Air induction systems for internal combustion engines

Abstract

Air induction systems are for an internal combustion engine. The air induction systems comprise an air intake plenum that conducts intake airflow to an air cleaner for cleaning prior to combustion in the internal combustion engine. The air intake plenum is movable with respect to the air cleaner between an open position separated from the air cleaner and a closed position connected to the air cleaner. A bellows connects the air intake plenum to the air cleaner when the air intake plenum is in the closed position. The bellows has an upstream first end that seals with the air intake plenum and a downstream second end that seals with the air cleaner. A spring is disposed in the bellows. The spring applies a biasing pressure on the bellows that encourages sealing between the bellows and at least one of the air intake plenum and the air cleaner when the air intake plenum is in the closed position. A shield is provided that blocks inflow of rain water to the bellows when the air intake plenum is in the open position.

Claims

1. An air induction system for an internal combustion engine, the air induction system comprising: an air intake plenum that conducts intake airflow to an air cleaner for cleaning prior to combustion in the internal combustion engine, the air intake plenum movable with respect to the air cleaner between an open position separated from the air cleaner and a closed position connected to the air cleaner; a bellows that connects the air intake plenum to the air cleaner when the air intake plenum is in the closed position, the bellows being axially elongated and having an interior channel extending between a first opening at an upstream first end thereof and a second opening at a downstream second end thereof; and a shield that blocks inflow of rain water to the bellows when the air intake plenum is in the open position, the shield comprising: an axial support member that axially extends along the interior channel; and a radial cover plate that radially extends from the axial support member, the radial cover plate having a radially outer edge that is located adjacent an inner perimeteral surface of the bellows when the air intake plenum is in the open position, the radially outer edge axially flush with the first opening at the first end of the bellows when the air intake plenum is in the open position.

2. The air induction system of claim 1, wherein the bellows comprises the upstream first end that seals with the air intake plenum and the downstream second end that seals with the air cleaner, the bellows forced into a compressed state when the air intake plenum is in the closed position, and wherein the bellows is biased into an extended state when the air intake plenum is in the open position.

3. The air induction system of claim 1, further comprising a biasing member disposed in the bellows, the biasing member applying a biasing pressure on the bellows that encourages sealing between the bellows and at least one of the air intake plenum and the air cleaner when the air intake plenum is in the closed position.

4. The air induction system of claim 1, wherein the shield blocks inflow of rain water to the bellows when the air intake plenum is in the closed position.

5. The air induction system of claim 1, wherein the shield blocks inflow of rain water to the bellows to a greater degree when the air intake plenum is in the open position than when the air intake plenum is in the closed position.

6. The air induction system of claim 1, wherein the shield remains stationary as the air intake plenum moves between the open position and the closed position.

7. The air induction system of claim 1, wherein the radially outer edge is axially spaced apart from the first end of the bellows when the air intake plenum is in the closed position so as to axially define a first perimeteral gap through which intake airflow passes to the air cleaner.

8. The air induction system of claim 7, further comprising a drain valve in the bellows, the drain valve draining rain water that enters the bellows via the first perimeteral gap.

9. The air induction system of claim 1, further comprising a pressurized inflatable ring on an outer perimeter of the bellows, wherein inflation of the pressurized inflatable ring creates a perimeter seal between the bellows and the air cleaner.

10. The air induction system of claim 9, wherein the pressurized inflatable ring is disposed in a perimeteral groove on the outer perimeter of the bellows.

11. The air induction system of claim 1, further comprising a magnet on an outer perimeter of the bellows and a metal ring disposed in the air cleaner, wherein the magnet is attracted to the metal ring and thereby creates a perimeteral seal between the bellows and the air cleaner.

12. The air induction system of claim 1, wherein the bellows and air cleaner are magnetically attracted to each other.

13. An air induction system for an internal combustion engine, the air induction system comprising: an air intake plenum that conducts intake airflow to an air cleaner for cleaning prior to combustion in the internal combustion engine, the air intake plenum movable with respect to the air cleaner between an open position separated from the air cleaner and a closed position connected to the air cleaner; a bellows that connects the air intake plenum to the air cleaner when the air intake plenum is in the closed position, the bellows being axially elongated and having an interior channel extending between a first opening at an upstream first end thereof and a second opening at a downstream second end thereof that seals with the air cleaner, the bellows forced into a compressed state when the air intake plenum is in the closed position and biased into an extended state when the air intake plenum is in the open position; and a shield that blocks inflow of rain water to the bellows when the air intake plenum is in the open position and the closed position, the shield comprising an axial support member that axially extends along the interior channel; and a radial cover plate that radially extends from the axial support member, the radial cover plate having a radially outer edge that is located adjacent an inner perimeteral surface of the bellows when the air intake plenum is in the open position, the radially outer edge sealing with the bellows when the air intake plenum is in the open position and axially spaced apart from the upstream first end of the bellows when the air intake plenum is in the closed position so as to define a first perimeteral gap through which intake airflow passes to the air cleaner.

14. The air induction system of claim 13, further comprising a biasing member disposed in the bellows, wherein the biasing member applies a biasing pressure on the bellows that encourages sealing between the bellows and at least one of the air intake plenum and the air cleaner when the air intake plenum is in the closed position.

15. The air induction system of claim 13, wherein the shield blocks inflow of rain water to the bellows to a greater degree when the air intake plenum is in the open position than when the air intake plenum is in the closed position.

16. The air induction system of claim 13, further comprising a drain valve in the bellows, the drain valve draining rain water that enters the bellows via the first perimeteral gap.

17. The air induction system of claim 13, further comprising a pressurized inflatable ring on an outer perimeter of the bellows, wherein inflation of the pressurized inflatable ring creates a perimeter seal between the bellows and the air cleaner.

18. The air induction system of claim 17, wherein the pressurized inflatable ring is disposed in a perimeteral groove on the outer perimeter of the bellows.

19. The air induction system of claim 13, further comprising a magnet on an outer perimeter of the bellows and a metal ring disposed in the air cleaner, wherein the magnet is attracted to the metal ring and thereby creates a perimeteral seal between the bellows and the air cleaner.

20. The air induction system of claim 13, wherein the bellows and air cleaner are magnetically attracted to each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Examples of air induction systems for internal combustion systems are described with reference to the following Figures. The same numbers are used throughout the Figures to reference like features and like components.

(2) FIG. 1 is a perspective view of a vehicle having a hood with an air intake plenum providing intake airflow to an air cleaner for cleaning prior to combustion in the internal combustion engine.

(3) FIG. 2 is a side view of the vehicle showing the hood and its air intake plenum in a closed position wherein intake airflow is directed to the air cleaner.

(4) FIG. 3 is a side view of the vehicle showing the hood and its air intake plenum in an open position wherein the air intake plenum is separated from the air cleaner.

(5) FIG. 4 is a perspective view of a device for connecting the air intake plenum to the air cleaner.

(6) FIG. 5 is another perspective view of the device of FIG. 4, when the hood and air intake plenum are in a closed position.

(7) FIG. 6 is a view of section 6-6 taken in FIG. 4.

(8) FIG. 7 is a view of section 7-7, taken in FIG. 5.

(9) FIG. 8 is a perspective view of another example of a device for connecting the air intake plenum to the air cleaner when the hood is in the closed position.

(10) FIG. 9 is view of section 9-9, taken in FIG. 8.

(11) FIG. 10 is a perspective view of the device of FIG. 8, when the air intake plenum is in the open position.

(12) FIG. 11 is a view of section 11-11, taken in FIG. 10.

(13) FIG. 12 is a section view of another example of a device that connects the air intake plenum to the air cleaner.

(14) FIG. 13 is a section view of yet another example of a device that connects the air intake plenum to the air cleaner.

DETAILED DESCRIPTION OF THE DRAWINGS

(15) Through research and development, the present inventors have endeavored to provide long-term flexible and durable sealing joints between air intake plenums and an air cleaners providing combustion air to internal combustion engines. In such applications, the present inventors have found it desirable to control intake air temperature rises to within 5 F. The present inventors have also found it desirable to prevent environmental elements such as rain, snow, dust, etc. from entering the sealing joint and interfering with operation of the air cleaner.

(16) FIGS. 1-3 depict an air induction system 20 for a vehicle 22. In this example, the air induction system 20 is adapted for use with a truck; however the air induction system 20 of the present disclosure can be adapted for use with a variety of different vehicles, including other types of on- and off-road trucks, cars, and/or the like. The air induction system 20 includes an air intake plenum 24 and an air cleaner 26 for cleaning the intake air prior to combustion in an internal combustion engine, shown schematically at 28. The air cleaner 26 is a conventional intake air filter having a housing and filter media for filtering particular matter and/or other contaminants from the intake air; however this example is not limiting. The air induction system 20 of the present disclosure can be adapted for use with any conventional device for cleaning intake air.

(17) As shown by arrows A, the air intake plenum 24 conducts intake airflow from the atmosphere surrounding the vehicle 22 to the air cleaner 26, which resides under the hood 30 of the vehicle 22. The air intake plenum 24 is formed under the hood 30 of the vehicle 22 and receives intake airflow via opposing inlets 32 on the hood 30. In this example, the air intake plenum 24 is formed with or attached to the hood 30; however other locations for the air intake plenum 24 are contemplated. Intake airflow travels from the opposing intake inlets 32 to a central opening 34 in a lower surface 37 of the air intake plenum 24. The exact configuration of the air intake plenum 24 can vary from that which is shown.

(18) As shown in FIGS. 2 and 3, the hood 30 and the associated air intake plenum 24 are together movable between a closed position shown in FIG. 2 and an open position shown in FIG. 3. The hood 30 is pivotable about a hinge 31 located at the front of the vehicle 22; however other types of movable connections between the hood 30 and the vehicle 22 can and often are employed. The hood 30 typically is moved into the open position during periods of non-use and sometimes during start-up of the vehicle 22. The hood 30 typically is in the closed position during travel of the vehicle 22.

(19) According to the present disclosure, the air induction system 20 includes a device 21 for connecting the air from the air intake plenum 24 to the air cleaner 26 in a manner that provides a long-term sealing joint and/or protects the air cleaner 26 from intrusion of environmental elements such as water and/or dust. The particular configuration of the device 21 can vary, examples of which are shown in FIGS. 2-7, 8-11, 12, and 13.

(20) FIGS. 2-7 depict an example of a device 21A having a bellows 36 that connects the air intake plenum 24 to the air cleaner 26 when the air intake plenum 24 is in the closed position. The bellows 36 is made of a resilient flexible material, such as rubber and/or the like, wherein under pressure the bellows 36 can be compressed into a compressed position and then will expand back under power of its own resiliency towards an expanded position when the pressure is released. The bellows 36 is axially elongated and has an upstream first end 38 that is configured to seal with the air intake plenum 24 and a downstream second end 40 that seals with the air cleaner 26. More specifically, the bellows 36 has an upper mating surface 42 that sealingly abuts against a lower mating surface 37 of the air intake plenum 24 when the hood 30 of the vehicle 22 is moved into the closed position. When the hood 30 is moved into the open position, the lower mating surface 37 of the air intake plenum 24 and mating surface 42 of the bellows 36 are separated, thereby opening the seal. The shape and construction of the mating surfaces 37 and 42 can vary from that which is shown as long as an effective seal is created between the bellows 36 and the air intake plenum 24 when the hood 30 is moved into the closed position. In this example, the mating surface 42 is relatively flat and square-shaped, and has a plurality of perimeteral sealing ribs 44 for encouraging the noted sealing contact between the mating surfaces 42 and 37.

(21) The bellows 36 has a plurality of corrugations 46 along its length. An axially lowermost corrugation 46 is received in a mating channel 48 of a static base member 50 connected in sealing relationship with an inlet opening of the air cleaner 26. Thus, the downstream second end 40 of the bellows 36 is sealed with the air cleaner 26. The manner of connection between the bellows 36 and air cleaner 26 can vary from that shown and described as long as a seal is provided therebetween. A spring 52 is disposed in the bellows 36 and applies a biasing pressure on the bellows 36 that encourages sealing between the bellows 36 and the air intake plenum 24 and between the bellows 36 and the air cleaner 26. The spring 52 has convolutions 54 that optionally can be interdigitated amongst the plurality of corrugations 46. The spring 52 has opposite first and second ends 56, 58. The first end 56 is engaged in a groove 60 on an internal surface 62 of one of corrugations 46 of the bellows 36. The opposite second end 58 abuts against an outer surface of the mating channel 48 on the base member 50. The manner of connection between the spring 52 and bellows 36 can vary from that shown as long as the spring 52 effectively applies a bias force on the bellows 36.

(22) In some other examples, the orientation of the bellows 36 could be the opposite from that shown, such that the first end 38 of the bellows 36 remains connected to the air intake plenum 24 when the hood 30 is moved into the open position. In these examples the second end 40 of the bellows 36 can have a mating surface for mating with a compatible mating surface on the air cleaner 26. In some examples, the orientation of the spring 52 could also be reversed, such that the first end 56 of the spring 52 abuts against an outer surface of a mating channel on a base member associated with the air intake plenum 24 and the second end 58 of the spring 52 is engaged in a groove 60 on an internal surface of one of corrugations of the bellows 36. In some other examples, both of the first and second ends 56, 58 of the spring 52 can be engaged in grooves on internal surfaces of corrugations of the bellows 36.

(23) FIGS. 2, 5 and 7 depict the situation where the hood 30 and its air intake plenum 24 are in the noted closed position. FIGS. 3, 4 and 6 depict the situation where the hood 30 and its air intake plenum 24 are in the noted open position. As shown by comparison of these figures, the spring 52 and bellows 36 are axially compressed when the hood 30 and air intake plenum 24 are in the noted closed position. The spring 52 and bellows 36 are not axially compressed, or are extended, when the hood 30 and the air intake plenum 24 are in the noted open position. The natural resiliency of the bellows 36 and the resiliency or spring force of the spring 52 both operate to bias the bellows 36 into the extended position shown in FIGS. 3, 4 and 6 when the hood 30 is moved into the open position. Engagement between the lower mating surface 37 of the air intake plenum 24 and the mating surface 42 of the bellows 36, including downward movement of the hood 30 into the position shown in FIG. 2, compresses the bellows 36 into the compressed state shown in FIGS. 2, 5 and 7. In the closed position, the combined biasing forces of the spring 52 and the natural resiliency of the bellows 36 operates to maintain effective sealing pressure over time, even when the resiliency of the bellows 36 itself does not provide an effective seal. Therefore rise of atmospheric air intake temperature can be better controlled.

(24) The device 21A shown in FIGS. 2-7 also has a shield 64A that at least partially covers the upstream first end 38 of the bellows 36, thereby limiting intrusion of environmental elements to the air cleaner 26. The shield 64A covers the upstream first end 38 to a greater degree when the hood 30 and air intake plenum 24 are in the open position, shown in FIG. 3, than when the hood 30 and air intake plenum 24 are in the closed position, shown in FIG. 2. That is, the shield 64A is configured such that a first axial, perimeteral cross-sectional area for intake airflow through the bellows 36 is defined when the bellows 36 is compressed into the compressed state shown in FIGS. 5 and 7 and a smaller, second axial, perimeteral cross-sectional area for intake airflow through the bellows 36 is defined when the bellows 36 is in the extended state shown in FIGS. 4 and 6. Thus the shield 64A is configured to block inflow of environmental elements, such as rain water, into the bellows 36 when the hood 30 and air intake plenum 24 are in the open position shown in FIG. 3. The shield 64A is also configured to block inflow of environmental elements such as rain water to the bellows 36 when the hood 30 and air intake plenum 24 are in the closed position. However the shield 64A blocks inflow of environmental elements such as rain water to the bellows 36 to a greater degree when the hood 30 and air intake plenum 24 are in the open position then when the hood 30 and air intake plenum 24 are in the closed position.

(25) In this example, the shield 64A is fixed to the inlet on the air cleaner 26 and remains stationary with respect to the air intake plenum 24 and hood 30 as the air intake plenum 24 and hood 30 move between the open and closed positions. As noted hereinabove, the bellows 36 is forced into the compressed state shown in FIG. 7 when the air intake plenum 24 is in the closed position and the bellows 36 is biased into an extended state shown in FIG. 6 when the air intake plenum 24 is in the open position. As shown in FIG. 7, the bellows 36 is elongated and defines an interior channel 66 that extends between an upstream first opening 68 at the upstream first end 38 and a downstream second opening 70 at the downstream second end 40. As shown in FIGS. 6 and 7, the shield 64A includes an axial support member 72 that axially extends along the interior channel 66. A radial cover plate 74 radially extends from the axial support member 72. The configuration of the axial support member 72 can vary from that which is shown. In this example, the axial support member 72 includes a center post 76 that has a plurality of throughholes 78 that allow intake of airflow therethrough from upstream to downstream. A plurality of radially extending ribs 80 support the center post 76 in the interior channel 66. The radial cover plate 74 has a radially outer edge 82 that is located adjacent an inner perimeteral surface 84 of the bellows 36 when the air intake plenum 24 is in the noted open position, see FIGS. 3 and 6, thereby reducing or eliminating inflow of environmental elements such as rain water through the bellows 36.

(26) In the example shown in FIGS. 2-7, the radially outer edge 82 has a bottom portion 86 that seals with the bellows 36 when the hood 30 and air intake plenum 24 are in the open position, shown in FIGS. 3 and 6. The radially outer edge 82 of the cover plate 74 is axially spaced apart from the first end 38 of the bellows 36 when the air intake plenum 24 is in the closed position so as to define a first perimeteral gap G1 shown in FIGS. 5 and 7 through which intake airflow passes to the air cleaner 26. As explained further herein below, the gap G1 also exists in the embodiment shown in FIGS. 8 and 9. A radial extension plate 88 is axially spaced apart from the radial cover plate 74 so as to define a second perimeteral gap G2 therebetween that is axially spaced apart from the first perimeteral gap G1 through which intake airflow passes to the air cleaner 26. The second perimeteral gap G2 continuously allows intake airflow to pass into the bellows 36 via a hole 39 in the cover plate 74, when the air intake plenum 24 is moved between the open and closed positions. The size of the shield 64A can be selected so that the gap G2 is big enough to allow sufficient airflow during idle conditions of the engine 28 and the combined gaps G1 and G2 are big enough to allow maximum speed operation of engine 28. An extension member 90 supports the radial extension plate 88 apart from the radial cover plate 74. The extension member 90 includes a center post 92 that has a plurality of throughholes 94 that allow intake airflow into the interior channel 66.

(27) FIGS. 8-11 depict another example of a device 21B for connecting the air intake plenum 24 to the air cleaner 26. FIGS. 8 and 9 show the device 21B when the hood 30 and air intake plenum 24 are in the closed position. FIGS. 9 and 10 show the device 21B when the hood 30 and air intake plenum 24 are in the open position. In this example, the bellows 36 and spring 52 are configured similar to the examples shown in FIGS. 1-7. The shield 64B has a different configuration from the shield 64A shown in FIGS. 1-7. In this example, the shield 64B does not include the radial extension plate 88 and extension member 90. Also, the cover plate 74 does not include the noted hole 39. The radial cover plate 74 has the noted radially outer edge 82 which, as shown in FIGS. 10 and 11, is located adjacent to the inner perimeteral surface 84 of the bellows 36 when the air intake plenum 24 is in the open position. In this example, the radially outer edge 82 is axially flush with the first opening 68 at the first end 38 of the bellows 36 when the air intake plenum 24 is in the open position. The radially outer edge 82 is axially spaced apart from the first end 38 of the bellows 36 when the air intake plenum 24 is in the closed position, as shown in FIGS. 8 and 9, so as to axially define a first perimeteral gap G1 through which the intake airflow passes to the air cleaner 26. A drain valve 98 is provided in the bellows 36. The drain valve 98 is a conventional one-way valve formed in one of the plurality of corrugations 46 and drains rainwater that enters the bellows 36. The drain valve 98 can be necessary in examples where the radially outer edge 82 of the radial cover plate 74 does not seal with the inner perimeteral surface 84 of the bellows 36, thus draining environmental elements, such as rainwater, that passes into the interior channel 66 of the bellows 36 between the radial outer edge 82 and the inner perimeteral surface 84. The location of the drain valve 98 can vary from that shown. For example the drain valve 98 can instead be located in base member 50.

(28) FIG. 12 depicts another example of a device 21C for connecting the air intake plenum 24 to the air cleaner 26 when the air intake plenum 24 is in the closed position. In this example, a magnet 100 is provided on the outer perimeter 102 of the bellows 36. The type of magnet can vary and could be a permanent magnet or an electromagnet. A metal ring 104 is disposed in the air cleaner 26. The magnet 100 is attracted to the metal ring 104 and thereby creates a perimeter seal between the bellows 36 and the air cleaner 26. In another example, the bellows 36 and air cleaner 26 can comprise a North and South magnet so that the bellows 36 and air cleaner 26 are magnetically attracted to each other, thereby forming a perimeteral seal therebetween.

(29) FIG. 13 depicts another example of a device 21D for connecting the air intake plenum 24 to the air cleaner 26 when the air intake plenum 24 is in the closed position. A pressurized inflatable ring 110 is disposed in a perimeteral groove 112 on the outer perimeter 102 of the bellows 36. Inflation of the ring 110 via a source of pressurized air 114 expands the inflatable ring 110 and thus presses radially inwardly into the perimeteral groove 112 onto the outer perimeter 102 of the bellows 36, thus pressing the outer perimeter 102 of the bellows 36 against the groove 112 in the housing 114 of the air cleaner 26, thus creating a perimeteral seal between the bellows 36 and the air cleaner 26. The type of source of pressurized air 114 can vary and can include, for example a pump.

(30) In the present disclosure, certain terms have been used for brevity, clearness and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different systems and methods described herein may be used alone or in combination with other systems and methods. Various equivalents, alternatives, and modifications are possible within the scope of the appended claims. Each limitation in the appended claims is intended to invoke interpretation under 35 USC 112, sixth paragraph, only if the terms means for or step for are explicitly recited in the respective limitation.