Housing for air filters of internal combustion engines and method for its production

Description

[0001] The present invention concerns a. housing for air filters of internal combustion engines, and a method of manufacturing said housing.

[0002] Internal combustion engines are generally equipped with an air intake system including a separator device or air filter. The air filter intercepts the flow of air sucked in by the motor from the external environment during the intake phase and separates particles with too big a size, which could damage the engine.

[0003] Conventional air filters generally are formed by a housing where a seat for accommodating a filtering element is defined.

[0004] Generally, the filtering element consists of a replaceable cartridge, made for instance of corrugated paper. The cartridge body divides the space inside the filter housing into two zones: a first zone where air to be filtered arrives and the retained material is collected, and a second zone from which air filtered by the cartridge leaves the filter.

[0005] Each zone further has an opening, generally equipped with a ring nut, for connection to an inlet duct through which air sucked in from the environment arrives at the filter, and to an outlet duct conveying the filtered air to the intake manifold of the engine, respectively.

[0006] Moreover, the housing can generally be opened to allow replacing the cartridge and removing deposits, if any, accumulated in the intake zone.

[0007] Depending on the applications, internal combustion engines can be either housed in a suitable compartment, called engine compartment, for instance in case of engines of vehicles, or secured to a frame or supporting structure, for instance in case of static applications, such as engines of hydraulic pumps, current generators, power take-offs, and so on.

[0008] In any case, the space occupied by the engine, whether it is an engine compartment in a vehicle or a supporting structure, generally contains a lot of ancillary devices, hydraulic and electric circuits, conduits of different kinds and so on, slaved to the operation of the engine or other devices associated with the engine.

[0009] In the past, especially in the motor vehicle field, for reasons of functionality and safety as well as for aesthetic reasons, efforts have been made to rationalise the arrangement of the parts and components typically associated with an internal combustion engine and located in an engine compartment.

[0010] As known, one of the circuits generally present in an internal combustion engine is the circuit for recovering the blow-by gases.

[0011] Actually, in internal combustion engines gas leaks ("blow-by") between the piston rings and the cylinder barrel towards the engine base occur. Such a phenomenon is very limited in engines in good mechanical conditions, but it tends to increase in time due to the wear of the rings and the cylinder barrels. The gas leaking to the engine base leaves the latter through a venting system, possibly equipped with a separator device, which for ecological reason is connected to the intake circuit, so as to allow the gases to return inside the cylinders where they are burnt.

[0012] In present engines, the hydraulic connection between the base and the intake circuit for blow-by gas return is generally obtained by means of a duct, possibly secured to the engine parts and/or other surrounding components by means of straps or clamps.

[0013] US 2003/226553 describes a blowby gas processing system which includes a breather tube extended from a breather port of an engine and connected to a connecting tube. A breather tube inside which an intake passage connecting a carburetor and an air cleaner is formed and an expanded part provided with a gas-liquid separating chamber adjacent to the intake massage are provided. An entrance joint connecting a lower part of the gas-liquid separating camber to the breather tube is integrated on one side of the connecting tube and a blowby gas exit communicating the upside of the gas-liquid separating chamber with the intake passage is provided in a partition between the gas-liquid separating chamber and the intake passage. The system is a low cost system having a simplified design enabling oil to be separated from blowby gas without having to include a special oil separator thank before the breather tube.

[0014] EP-A-1 447 533 discloses an apparatus for circulating a blowby gas to engine cylinders in an internal combustion engine, including a cylinder head cover (2) including a first wall (2B) defining a first passage (11), and a first flange (2A) outwardly expending from the first wall (2B), and a cylinder head (1) including a second wall (1A) and a second flange (12) cooperating with the first flange (2A) to form an abutting surface (P) therebetween on which a second passage (13) is arranged. The second passage (13) is connected with the first massage (11) and extending in a direction of a row of the engine cylinders. The second wall (1A) defines a plurality of third passages (14) each having one end that is open to the second flange (12) and communicated with the second passage (13) and an opposite end open to an intake port (6) of each of the engine cylinders.

[0015] US-A-4 653 457 relates to a crankcase breather for use in the air cleaner of the type used on an internal combustion engine. The crankcase breather is provided with a grooved, raised boss retainer portion on the outboard wall of the air filter container portion of the crankcase breather so as to encircle the nipple of the crankcase breather and the outer housing shell of the air cleaner is provided with a conforming aperture so that a part of the outer housing shell is received in the groove thus permitting the rest of the praised boss retainer portion to be snapped into locking engagement with the material edges defining the aperture.

[0016] EP-A-0 741 242 describes an intake circuit unit which consists of a housing (2) with an air outlet (3), an air intake, and a crankcase gas intake (5). The crankcase gas intake interacts with deflectors (6) inside the housing which guide the gases towards the housing wall. Each deflector is in the form of a tabular element linked to the crankcase intake and extending along the housing wall. It is closed at one end and has an opening (8) at the other directed towards the wall. The gas intake deflectors are made in one piece with the housing and are basically semi-circular in cross-section.

[0017] FR-A-1 544 415 discloses an air filter for internal combustion engines, in particular having a housing which is intended to receives the filtering cartridge. The housing comprises an upper and lower half-shell which are connected to each other. The lower shell comprises an intake duct which is made in a single piece with such duct, and a further auxiliary intake duct which can receive the blow-by gases coming from the internal combustion engine and intended to be filtered by the partridge contained in the housing.

[0018] It is a first object of the invention to solve the problem of how to make the space occupied by the engine and the associated ancillary devices more ordered.

[0019] It is a second object of the present invention to provide a solution to the above problem, which solution is easy and cheap to implement.

[0020] The above and other objects are achieved as claimed in the appended claims.

[0021] One of the advantages of the invention is the reduction of the number of separate ducts concerning the operation of an internal combustion engine and the consequent rationalisation of the arrangement of the parts.

[0022] Another advantage of the invention is the reduction of the overall size of the devices associated with the engine,

[0023] Advantageously, since the duct is preferably integrated into the wall of the housing of the air filter, the space inside the housing is not significantly reduced, whereby pressure drops are avoided.

[0024] A further but not the last advantage of the invention is the reduction of the manufacturing costs, thanks to the possibility of obtaining at least one section of an ancillary duct at substantially the same cost as the filter housing.

[0025] Further features and advantages of the invention will become apparent from the following description, given by way of non-limiting example with reference to the accompanying drawings, in which:

• Fig. 1 is a top plan view of an embodiment of the housing according to the invention;
• Fig. 2 is a side view of the housing shown in fig. 1;
• Fig. 3 is a top perspective view of a first part of the housing shown in fig. 1;
• Fig. 4 is a bottom perspective view of a second part of the housing shown in fig. 1.

[0026] Referring to the accompanying Figures, reference numeral 11 generally denotes the housing for an air filter, in a preferred embodiment of the invention intended e.g. for use in the intake system applied to the diesel cycle internal combustion engine of a vehicle.

[0027] In this embodiment, housing 11 includes a hollow shell 13, preferably made of two parts 15, 17, e.g. of moulded plastics, joined together, for instance welded. along the corresponding peripheral edge 19, 21, respectively.

[0028] Always referring to this exemplary embodiment of the invention, lower part 15 of shell 13 is divided by a partition 15c into two zones 15a, 15b. The first zone 15a has an opening 23 intended to be associated with the outlet duct supplying air to the intake manifold of the engine, whilst the second zone 15b has an opening 25 intended to be associated with the duct for air intake from the outside.

[0029] Upper part 17 of shell 13 correspondingly has a pair of windows 17a and 17b, respectively, and a partition 17c, which are superimposed to zones 15a, 15b and partition 15c of lower part 15 when shell 13 is assembled.

[0030] Shell 13 further includes a cover 27 closing openings 17a and 17b and housing a filtering element.

[0031] According to the invention, shell 13 has associated therewith a duct 29 that is advantageously used in a circuit other than that of the intake system where housing 11 of air filter described herein is included.

[0032] More particularly, said duct 29 can advantageously be used in the circuit for recovering the blow-by gases coming from the base of the internal combustion engine.

[0033] Said duct 29 is preferably equipped, at its opposite ends 31, 33, with respective fast couplings 35 allowing associating the pipes, generally flexible rubber pipes, of the circuit for recovering the blow-by gases with duct 29.

[0034] According to the illustrated embodiment, a first portion 29a of duct 29 is formed in lower part 15 of shell 13, and a second portion 29b is formed in upper part 17.

[0035] Each portion 29a, 29b is equipped with a corresponding portion of a connector 37a, 37b, e.g. of the male-female kind. Said portions 37a, 37b are joined together, for instance by welding or simply by fitting, while edges 19, 21 are being joined for assembling shell 13.

[0036] In the illustrated example, both portions 29a, 29b of duct 29 are L-shaped and define a radial first section 39a, 39b, respectively, coming out from shell 13, and an axial second section 41a, 41b, respectively, substantially perpendicular to the radial first section 39a, 39b and extending inside shell 13. Radial sections 39a, 39b coming out from shell 13 are moreover substantially diametrically opposite.

[0037] According to the invention, said duct 29 is preferably integrated into the respective wall 43, 45 of the corresponding part 15, 17 of shell 13.

[0038] Preferably duct 29, after shell 13 has been assembled, extends without interruption. Yet, duct 29 could even be interrupted or could have windows or openings on its wall, should said duct be used for instance for the passage of cables or pipes.

Claims

1. A housing (11) for an air filter of an internal combustion engine, the housing comprising a shell (13) having an inlet opening (25) and an outlet opening (23) for the inflow of air to be filtered and the outflow of filtered air, respectively, said inlet opening (25) being associatable with the duct of the intake system of the engine for air intake from the outside and said outlet opening (23) being associatable with the outlet duct of the intake system of the engine for supplying air to the engine, whereby said housing is capable of being included in said intake system of the engine by means of said inlet and outlet openings, said housing (11) further comprising at least one duct (29) associated with said shell (13); said housing being characterised in that said duct (29) extends between respective opposite ends both of which lead to a circuit other than that of the air intake system of the engine.

2. The housing as claimed in claim 1, wherein said shell (13) is made of at least two parts (15, 17) of moulded plastics, joined together along the corresponding peripheral edge (19, 21),
a first portion (29a) of said duct (29) being formed in a first part (15) of the shell (13), and a second portion (29b) of said duct (29) being formed in a second part (17).

3. The housing as claimed in claim 2, wherein each portion (29a, 29b) of said duct (29) is equipped with a corresponding portion of a connector (37a, 37b).

4. The housing as claimed in claim 3, wherein said connector is of the male-female kind.

5. The housing as claimed in claim 4, wherein said portions (29a, 29b) of the duct (29) are L-shaped and define a radial first section (39a, 39b) coming out from said shell (13), and an axial second section (41a, 41b) substantially perpendicular to the first section.

6. The housing as claimed in claim 5, wherein said radial sections (39a, 39b) coming out from the shell (13) are substantially diametrically opposite

7. The housing as claimed in any preceding claim, wherein said duct (29) extends without interruption.

8. The housing as claimed in any preceding claim, wherein said duct (29) is equipped, at its opposite ends (31, 33), with respective fast couplings (35) allowing associating the pipes of the circuit for recovering the blow-by gases of said engine with said duct (29).

9. An air filter for an internal combustion engine, characterised in that it comprises a housing as claimed in any of claims 1 to 8.

10. A method of manufacturing a housing (11) for an air filter of internal combustion engines as claimed in any preceding claim, comprising the steps of:

- forming a shell (13) having an inlet opening (25) for air to be filtered and an outlet opening (23) for filtered air, said inlet opening (25) being associatable with the duct of the intake system of the engine for air intake from the outside and said outlet opening (23) being associatable with the outlet duct of the intake system of the engine for supplying air to the engine, whereby said housing is capable of being included in said intake system of the engine by means of said inlet and outlet openings;

- equipping said housing (11) with at least one duct (29) associated with said shell (13);

- said method being characterised in that it comprises the step of making said at least one duct (29) to extend between respective opposite ends which lead to a circuit other than that of the air intake system of the engine.

11. The method as claimed in claim 10, wherein said shell (13) is made of plastic material and is formed by the steps of:

- moulding a first part (15) and a second part (17) of said shell (13); and

- welding said parts (15, 17) together so as to form said shell (13);

wherein a first portion (29a) of said duct (29) is formed on a first part of said shell (13), and a second portion (29b) of said duct (29) is formed on a second part of said shell (13).

Ansprüche

1. Gehäuse (11) für einen Luftfilter eines Verbrennungsmotors, wobei das Gehäuse eine Außenwand (13) aufweist, die eine Einlassöffnung (25) für das Einströmen von zu filternder Luft und eine Auslassöffnung (23) für das Ausströmen von gefilterter Luft hat, wobei die Einlassöffnung (25) an den Kanal des Ansaugsystems des Motors zum Ansaugen von Umgebungsluft anschließbar ist und die Auslassöffnung (23) an den Auslasskanal des Ansaugsystems des Motors zur Luftversorgung des Motors anschließbar ist, wobei das Gehäuse in das Ansaugsystem des Motors über die Einlass- und Auslassöffnungen eingefügt werden kann, und wobei das Gehäuse (11) zudem wenigstens einen Kanal (29) aufweist, welcher mit der Außenwand (13) verbunden ist; und wobei das Gehäuse dadurch gekennzeichnet ist, dass der Kanal (29) sich zwischen gegenüberliegenden Enden erstreckt, die beide zu einem anderen System als dem Ansaugsystem des Motors führen.

2. Gehäuse nach Anspruch 1, wobei die Außenwand (13) aus wenigstens zwei Teilen (15, 17) aus geformten Kunststoff besteht, die entlang des entsprechenden äußeren Rands (19, 21) zusammengefügt sind, wobei ein erster Abschnitt (29a) des Kanals (29) in einem ersten Teil (15) der Außenwand (13) gebildet ist und ein zweiter Abschnitt (29b) des Kanals (29) in einem zweiten Teil (17) gebildet ist.

3. Das Gehäuse nach Anspruch 2, wobei jeder Abschnitt (29a, 29b) des Kanals (29) mit einem entsprechenden Teil eines Verbinders (37a, 37b) versehen ist.

4. Gehäuse nach Anspruch 3, wobei der Verbinder ein Steckverbinder ist.

5. Gehäuse nach Anspruch 4, wobei die Abschnitte (29a, 29b) des Kanals (29) L-förmig sind und einen radialen ersten Teil (39a, 39b), der aus der Außenwand (13) herauskommt, sowie einen axialen zweiten Teil (41a, 41b), der im Wesentlichen senkrecht zu dem ersten Abschnitt ist, definieren.

6. Gehäuse nach Anspruch 5, wobei die radialen Teile (39a, 39b), die aus der Außenwand (13) herauskommen, sich im Wesentlichen diametral gegenüber liegen.

7. Gehäuse nach einem der vorstehenden Ansprüche, wobei der Kanal (29) ohne Unterbrechung verläuft.

8. Gehäuse nach einem der vorstehenden Ansprüche, wobei der Kanal (29) an seinen entgegengesetzten Enden (31, 33) mit passenden Schnellverbindern (35) versehen ist, die es ermöglichen, die Rohre des Systems zum Auffangen von Blowby-Gasen des Motors an den Kanal (29) anzuschließen.

9. Luftfilter für einen Verbrennungsmotor dadurch gekennzeichnet, dass er ein Gehäuse nach einem der Ansprüche 1 bis 8 aufweist.

10. Verfahren zum Herstellen eines Gehäuses (11) für einen Luftfilter von Verbrennungsmotoren, wie in einem der vorstehenden Ansprüche beansprucht, mit den folgenden Schritten:

- Formen einer Außenwand (13), die eine Einlassöffnung (25) für zu filternde Luft und eine Auslassöffnung (23) für gefilterte Luft aufweist, wobei die Einlassöffnung (25) an den Kanal des Ansaugsystems des Motors zum Ansaugen von Umgebungsluft anschließbar ist und die Auslassöffnung (23) an den Auslasskanal des Ansaugsystems des Motors zur Luftversorgung des Motors anschließbar ist, wobei das Gehäuse dafür geeignet ist, in das Ansaugsystem des Motors über seine Einlass- und Auslassöffnungen eingefügt zu werden,

- Versehen des Gehäuses (11) mit wenigstens einem Kanal (29), welcher der Außenwand (13) zugeordnet ist,

- wobei das Verfahren dadurch gekennzeichnet ist, dass es den Schritt aufweist, den wenigstens einen Kanal (29) sich zwischen gegenüberliegenden Enden erstrecken zu lassen, die zu einem anderen System als dem Ansaugsystem des Motors führen.

11. Verfahren nach Anspruch 10, wobei die Außenwand (13) aus Kunststoff hergestellt wird und durch die folgenden Schritte geformt wird:

- Form eines ersten Teils (15) und eines zweiten Teils (17) der Außenwand (13), und

- Verschweißen der Teile (15,17), so dass diese die Außenwand (13) bilden, wobei ein erster Abschnitt (29a) des Kanals (29) an einem ersten Teil der Außenwand (13) und ein zweiter Abschnitt (29b) des Kanals (29) an einem zweiten Teil der Außenwand (13) geformt wird.

Revendications

1. Boîtier (11) destiné à un filtre à air d'un moteur à combustion interne, le boîtier comprenant une enveloppe (13) comportant une ouverture d'entrée (25) et une ouverture de sortie (23) destinées, respectivement, au flux d'entrée d'air à filtrer et au flux de sortie d'air filtré, ladite ouverture d'entrée (25) pouvant être associée à la conduite du système d'admission du moteur pour une admission d'air provenant de l'extérieur et ladite ouverture de sortie (23) pouvant être associée à la conduite de sortie du système d'admission du moteur pour une alimentation en air du moteur, ce par quoi ledit boîtier peut être compris dans ledit système d'admission du moteur au moyen desdites ouvertures d'entrée et de sortie, ledit boîtier (11) comprenant en outre au moins une conduite (29) associée à ladite enveloppe (13) ; ledit boîtier étant caractérisé en ce que ladite conduite (29) s'étend entre des extrémités opposées respectives qui mènent toutes les deux à un circuit autre que celui du système d'admission d'air du moteur.

2. Boîtier selon la revendication 1, dans lequel ladite enveloppe (13) est constituée d'au moins deux parties (15, 17) de matière plastique moulée, liées l'une à l'autre le long du bord périphérique correspondant (19, 21),
une première partie (29a) de ladite conduite (29) étant formée dans une première partie (15) de l'enveloppe (13), et une seconde partie (29b) de ladite conduite (29) étant formée dans une seconde partie (17).

3. Boîtier selon la revendication 2, dans lequel chaque partie (29a, 29b) de ladite conduite (29) est équipée d'une partie correspondante d'un dispositif de raccordement (37a, 37b).

4. Boîtier selon la revendication 3, dans lequel ledit dispositif de raccordement est du type mâle-femelle.

5. Boîtier selon la revendication 4, dans lequel lesdites parties (29a, 29b) de la conduite (29) ont une forme de L et définissent une première section radiale (39a, 39b) sortant de ladite enveloppe (13), et une seconde section axiale (41a, 41b) sensiblement perpendiculaire à la première section.

6. Boîtier selon la revendication 5, dans lequel lesdites sections radiales (39a, 39b) sortant de l'enveloppe (13) sont sensiblement diamétralement opposées.

7. Boîtier selon l'une quelconque des revendications précédentes, dans lequel ladite conduite (29) s'étend sans interruption.

8. Boîtier selon l'une quelconque des revendications précédentes, dans lequel ladite conduite (29) est équipée, au niveau de ses extrémités opposées (31, 33), de raccords rapides respectifs (35) permettant d'associer les conduites des circuits pour récupérer les gaz de contournement de pistons dudit moteur au moyen de ladite conduite (29).

9. Filtre à air destiné à un moteur à combustion interne, caractérisé en ce qu'il comprend un boîtier selon l'une quelconque des revendications 1 à 8.

10. Procédé de fabrication d'un boîtier (11) destiné à un filtre à air de moteurs à combustion interne selon l'une quelconque des revendications précédentes, comprenant les étapes consistant à :

- former une enveloppe (13) comportant une ouverture d'entrée (25) destiné à de l'air à filtrer et une ouverture de sortie (23) destinée à l'air filtré, ladite ouverture d'entrée (25) pouvant être associée à la conduite du système d'admission du moteur pour une admission d'air provenant de l'extérieur et ladite ouverture de sortie (23) pouvant être associée à la conduite de sortie du système d'admission du moteur pour une alimentation en air du moteur, ce par quoi ledit boîtier peut être compris dans ledit système d'admission du moteur au moyen desdites ouvertures d'entrée et de sortie ;

- équiper ledit boîtier (11) d'au moins une conduite (29) associée à ladite enveloppe (13) ;

- ledit procédé étant caractérisé en ce qu'il comprend les étapes consistant à concevoir ladite au moins une conduite (29) pour qu'elle s'étende entre des extrémités opposées respectives qui mènent à un circuit autre que celui du système d'admission d'air du moteur.

11. Procédé selon la revendication 10, dans lequel ladite enveloppe (13) est constituée de matière plastique et est formée par les étapes consistant à :

- mouler une première partie (15) et une seconde partie (17) de ladite enveloppe (13) ; et

- souder l'une à l'autre lesdites parties (15, 17) de façon à former ladite enveloppe (13) ;

dans lequel une première partie (29a) de ladite conduite (29) est formée sur une première partie de ladite enveloppe (13), et une seconde partie (29b) de ladite conduite (29) est formée sur une seconde partie de ladite enveloppe (13).

Drawing