Abstract:
An intake flow device and system is disclosed. The flow device may be cylindrically shaped and flexible. An intake conduit may be fitted around the flow device, such that the intake conduit may retain a large diameter for increased air flow, rather than necking down. The flow device may incorporate compression ribs around its outer circumference for positively mating with the air intake conduit. The flow device may also include graduated portions and be configured to direct air to an air metering device. Guide vanes may also be provided within the flow device to control and direct air to the air metering device.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention is generally related to air intake flow devices and systems, and more particularly to devices and systems for adapting large-diameter air intake conduits and flow components to vehicles. In one embodiment, a collar may be configured to mate a large-diameter air intake conduit to a smaller-diameter turbocharger intake. In another embodiment, a collar may be configured to direct air flowing through a large-diameter conduit to an air metering device for accurate measurement. 
       BACKGROUND ART 
       [0002]    Relatively large internal diameter air intake kits are frequently used to increase the performance of existing internal combustions engines, such as those used in modern vehicles. The intake kits may have relatively larger internal diameters than original equipment manufacturer intakes to increase the volume of air delivered to the engine and to reduce pressure losses from the air filter to the engine&#39;s air intake or turbocharger inlet. While such air intakes may initially have intake conduits with larger internal diameters than corresponding original equipment manufacturer parts, they frequently taper down to mate with the engine&#39;s intake, such as a turbocharger, which may have an intake flange with a relatively smaller external diameter. For example, a turbocharger may have an air intake flange with an external diameter of approximately 2.875 inches. If the intake conduit has an initial internal diameter of 3.875 inches, such as where it mates to an air filter, that internal diameter will frequently reduce down to approximately 2.875″ to mate with the intake flange of the turbocharger. When the diameter is shrunk from one end of the conduit to the next, air flow may be reduced, there may be undesirable steps in the conduit, and/or there may be flow inhibiting shapes present in the conduit. This may cause undesirable interruptions to the flow of intake air, undesirable pressure differentials, and may detrimentally impact performance. Further, it may be economically desirable for an air intake manufacturer to produce air intakes generally having a fixed configuration. Accordingly, the internal diameter of the portion of the air intake conduit that mates to a turbocharger of a particular vehicle may be too large for another vehicle. Further, when a manufacturer changes the intake flange dimensions of, for example, a turbocharger, a new intake conduit may need to be made to accept the newly-sized intake flange. It may therefore be prohibitively expensive for an air intake conduit manufacturer to constantly be retooling its products for only slightly different applications. Additionally, a coupler may need to be used to bridge the intake flange of the turbocharger with the intake conduit. The coupler may incorporate ridges therein which may further impede and/or disturb air flow. In addition, the coupler may need to be coupled on one side to the air intake conduit, and on the other side to the intake flange-necessitating two clamps to secure the air intake to the turbocharger. What is needed is an intake flow device configured to efficiently transfer air from an air intake conduit to an intake flange. 
         [0003]    While relatively larger internal diameters of aftermarket intake kits may increase the volume of air delivered to the engine, such air intakes may detrimentally impact the metering of air, upstream of the turbocharger, or otherwise. In particular, by increasing the internal diameter of air intake conduits, the velocity of the air traveling through an air metering device, such as a mass air flow sensor, may decrease or change character and cause the air metering device to incorrectly report the volume, mass, or speed of the air flowing through the larger-diameter conduit. This problem may manifest if the original air metering device, designed to measure air flowing through a smaller diameter air intake conduit, is used in connection with an aftermarket air intake conduit. Such misreporting can cause the engine to run poorly, and even cause damage to the engine, such as in the case of a lean condition. What is needed is an intake flow device configured to condition air flow to an air metering device in the case of at least larger-diameter intake conduits. 
       SUMMARY 
       [0004]    Non-exclusive, non-limiting embodiments of the invention illustrated herein provide an intake flow device in the form of a collar having an inner surface with a first diameter, outer surface with a second diameter, and a graduated side surface for directing air flow. The flow device may be configured to fit onto a turbocharger&#39;s compressor intake flange or onto the intake flange of a normally-aspirated engine. The collar may be formed from a rubber-like material such as polyurethane, silicone, or other suitable materials designed to comply with, and effectively seal the engine&#39;s intake tract in the proximity of the intake opening, such as the turbocharger&#39;s compressor intake. 
         [0005]    In application, the flexible collar may be placed over the intake flange of, for example, a turbocharger&#39;s compressor. The fit may be an interference fit such that the collar is positively located on the intake flange. As such, the outer diameter of the intake flange along its outer surface may be slightly larger than the internal diameter of the collar along its inner surface. The collar may also incorporate a recess along at least a portion of its inner surface. The recess may be configured to conform to a lip on the compressor&#39;s intake flange or to the end or another portion of the intake flange. Furthermore, an end of the collar opposite from the graduated end may be configured to lie flush with a side surface of the turbocharger&#39;s compressor. The combination of the snug interference fit, recess, and abutting arrangement may help the collar stay in place on the flange. A front portion of the collar, in some cases corresponding to portions of the graduation, may also drape over the intake flange such that there is a smooth, uninterrupted flow of air from the intake conduit to the compressor&#39;s blades. 
         [0006]    The intake conduit may have an internal diameter generally corresponding to the outer diameter of the collar or slightly smaller than the outer diameter of the collar to form another interference fit. As such, one may place the intake conduit on the collar (already fitted to the intake flange) to seal the compressor&#39;s intake. Therefore, in some embodiments, the intake conduit may be formed with a relatively constant internal diameter, from end to end, that supports high air flow. Further, the intake conduit may be shaped and tuned for desired air flow characteristic such as increased throttle response and reduced lag in turbocharged applications. Such shaping and tuning may include, but is not limited to, varying the internal diameter, incorporating chambers, and creating different geometries in the intake conduit to support the desired air flow characteristics. A clamp or band may be used to tighten the conduit around the collar. The intake conduit may also incorporate openings around its diameter, such as slots, that, when tightened around the collar, compress to make a tight seal against the collar. The collar may also incorporate ribs on its outer surface capable of compressing when the intake conduit is fitted thereto, to increase the effectiveness of the seal. Further, the collar may incorporate flanges or vanes therein to direct air flow to the compressor wheel effectively. Said vanes may be configured in a variety of different fashions and may be straight or angled depending on application. 
         [0007]    The collar may also be formed with a graduated front surface on one end such that air flowing from the intake conduit may smoothly transfer from the larger diameter of the intake conduit to the smaller diameter of the intake flange. This graduation may take different sizes and shapes depending on application. Such collars may be formed with different internal and external dimensions such that they can be capable of coupling different sized intake conduits to different sized intake flanges and may also be configured to work with naturally aspirated vehicles by mating to an intake flange of an engine&#39;s intake, rather than its compressor. 
         [0008]    In another embodiment, an air intake system may include an air intake conduit having a proximal end and a distal end, an air metering device fitted to the air intake conduit, a collar formed from a rubber-like material and having an inner surface for conditioning air flow, and an outer surface having at least a portion thereof configured so that the collar fits snugly into the air intake conduit. The proximal end of the collar may include a bead which mates the collar to the proximal end of the air intake conduit. A proximal portion of the collar may have a graduated surface for supporting incoming air flow, necking the air down from a first diameter intake conduit to a second, smaller diameter for accurately passing through the air metering device. The graduated surface may also have one or more stepped surfaces and one or more flanges or vanes may be disposed along the graduated surface and/or the inner surface of the collar to direct air flow. The vanes may be configured in a variety of different fashions and may be straight or angled depending on application. The collar may be formed from a number of materials including, but not limited to, polyurethane, silicone, and rubber. Such collars may be formed with different internal and external dimensions such that they can be capable of coupling to different sized intake conduits and different sized air metering devices. 
         [0009]    The intake conduit may be shaped and tuned for desired air flow characteristic such as increased throttle response and reduced lag in turbocharged applications. Such shaping and tuning may include, but is not limited to, varying the internal diameter, incorporating chambers, and creating different geometries in the intake conduit to support the desired air flow characteristics. 
         [0010]    In application, the collar may be fitted inside the proximal end of an air intake conduit in the intake air stream of an engine. A bead protruding from the collar may be configured to lie flush with a proximal end of the air intake conduit. This arrangement, in connection with a snug interference fit, may help the collar stay in place in the air intake conduit. The collar may also abut an upstream air intake conduit or other device, such as an air filter. In one example, a silicone coupler is connected to a down stream air intake conduit and collar on one end, and an upstream air intake conduit on the other. Clamps may be placed at each end of the silicone coupler to seal the intake and securely hold the aforementioned components together. The air intake conduit may be an aftermarket unit that has a larger internal diameter than an original equipment manufacturer (OEM) part. The larger diameter of the air intake conduit provides for less restriction to air flow and therefore potentially aids in power production and efficiency. An OEM air metering device, such as a mass air flow sensor, may be removed from the OEM air intake conduit and inserted into the larger, replacement air intake conduit. The collar necks down the internal diameter briefly and conditions the air to pass through the air metering device in an accurately measurable manner. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The present invention is illustrated by way of example and not by limitation in the accompanying figures, in which like references indicate similar elements, and in which: 
           [0012]      FIG. 1  is an illustration of a perspective view of an embodiment of an intake flow collar  10  in accordance with the teaching of the invention herein; 
           [0013]      FIG. 2  is an illustration of a cross-sectional side view of an embodiment of an intake flow collar  10  in accordance with the teaching of the invention herein; 
           [0014]      FIG. 3  is an illustration of a perspective view of an embodiment of an intake flow collar  10  inserted into an air intake conduit  12  in accordance with the teaching of the invention herein; 
           [0015]      FIG. 4  is an illustration of a partial cross-sectional view of an embodiment of an intake flow collar  10  inserted into an air intake conduit  12  and onto an intake flange  36  of a turbocharger  34  in accordance with the teaching of the invention herein; 
           [0016]      FIG. 5  is an illustration of a perspective view of an embodiment of an intake flow collar  100  in accordance with the teaching of the invention herein; 
           [0017]      FIG. 6  is an illustration of a cross-sectional view of an embodiment of an air metering reducer collar  640  inserted into an air intake conduit  610  in accordance with the teaching of the invention herein; 
           [0018]      FIG. 7  is an illustration of a bottom view of an embodiment of an air metering reducer collar  640  in accordance with the teaching of the invention herein; and 
           [0019]      FIG. 8  is an illustration of a perspective view of an embodiment of an air metering reducer collar  640  in accordance with the teaching of the invention herein. 
       
    
    
       [0020]    Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present invention. 
       DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0021]      FIG. 1  illustrates a perspective view of an embodiment of an air intake flow device. The flow device may be in the form of a collar and may be made out a number of materials suitable for use in connection with an internal combustion engine. In this embodiment, collar  10  is formed from polyurethane, although in alternative embodiments the collar may be made from a number of additional materials such as silicone, rubber, and other materials suitable for a given application. As such, collar  10  is flexible and pliant and has material properties suitable for use in connection with under-hood heat generated from an internal combustion engine. Moreover, the polyurethane makes installation relatively easy as collar  10  may be pressed over a turbocharger&#39;s intake flange  36  and within an air intake conduit  24  (as shown in  FIG. 4 ). 
         [0022]    Collar  10  has an inner surface  12 , outer surface  14 , distal end  16 , and proximal end  18 . The inner surface  12  has an inner diameter that may be slightly smaller than the outer diameter of an intake flange that it may be mounted to. In particular, in the case of a turbocharger application, as shown in  FIG. 4 , the outer diameter of intake flange  36  may be slightly larger than the inner diameter of collar  10 . The slight difference in diameter may provide for a desirable interference fit whereby the collar  10  may be held tightly about the intake flange  36 . In addition, collar  10  may be formed with a recess  20  within its interior surface  12 . Recess  20  may conform to a lip  38  on intake flange  36  and further function to hold collar  10  securely on the intake flange. Further, collar may incorporate a collar flange  15 . As shown in  FIGS. 3-4 , collar flange  15  may rest flush with a proximal end  28  of an air intake conduit  24  on one side and a turbocharger&#39;s  34  compressor housing on the other side. This configuration may further secure the relationship of the intake conduit  24 , collar  10 , and turbocharger  34  from undesirable movement. For different applications, it may be desirable to form the collar in different forms, such as elliptical shapes. The elliptical form may be particularly useful in connection with coupling the air intake to a throttle body which may also have an elliptical configuration. Furthermore, the collar may be configured for an interference fit, or not, depending on application and may have no recess or more than one recess depending on application and may also incorporate a flange, or not, depending on application. 
         [0023]    As shown in  FIG. 2 , collar  10  has a proximal end  18  with a graduated surface  52 . The graduation, which may take numerous shapes, tends to direct air into the compressor&#39;s intake blades. Collar  10  may also be configured as shown herein to provide a smooth surface for air to flow from the graduation to the interior of intake flange  36 . In particular, as shown in  FIG. 4 , a portion of collar  10 , in this case corresponding to the graduated surface, may protrude over the intake flange  36  in the direction of incoming air. The inner diameter may be similar to, or the same as, the internal diameter of the intake flange  36 . In this manner, the “step” between collar  10  and intake flange  36  may be reduced or eliminated. 
         [0024]    Referring to  FIGS. 1-2 , collar  10  may be formed with one or more ribs  22  on its outer surface  14 . Ribs  22  may be molded into collar  10  and made from the same material. In this embodiment, ribs  22  are configured to compress when air intake conduit  24  is fitted over collar  10 , as shown in  FIG. 3 . The compression may be accomplished using devices such as an adjustable hose clamp  44  as illustrated in  FIG. 4 , though alternative means of securing are contemplated. In some cases, a clamp may not even be necessary depending on the relationship of the components. The compression of the ribs  22  helps to complete a seal along the intake tract. Similar to the interference fit arrangement of collar  10  and intake flange  36 , air intake conduit  24  may be configured with a slightly smaller internal diameter than the outer diameter of the outer surface of collar  10 . Accordingly, a tight seal may be formed when intake conduit  24  is clamped onto intake flange  36 , around collar  10 . Several slots  30  may be formed in air intake conduit  24  to help it compress under pressure. When clamp  44  is tightened, slots  30  may compress together, effectively shrinking the inner diameter of intake conduit  24 . 
         [0025]      FIG. 3  illustrates collar  10  within intake conduit  24 . In this embodiment, intake conduit is formed from cross-linked polyethylene (“XLPE”), although in alternative embodiments, other materials including, but not limited to, aluminum, steel, and other plastics, metals, and composites may be used depending on application. As shown, the internal diameter of intake conduit is relatively constant from distal end  26  to proximal end  28 . Dimensions of intake conduit  24  may be varied according to application. As set forth above, several slots  30  may be formed in air intake conduit  24  to help it compress under pressure such as when used in connection with a clamp  44  as shown in  FIG. 4 . Other well-known variations may be used to enable intake conduit  24  to compress according to application. 
         [0026]      FIG. 4  illustrates collar  10  in connection with intake conduit  24  and turbocharger  34  as such devices may be coupled together. As shown, intake conduit  24  may be coupled to turbocharger  34  with only one clamp  44 , rather than two clamps that may be used in connection with a conventional coupling. As such, there are fewer parts to assemble, tighten, and potentially come loose. In application, air will travel from an air filter, through intake conduit  24 , through the graduated portion  52  of collar  10  into the turbocharger&#39;s  34  compressor intake flange  36 , and thereafter be compressed by the turbocharger. 
         [0027]    In the embodiment shown in  FIGS. 1-4 , the collar has an outer diameter of approximately 3.875 inches and an inner diameter of approximately 2.875 inches. Along inner surface  12 , recess  20  has a diameter of approximately 3 inches and is approximately 0.25 inches wide and 0.125 inches deep. As set forth above, collar  10  has a proximal end  18  with a graduated surface  52  configured to direct air to the turbocharger. The graduation is approximately 0.625 inches wide, the graduation starting with a diameter of approximately 3.75 inches and tapering down to approximately 2.875 inches to correspond to the internal diameter of intake flange  36 . 
         [0028]      FIG. 5  illustrates an alternative collar  100  which may be formed with one or more vanes  170  for directing airflow into the intake. Similar to collar  10 , collar  100  may have an inner surface  120 , outer surface  140 , distal end  160 , and proximal end  180 . The inner surface  120  may have an inner diameter that may be slightly smaller than the outer diameter of an intake flange that it may be mounted to. In addition, collar  100  may be formed with a recess  200  within its interior surface  120 . For different applications, it may be desirable to form the collar in different forms, such as elliptical shapes. Collar  100  may have a proximal end  180  with a graduated surface  520  and may be formed with one or more ribs  220  on its outer surface  140 . 
         [0029]    It has been noticed that air being drawn in large volumes into distal side  26  ( FIG. 3 ) exhibits a tendency to reduce the flow rate of air passing by a typical air flow meter (mass air flow sensor, MAS). As is depicted in  FIG. 6 , this occurs because the wider diameter of the aforementioned conduits  610  causes air to move at a slower rate (despite being a greater air volume) than expected by a stock MAS  630 , causing the MAS  630  to react as if the vehicle was moving more slowly and requiring less power. In some other cases, the air flowing through the MAS may become unpredictable and thus difficult to accurately measure. This performance sapping phenomenon is contrary to the actual increased air flow in the conduit, thereby causing a conundrum with using larger conduits to supply greater air flow and to increase power supplied by the engine. In response, mass air sensor reducer collar (MASRC)  640 , can be inserted into the intake airflow conduit system just upstream of the MAS  630 . MASRC  640  can be configured with a wider entrance throat opening  650  (4.5 inches) than an exit throat opening  660  (3.2 inches), causing an increase in velocity of air past MAS  630  (flow: left to right), and thereby velocity-compensating for the otherwise increased, but slower, flow of intake air. Seven vanes  620  can be space generally equidistantly around the inner circumference of MASRC  640 . Although straight vane geometry is shown, vanes also may be slightly curved, as is shown with vane  170  in  FIG. 5 . Of course, other numbers, geometries, depths, widths, and placement of vanes can be used. Vanes  620  also tend to be slightly wider and deeper at entrance throat opening  650  than at exit throat opening  660 . The increased velocity of air is properly sensed by MAS  630  allowing for a corresponding signal to be sent to an engine&#39;s electronic control unit (ECU), to adjust the parameters of the engine. For example, the ECU may increase fuel in response to the greater air flow. 
         [0030]      FIG. 7  depicts a bottom view of MASRC  640  with the section illustrating MASRC  640  in  FIG. 6  being depicted through the A-A′ section of  FIG. 7 . In  FIG. 7 , MASRC  640  has five ribbed braces  610  positioned around its circumference. Each ribbed brace is configured to produce a snug fit and seal in the conduit in which it is inserted and contacted. The minor portion of vanes  620  can be seen in exit throat  660 . As is seen in  FIG. 7 , exit throat  660  tends to be configured with a narrower diameter than the entrance throat around which can be seen entrance seal bead  635 . 
         [0031]      FIG. 8  illustrates a perspective view of MASRC  640 , taken from the collar bottom. MASRC  640  can include body  605 , braces  610  with ribs (generally at  615 ) and entrance seal bead  635 . Vanes  620  can be interposed in inner throat wall  645  and a flare  665  may extend from entrance throat opening  650  to throat inflection region  655 . The throat continues from inflection region  655  to exit throat opening  660 . Body  605 , braces  610  and ribs  615  can be made of a resilient, elastomeric rubber-like material to facilitate manufacturing and installation. 
         [0032]    Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims. As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. The terms “a” or “an”, as used herein, are defined as one, or more than one. The term “plurality”, as used herein, is defined as two, or more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as “comprising” (i.e., open language). The term “attached”, as used herein, is defined as connected, although not necessarily directly. 
         [0033]    While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention, as defined by the appended claims.