Abstract:
A field replaceable unitary manifold housing for providing combustion air and combustion fuel to an internal combustion engine is disclosed. The housing includes an air purification cavity having a spaced apart air intake and air discharge. The housing also includes a filter for purifying air disposed in the air purification cavity intermediate the air intake and the air discharge. The housing also includes a hollow elongate member having a first end coupled to the filter and a second end coupled to a plenum chamber for directing the air, the plenum chamber being integral with the air purification cavity. The housing also includes a plurality of channels, each channel integral with the housing and having a first end integral with the plenum chamber and a second end coupled to a cylinder head of the engine. The air intake induces air into the air purification cavity, the induced air is purified by the filter, the hollow elongate member directs the air from the filter to the plenum chamber, and the plurality of channels direct the air from the plenum chamber to the cylinder head.

Description:
The present application is a divisional of U.S. patent application Ser. No.: 09/336,081 filed Jun. 18, 1999. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a manifold for motor vehicles. In particular, the present invention relates to a manifold system to provide combustion air and combustion fuel to a cylinder head of an internal combustion engine. 
     BACKGROUND OF THE INVENTION 
     It is well known to purify raw air in an air cleaner before routing the purified air and combustion fuel through an intake manifold and supplying the air and fuel to an internal combustion engine. Such known air cleaners typically include a filter disposed in a housing. An air exhaust of the air cleaner typically leads to the separate intake manifold. In operation, such known air cleaners provide for the intake of raw air, the purification of the raw air and the routing of the purified air to the air exhaust; such known intake manifolds provide for the routing of the purified air and the combustion fuel to the cylinder head of the engine. 
     A problem with such known air cleaners and intake manifolds is that such components are separate and distinct. Such separateness and distinctness can result in mechanical incompatibility between such components, the need for additional hoses and tubes to connect such components, decreased accessibility to such components for servicing and a reduction in the physical underhood space available for accessory components. 
     What is needed, therefore, is a unitary manifold system. It would also be advantageous to have a manifold system capable of rapid installation in an engine. It would further be advantageous to have a manifold system that is readily accessible for rapid service, repair or replacement. It would further be advantageous to provide a manifold system with multiple detachment points for easy servicing. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention relates to a field replaceable unitary manifold housing for providing combustion air and combustion fuel to an internal combustion engine. The housing includes an air purification cavity having a spaced apart air intake and air discharge. The housing also includes a filter for purifying air disposed in the air purification cavity intermediate the air intake and the air discharge. The housing also includes a hollow elongate member having a first end coupled to the filter and a second end coupled to a plenum chamber for directing the air, the plenum chamber being integral with the air purification cavity. The housing also includes a plurality of channels, each channel integral with the housing and having a first end integral with the plenum chamber and a second end coupled to a cylinder head of the engine. The air intake induces air into the air purification cavity, the induced air is purified by the filter, the hollow elongate member directs the air from the filter to the plenum chamber, and the plurality of channels direct the air from the plenum chamber to the cylinder head. 
     The present invention further relates to a field replaceable unitary manifold housing for providing combustion air and combustion fuel to an internal combustion engine of an automobile. The housing includes an air purification cavity having a spaced apart intake means for inducing air into the air purification cavity and a discharge means for venting air from the housing. The housing also includes means for purifying the induced air being disposed in the air purification cavity intermediate the air intake means and the air discharge means. The housing also includes means for directing air from the air purification cavity to a plenum means for directing the air, the plenum means being integral with the air purification cavity. The housing also includes means for providing fuel to the channel means. The housing also includes channel means for directing air from the plenum means to a cylinder head of the internal combustion engine. 
     The present invention further relates to a method for coupling a first molded flange of a manifold for providing combustion air and combustion fuel to a cylinder of a vehicular internal combustion engine to a second molded flange of an extension of the manifold. The method includes molding the first flange of the manifold and the second flange of the extension. The method also includes molding an alignment member integral with the second flange. The method also includes forming a first aperture in the first flange. The method also includes forming a second aperture in the alignment member. The method also includes positioning the first flange and the second flange such that the first aperture is generally aligned with the second aperture. The method also includes inserting a threaded insert in the first aperture and at least partially in the second aperture. The method also includes inserting a threaded fastener into the threaded insert such that the fastener is circumscribed by the insert and extends into the first flange and at least partially into the second flange. 
     It is an object of this invention to provide a unitary manifold housing. It is also an object of this invention to provide a manifold housing that is capable of rapid replacement in an engine. It is a further object of this invention to provide a manifold housing that is readily accessible for rapid servicing, repairing or replacing. It is a further object of this invention to provide a manifold system with multiple detachment points for easy servicing. It is a further object of this invention to decrease manufacturing costs by providing a manifold housing constructed of readily available materials. 
    
    
     Other principal features and advantages of the invention will become apparent to those skilled in the art upon review of the following drawings, the detailed description and the appended claims. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a fragmentary perspective view of a manifold system in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is a fragmentary section view of the system of FIG. 1 along line  2 — 2  of FIG. 1; 
     FIG. 3 is a fragmentary section view of the system of FIG. 1 along line  3 — 3  of FIG. 1; 
     FIG. 4 is a fragmentary perspective view of a lower plenum and manifold assembly; 
     FIG. 5 is a fragmentary exploded perspective view of a lower plenum and manifold assembly; and 
     FIG. 6 is a fragmentary section view of the lower plenum and manifold assembly of FIG. 5 along line  6 — 6  of FIG.  5 . 
    
    
     Before explaining at least one embodiment of the invention in detail it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or shown in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows a manifold or housing system  10  for providing a mixture of combustion fuel  134  and purified combustion air  42  to a cylinder head  180  of an internal combustion engine (not shown) according to a preferred embodiment of the present invention. System  10  includes an air induction system  20  mounted to a manifold assembly  100 . Air induction system  20  purifies raw air (e.g., atmospheric, ambient, unpurified, dirty air, etc.) and includes an air intake or air induction tube (shown as a dirty air tube  12 ) partially disposed within a housing  16 . An air filter assembly  30  is provided within the interior of housing  16 . A hose (shown as an airflow tube  70 ) is mounted to a filter assembly  30  and serves to direct purified air  42  from filter assembly  30  to a throttle assembly  80 . Purified air  42  flows through throttle assembly  80  to a reservoir or plenum chamber (shown as a cavity  22 ). A system of hollow tubes or channels (shown as manifold runners  122 ) direct purified air  42  from housing  16  through manifold assembly  100  and a manifold extension  160  to cylinder head  180  of the engine. System  10  is selectively removable from cylinder head  180  for rapid repair, servicing or replacement. 
     Referring to FIG. 2, air induction system  20  includes an air induction reservoir or air purification cavity (shown as a cavity  18 ) and cavity  22  or purified air  42 . A partition (shown as a wall  26 ) separates cavity  18  from cavity  22  such that the raw, dirty or unpurified air stored in cavity  18  is generally sealed or separated from cavity  22 . Dirty air tube  12  includes an inlet  14  to direct the raw air from the exterior of housing  16  into cavity  18  of housing  16 . An outlet (shown as a tuning tube  58 ) mounted to dirty air tube  12  further directs the raw air from inlet  14  to cavity  18  of housing  16 . The center of tuning tube  58  is narrower than the end (e.g., crimped or horn-shaped with a trumpet-shaped portion). Not wishing to be limited by theory, it is believed that the shape of the outlet may provide an overall noise reduction by matching the natural frequency of the raw air to the frequency of the engine. According to an alternative embodiment, the purified air reservoir may include a number of baffles into which the raw air is directed (i.e., the baffles may further serve to reduce the overall noise level of the manifold system). 
     Filter assembly  30  is disposed within cavity  18  of housing  16  and may be supported by wall  26 . Filter assembly  30  includes a generally circular-shaped air filter element (shown as a canister  32 ). Canister  32  includes an air receiving surface (shown as an outer wall  36 ) and an air-emitting surface (shown as an inner wall  46 ). Raw air stored in cavity  18  enters canister  32  through outer wall  36  and is directed through a filter media (not shown) such as a pretreated or pleated corrugated paper. During the purification or filtering of the raw air by canister  32 , impurities (e.g., debris, particulates, gasses, dirt, pollution, etc.) may be entrapped within the filter media. Purified air  42  exits the filter media through inner wall  46  of canister  32 . A covering (shown as an end cap  34 ) circumscribes and surrounds a lower end  28  of canister  32 . End cap  34  promotes the entry of raw air through outer wall  36  by covering or blocking lower end  28  of canister  32 . A generally flexible, compressible seal  44  is mounted to an upper end  48  of canister  32 . Seal  44  extends radially around canister  32  beyond the periphery of an aperture  192  having a diameter  190 . A fastener (not shown), such as an adhesive or glue, may secure seal  44  to canister  32 . Such fastener may also secure a left end  38  of the filter media to a right end  40  of the filter media. According an alternative embodiment, the seal may be integrally molded to the filter element or the seal may be removably coupled to the filter element. 
     Airflow tube  70  is generally U-shaped and engages upper end  48  of canister  32  to provide a conduit for directing purified air  42  from canister  32  to throttle assembly  80 . An end portion  72  of airflow tube  70  is provided at least partially within canister  32 . (End portion  72  has a diameter  188  less than a diameter  186  of an inlet  74  of airflow tube  70  and less than diameter  190  of aperture  192  of canister  32 .) In operation of air induction system  20 , purified air  42  is directed from canister  32  through end portion  72  to inlet  74  of airflow tube  70 . 
     Throttle assembly  80  regulates the amount of purified air  42  directed from air induction system  20  to cylinder head  180  of the engine. A fastener (shown as a capture clamp  88 ) mounts a throttle valve  90  of throttle assembly  80  to an outlet  76  of airflow tube  70 . (The diameter of outlet  76  is greater than the diameter of throttle valve  90  such that throttle valve  90  may be inserted into outlet  76  and secured by a capture clamp  88 .) Throttle assembly  80  includes a choke assembly  82  providing a flap  84  controlled by a lever  86  to regulate the amount of purified air  42  that passes through choke assembly  82 . After passing through throttle assembly  80 , purified air  42  is directed into cavity  22  of housing  16 , and ultimately to cylinder head  180  of the engine. According to an alternative embodiment, the flap of the choke assembly may be controlled by a computer system. 
     Referring to FIG. 5, manifold assembly  100  includes a service plenum  114  mounted to a manifold extension  160  by a fastener assembly  170  (see FIG.  6 ). Manifold assembly  100  includes runners  122  to direct purified air  42  from cavity  22  to cylinder head  180  of the engine. Runners  122  span manifold assembly  100  and manifold extension  160 . According to alternative embodiments, the manifold system may contain any number of channels or runners in any configuration (e.g., a manifold system adapted to provide combustion air and combustion fuel to the cylinder head of a V-8 or straight-6 internal combustion engine as is known in the automotive arts). 
     Manifold assembly  100  is selectively removable from manifold extension  160  such that manifold system  10  may be easily accessed for repair or replacement. Referring to FIG. 3, manifold assembly  100  includes upper plenum  112 , service plenum  114  having a service flange  124  and a common fuel source or fuel conduit (shown as a fuel rail  130 ). A weld joint (shown as a flange  24 ) integrally connects the upper end of upper plenum  112  to housing  16 . The lower end of upper plenum  112  is integrally connected to the upper end of service plenum  114  by a weld joint (shown as a flange  116 ). According to a preferred embodiment, the weld joint between the upper plenum and the service plenum is flared outwardly such that the interior of the runner is generally smooth for optimum airflow through the runner. 
     Referring to FIG. 6, fastener assembly  170  connects service flange  124  of service plenum  114  to a service flange  162  of manifold extension  160 . To connect service flange  124  to service flange  162 , an aperture (shown as a bore  198 ) having a slight inward taper is aligned with a protrusion or alignment pin (shown as a post  178 ) of service flange  162 . An aperture (shown as an inner bore  196 ) having a slight outward flare is provided within the interior of post  178  and extends into the interior of service flange  162 . A spacer (shown as a generally circular-shaped, hollow, threaded insert  176 ) is inserted into bore  198  of service flange  124  and extends into bore  196  of post  178  such that threaded insert  176  is generally flush with the surface of service flange  124 . A fastener (shown as a threaded, hexagonal-headed, machine screw  172 ), the head of which is circumscribed by a spacer (shown as a washer  174 ), is inserted into threaded insert  176 . A seal (shown as an O-ring  168 ) is provided in a groove  166  of service flange  162  to inhibit purified air  42  from leaking from manifold system  10 . The protrusions may be molded to the service flange by any known method such as blow molding, vibration welding, friction welding, etc. Any known method such as boring, drilling, molding, etc. may form the apertures. According to a preferred embodiment as shown in FIG. 6, the inner bore of the service flange is a “blind” bore such that the aperture of the bore does not extend all the way through the service flange of the manifold assembly. 
     Referring to FIGS. 4 and 5, a suitable fastener (e.g., a vibration weld) mounts fuel rail  130  to service plenum  114 . A fastener (shown as a capture clamp  138 ) connects fuel rail  130  to a duct (shown as a hose  136 ) of a fuel source  132  (see FIG.  4 ). A control device (shown as a fuel regulator  140 ) controls the amount of fuel  134  provided to fuel rail  130 . According to an alternative embodiment as shown in FIG. 4, fuel regulator  140  may be a returnless fuel regulator (as is known in the automotive arts) that inhibits the “back flow” of fuel  134  from fuel rail  130  back into to fuel source  132 . An aperture  142  provides a passage for fuel  134  to be directed from fuel rail  130  to a conduit (as shown best in FIG. 4 as a top feed fuel injector  150 ). In operation of manifold assembly  100 , fuel  134  is directed from fuel rail  130 , through aperture  142  and to an inlet  152  of injector  150 . Fuel  134  flows from inlet  152  to a passageway  154  of injector  150 , and end exits injector  150  through an outlet  156  to an injector bore  158  of manifold extension  160 . Fuel  134  is dispersed from injector bore  158  as a fuel spray  128 . Ultimately, fuel spray  128  and purified air  42  are mixed at cylinder head  180 . A fastener (shown as a hexagonal-headed machine screw  194 ) is inserted through an aperture  182  to mount a cylinder flange  164  of manifold extension  160  to cylinder head  180  of the engine. According to an alternative embodiment, a seal (e.g., O-ring) may be provided between a seal groove of the cylinder flange and the cylinder head. According to other alternative embodiments, the fuel rail may be molded to the service flange of the manifold assembly. 
     Referring to FIG. 2, a locking mechanism (shown as a twist lock system  50 ) selectively connects filter assembly  30  to airflow tube  70  such that filter assembly  30  may be readily removed from cavity  18  of housing  16 . To engage and disengage twist lock system  50 , airflow tube  70  is rotated about ninety degrees. Twist lock system  50  includes a tube connector system  52  and a housing connector system  60 . Housing connector system  60  includes a number of outwardly extending protrusions (shown as a finger  62 ) and a number of inwardly extending indentations (shown as finger  64 ) spaced generally evenly about the periphery of an aperture  184  of cavity  18 . Tube connector system  52  includes reciprocal outwardly extending protrusions (shown as a finger  54 ) and inwardly extending indentations (not shown) spaced generally evenly about the periphery of a flange  56  of airflow tube  70 . To create an effective closure or connection between filter assembly  30  and airflow tube  70 , a compressive force is applied to airflow tube  70  to compress seal  44  (which may be a flexible seal) between a seal engaging surface of flange  56  and canister  32 . (A stop mechanism  144  applies an opposite force to end cap  34  of filter assembly  30 .) Finger  54  of tube connector system  52  is aligned with and inserted into finger  64  of housing connector system  60 . Finger  54  is rotated relative to housing  16  (or vice versa) such that finger  54  is aligned with finger  62  of housing connector system  60  (i.e., the finger of the housing connector system and the tube connector system are rotated until they are intertwined and interconnected). The compression of seal  44  and the interconnection of finger  54  and finger  62  maintain such compressive force. According to an alternative embodiment, an indexing system may be provided to inhibit further rotation of the airflow tube relative to the housing (i.e., such rotation may cause a disconnection between the outwardly extending protrusion of the housing connector system and the outwardly extending protrusion of the tube connector system). 
     Referring to FIGS. 2 and 3, a locking mechanism  92 , similar to twist lock system  50 , may connect throttle assembly  80  to cavity  22  housing  16 . According to an alternative embodiment as shown in FIG. 3, a locking assembly  94  may connect throttle assembly  80  to cavity  22  of housing  16 . Locking assembly  94  includes an aperture  148  circumscribed by a flexible tapered portion  96  and adapted to receive throttle valve  90 . A flexible seal  98  may be positioned between cavity  22  and throttle assembly  80  to inhibit purified air  42  from leaking from throttle assembly  80  to the exterior of housing  16 . According to other alternative embodiments, the air induction tube may be connected to the housing by a locking mechanism similar to twist lock system  50  shown in FIG.  2 . 
     According to a particularly preferred embodiment, the manifold system purifies raw air before the raw air is routed to the cylinders of an automotive or vehicular engine. The air induction housing, the plenum assembly, the manifold assembly and the fuel rail are preferably constructed of plastic. The plenum assembly is vibration welded to the housing, and the upper plenum is vibration welded to the service plenum. Preferably, the vibration welding operation is conducted at about 120 hertz. The fuel rail is molded to the upper plenum and has a diameter of about one inch. The filter element holds about one quart of purified air and the filter media is preferably constructed of paper folded in a zigzag configuration. The cover of the filter assembly is preferably constructed of aluminum metal and is encapsulated in urethane. The seal of the filter assembly is preferably generally “V”-shaped and constructed of urethane rubber. The height of each of the protrusions of the fastener assembly is substantially identical to the thickness of the service flange of the manifold assembly. The aperture of the protrusion of the fastener assembly is preferably deeper than the length of the threaded insert, which is preferably constructed of brass. The O-ring seals are preferably constructed of urethane rubber. 
     While a preferred embodiment of the invention is as described above, there are several substitutions that may be made without departing from the beneficial features of the above-described invention such as variations in sizes, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, or use of materials. For example, according to an alternative embodiment the fuel rail may be molded or integral with the service flange of the manifold assembly. The fuel rail may be mounted to either the upper plenum or to the manifold assembly. The regulator of the fuel rail may be positioned within the housing. Any suitable fastening device (e.g., welding, ultrasonic welding, vibration welding, molding, glue, screws, rivets, clamps or other conventional methods) may attach the housing to the plenum assembly and may attach the upper plenum to the service plenum. 
     According to other alternative embodiments associated with the filter assembly, the filter element may be disposable. The filter material may be constructed of a porous material (e.g., cardboard, corrugated paper, carbon block, etc.) or a natural or synthetic fibrous material (e.g., spun polyethylene, glass wool, microbial filter, etc.). The effective closure or seal between the tube connector system and the housing connector system may be formed by any known connection system (such as a bayonet connector system, a threaded connection, a clamp, etc.) and may be maintained by any locking mechanism (e.g., a detent, a tumbler lock, a tacky adhesive, etc.). The seal of the filter assembly may be round-shaped, V-shaped, diamond-shaped or any other shape or configuration. The seal of the filter assembly may be mounted to the housing, fixed to a rigid or semi-rigid framework that also extends about the periphery of the filter element, or detached from both the housing and the filter element. The seal of the filter assembly may be positioned between the filter element and the airflow tube or between the airflow tube and the housing. A panel-type filter assembly may be mounted directly to the plenum. 
     It should be noted that the use of the term “conduit” is not meant as a term of limitation, insofar as any valve, hose, tube, passage or like structure providing a channel or passageway through which air may flow is intended to be included in the term. It should also be noted that the use of the term “directed” is not meant as a term of limitation, insofar as any routing or leading of raw air, purified air or fuel into, through and out of the air induction system and the manifold system is intended to be included in the term. It should also be noted that the use of the term “engine” is not meant as a term of limitation, insofar as any “engine” or like machine for using fuel to produce motion is intended to be included in the term. 
     Thus, it should be apparent that there has been provided in accordance with the present invention a manifold system that fully satisfies the objectives and advantages as set forth above. Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred embodiments without departing from the spirit of the invention as expressed in the appended claims.