Intake cleaner and dispense mechanism

An apparatus for cleaning an intake system of an engine includes a pressure-resistant container having a reservoir chargeable with an engine cleaner composition and a discharge orifice for discharging the engine cleaner composition from the reservoir. The apparatus also includes a dispensing assembly including an assembly inlet connectable to the discharge orifice of the pressure-resistant container for receiving the engine cleaner composition discharged from the pressure-resistant container. The dispensing assembly further includes an assembly outlet, and a length of tubing for receiving the engine cleaner composition from the dispensing assembly. The apparatus further includes a timer configured to control a timed valve that, when opened, allows the engine cleaner composition to discharge from the pressure-resistant container. The timer is configured to delay opening of the timed valve for a predetermined period of time after actuation of the timer.

FIELD OF THE DISCLOSURE

The present disclosure relates to an apparatus for cleaning the intake system of an automotive internal combustion engine having an air intake manifold.

BACKGROUND OF THE DISCLOSURE

Gas direct injection (“GDI”) engines are highly prone to carbon deposits on their intake valves. Large amounts of carbon may get deposited on the intake valves due to the burning of fuel in GDI engines. This causes reduction in performance, horsepower, and gas mileage. Cleaning these deposits is not only time consuming but also complicated and requires more than one person to perform this cleaning process. Furthermore, it is desirable to clean gas direct injection engines frequently, e.g., as often as every 10,000 miles.

Regular cleaning of intake valves is required to maintain engine performance. However, known methods of cleaning intake valves are time consuming, not user-friendly, and require more than one person to perform the cleaning. For example, cleaning intake valves may require one person to remain in a vehicle having the GDI engine and that person must start and rev, or throttle, the GDI engine. A second person may be required to open a hood of the vehicle and manually deliver a cleaning formula to the intake valve, during the time the first person is revving the engine.

SUMMARY OF THE DISCLOSURE

Disclosed is an apparatus for cleaning an intake system of an engine. The apparatus includes a pressure-resistant container having a reservoir chargeable with an engine cleaner composition and a discharge orifice for discharging the engine cleaner composition from the reservoir. The apparatus also includes a dispensing assembly including an assembly inlet connectable to the discharge orifice of the pressure-resistant container for receiving the engine cleaner composition discharged from the pressure-resistant container. The dispensing assembly further includes an assembly outlet, a length of tubing including a tubing inlet, a tubing outlet, and a central bore extending from the tubing inlet to the tubing outlet. The tubing inlet is in fluid communication with the assembly outlet for receiving the engine cleaner composition from the dispensing assembly. The apparatus further includes a timer configured to control a timed valve that, when opened, allows the engine cleaner composition to discharge from the pressure-resistant container. The timer is configured to delay opening of the timed valve for a predetermined period of time after actuation of the timer.

Also disclosed is a method of using an apparatus for cleaning an engine having an air intake manifold. The apparatus includes a fluid-dispensing device having a pressure-resistant container having a reservoir and a discharge orifice. The reservoir is charged with an engine cleaner composition. The apparatus also includes a dispensing assembly having a timer controlling a timed valve, an assembly inlet connected to the discharge orifice, and an assembly outlet. The apparatus further includes a length of tubing having a tubing inlet connected with the assembly outlet, a tubing outlet, and a central bore extending from the tubing inlet to the tubing outlet. The method includes inserting the tubing outlet into the air intake manifold of the engine and actuating the timer to delay an opening of the timed valve for a predetermined period of time after actuation of the timer. The method also includes automatically opening the timed valve after the predetermined period of time after actuation of the timer, the timed valve allowing the engine cleaner composition to discharge from the pressure-resistant container, through the timer, and through the length of tubing.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather a purpose of the embodiments chosen and described is so that the appreciation and understanding by others skilled in the art of the principles and practices of the present disclosure may be facilitated.

Turning now to the Figures,FIG.1is a perspective view of one suitable embodiment of a dispensing apparatus, indicated generally at100, for cleaning an intake system of a GDI engine. For example, the GDI engine may be an automotive internal combustion engine having an air intake manifold (not shown). Dispensing apparatus100includes a pressure-resistant container, indicated at110, including reservoir112and discharge orifice414(shown inFIG.4). In some embodiments, reservoir112is charged with an engine cleaner composition. Dispensing apparatus100further includes a dispensing assembly120configured to receive fluid discharged from reservoir112. In the illustrated embodiment, pressure-resistant container110and dispensing assembly120are in a coupled state, characterized in that dispensing assembly120is in fluid communication with pressure-resistant container110.

Dispensing assembly120includes housing121, assembly inlet150, and assembly outlet140in fluid communication with assembly inlet150. Assembly inlet150includes an interior region configured to house discharge orifice414when the dispensing assembly120and pressure-resistant container110are in a coupled state.

Dispensing assembly120includes length of tubing130including tubing inlet332(shown inFIG.3) housed within housing121proximal to discharge orifice414and tubing outlet134located at a distal end of tubing130. Tubing130includes a central bore extending from tubing inlet332to tubing outlet134. Tubing130may have an outer diameter (OD), for example, within the range of about 1 mm to about 15 mm, and an inner diameter of about 0.5 mm to 10 mm. For example, in embodiments the OD can be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 12 mm, or about 15 mm. For example, in embodiments the ID can be about 0.5 mm, about 1 mm, about 1.5 m, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 10 mm. In some embodiments, tubing130comprises flexible material, for example rubber, silicone, flexible polymer, or any material that enables dispensing apparatus100to operate as described herein. Tubing inlet332is fluidly coupled to assembly outlet140for receiving fluid discharged from pressure-resistant container assembly110through dispensing assembly120. In some embodiments, tubing130is sufficiently transparent to enable visual observation of fluid, within, or flowing through tubing130. In embodiments, tubing130is formed from a material that is chemically resistant to the engine cleaner composition described herein. In the illustrated embodiment, tubing130includes tubing outlet134configured for insertion into an air intake manifold of a GDI engine. In some embodiments, a tubing outlet134(e.g., a tubing outlet end) includes rigid tubing section133to facilitate insertion of outlet134of tubing130into an air intake manifold of a GDI engine. In some embodiments, rigid tubing section133is a stiff member, for example metal guide, a stiff rod, tube or partial tube, attached to tubing130. In some embodiments, rigid tubing section133includes a sleeve covering a portion of tubing130. In some embodiments, rigid tubing section133is made from a material selected from metal and plastic. In yet other embodiments, rigid tubing section133is part of tubing130and formed of a material more rigid than tubing130.

In some embodiments, dispensing assembly120includes at least one valve (not shown) configured to regulate a flowrate of engine cleaner composition through tubing130. A wide variety of valves could be positioned in dispensing assembly120to regulate flow of engine cleaner fluid through tubing130. In some embodiments, a valve such as a ball valve can be positioned in tubing130(e.g., proximal to the middle of tubing130) to allow a user to manually adjust the valve, thereby regulating the flow of engine cleaner fluid through tubing130.

In some embodiments, the engine cleaner composition comprises a cleaning fluid and a propellant. Example cleaning fluids may comprise amines, aminoesters, xylene, butyl cellosolve, ethyl benzene, and combinations thereof. Examples of cleaning fluids are described in, for example, U.S. Pat. Nos. 5,858,942; 6,541,435; 8,632,638; 8,809,248; US Patent Application No. 2018/0002645 and the like, the disclosures of which are incorporated herein by reference. In some embodiments, the propellant may be selected from one or more hydrocarbon propellants (e.g., a mixture of butane and propane), carbon dioxide, nitrogen, R134a, R1 234ze, HF0-1234yf, or any propellant that enables dispensing apparatus100to operate as described herein.

FIG.2is a perspective view of another suitable embodiment of a dispensing assembly220, which may be equivalent to dispensing assembly120ofFIG.1, for cleaning the intake system of an engine having an air intake manifold. In the illustrated embodiment, dispensing assembly220includes housing221and length of tubing230. Dispensing assembly220further includes inlet250and outlet240. In the illustrated embodiment, dispensing assembly220is in an uncoupled state, characterized in that dispensing assembly220is not in fluid communication with a pressure-resistant container110. In other embodiments, dispensing assembly220may be separately provided to a product assembler, or separately to a user, without a pressure-resistant container110or length of tubing130. In other embodiments, dispensing assembly220may be provided as a kit with a pressure-resistant container110and/or length of tubing130.

In the illustrated embodiment, length of tubing230, which may be equivalent to tubing130shown inFIG.1, includes rigid tubing section233to facilitate insertion of tubing outlet234into an air intake manifold of an engine. In some embodiments, tubing outlet234may be biased in a general direction such that tubing outlet234(e.g., a tubing outlet end) tends to remain in a desired positioned. For example, tubing outlet234may be biased such that tubing outlet234resists moving out of an air intake manifold as an engine cleaner composition is discharged through tubing outlet234into the air intake manifold.

In the illustrated embodiment, length of tubing230includes curving portion232configured to orient tubing outlet234in a desired direction. In some embodiments, curving portion232is configured to prevent undesired movement of length of tubing230which may cause length of tubing230to move out of an air intake manifold as an engine cleaner composition is discharged through length of tubing230into the air intake manifold. In the illustrated embodiment, rigid tubing section233includes a curve substantially corresponding to a hook shape. In other embodiments, length of tubing230may include an L-shaped curving portion, a U-shaped curving portion, a V-shaped curving portion, or any other curve or curving shape that enables dispensing assembly220to operate as described herein.

In the illustrated embodiment, dispensing assembly220includes timer222configured to control a timed valve (shown inFIG.3) housed within housing221that regulates fluid flow through dispensing assembly220. When in an open position, the timed valve allows fluid to discharge from the pressure-resistant container110(shown inFIG.1), through dispensing assembly220, and through length of tubing230. In some embodiments, the timed valve includes a plunger, a bisecting cylinder, a diaphragm, or any other structure that enables dispensing assembly220to operate as described herein.

In the illustrated embodiment, timer222includes winding mechanism238configured to control the timed valve housed within housing221. Winding mechanism238enables a user to activate the timed valve such that timed valve opens after a predetermined length of time. In the illustrated embodiment, winding mechanism238includes rotatable dial switch239and indicator241. In the illustrated embodiment, the predetermined length of time is determined by a clockwise rotation of rotatable dial switch239between an “O” and an “I” indicia of indicator241. In other embodiments, winding mechanism238includes a vertically displacing switch, a horizontally displacing switch, or any other switch that enables dispensing assembly220to operate as described herein.

In some embodiments, timer222includes an electric timer having a control mechanism that activates the timed valve to open after the predetermined length of time. In some embodiments, the electric timer is powered by a battery. In some embodiments, the electric timer operates a switch that releases the timed valve, wherein the timed valve is positioned by a biasing member, for example a spring. In some embodiment, the electric timer operates a timed valve including a solenoid circuit on-off valve.

The predetermined length of time, or time delay, may be set to any desirable length of time. For example, the predetermined length of time may be 15 seconds, 30 seconds, one minute, two minutes, 3 minutes, 4 minutes, 5 minutes, or any other length of time that enables dispensing assembly220to operate as described herein. In the illustrated embodiment, the predetermined length of time begins after actuation of winding mechanism238. In some embodiments, winding mechanism238is configured to delay opening of the timed valve for from 15 seconds to one minute after actuation of winding mechanism238. In some embodiments, the predetermined length of time may be adjusted based on an average time it would take a user to activate winding mechanism238and proceed to enter a vehicle housing a GDI engine in need of cleaning, start the GDI engine, and rev the GDI engine.

In some embodiments, dispensing assembly220includes a solenoid circuit configured to start or stop the flow of an engine cleaner composition. For example, a user device could be used to remotely (e.g., while sitting in a vehicle) actuate the solenoid circuit to an on position or an off position by transmitting a wireless signal via a transmitter to a receiver in dispensing assembly220. In some embodiments, the wireless signal is a Bluetooth signal, or other short range wireless signal. In some embodiments, the user can continuously actuate the solenoid circuit in an open position for a desired time period and then stop the flow of engine cleaner composition when cleaning is complete. Alternatively, a user could pulse the solenoid circuit on and off to provide a corresponding pulsed flow of engine cleaner composition to a manifold while the engine is running.

In the illustrated embodiment, dispensing assembly220includes shut-off valve assembly224including shut-off valve actuator225. When actuated by a user, shut-off valve actuator225engages a drive shaft housed within housing221(as shown inFIG.3). When engaged by shut-off valve actuator225, the drive shaft is configured to raise a distal end of a lever housed within housing221. When the distal end of the lever is in a raised position, shut-off valve assembly224is in a closed position. In the closed position, shut-off valve assembly224seals a pressure-resistant container from the tubing inlet of dispensing assembly220when dispensing assembly220is coupled to the pressure-resistant container. Shut-off valve assembly224is configured to prevent inadvertent discharge of an engine cleaner composition. Additionally, separately operable shut-off valve assembly224permits an operator to stop flow of the engine cleaner composition if a cleaning procedure needs to be halted. Shut-off valve assembly224may be used to start or stop the flow at any point of time. When in the closed position, shut-off valve assembly224enables actuation of winding mechanism238to begin the predetermined length of time.

In the illustrated embodiment, dispensing assembly220includes attachment device236configured to facilitate attachment of dispensing assembly220to a supporting structure. For example, attachment device may include a hook shape, a magnet, suction cup, adhesive or other structure capable of facilitating attachment of the dispensing assembly220as described herein. For example, during a procedure for cleaning an engine of a vehicle, attachment device236may facilitate attachment, such as by hanging, of dispensing assembly220to a portion of the vehicle such that dispensing assembly220maintains an optimal position or orientation during the cleaning procedure.

It is noted that dispensing assembly220described herein could be used for a variety of fluids instead of an engine cleaner composition. Nonlimiting examples of such fluids include insecticides, fragrances, paints, foams, and the like. Such fluids could be used in combination with a propellant. Also, an apparatus that includes on-off valve and timer as described herein may be modified as desired depending on the fluid that is being discharged. For example, the assembly outlet may not be coupled to a hose and/or may be coupled to a nozzle that disperses the fluid into a surrounding environment.

FIG.3is a sectional view of dispensing assembly320including timer322and shut-off valve assembly324. Dispensing assembly320may be equivalent to dispensing assembly120ofFIG.1. Dispensing assembly320further includes housing321and length of tubing330. Length of tubing330includes tubing inlet332within housing321and tubing outlet334. In the illustrated embodiment, dispensing assembly320may be included in a dispensing apparatus for cleaning an intake system of a GDI engine, in which dispensing assembly320is coupled to a pressure-resistant container at assembly inlet350. In the illustrated embodiment, assembly inlet350is fluidly coupled to tubing inlet332. Length of tubing330exits dispensing assembly320at assembly outlet340.

In the illustrated embodiment, length of tubing330includes rigid tubing section333to facilitate insertion of tubing outlet334into an air intake manifold of an engine. In some embodiments, tubing outlet334may be biased in a general direction such that tubing outlet334(e.g., a tubing outlet end) tends to remain in a desired positioned. For example, tubing outlet334may be biased such that tubing outlet334resists moving out of an air intake manifold as an engine cleaner composition is discharged through tubing outlet334into the air intake manifold.

In the illustrated embodiment, dispensing assembly320includes timer322configured to control timed valve380within housing321that regulates fluid flow through dispensing assembly320. When in an open position, timed valve380allows fluid to discharge from the pressure-resistant container, through dispensing assembly320, and through length of tubing330. In the illustrated embodiment, timed valve380includes biasing member326to bias timed valve380in a desired position. In the illustrated embodiment, biasing member326is a spring. In other embodiments, timed valve380includes a plunger, a bisecting cylinder, a diaphragm, or any biasing member that enables dispensing assembly320to operate as described herein.

In the illustrated embodiment, timer322includes winding mechanism338configured to control timed valve380housed within housing321. Winding mechanism238enables a user to activate timed valve380such that timed valve380opens after a predetermined length of time. In the illustrated embodiment, winding mechanism338includes rotatable dial switch339. In other embodiments, winding mechanism338includes a vertically displacing switch, a horizontally displacing switch, or any other mechanical, electronic or digital switch that enables dispensing assembly320to operate as described herein.

In the illustrated embodiment, dispensing assembly320includes separately operable shut-off valve assembly324including shut-off valve actuator325. When actuated by a user, shut-off valve actuator325engages drive shaft327. When engaged by shut-off valve actuator325, drive shaft327is configured to engage a proximal end328of lever335to raise distal end329of lever335. When distal end329of lever335is in a raised position, shut-off valve assembly324is in a closed position. In the closed position, shut-off valve assembly324seals a pressure-resistant container from tubing inlet332of dispensing assembly320when dispensing assembly320is coupled to the pressure-resistant container. Shut-off valve assembly324is configured to prevent inadvertent discharge of an engine cleaner composition. Additionally, shut-off valve assembly324permits an operator to stop flow of the engine cleaner composition if a cleaning procedure needs to be halted. Shut-off valve assembly324may be used to start or stop the flow at any point of time. When in the closed position, shut-off valve assembly324enables actuation of winding mechanism338to begin the predetermined length of time.

In the illustrated embodiment, dispensing assembly320includes attachment device336configured to facilitate attachment of dispensing assembly320to a supporting structure. For example, during a procedure for cleaning an engine of a vehicle, attachment device336may facilitate attachment of dispensing assembly320to a portion of the vehicle such that dispensing assembly320maintains an optimal position or orientation during the cleaning procedure.

During a cleaning operation, an engine cleaner composition is discharged from a pressure-resistant container into assembly inlet350, and the engine cleaner composition flows past shut-off valve assembly324. As shown, the shut-off valve assembly324is actuated by shut-off valve actuator325. In the illustrated embodiment, shut-off valve actuator325includes a rotatable knob. When the shut-off valve actuator325is in an “off” position, drive shaft327is pressed down and distal end329of lever335is moved upward. At this time, timed valve is closed and winding mechanism338of timer322can be rotated to begin the predetermined length of time.

After opening of shut-off valve assembly324, flow of engine cleaner composition is determined by timer322, which controls timed valve380. Timed valve380includes a valve structure that impedes flow through dispensing assembly320and, when opened, allows engine cleaner composition to discharge from the pressure-resistant container, through dispensing assembly320, and through length of flexible tubing330. When the predetermined length of time has elapsed while shut-off valve assembly324is in the open position, distal end329of lever335is forced down by biasing member326, which actuates an aerosol valve structure in the pressure-resistant container such that engine cleaner composition can flow through assembly320as described herein.

In use, any one of the fluid-dispensing devices as described herein is provided, and the user opens the hood of the vehicle and locates the vehicle's engine air intake. The pressure-resistant container including the cleaner composition is preferably secured, so that it does not need to be held by a person during the cleaning process.

In an embodiment, the pressure-resistant container can be secured under the hood or can be hung using an attachment device, for example attachment device236. In an embodiment, the pressure-resistant container is secured in an orientation wherein the on-off valve and timer is positioned below the pressure-resistant container (i.e. the pressure-resistant container is inverted).

FIG.4shows an embodiment of pressure-resistant container410having reservoir412and valve413including discharge orifice414. Pressure-resistant container410may be equivalent to pressure-resistant container110shown inFIG.1. In some embodiments, valve413is an aerosol valve and discharge orifice414is a valve stem. In the illustrated embodiment, valve413is adapted to contain fluid contents in reservoir412until valve413is actuated to allow the engine cleaner composition to flow from discharge orifice414due to the fluid being at a relatively higher pressure in reservoir412. In some embodiments, pressure-resistant container410is provided with attachment device416for mounting pressure-resistant container410in an inverted position during use.

In some embodiments, pressure-resistant container410is secured in an orientation wherein the timer is positioned above the pressure-resistant container410such that the pressure-resistant container is upright so that discharge orifice414is positioned upright.

FIG.5is a simplified flowchart illustrating an example cleaning process utilizing an apparatus for cleaning an intake system of an engine. For example, the end of the flexible tubing, for example a rigid end of tubing section133of tubing outlet134shown inFIG.1, is placed inside the intake manifold502at appropriate distance and secured so that it remains in place throughout the cleaning process. During some cleaning processes, the engine may be run for several minutes before initiating the cleaning process, which can be before, during or after set up of the fluid-dispensing device as described above.

To carry out a cleaning process, a user opens the separately operable shut-off valve504, if present, to enable delivery of the engine cleaner composition to the air intake manifold. Then the user actuates the timer506.

The timer provides a short delay time to opening of the on-off valve508for as long as two minutes after actuation of the timer506to provide the user with enough time to get into the car, turn on the engine (if not already running) and rev the engine to the desired rpms510(e.g., from about 1500 to about 2500 rpms) for proper cleaning. The incorporation of a timer delay thus greatly facilitates completion of the cleaning process by a single person, without assistance.

The user continues to operate the car engine at the desired rpm510rate until the flow of the engine cleaner composition has stopped512. The completion of delivery of engine cleaner composition may be determined by waiting for the time period usually associated with delivery of the engine cleaner composition for the particular fluid-dispensing device being used. Alternatively, the delivery of engine cleaner composition may be confirmed by visually ensuring that the flow has stopped from the pressure-resistant container into the intake manifold. The transparent nature of hose in certain embodiments greatly facilitates visual confirmation of completion of the flow of the engine cleaner composition.

It has been found that the apparatus and method as described herein greatly facilitates delivery of engine cleaner composition to the intake system of an automotive internal combustion engine in a precise, controlled manner, and the resulting method in particular is effective in chemically cleaning undesired carbon deposits in the engine.

In an embodiment, the method is carried out on an internal combustion engine. In an embodiment, the method is carried out on a fuel injected internal combustion engine. In an embodiment, the method is carried out on a Gas Direct Injection internal combustion engine.

Throughout this specification and claims, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integer or step. When used herein “consisting of” excludes any element, step, or ingredient not specified in the claim element. When used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. In the present disclosure of various embodiments, any of the terms “comprising”, “consisting essentially of” and “consisting of” used in the description of an embodiment may be replaced with either of the other two terms.

All percentages and ratios used herein are weight percentages and ratios unless otherwise indicated. All patents, patent applications (including provisional applications), and publications cited herein are incorporated by reference as if individually incorporated for all purposes. Numerous characteristics and advantages of the embodiments meant to be described by this document have been set forth in the foregoing description. It is to be understood, however, that while particular forms or embodiments have been illustrated, various modifications, including modifications to shape, and arrangement of parts, and the like, can be made without departing from the spirit and scope of the disclosure.