate, or at least partially address, problems in the prior art, and assist the manufacturers, consumers, and suppliers of the water separators.
[0026] In another embodiment, the present invention discloses a water separator for separating liquid water from intake air flow to a filter assembly. The water separator includes an inlet air assembly; an intermediate assembly coupled to the inlet air assembly and receiving inlet air from the inlet air assembly; and an outlet air assembly coupled to the intermediate assembly and receiving inlet air from the intermediate assembly. Characterized in that the inlet air assembly includes a louver arrangement having plurality of louvers for removing water from the inlet air entering the water separator; and a water drain opening provided after the louver arrangement and at the bottom of the inlet air assembly for draining water removed by the louver arrangement. The intermediate assembly includes a first end; a second end; a C-shaped enclosed structure, the top of the C-shaped enclosed structure directing the incoming inlet air downwards and the bottom of the C-shaped enclosed structure directing the incoming inlet air upwards against the gravity changing the flow direction; and a plurality of flow diverters provided near the top of the C-shaped enclosed structure and extending up to the bottom of the C-shaped enclosed structure. The outlet air assembly includes a long enclosed structure narrow at the top and expanded near the bottom, the top of the long enclosed structure coupled to the second end of the intermediate assembly and the bottom configured to provide outlet to the inlet air. Wherein, the inlet air assembly is placed before the intermediate assembly and the outlet air assembly, the intermediate assembly is placed after the inlet air assembly and before the outlet air assembly, and the outlet air

assembly is placed after the inlet air and intermediate assembly; and wherein the louver arrangement causes water removal from the inlet air, then the plurality of flow diverters causes water removal from the inlet air, and then the change in flow direction caused by the bottom of the C-shaped enclosed structure causes water removal from the inlet air.
[0027] Referring now to the drawings, Fig. 1A and 1B illustrate a water separator 100 in an assembled state, according to the present invention. The water separator 100 may include different functional elements assembled into it, according to various embodiments of the present disclosure. As shown in Fig. 1A and 1B, the water separator 100 includes an inlet air assembly 102, an intermediate assembly 104, and an outer assembly 106. The inlet air assembly 102 and the intermediate assembly 104 are coupled together, according to aspects of the present disclosure. The intermediate assembly 104 and the outer assembly 106 are coupled together, according to aspects of the present disclosure.
[0028] As may be further seen in Fig. 1B, the inlet air assembly 102 comprises a louver arrangement 108 having plurality of louvers 110 for removing water from the inlet air entering the water separator 100. In an embodiment of the present disclosure, the plurality of louvers 110 are evenly spaced apart from each other. In another embodiment of the present disclosure, the plurality of louvers 110 are upwardly inclined.
[0029] Fig. 1A and 1B are merely examples. A person skilled in the art will recognize many variations, alternatives, and modifications of the embodiments of the present disclosure.

[0030] Fig. 2 illustrates a perspective view depicting the water separator 100. As illustrated in the view, the inlet air assembly 102 of the water separator 100 comprises a water drain opening 200 provided after the louver arrangement 108 and at the bottom 202 of the inlet air assembly 102 for draining water removed by the louver arrangement 108. In an embodiment of the present disclosure, the water drain opening 200 may be merely an opening or may include an automatic valve triggered by the quantity of water accumulated at the bottom 202 of the inlet air assembly 102. In operation, when inlet air passes through the plurality of louvers 110 during movement of vehicle (not shown), the water carried with the inlet air gets collected on the louvers under the influence of gravity and drains outside via the water drain opening 200. Thus, the louver arrangement 108 causes water removal from the inlet air.
[0031] Again referring to Fig. 2, the intermediate assembly 104 of the water separator includes a first end 204 coupled to the inlet air assembly 102 and further includes a second end 206 coupled to the outer assembly 106. In operation, the first end 204 allows the incoming inlet air from the inlet air assembly to enter the intermediate assembly 104 and the second end 206 allows the inlet air to move on to the outer assembly 106. In addition to this, the second 206 also acts as a water stopper such that it stops water droplets from flowing further through the path. Thereafter the water droplets flow backwards and are drained through a dust election valve 216.
[0032] In accordance with Fig. 2, the intermediate assembly 104 of the water separator 100 comprises a C-shaped enclosed structure 208, according to embodiments of the present disclosure. As may be seen clearly, the C-shaped enclosed structure 208 has a distorted C-shape and not necessarily

a perfect C-shape, according to aspects of the present disclosure. The nomenclature “C-shaped” is only used to define the shape of the C-shaped enclosed structure 208 as depicted in enclosed Figures. Any and all nearby variations of “C-shape”may have different effects on the flow direction and water separation efficiency of the water separator 100.
[0033] Further referring to Fig. 2 and in accordance with embodiments of the present disclosure, the C-shaped enclosed structure 208 includes a top 210 and a bottom 212. The top 210 of the C-shaped enclosed structure 208 directs the incoming inlet air downwards. The bottom 212 of the C-shaped enclosed structure 208 directs the incoming inlet air upwards against the gravity changing the flow direction, according to aspects of the present disclosure. In various embodiments, the C-shaped enclosed structure 208 comprises a plurality of flow diverters 214 provided near the top 210 of the C-shaped enclosed structure 208 and extend up to the bottom 212 of the C-shaped enclosed structure 208. In an embodiment, the plurality of flow diverters 214 may include rib-like structures on an inner surface (not shown) of the C-shaped enclosed structure 208. In an embodiment of the present disclosure, the intermediate assembly 104 comprises the dust ejection valve 216 placed at the bottom 212 of the C-shaped enclosed structure 208. According to aspects of the present disclosure, the dust ejection valve 216 is also used for draining separated water from inlet air.
[0034] In embodiments of the present disclosure and according to Fig. 2, the outer assembly 106 of the water separator 100 comprises a long enclosed structure 218. According to aspects of the present disclosure, the long enclosed structure 218 is narrow at the top 220 and expands near the bottom 222. This narrow structure at the top 220 and expanded structure at the

bottom 222 solves all problems of air restrictions and ensures smooth flow of the incoming inlet air. As may be further seen, the top 220 of the long enclosed structure 218 is coupled to the second end 206 of the intermediate assembly 104 and the bottom 222 is configured to provide outlet to the inlet air, according to embodiments of the present disclosure. In various embodiments of the present disclosure, the inlet air coming out of the bottom 222 is provided to an air filter assembly (not shown) of an internal combustion engine (not shown).
[0035] 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.
[0036] Moving on to Fig. 3, in operation, incoming inlet air enters the air inlet assembly 102 via the louver arrangement 108. The plurality of louvers 110 of the louver arrangement 108 causes water removal from the inlet air. The inlet air then passes on to the intermediate assembly 104 and then the plurality of flow diverters 214 of the C-shaped enclosed structure 208 causes water removal from the inlet air and directs the separated water towards the dust ejection valve 216 situated at the bottom 212 of the C-shaped enclosed structure 208. The inlet air then moves on and the change in flow direction is caused by the bottom 212 of the C-shaped enclosed structure 208 causing water removal from the inlet air. The separated water by this change in flow direction is directed towards the bottom 212 of the C-shaped enclosed structure. The inlet air free of the separated water then moves on to the filter assembly (not shown) of the internal combustion engine (not shown).

[0037] 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.
[0038] Embodiments of the present disclosure can be used for various purposes, including, though not limited to, manufacturing and servicing of oil mist separators or cylinder head cover.
[0039] 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.

WE CLAIM:
1. A water separator for separating liquid water from intake air flow to a filter assembly, the water separator comprising: an inlet air assembly;
an intermediate assembly coupled to the inlet air assembly and receiving inlet air from the inlet air assembly; and
an outlet air assembly coupled to the intermediate assembly and receiving inlet air from the intermediate assembly; characterized in that: the inlet air assembly comprising:
a louver arrangement having plurality of louvers for removing water from the inlet air entering the water separator; and
a water drain opening provided after the louver arrangement and at the bottom of the inlet air assembly for draining water removed by the louver arrangement;
the intermediate assembly comprising: a first end; a second end;
a C-shaped enclosed structure, the top of the C-shaped enclosed structure directing the incoming inlet air downwards and the bottom of the C-shaped enclosed structure directing the incoming inlet air upwards against the gravity changing the flow direction; and

a plurality of flow diverters provided near the top of the C-shaped enclosed structure and extending up to the bottom of the C-shaped enclosed structure; the outlet air assembly comprising:
a long enclosed structure narrow at the top and expanded near the bottom, the top of the long enclosed structure coupled to the second end of the intermediate assembly and the bottom configured to provide outlet to the inlet air;
wherein, the inlet air assembly is placed before the intermediate assembly and the outlet air assembly, the intermediate assembly is placed after the inlet air assembly and before the outlet air assembly, and the outlet air assembly is placed after the inlet air and intermediate assembly; and
wherein the louver arrangement causes water removal from the inlet air, then the plurality of flow diverters causes water removal from the inlet air, and then the change in flow direction caused by the bottom of the C-shaped enclosed structure causes water removal from the inlet air.
2. The water separator of claim 1, wherein the plurality of louvers are upwardly inclined.
3. The water separator of claim 1, wherein the plurality of louvers are evenly spaced apart from each other.

4. The water separator of claim 1, wherein the intermediate assembly comprising a dust ejection valve placed at the bottom of the C-shaped enclosed structure.
5. The water separator of claim 4, wherein the dust ejection valve is also used for draining separated water from inlet air.