Engine air intake duct with orifice cap and manufacture thereof

An engine air intake duct includes a duct wall and an orifice cap. The duct wall extends between an air inlet and an air outlet and has at least one orifice disposed therethrough. The duct wall has an integrally-formed closure mechanism adjacent the orifice. The orifice cap is moveable relative to and securable to the closure mechanism to substantially cover the orifice.

TECHNICAL FIELD

The present disclosure relates to an air induction system, and more specifically to an air induction system for an internal combustion engine of an automobile.

BACKGROUND

Internal combustion engines employed to power vehicles generally operate with air intake systems that include an air intake duct to direct the air flow into the engine. Air intake ducts often present acoustic resonances. Various approaches have been implemented to mitigate such acoustic resonances. However, some approaches provide an ingress through which engine-heated air may enter the intake duct, which may reduce engine thermal efficiency. Furthermore, some approaches provide an ingress through which water may enter the intake duct.

SUMMARY

In at least one approach, a vehicle is provided. The vehicle may include an engine and an air intake system. The air intake system may be adapted to direct fluid to the engine. The air intake system may have an air intake duct that includes a first body portion secured to a second portion to form a shell. The shell may define an air inlet at a first end and an air outlet at a second end opposite the first end. The first body portion may define a plurality of orifices disposed therethough. The first body portion may further define an integrally-formed closure interface including a closure frame, a hinge, and an orifice cap. The closure frame may have an upstanding wall extending from the first body portion at a perimeter of the plurality of orifices and an upstanding closure member extending from the first body portion. The hinge may be connected to and extend from the closure frame. The orifice cap may be connected to and extend from the hinge and may have an aperture sized to receive the upstanding closure member. The orifice cap may be rotatable between a first position in which the orifice cap is spaced from the closure frame and a second position in which the orifice cap is engaged with the upstanding closure member of the closure frame.

In at least one approach, an engine air intake duct is provided. The engine air intake duct may include a duct wall and an orifice cap. The duct wall may extend between an air inlet and an air outlet and may have at least one orifice disposed therethrough. The duct wall may have an integrally-formed closure mechanism adjacent the orifice. The orifice cap may be moveable relative to and securable to the closure mechanism to substantially cover the orifice.

In at least one approach, a method of forming an engine air intake duct is provided. The method may include forming a shell having a duct wall extending between an air inlet and an air outlet and having an orifice disposed therethrough. The shell may have an integrally-formed closure interface adjacent the orifice. The closure interface may include a closure mechanism formed with and disposed on the duct wall, a hinge formed with and extending from the duct wall, and an orifice cap formed with and extending from the hinge.

DETAILED DESCRIPTION

Referring now toFIG. 1, a vehicle10may be provided with an air induction system12for providing intake air to an engine14, such as an internal combustion engine. The air induction system12may include an intake duct16for receiving and directing the intake air to the engine14. The intake duct16may be designed and intended to be located at an appropriate point upstream of the engine14. For example, the intake duct16may extend in fluid communication with an air cleaner box34and an intake plenum and/or throttle body36. The upstream and downstream ends of intake duct16may be connected with the adjoining portions of the air induction system12by any suitable approach.

Referring toFIG. 2, an intake duct16may comprise a first body portion20and a second body portion22. The first body portion20may be referred to as a top body portion, and the second body portion22may be referred to as a bottom body portion. As used herein, “top” and “bottom” may refer to relative positioning of the body portions when the intake duct16is in the installed configuration (e.g., as inFIG. 1). The first and second body portions20,22may be formed, for example, of a plastic material, and may be formed by an appropriate process, such as blow-molding or injection-molding. The first body portion20may be secured to the second body portion22in any suitable manner, such as through an interference fit or mechanical fastener. In still another approach, the intake duct16may be formed of more than two body portion. In still another approach, the intake duct16may be a one-piece, tubular shell.

In the assembled configuration, the first and second body portions20,22may define a shell24. The shell24may have a top wall, a bottom wall, and sidewalls extending therebetween. The shell24may define an air inlet26at a first end of the shell24, and an air outlet28at a second end of the shell24opposite the first end. The air inlet26may draw air into the intake duct16(for example, via an air filter positioned upstream of the air inlet26). The air outlet28may provide air to the engine. In one example, the air outlet28may be in fluidic communication with downstream components such as a throttle, a compressor, etc.

The shell24may define a generally oval cross section and may include an approximately 45° bend. In this way, the shell24may define a first region24aproximate and downstream of the air inlet26, a second region24bdownstream of the first region24band defining a curve or bend, and a third region24cdownstream of the second region24band proximate the air outlet28. The dimensions and shape of the shell24may be based upon many variables and may be influenced by the available package space within the engine compartment.

The intake duct16may also include a gasket38. The gasket38may be a foam gasket that may be disposed about the shell24; for example, at the first region24aproximate the air inlet26. The gasket38may be adapted to inhibit or reduce airflow into the air inlet26of the intake duct16.

One or more components of the intake duct16may define an orifice or plurality of orifices. As used herein, an orifice may refer to a hole that extends through an entire thickness of the body through which it is disposed. In this way, fluid (such as air) may pass from outside of the intake duct16, through the orifice, and into an interior cavity of the intake duct16.

The orifice or orifices may be disposed at one or more locations of the intake duct. For example, orifices may be disposed through the first body portion20at the first region24a, the second region24b, or the third region24c, through the second body portion22at the first region24a, the second region24b, or the third region24c, or any combination thereof. In one example approach, the second body portion22has a first plurality of orifices disposed through the first region24aand a second plurality of orifices disposed through the second region24b.

Referring toFIG. 3, the first body portion20may define a first orifice or plurality of orifices30(which may be arranged, for example in an array or matrix). The first plurality of orifices30may include a plurality of rows and columns of aligned orifices. For example, an array may have at least two orifices aligned in a column and at least two orifices aligned in a row extending orthogonal to the column.

The first plurality of orifices30may be formed in the first body portion20proximate the air inlet26. The second body portion22may define a second orifice or plurality of orifices32(which may be arranged, for example in an array or matrix). The second plurality of orifices32may include a plurality of rows and columns of aligned orifices. The second plurality of orifices32may be formed in the second body portion22proximate the air outlet28. The orifices may contribute to the reduction or mitigation of acoustic resonances in the intake duct16.

Referring now toFIGS. 4-6, the intake duct16may include a closure interface40. The closure interface40may be formed such that an orifice cap42may be secured to the shell24to substantially cover the orifices. The orifice cap42may engage the shell24, for example, at a closure frame44.

The closure frame44may include one or more upstanding walls46disposed at a perimeter of the orifices30,32. The walls46may extend away from the shell24.

The closure frame44may also include one or more closure features, such as an upstanding closure member48. The upstanding closure member48may be disposed at a periphery of the closure frame44. The upstanding closure member48may have a neck region and a head region. The head region may have a width or thickness greater than that of the neck region. In at least one approach, the upstanding closure member48may be a slide lock adapted to be received in a slide lock interface of the orifice cap42. In at least another approach, the upstanding member may be a resilient tab. The resilient tabs may have head region extending from the neck region and forming a sloped upper surface and a lower lip surface. The resilient tabs may be adapted to flex in response to a biasing force at the sloped upper surface, and to return to an unflexed position in the absence of a biasing force.

The closure frame44, upstanding walls46, and the upstanding closure member48may be individually or collectively referred to as a closure mechanism.

The orifice cap42may be secured to the shell24through a hinge50. In at least one approach, the hinge50is a living hinge. The living hinge may extend from the closure frame (e.g., In this way, movement of the orifice cap42toward and away from the closure frame44may cause the hinge50may flex (e.g., rotate) between various positions.

In still another approach, the hinge50includes a hinge pin that may rotatably secure the orifice cap42to the shell24. In still another approach, the orifice cap42may be a removable cap that is not connected to the shell24(e.g., is a discrete component not connected through a hinge).

The orifice cap42may include one or more closure features that may be, for example, complementary to the closure features of the closure frame44. In at least one approach, the orifice cap closure features may be apertures52disposed opposite, and sized and adapted to receive, the upstanding members48of the closure frame44. In the slide lock approach, the apertures52may be irregularly-shaped apertures adapted to receive the head regions of the slide lock upstanding closure member48in an enlarged region of the aperture52, and may be moved (e.g., slid or rotated) such that the neck region is received in a narrowed region of the aperture52. In this way, the head region may engage a top surface of the orifice cap42to inhibit movement of the orifice cap42(e.g., in a distance away from the shell24). In the resilient tab approach, engagement between the orifice cap42and the resilient tabs (e.g., at the sloped surface of the head region) may cause the orifice cap42to bias the resilient tabs to a flexed position. When the head region is sufficiently received in the aperture52, the sloped surface may no longer engage the orifice cap42, and the resilient tab may return to an unflexed (e.g., relaxed) position. In this position, the lip surface may engage a top surface of the orifice cap42to inhibit movement of the orifice cap42(e.g., in a distance away from the shell24).

In at least one approach, a closure interface40may be integrally formed with at least a portion of the intake duct16. For example, when the intake duct16is a one-piece shell24, the closure interface40may be integrally formed with the one-piece shell24. When the intake duct16is a multicomponent shell24(e.g., having first and second body portions20,22), a closure interface40may be integrally formed on one or more of the components. As used herein, “integrally formed” may refer to the closure interface40and the shell component being created or constructed as a single unit or component in a manufacturing process. The integrally formed closure-shell component may be formed, for example, through blow-molding, injection-molding. Other suitable manufacturing processes such as casting are contemplated.

The closure interface40may be adapted to reduce fluid flow from an exterior of the intake duct16through the orifices30,32to an internal cavity of the intake duct16. For example, when the orifice cap42is engaged with the closure frame44, the closure interface40may partially or completely cover (e.g., extend over) the orifices30,32to reduce heated air produced by the engine14from being admitted into the internal cavity of the intake duct16. Partial or complete coverage of the orifice cap42over the orifices30,32may also reduce water from entering the internal cavity of the intake duct16.

In at least one approach, the upstanding walls46may extend a height from the shell24such that when the orifice cap42is in the closed configuration, the upstanding walls46are spaced from the orifice cap42. In this approach, the orifice cap42and the upstanding walls46may define a gap therebetween. The gap may be, for example approximately 1 millimeter to approximately 6 millimeters, and more particularly, approximately 2 millimeters. The gap may be optimized such that a reduced airflow may pass through the closure interface40, through the orifices, an into an internal cavity defined by the shell24. The reduced airflow may mitigate resonance at the intake duct16. In still another approach, the upstanding walls46may extend a sufficient height from the shell24such that when the orifice cap42is in the closed configuration, the upstanding walls46engage the orifice cap42(e.g., at a bottom surface of the orifice cap42).

FIGS. 4 and 5depict an exemplary closure interface40disposed in the first body portion20at a first region24aof the shell24. InFIG. 4, the orifice cap42is disposed in a first configuration, that may be referred to as a closed configuration. In the closed configuration, the orifice cap42engages the shell24; for example, at the closure frame44. More particularly, the orifice cap42may engage the upstanding closure member48of the closure frame44. For example, the resilient tabs of the closure frame44may engage and inhibit movement of the orifice cap42relative to the closure frame44. In this configuration, the orifice cap42extends over the orifices30,32that extend through the first body portion20.

In at least one approach, a method of forming an engine air intake duct is provided. The method may include forming a shell having a duct wall extending between an air inlet and an air outlet and having an orifice disposed therethrough. The shell may have an integrally-formed closure interface adjacent the orifice. The closure interface may include a closure mechanism formed with and disposed on the duct wall, a hinge formed with and extending from the duct wall, and an orifice cap formed with and extending from the hinge.

In at least one approach, the shell, the closure mechanism, the hinge, and the orifice cap may be a one-piece component integrally formed in a molding process. The molding process may include forming the hinge in an extended configuration. The method may further include, after the molding process, rotating the orifice cap relative to the duct wall to flex the hinge from the extend configuration to a bent configuration. The method may further include engaging the closure mechanism with the orifice cap to mechanically secure the orifice cap to the closure mechanism over the orifice.