Air-intake module for internal combustion engine

• US 6,024,066 A
• Filed: 08/07/1998
• Issued: 02/15/2000
• Est. Priority Date: 10/30/1997
• Status: Expired due to Term

• Current Assignee: DENSO Corporation, Toyota Boshoku Corporation (Toyota Motor Corporation)
• Original Assignee: DENSO Corporation, Toyota Boshoku Corporation (Toyota Motor Corporation)
• Inventors: Inaba, Hideki, Nakayama, Toshiaki
• Primary Examiner(s): Kamen, Noah P.
• Assistant Examiner(s): HUYNH, HAI H
• Application Number:
  US09/131,396
• Time in Patent Office: 557 Days
• Field of Search: 123/184.21, 123/198 E, 123/184.24, 123/184.34, 123/184.42, 123/184.47
• US Class Current: 123/184.21
• CPC Class Codes: F02M 35/02 Air cleaners
• CPC Class Codes: F02M 35/10052 special shapes or arrangements of plenum chambers; Constructional details
• CPC Class Codes: F02M 35/10111 Substantially V-, C- or U-shaped ducts in direction of the flow path
• CPC Class Codes: F02M 35/10255 Arrangements of valves; Multi-way valves F02M35/10032 takes precedence; valves in the plenum chamber F02M35/10065; check valves F02M35/10275
• CPC Class Codes: F02M 35/112 for engines with cylinders all in one line

Abstract

All the components constituting an air-intake module for an internal combustion engine, including an air cleaner for cleaning air and manifold pipes for distributing air into each cylinder of the engine, are integrated in a single unit. A mounting flange connected to engine side ends of the manifold pipes is fixed to the engine for mounting the air-intake module as a whole. The air cleaner and other components of the module are located under the mounting flange and the manifold pipes, so that the mounting of the module is not obstructed by components constituting the module. An air cleaner element for filtering the intake air is slidably inserted into the air cleaner at a position where the element can be easily serviced from the outside of the module without dismounting any components of the module.

Claims

1. An air-intake module for an internal combustion engine comprising:

an air cleaner including an air cleaner case and an air cleaner element disposed in said air cleaner case for cleaning air flowing therethrough;

a plurality of intake manifold pipes, one end of each intake manifold pipe being connected to the air cleaner case through connecting members for receiving clean air therefrom; and

a mounting flange having a mounting surface provided at the other end of each intake manifold pipe for mounting said intake manifold pipes to the engine, wherein;

the air cleaner case, the intake manifold pipes, said connecting members, and the mounting flange are all integrated into a single module,

a working line for mounting said single module on the engine is defined in a direction substantially perpendicular to and intersecting said mounting surface of said mounting flange,

at least a substantial portion of the air cleaner case is positioned in an area vertically below at least a portion of the manifold pipes so that the manifold pipes embrace the air cleaner case thereunder, the air cleaner element is disposed substantially immediately adjacent the manifold pipes, and the working line is defined above the air cleaner case,

the air cleaner is disposed within a horizontal length of the manifold pipes, and

said air cleaner element is mounted so as to be removable from said module by displacing said air cleaner element outwardly relative to a wall of said air cleaner case, said air cleaner case and said air cleaner element being positioned relative to said manifold pipes, said mounting flange and the engine such that when the mounting flange is mounted to the engine, said air cleaner element is removable in a manner free from interference from said manifold pipes and the engine.

2. The air-intake module for an internal combustion engine as in claim 1, wherein:

the air cleaner element is substantially vertically disposed in the air cleaner case at a side portion of the air cleaner case, the side portion being laterally offset from a vertical plane of the manifold pipes located above the air cleaner case.

3. The air-intake module for an internal combustion engine as in claim 2, wherein:

the air cleaner element is inserted into and removed from the air cleaner case by sliding the air cleaner element in a substantially vertical direction.

4. The air-intake module for an internal combustion engine as in claim 1, wherein:

the air cleaner element is substantially horizontally disposed in the air cleaner case at an upper portion of the air cleaner case; and

the air cleaner element is inserted into and removed from the air cleaner case by sliding the air cleaner element in a substantially horizontal direction.

5. The air-intake module for an internal combustion engine as in claim 1, further comprising an air-intake port defining an air inlet to said air cleaner case, and wherein:

the air cleaner element is cylinder-shaped having a cylindrical side wall, an open end and a closed end wall; and

the cylinder-shaped air cleaner element is attached to the air-intake port so that a longitudinal axis of the air cleaner element extends in a horizontal direction.

6. The air-intake module for an internal combustion engine as in claim 5, wherein:

the cylindrical side wall of the air cleaner element is serpentined whereby the cylindrical side wall is expandable and contractible in an axial direction.

7. The air-intake module for an internal combustion engine as in claim 5, wherein:

the open end of the air cleaner element is attached to the air-intake port so that the cylindrical side wall of the air cleaner element extends into the air cleaner case.

8. The air-intake module for an internal combustion engine as in claim 5, wherein:

the air-intake port extends horizontally outwardly from the wall of the air cleaner case and terminates in an outer end; and

the open end of the air cleaner element is attached to the outer end of the air-intake port so that the air cleaner element extends toward an interior of the air cleaner case.

9. The air-intake module for an internal combustion engine as in claim 1, further comprising an air-intake port defining an air inlet to said air cleaner case, said air-intake port extending vertically upwardly from an upper wall of said air cleaner case.

10. An air-intake module for an internal combustion engine, comprising:

an air cleaner including an air cleaner case having an air-intake port defining an air inlet to said air cleaner case;

an air cleaner element mounted to one of said air-intake port and said air cleaner case for cleaning air flowing through said air cleaner case;

a plurality of intake manifold pipes, a first end of each intake manifold pipe being operatively coupled to the air cleaner case for receiving clean air therefrom; and

a mounting flange having a mounting surface provided at a second end of each intake manifold pipe for mounting said intake manifold pipes to the engine, wherein;

the air cleaner case, the intake manifold pipes, and the mounting flange are all integrated into a single module,

a working line for mounting said single module on the engine is defined in a direction substantially perpendicular to and intersecting said mounting surface of said mounting flange,

at least a substantial portion of the air cleaner case is positioned in an area vertically below at least a portion of the manifold pipes so that the manifold pipes extend over the air cleaner case and said working line is defined vertically above the air cleaner case,

the air cleaner is disposed in said one of said air cleaner case and said air intake port being disposed substantially immediately adjacent the manifold pipes, and

the air cleaner, including said air cleaner case, said air intake port, and said air cleaner element, is disposed within a horizontal length of the manifold pipes.

11. The air-intake module as in claim 10, wherein said first ends of said manifold pipes are connected to a surge tank, a throttle body is connected to said surge tank, and a duct connects the throttle body and the air cleaner case so that clean air from said air cleaner case flows through said duct, said throttle body, and said surge tank into said manifold pipes, and wherein said surge tank, said throttle body and said duct are integrated into said single module.

12. The air-intake module as in claim 10, wherein:

the air cleaner element is generally vertically disposed in the air cleaner case at a side portion of the air cleaner case, the side portion being laterally offset from a vertical plane of the manifold pipes, and wherein said air cleaner element is mounted so as to be removable from said air cleaner case by displacing said air cleaner element generally vertically upwardly, outwardly relative to an upper wall of said air cleaner case.

13. The air-intake module as in claim 10, wherein:

the air cleaner element is generally horizontally disposed in the air cleaner case in an upper portion of the air cleaner case, and

said air cleaner element is mounted so as to be removable from said air cleaner case by sliding said air cleaner element generally horizontally, outwardly relative to a wall of said air cleaner case.

14. The air-intake module for an internal combustion engine as in claim 10, wherein:

the air cleaner element has a cylindrical side wall, an open end and a closed end wall; and

the air cleaner element is attached to the air-intake port so that a longitudinal axis of the air cleaner element extends in a horizontal direction.

15. The air-intake module as in claim 14, wherein:

the cylindrical side wall of the air cleaner element is undulated whereby the cylindrical side wall is expandable and contractible along said longitudinal axis.

16. The air-intake module as in claim 14, wherein:

the open end of the air cleaner element is attached to the air-intake port so that the air cleaner element extends into an interior of the air cleaner case.

17. The air-intake module as in claim 14, wherein:

the air-intake port extends outwardly from the wall of the air cleaner case and terminates in an outer end; and

the open end of the air cleaner element is attached to the outer end of the air-intake port so that the air cleaner element extends toward an interior of the air cleaner case.

18. The air-intake module as in claim 10, wherein said air-intake port extends vertically upwardly from an upper wall of said air cleaner case.