United States Patent: 6464761 Page 1 of9 

USPTO PATENT FUL.L-TEXT AND IMAGE DATABAS E 

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United States Patent 

BugH 

6,464,761 

October 15, 2002 

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Air induction filter assembly 

Abstract 

An air induction filter assembly includes a housing and a plurality of filter layers disposed in the housing. One of the 

filter layers is a carbon impregnated polyurethane foam layer to remove residual hydrocarbon (HC) vapors diffusing 

through an air inlet to the filter. 

···--- -·-----------------·------------····-------·-···-------------- ---------·-··---------·-···----

Inventors: Bugli; Neville Jimmy (Novi, MI) 

Assignee: Visteon Global Technologies, Inc. (Dearborn, MI) 

Family ID: 23867538 

Appl. No.: 09/470,410 

Filed: December 22, 1999 

Current U.S. 

Class: 

Current CPC 

Class: 

Current 

Inter national 

Class: 

Field of 

Search: 

96/135 ; 123/198£; 55/385.3; 55/487; 55/524; 55/DIG.24; 55/DIG.42 

F02M 35/024 (201 30101); B01 D 39/1692 (20130101); BOI D 46/0036 (20130101); BOlD 

46/12 (20130101); BOl D 53/02 (20130101); F02M 25/08 (20130101); BOl D 2253/102 (20130101); 

BOlD 2253/25 (2013010 1); BOlD 2253/311 (20130101); BOlD 22571702 (20130101); BOlD 

2258/01 (20130101); BOlD 2259/4146 (20130101); BOlD 2259/4566 (20130 101); BOl D 

2275/10 (20130 I 0 I); BOI D 2275/307 (201301 01); BOlD 2279/60 (201301 01 ); Yl OS 

55/42 (20130101); YIOS 55/24 (20130101) 

BO I D 46/10 (200601 0 I); BO ID 46/12 (20060 I 01); BOlD 39/16 (20060 10 I); BO I D 

53/04 (20060101); F02M 25/08 (20060101); F02M 35/02 (20060101); F02M 35/024 (20060101); 

BO I D 046/00 () 

;96/134, 135, 136,147,153,154, 121,131,132 ;55/486,487,524,DIG.13,DIG.24,DIG.42,385.3 ; 123/198E 

----------------------·-------------------·----

2822059 

2966960 

3221724 

3477210 

3541765 

References Cited [Referenced Byl 

-------------------- ------- U.S. Patent Documents 

February 1958 

January 1961 

December 1965 

November 1969 

November 1970 

Lunn et al. 

Rochlin 

Wentworth 

Hervert 

Adler et al. 

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United States Patent: 6464761 

3572013 March 1971 

3665906 May 1972 

372 1072 March 1973 

4259096 March 1981 

44 18662 December 1983 

4629479 December 1986 

4631077 December 1986 

4684382 August 1987 

4684510 August 1987 

4758460 July 1988 

4938787 July 1990 

5221573 June 1993 

5338253 August 1994 

5350444 September 1 994 

543770 1 August 1995 

54531 18 September 1995 

5478379 December I 99 5 

55738 11 November 1996 

5762692 June 1998 

5871 569 February 1999 

5891207 April 1999 

6136075 October 2000 

6156089 December 2000 

6231646 May 2001 

Foreign Patent Documents 

19505723 Aug 1996 

0 59 1 673 Apr 1994 

2 138 695 Oct 1984 

Primary Examiner: Simmons; David A. 

Assistant Examiner: Lawrence; Frank M. 

Attorney, Agent or Firm: Shelton; Larry I. 

Claims 

What is claimed is: 

Page 2 of9 

Hansen 

De Palma 

Clapham 

Nakamura et al. 

Engler et al. 

Can toni 

Spicer et al. 

Abu-Isa 

Harkins 

Spicer et al. 

Simmerlein-Erlbacher 

Baigas, Jr. 

Damsohn et al. 

Gould et al. 

Townsley 

Heiligman 

Bevins 

Townsley 

Dumas et al. 

Oehler et al. 

Katta 

Bragg et al. 

Stemmer et al. 

Schweizer et al. 

DE 

EP 

GB 

I. An air induction fi lter assembly comprising: a housing; a filter disposed in said housing; and said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-filter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an a ir inlet to said fi lter. 

2. An air induction filter assembly as set forth in claim 1 wherein said pre-filter foam layer is disposed on an air inlet 

side of said carbon impregnated foam layer. 

3. An air induction filter assembly as set forth in claim 1 wherein said post-filter foam layer is disposed adjacent an 

air outlet side of said carbon impregnated layer. 

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4. An air induction filter assembly comprising: a housing; a filter disposed in said housing; said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-filter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an air inlet to said filter; and wherein said pre-filter foam layer has a porosity of 

approximately 15 ppi to approximately 45 ppi. 

5. An air induction filter assembly comprising: a housing; a filter disposed in said housing; said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-filter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an air inlet to said filter; and wherein said carbon impregnated foam layer has a porosity of 

approximately IS ppi to approximately 30 ppi. 

6. An air induction filter assembly comprising: a housing; a fi lter disposed in said housing; said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-fi Iter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an air inlet to said filter; and wherein said carbon impregnated foam layer contains carbon in 

an amount of approximately one hundred percent to approximately three hundred percent by weight of said foam 

layer. 

7. An air induction filter assembly comprising: a housing; a filter disposed in said housing; said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-fi Iter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an air inlet to said filter; and wherein said post-filter foam layer has a porosity of 

approximately 45 ppi to approximately I 00 ppi. 

8. An air induction filter assembly as set forth in claim 7 wherein said pre-filter foam layer and said post-filter foam 

layer are treated with a tackifier. 

9. An air induction filter assembly comprising: a housing; a filter disposed in said housing; said filter having a 

plurality of individual and separate layers made of a foam material stacked together in a direction from a bottom of 

said housing to a top of said housing, said layers including a pre-filter foam layer disposed adjacent the bottom of 

said housing, a post-filter foam layer disposed adjacent the top of said housing, and a carbon impregnated foam layer 

disposed between said pre-fi Iter foam layer and said post-filter foam layer to remove residual hydrocarbon (HC) 

vapors diffusing through an air inlet to said filter; and wherein said layers include a medium porosity foam layer 

disposed between said carbon impregnated foam layer and said post-filter foam layer. 

I 0. An air induction filter assembly as set forth in claim 9 wherein said medium porosity foam layer has a porosity of 

approximately 45 to approximately 65 ppi. 

I I. An air induction filter assembly as set forth in claim I 0 wherein said medium porosity foam layer is treated with a 

tackifier. 

12. An air induction filter assembly comprising: a housing for operative connection to an engine of a vehicle having 

an air cleaner tray and an air c leaner cover; a filter disposed in said housing between said air cleaner tray and said air 

cleaner cover; and said filter having a plurality of individual and separate layers made of a foam material stacked 

together in a direction from a bottom of said air cleaner tray to a top of said air cleaner cover, said layers including a 

pre-filter foam layer disposed adjacent said air cleaner tray, a post-filter foam layer disposed adjacent said air cleaner 

cover, and a carbon impregnated foam layer disposed between said pre-filter foam layer and said post-filter foam 

layer to remove residual hydrocarbon (HC) vapors diffusing through an air inlet of the engine after the vehicle is 

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shut-off. 

13. An air induction filter assembly as set forth in claim 12 wherein said pre-filter foam layer is disposed on an air 

inlet side of said carbon impregnated foam layer. 

14. An air induction filter assembly as set forth in claim 12 wherein said carbon impregnated foam layer contains 

carbon in an amount of approximately one hundred percent to approximately three hundred percent by weight of said 

foam layer. 

15. An air induction filter assembly as set forth in claim 12 wherein said post-filter foam layer is disposed adjacent an 

air outlet side of said carbon impregnated layer. 

16. An air induction filter assembly for an engine of a vehicle comprising: a housing having an air cleaner tray and an 

air cleaner cover; a filter disposed in said housing between said air cleaner tray and said air cleaner cover; said filter 

having a plurality of individual and separate layers made of a foam material stacked together in a direction from a 

bottom of said air cleaner tray to a top of said air cleaner cover, said layers including a pre-filter foam layer disposed 

adjacent said air cleaner tray, a post-filter foam layer disposed adjacent said air cleaner cover, and a carbon 

impregnated foam layer disposed between said pre-filter foam layer and said post-filter foam layer to remove residual 

hydrocarbon (HC) vapors diffusing through an air inlet of the engine after the motor vehicle is shut-off; and wherein 

said pre-filter foam layer has a porosity of approximately I 5 ppi to approximately 45 ppi. 

17. An air induction filter assembly for an engine of a vehicle comprising: a housing having an air cleaner tray and an 

air cleaner cover; a filter disposed in said housing between said air cleaner tray and said air cleaner cover; said filter 

having a plurality of individual and separate layers made of a foam material stacked together in a direction from a 

bottom of said air cleaner tray to a top of said air cleaner cover, said layers including a pre-filter foam layer disposed 

adjacent said air cleaner tray, a post-filter foam layer disposed adjacent said air cleaner cover, and a carbon 

impregnated foam layer disposed between said pre-filter foam layer and said post-filter foam layer to remove residual 

hydrocarbon (HC) vapors diffusing through an air inlet of the engine after the motor vehicle is shut-off; and wherein 

said carbon impregnated foam layer has a porosity of approximately 15 ppi to approximately 30 ppi. 

18. An air induction filter assembly for an engine of a vehicle comprising: a housing having an air cleaner tray and an 

air cleaner cover; a fi lter disposed in said housing between said air cleaner tray and said air cleaner cover; said filter 

having a plurality of individual and separate layers made of a foam material stacked together in a direction from a 

bottom of said air cleaner tray to a top of said air cleaner cover, said layers including a pre-filter foam layer disposed 

adjacent said air cleaner tray, a post-filter foam layer disposed adjacent said air cleaner cover, and a carbon 

impregnated foam layer disposed between said pre-filter foam layer and said post-filter foam layer to remove residual 

hydrocarbon (HC) vapors diffusing through an air inlet of the engine after the motor vehicle is shut-off; and wherein 

said post-filter foam layer has a porosity of approximately 45 ppi to approximately 100 ppi. 

19. An air induction filter assembly as set forth in claim 18 wherein said post-filter foam layer is treated with a 

tackifier. 

20. A vehicle comprising: an engine; a housing operatively connected to said engine having an air cleaner tray and an 

air cleaner cover; a filter disposed in said housing between said air cleaner tray and said air cleaner cover; and said 

filter having a plurality of individual and separate layers made of a foam material stacked together in a direction from 

a bottom of said air cleaner tray to a top of said air cleaner cover, said layers including a pre-filter foam layer 

disposed adjacent said air cleaner tray, a post-filter foam layer disposed adjacent said air cleaner cover, and a carbon 

impregnated foam layer disposed between said pre-filter foam layer and said post-filter foam layer, said carbon 

impregnated layer having an air inlet side disposed adjacent the pre-filter foam layer for removing residual 

hydrocarbon (HC) vapors diffusing through an air inlet of said engine after the vehicle is shut-off . . ____________ , ____ _ Description 

BACKGROUND OF THE INVENTION 

1. Field of the Invention 

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The present invention relates generally to filters and, more specifically, to an air induction filter assembly for both 

automotive and non-automotive air intake applications. 

2. Description of the Related Art 

It is known to provide an air induction filter for an engine of a motor vehicle to filter out contaminants in air entering 

the engine. In the past, the air induction filter was typically made of pleated paper housed in a plastic or metal frame. 

The air induction filter and frame were mounted in an engine compartment of the motor vehicle. These air induction 

filters were used once and discarded. 

Currently, the reticulated foam filter is typically made of a foam material and housed in a plastic housing made out of 

glass filled nylon due to the high temperatures in the engine compartment. The foam material is several layers thick. 

An example of such an air induction filter is disclosed in U.S. Pat. No. 5,437,701. In this patent, the air induction 

filter has a molded or extruded housing which contains several layers of filter material. The layers can be either 

relatively thin or thick and treated or untreated. If the layer is treated, it contains an additive such as oil. 

It is also known that virtually all components in the motor vehicle contribute to evaporative emissions. It has been 

established that there is a significant amount of hydrocarbon vapors (15 mg of gasoline per i_njector) in a range of 

about ISO to 300 mg per day escaping through an air inlet of the engine as measured by a shed test known in the art. 

These emissions are emitted by raw fuel in the inlet manifold and some leakage through the injectors. 

Therefore, it is desirable to provide an air induction filter that will adsorb some of the hydrocarbon vapors. It is also 

desirable to provide an air induction filter that will control contaminants entering the engine and will remove 

hydrocarbon vapors exiting from the engine at the same time. It is desirable to provide an air induction filter that has 

150,000 miles of service for automotive applications and extended service life for non-automotive applications. It is 

further desirable to provide an air induction filter that will not require servicing up to 150,000 miles under normal 

driving conditions. Therefore, there is a need in the art to provide an air induction filter assembly that meets these 

desires. 

SUMMARY OF THE INVENTION 

Accordingly, the present invention is an air induction filter assembly including a housing and a filter disposed in the 

housing. The filter has a plurality of layers with one of the layers being a carbon impregnated foam layer to remove 

residual hydrocarbon (HC) vapors diffusing through an air inlet to the filter. 

One advantage of the present invention is that a new air induction filter assembly is provided for an engine of a motor 

vehicle. Another advantage of the present invention is that the air induction filter assembly uses reticulated multilayered foam with carbon impregnation to remove residual hydrocarbon (HC) vapors diffusing through the inlet 

manifold of the engine after the engine is shut-off. Yet another advantage of the present invention is that the air 

induction filter assembly wi II control contaminants and hydrocarbon vapors at the same time. Still another advantage 

of the present invention is that the air induction filter assembly has a long life and may require no changing or 

servicing up to 150,000 miles under normal driving conditions. A further advantage of the present invention is that 

the air induction filter assembly has low restriction of the carbon impregnated layer, which protects against shedding 

of carbon particles, i. e. the carbon is contained. Yet a further advantage of the present invention is that the air 

induction filter assembly has a carbon impregnated layer that is protected against dust, water and snow. Still a further 

advantage of the present invention is that the air induction filter assembly has reduced weight, cost, parts and 

complexity. Another advantage of the present invention is that the air induction filter assembly has packaging 

flexibility (shape and size) and can be packaged outside an engine compartment of the motor vehicle. Yet another 

advantage of the present invention is that the air induction filter assembly has lower inlet air temperatures, resonator 

requirements, and noise. 

Other features and advantages of the present invention will be readily appreciated, as the same becomes better 

understood after reading the subsequent description when taken in conjunction with the accompanying drawings. 

BRIEF DESCRIPTION OF THE ORA WINGS 

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FIG. I is a perspective view of an air induction filter assembly, according to the present invention, illustrated in 

operational relationship with an engine of a vehicle. 

FIG. 2 is an enlarged perspective view of the air induction filter assembly of FIG. 1. 

FIG. 3 is a sectional view taken along line 3--3 of FIG. 2. 

FIG. 4 is an enlarged fragmentary view of a filter for the air induction filter assembly of FIG. 1. 

FIG. 5 is a view similar to FIG. 4 of another embodiment, according to the present invention, of the filter for the air 

induction filter assembly of FIG. I. 

FIG. 6 is a view similar to FIG. 4 of yet another embodiment, according to the present invention, of the filter for the 

air induction filter assembly of FIG. 1. 

DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 

Referring now to the drawings and in particular FIG. 1 through 3, one embodiment of an air induction filter assembly 

10, according to the present invention, is shown for a motor vehicle, generally indicated at 12. The motor vehicle I2 

includes a vehicle body 14 and an engine 16 mounted to the vehicle body 14. The motor vehicle I2 incl udes an air 

outlet tube I8 operatively connected to a throttle body (not shown) of the engine I6 and to the air induction filter 

assembly I 0. The motor vehicle 12 also includes an air inlet tube 20 operatively connected to the air induction filter 

assembly I 0. The air induction filter assembly 10 is also mounted to the vehicle body 14 by suitable means such as 

fasteners (not shown). It should be appreciated that, except for the air induction filter assembly I 0, the motor vehicle 

12 is conventional and known in the art. It should also be appreciated that the air induction filter assembly I 0 may be 

used for non-automotive air intake applications such as HV AC applications, compressor intake, turbine air intake, 

indoor air, etc. 

The air induction filter assembly IO includes a housing, generally indicated at 22. The housing 22 is mounted by 

suitable means (not shown) to the vehicle body 14, preferably outside of an engine compartment (not shown) behind 

a bumper 24 and front fascia 26. The housing 22 includes an air cleaner tray 28 and an air cleaner cover 30. The air 

cleaner tray 28 is generally rectangular in shape, but may have any suitable shape. The air cleaner tray 28 includes a 

base wall 31 having an opening 31 a for connection to the air inlet tube 20. The base wall 46 is generally planar and 

may be rectangular in shape or any other suitable shape dictated by packing space requirements. The air cleaner tray 

28 has a side wall 32 forming a first cavity 34 and a first flange 36 extending generally perpendicularly to the side 

wall 32 and a second flange 38 extending generally perpendicularly to the first flange 36 to form a second cavity 40. 

The air cleaner tray 28 also has a plurality of support posts 42 extending longitudinally and spaced laterally from the 

side wall 32 for stiffing the air cleaner tray 28 and reduce noise. The air cleaner tray 28 is made of a relatively rigid 

material, preferably a plastic material such as polypropylene. The air cleaner tray 28 is a monolithic structure being 

integral, unitary and one-piece. It should be appreciated that the air cleaner tray 28 is operatively connected to the air 

inlet tube 20 which extends to a point above the bumper 24 and in a grill opening 43 to lessen a potential for snow 

and water ingestion. It should also be appreciated that the air cleaner tray 28 may be supported by a strap 44 attached 

by suitable means such as fasteners (not shown) to the vehicle body 14. 

The air cleaner cover 30 includes a base wall 46 having an opening 48 for connection to the air outlet tube 18. The 

base wall 46 is generally planar and may be rectangular in shape or any other suitable shape dictated by packing 

space requirements. The air cleaner cover 30 also has a side wall 50 extending generally perpendicular from the base 

wall 46 and a first flange 52 extending perpendicularly to the side wall 50. The air cleaner cover 30 also includes a 

second flange 54 extending perpendicularly to the first flange 52 to form a cavity 56. The second flange 54 may 

include a projection 58 extending laterally and inwardly to overlap the second flange 38 of the air cleaner tray 28. 

The air cleaner cover 30 may include a plurality of support posts 60 extending longitudinally and spaced laterally 

from the side wall 50 to stiffen the air cleaner cover 30 and reduce noise. The air cleaner cover 30 is made of a 

relatively rigid material, preferably a plastic material such as polypropylene. The air cleaner cover 30 is a monolithic 

structure being integral, unitary and one-piece. It should be appreciated that the air cleaner cover 30 is operatively 

connected to the air outlet tube 18. It should also be appreciated that the housing 22 may have any suitable shape and 

size for the filter 62 to be described. 

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The air induction filter assembly I 0 includes a filter, generally indicated at 62, disposed in the housing 22 to filter 

contaminants from the air to the engine 16 and absorb hydrocarbon vapors from the engine 16. The filter 62 is 

generally rectangular in shape, but may have any suitable shape, preferably complementary to the cavities 34 and 40. 

The filter 62 is also oversized relative to the cavity 34 to create an interference fit between the filter 62 and the air 

cleaner tray 28. The filter 62 is multi-layered and includes a plurality of individual and separate layers 

64,66,68,70,72,74. Preferably, the filter 62 has four to six layers 64,66,68,70,72,74. The layers 64,66,68,70,72,74 are 

made of a foam material, preferably an open cell or reticulated foam, more preferably reticulated "open cell" 

polyurethane foam. The density of the open cell foam is about 1.75 lb./cuft or 796 gms/cuft or 28111 gms/cuM. The 

filter 62 has selective layers, which may be treated with a tackifier. It should be appreciated that the reticulated foam 

has about 97% porosity, which is beneficial to airflow. 

As illustrated in FIGS. 3 and 4, the filter 62 has six layers 64,66,68,70,72,74. Adjacent the air cleaner tray 28 is a prefilter layer 64. The pre-filter layer 64 is relatively thin and is dry or untreated. The pre-filter layer 64 has a 

predetermined thickness such as in a range of0.25 inches to 0.75 inches. The pre-filter layer 64 has approximately 

fifteen (15) to approximately forty-five (45) pores per inch (ppi) foam. It should be appreciated that the pre-filter 

layer 64 has a coarse porosity foam media. It should also be appreciated that the pre-filter layer 64 is conventional 

and known in the art. 

The filter 62 also includes a carbon impregnated layer 66 adjacent the pre-filter layer 64. The carbon impregnated 

layer 66 has a predetermined thickness such as in a range of0.25 inches to 0.75 inches. The carbon impregnated layer 

66 is a carbon impregnated foam having carbon present in an amount of one hundred percent (1 00%) by weight to 

three hundred percent (300%) by weight of the foam layer. The carbon impregnated layer 66 has approximately 

fifteen ( 15) to approximately thirty (30) pores per inch (ppi) foam. The carbon impregnated layer 66 could also be 

made up of an open fibrous felt (non-woven) layer with coarse fibers. The permeability of such layer may be greater 

than 500 cfm Frazier. The felt layer will have coarse fibers in a range of about 50 .mu.m to about 100 .mu.m. It 

should be appreciated that the foam will have enough carbon to remove a majority of the HC vapors being generated 

in the engine 16. It should also be appreciated that the carbon impregnated layer 66 is optional for non-automotive 

applications. 

The filter 62 includes a first post-carbon layer 68 disposed adjacent the carbon impregnated layer 66. The first postcarbon layer 68 is relatively thin and is dry or untreated. The first post-carbon layer 68 has a predetermined thickness 

such as 0.25 inches to 0. 75 inches. The first post-carbon layer 68 has approximately forty-five ( 45) to approximately 

eighty-five (80) pores per inch (ppi) foam. The first post-carbon layer 68 may or may not be treated with a tackifier 

such as oil. If treated, the first post-carbon layer 68 will have about twenty-five (25%) to about seventy-five (75%) by 

weight of oil. It should be appreciated that the first post-carbon layer 68 has a medium porosity foam media. It should 

also be appreciated that the first post-carbon layer 68 is conventional and known in the art. 

The filter 62 includes a second post-carbon layer 70 disposed adjacent the first post-carbon layer 68. The second 

post-carbon layer 70 is relatively thin and is treated with a tackifier such as oil. The oil is approximately twenty-five 

percent (25%) to approximately seventy-five percent (75%) by weight of the foam layer. The second post-carbon 

layer 70 has a predetermined thickness such as 0.25 inches to 0.75 inches. The second post-carbon layer 70 has 

approximately forty-five ( 45) to approximately eighty (80) pores per inch (ppi) foam. It should be appreciated that 

the second post-carbon layer 70 has a medium porosity foam media. It should also be appreciated that the second 

post-carbon layer 70 is conventional and known in the art. 

The filter 62 includes a third post-carbon layer 72 disposed adjacent the second post-carbon layer 70. The third postcarbon layer 72 is relatively thin and is treated with a tackifier such as oil. The oil is approximately twenty-five 

percent (25%) to approximately fifty percent (50%) by weight of the foam layer. The third post-carbon layer 72 has a 

predetenuined thickness such as 0.25 inches to 0.5 inches. The third post-carbon layer 72 has approximately eighty 

(80) to approximately one hundred (I 00) pores per inch (ppi) foam. It should be appreciated that the third post-carbon 

layer 72 has a fine porosity foam media. It should also be appreciated that the third post-carbon layer 72 is 

conventional and known in the art. 

The filter 62 includes a fourth post-carbon layer 74 disposed adjacent the third post-carbon layer 72. The fourth postcarbon layer 74 is relatively thin and is dry or untreated. The fourth post-carbon layer 74 has a predetermined 

thickness such as 0.25 inches to 0.5 inches. The fourth post-carbon layer 74 has approximately eighty (80) to 

approximately one hundred (1 00) pores per inch (ppi) foam. Alternatively, the fourth post-carbon layer 74 may be 

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treated with a tackifier such as oil. The oil is approximately twenty-five percent (25%) to approximately fifty percent 

(50%) by weight of the foam layer. It should be appreciated that the fourth post-carbon layer 74 has a fine porosity 

foam media. It should also be appreciated that the fourth post-carbon layer is conventional and known in the art. It 

should further be appreciated that the layers 64,66,68,70,72,74 may be adhesively secured together to form an 

integral and one-piece filter 62. 

The air induction filter assembly I 0 may include a screen 76 disposed adjacent one side of the filter 62 between the 

support posts 42 of the air cleaner tray 28 and the pre-filter layer 64 of the filter 62. The air induction filter assembly 

10 may also include a screen 78 disposed adjacent the other side of the filter 62 between the support posts 60 of the 

air cleaner cover 30 and the fourth post-carbon layer 74. The screens 76 and 78 filter larger particulate matter before 

it contacts the filter 62 to protect the filter 62. The screens 76 and 78 compress the layers 72 and 74 of foam of the 

filter 62 approximately five percent (5%) of its original thickness. The screen 78 and flanges 36 and 52 may 

compress the layers 72 and 74 or just layer 74 to achieve a firmness of about 10 to about 20 to provide a sealing 

surface. It should be appreciated that the screens 76 and 78 are optional. 

The air induction filter assembly 10 may include at least one, preferably a plurality of darts 80 extending from the 

side wall 32 and first flange 36 of the air cleaner tray 28 to prevent the filter 62 from pulling away from the housing 

22. The highly compressed filter 62 and darts 80 prevent leakage of unfiltered air past the filter 62, resulting in 

increased reliability. Alternatively, instead of darts, a continuous staggered compression bead on flanges 36 and 52 

may be used to provide additional sealing integrity. It should be appreciated that the darts penetrate the filter 62 and 

hold it in place. 

The air induction filter assembly 10 may include an interlocking mechanism 82 such as a dart extending laterally 

from the second flange 38 of the air cleaner tray 28 when the housing 22 is snapped closed. The compressed foam 

layers between the air cleaner tray 28 and air cleaner cover 30 act like a spring to hold the assembly 10 together 

tightly and also keeps the entire assembly 10 from rattling. 

The air cleaner cover 30 and the fine porosity foam layers 72 and 74 of the filter 62 may be oversized relative to the 

air cleaner tray 28 to allow the air cleaner tray 28 to compress the layers 72 and 74. The fine porosity foam layers 72 

and 74 will be compressed to achieve a firmness of about 5 to 7 such that it is highly compressed to seal the assembly 

10. This also allows the foam of the filter 62 to be visible along cover/tray interface to verify that the filter 62 is 

inserted into the housing 22 properly during assembly and serves as an assembly check. It should be appreciated that 

the highly compressed layer of foam will repel water and reduce the risk of ingestion through the cover/tray interface. 

In operation of the air induction filter assembly 10, air enters the air inlet tube 20 and flows through the air cleaner 

tray 28 to the filter 62. The screen 76 in the air cleaner tray 28 filters particulate matter in the inlet air. The screened 

inlet air flows through the layers 64,66,68,70,72,74 of the filter 62, which filter contaminants from the inlet air. The 

filtered air flows through the screen 78 in the air cleaner cover 30 and into the air outlet tube 18 to the engine 16. 

When the engine 16 is turned off, residual HC vapors diffuse from the inlet manifold through the air outlet tube 18 

and air cleaner cover 30 to the filter 62. The vapors are absorbed by the carbon impregnated layer 66 of the filter 62. 

Referring to FIG. 5, another embodiment 162, according to the present invention, of the filter 62 of the air induction 

filter assembly 10 is shown. Like parts of the filter 62 have like reference numerals increased by one hundred (1 00). 

In this embodiment, the filter 162 includes the pre-filter layer 164 and the carbon impregnated layer 166. The filter 

162 includes a first post-carbon layer 170 disposed adjacent the carbon impregnated layer 166. The filter 162 

includes a second post-carbon layer 172 disposed adjacent the first post-carbon layer 170. The first post-carbon layer 

170 is relatively medium porosity foam media and is treated with a tackifier such as oil. The first post-carbon layer 

170 has a predetermined thickness such as 0.5 inches to 1.0 inches. The first post-carbon layer 170 has approximately 

forty-five ( 45) to approximately sixty-five (65) pores per inch (ppi) foam. It should be appreciated that the first postcarbon layer 170 is conventional and known in the art. 

The second post-carbon layer 172 is relatively fine porosity foam media and is treated with a tackifier such as oil. 

The second post-carbon layer 172 has a predetermined thickness such as 0.25 inches to 0.5 inches. The second postcarbon layer 172 has approximately eighty (80) to approximately one hundred (1 00) pores per inch (ppi) foam. It 

should be appreciated that the second post-carbon layer 172 is conventional and known in the art. It should also be 

appreciated that the filter 162 operates similar to the filter 62. 

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United States Patent: 6464761 Page 9 of9 

Referring to FIG. 6, yet another embodiment 262, according to the present invention, of the filter 62 of the air 

induction filter assembly 10 is shown. Like parts of the filter 62 have like reference numerals increased by two 

hundred (200). In this embodiment, the filter 262 includes the pre-filter layer 264 and a first pre-carbon layer 268 

disposed adjacent the pre-filter layer 264. The filter 262 includes a second pre-carbon layer 270 disposed adjacent the 

first pre-carbon layer 268. The filter 262 includes a third pre-carbon layer 272 disposed adjacent the second precarbon layer 270. The filter 262 includes the carbon impregnated layer 266 disposed adjacent the third pre-carbon 

layer 272. The filter includes the post-carbon layer 274 disposed adjacent the carbon impregnated layer 266. The 

operation of the filter 262 is similar to the filter 62. 

The present invention has been described in an illustrative manner. It is to be understood that the terminology, which 

has been used, is intended to be in the nature of words of description rather than of limitation. 

Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, 

within the scope of the appended claims, the present invention may be practiced other than as specifically described. 

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http://patft.uspto.gov/netacgi/nph-Parser?Sectl=PTOl&Sect2=HITOFF&d=PA... 12/9/2013