Abstract:
A housing for abating noise and receiving an air cleaner is disclosed. The housing is configured for separable coupling to an internal combustion engine of an automobile. The engine includes a plurality of belt driven accessories driven by a crankshaft. The housing includes an internal air cavity disposed in the housing. The cavity provides an air induction chamber adjacent an intake for inducing air into the air induction chamber from an external source and a filtering chamber adjacent an air discharge for venting air from the filtering chamber. The filtering chamber is configured to receive a filter for purifying air disposed intermediate the intake and the discharge. The engine further includes a shroud integral with the exterior of the housing. The shroud provides a peripheral wall defining a recess configured to at least partially surround at least a portion of at least two belt driven accessories. The shroud substantially reduces noise generated by the engine.

Description:
This application claims benefit to provisional application No. 60/090513 filed Jun. 24, 1998. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to abating engine noise and providing an air purification unit associated with the engine of a motor vehicle. In particular, the present invention relates to a housing system configured to substantially reduce the noise generated by an automobile engine and provide a housing configured to receive an air filter. 
     BACKGROUND OF THE INVENTION 
     It is well known to purify raw air before routing the air and fuel through a manifold and supplying the air and fuel to a cylinder head of an internal combustion engine. Such known air cleaners typically include a filter disposed in a container. In operation, such known air cleaners provide for the intake of raw air, the purification of the raw air and the routing of purified air to the manifold. Such known manifolds provide for the routing of the purified air and the fuel to the cylinder head of the engine. 
     It is also well known to reduce the amount of noise generated by an automobile and its associated components. For example, a muffler may be connected to an engine exhaust to reduce the noise generated by the ignition of the fuel and the air in the engine. In addition, it is known to provide sound absorbing materials under the hood of an automobile and in the driver compartment of the automobile to reduce the amount of engine and ambient noise perceptible to the driver. 
     A problem with such known air cleaners and their containers is that they are not typically configured to reduce engine noise or noise generated by belt driven engine accessories. Further, such containers typically have a single purpose (i.e., containing the air cleaner) and are not easily accessible for servicing of the air cleaner. 
     What is needed, therefore, is a housing system configured to receive an air cleaner and reduce the amount of noise generated by an engine and its associated belt driven accessories. It would also be advantageous to have a housing system onto which cavity accessories and mechanical accessories may be secured. It would further be advantageous to have a housing system that is capable of cooling such accessories. It would also be advantageous to provide a housing system of simple structure that occupies the unused underhood space of an automobile. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention relates to a housing for abating noise and receiving an air cleaner. The housing is configured for separable coupling to an internal combustion engine of an automobile. The engine includes a plurality of belt driven accessories driven by a crankshaft. The housing includes an internal air cavity disposed in the housing. The cavity provides an air induction chamber adjacent an intake for inducing air into the air induction chamber from an external source and a filtering chamber adjacent an air discharge for venting air from the filtering chamber. The filtering chamber is configured to receive a filter for purifying air disposed intermediate the intake and the discharge. The engine further includes a shroud integral with the exterior of the housing. The shroud provides a peripheral wall defining a recess configured to at least partially surround at least a portion of at least two belt driven accessories. The shroud substantially reduces noise generated by the engine. 
     The present invention further relates to an automotive power supply system. The system includes an internal combustion engine. The engine includes a throttle valve for regulating the amount of air provided to a valve cover. The throttle valve includes a throttle intake, a throttle discharge and a throttle plate disposed between the throttle intake and the throttle discharge. The throttle discharge is intermediate the throttle intake and the valve cover. The engine also includes a manifold for providing air from the throttle valve to the valve cover. The engine also includes a hollow elongate member for venting air from the valve cover to the throttle valve disposed between the valve cover and a filter for purifying air. The engine also includes a common fuel source for providing fuel to the manifold coupled to the manifold. The engine also includes a radiator for cooling the engine coupled to the engine. The engine also includes a plurality of belt driven accessories coupled to the engine and driven by a crankshaft. 
     The system also includes a housing for abating engine noise and receiving the filter. The housing is mounted to the engine and includes an internal air cavity disposed in the housing. The cavity provides an air induction chamber adjacent an air intake for inducing air into the air induction chamber from an external source, and a filtering chamber adjacent an air discharge for venting air from the filtering chamber. The filter is disposed in the filtering chamber intermediate the air intake and the air discharge. The system also includes a shroud integral with the exterior of the housing. The shroud provides a peripheral wall defining a recess at least partially surrounding at least a portion of at least two of the belt driven accessories of the plurality of belt driven accessories. The shroud substantially reduces noise generated by the engine and the air discharge of the air induction chamber is fluidly coupled to the throttle valve. 
     It is an object of this invention to provide a housing system configured to receive an air cleaner and reduce the amount of noise generated by an engine and its associated belt driven accessories. It is a further object of this invention to have a housing system onto which cavity accessories and mechanical accessories may be secured. It is a further object of this invention to have a housing system that is capable of cooling such accessories. It is a further object of this invention to have a housing system of simple structure that occupies the unused underhood space of an automobile. 
     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 front elevation view of the housing system in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is side elevation view of the system of FIG. 1; 
     FIG. 3 is a fragmentary cross sectional view of the system of FIG. 1 along line  1 — 1  of FIG. 1; 
     FIG. 4 is a cross sectional view of the system of FIG. 1 along line  4 — 4  of FIG. 2; 
     FIG. 5 is a fragmentary cross sectional view of the system of FIG. 1 along line  5 — 5  of FIG. 5; 
     FIG. 6 is a front elevation view of a housing system in accordance with an alternative embodiment of the present invention; and 
     FIG. 7 is side elevation view of the system of FIG.  6 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows a housing system  10  for reducing engine noise and receiving a filter assembly  40  according to a preferred embodiment of the present invention. System  10  includes a housing  20  mounted to an engine block  182  of a vehicular internal combustion engine  98 . Housing  20  includes an air reservoir (shown as a cavity  24 ) and an external cavity (shown as a recess  34 ). Filter assembly  40  is disposed between an air intake  66  of housing  20  and a throttle assembly  130 . In operation, raw air  62  (e.g., atmospheric, ambient, unpurified, dirty air, etc.) enters intake  66  and is directed through cavity  24 . Raw air  62  is then filtered by filter assembly  40  and exits cavity  24  through a discharge (e.g., outlet, vent, exhaust, etc. shown as an aperture  128 ) of housing  20 . Purified air  48  is then regulated or throttled by throttle assembly  130  and is directed to a valve cover  186  of engine  98 . 
     Referring to FIG. 3, an exterior wall  22  defines cavity  24  of housing  20 . Cavity  24  includes a dirty air chamber  26  and an air filtering chamber  28 . A raw air inlet  68  is integral with wall  22  and projects outwardly from the front housing  20 . As best shown in FIG. 1, inlet  68  is positioned off center from the front of housing  20 . A fastener (shown as a capture clamp  72 ) connects an extension tube  70  to inlet  68 . Extension tube  70  provides raw air  62  from a raw air source (not shown) such as the atmosphere. Raw air  62  that is induced into dirty air chamber  26  is directed toward filtering chamber  28  for purification or filtering by filter assembly  40 . 
     Referring to FIG. 2, the exterior of housing  20  includes recess  34  surrounding belt driven accessories  150  mounted to the front of engine block  182 . Recess  34  is defined by a peripheral wall  36  of a shroud  38 . Wall  36  partially circumscribes and surrounds belt driven accessories  150  to partially enclose a belt system  148  and belt driven accessories  150  within recess  34 . Recess  34  is in close proximity to belt system  148  and belt driven accessories  150 . Each belt driven accessory  150  includes a pulley or wheel  168  connected by a rod  170  to a base  174 , such that wheel  168  is rotated when rod  170  is rotated. Belt system  148  interconnects belt driven accessories  150 . A serpentine or drive belt  152  interconnects wheel  168  of a crank  160  driven by a crankshaft (not shown) to wheel  168  of a water pump  162  and wheel  168  of an alternator  164 . As wheel  168  of crank  160  is rotated, drive belt  156  causes wheel  168  of water pump  162  and alternator  164  to likewise rotate. A tensioning belt  158  for removing slack in drive belt  156  interconnects wheel  168  of a tensioning device (shown as an idler  166 ) to wheel  168  of crank  160 . 
     A cavity or resonator  30  for holding raw air  62  and a resonator  32  are provided within the interior of housing  20 . Referring to FIG. 4, resonators  30  and  32  are positioned adjacent to cavity  24 . An intake or inlet (shown as an aperture  74  of resonator  30  and an aperture  76  of resonator  32 ) provide a passage for the ingress and egress of raw air  62  between cavity  24  and resonator  30  and cavity  24  and resonator  30  (see FIG.  5 ). Without wishing to be limited by theory, it is believed that noise (such as vibrations) generated from the engine and the induction of raw air into the air reservoir may be substantially reduced, dampened or muffled by bouncing or ricocheting against the boundaries of the resonators. According to an alternative embodiment, the intake of the resonator may be or horn-shaped (e.g., crimped, trumpet-shaped portion, curved, etc.). Not wishing to be limited by theory, it is believed that the horn shape of the intake of the resonator may provide an overall noise reduction by partially matching the natural frequency of the raw air and the engine to the natural frequency of the resonator. According to other alternative embodiments, the resonators may include a number of molded baffles or maze-like structures (which may be lined with a sound absorbent material as is known in the office furnishings art) into which the raw air is directed (i.e., the baffles may further serve to reduce the overall noise level of the engine and the induction of air into the air cavity). 
     A variety of accessories may be mounted to the interior or the exterior of housing  20 . Referring to FIG. 4, cavity accessories  100  providing a reservoir or storage area for an item (such as a liquid) are shown mounted to the exterior of housing  20 . A coolant reservoir (shown as a radiator overflow bottle  102 ) having a storage area  106  may be molded to or integral with housing  20 . A cover  110  is provided on the top of bottle  102  to reduce the likelihood of items escaping from storage area  106  of bottle  102 . A fastener  116  (e.g., threaded screw top, snap-on top, lid, etc.) may provide bottle  102  with a generally airtight seal. A solvent reservoir (shown as a windshield wiper fluid bottle  104 ) having a storage area  108  may be molded to or integral with housing  20 . A cover  112  is provided on the top of bottle  104  to reduce the likelihood of items (such as windshield wiper fluid) from escaping storage area  108  of bottle  104 . A fastener  114  (e.g., threaded screw top, snap top, lid, etc.) may provide a generally watertight seal to bottle  104 . According to an alternative embodiment, a variety of mechanical accessories (e.g., radiator fan, windshield pump, air induction fan, etc.) may be mounted to the interior or the exterior of the housing. According to other alternative embodiments as shown in FIG. 4, any number of internal cavities may be provided within housing  20  such as a side cavity  176 , a closure cavity  178 , or a front cavity  148  to provide additional space or surface area for mounting accessories. 
     Referring to FIG. 3, a filter assembly  40  is disposed within filtering chamber  28  of cavity  24  and may be supported by a support structure such as a flange (not shown). Filter assembly  40  includes a generally circular-shaped air filter element (shown as a canister  42 ). A projection tube  118  of housing  20  fits within an aperture  128  of an upper end  52  of canister  42  to support filter assembly  40 . (Projection tube  118  has a diameter less than the diameter of aperture  128  of canister  42 .) Canister  42  includes an air receiving surface (shown as an outer wall  44 ) and an air-emitting surface (shown as an inner wall  46 ). Raw air  62  stored or induced in cavity  24  enters canister  42  through outer wall  44  and is directed through a filter media (not shown) such as a pretreated or pleated corrugated paper. During the purification or filtering of raw air  62  by canister  42 , impurities (e.g., debris, particulates, gasses, dirt, pollution, etc.) may be entrapped within the filter media. Purified air  48  exits the filter media through inner wall  46  of canister  42 . A covering (shown as an end cap  58 ) circumscribes and surrounds a lower end  50  of canister  42 . End cap  58  promotes the entry of raw air  62  through outer wall  44  by covering or blocking lower end  58  of canister  42 . A generally flexible, compressible seal  56  is mounted to upper end  52  of canister  42 . Seal  56  extends radially around canister  42  beyond the periphery of aperture  128 . A fastener (not shown), such as an adhesive or glue, may secure seal  56  to canister  42 . Such fastener may also secure a left end of the filter media to a right end of the filter media to form a generally circular-shaped filter media. According to an alternative embodiment, the seal may be integrally molded to the filter element and/or the seal may be removably coupled to the filter element. 
     A twist lock system  120  (such as a bayonet mount) secures air filter assembly  40  in housing  20  such that canister  42  may be readily installed or removed from air filtering chamber  28 . To secure or remove canister  42 , a grip  124  of a cap  122  having molded projections or ears (shown as fingers  126 ) is rotated about 120 degrees relative to housing  20 . Fingers  126  are spaced generally evenly about the periphery of cap  122 . Cap  122  urges seal  56  of canister  42  against wall  22 . Upon rotation of grip  124 , fingers  126  of cap  122  are interconnected with wall  22  of housing  20 . Such interconnection of fingers  126  and wall  22  maintain a compressive force between seal  56  and projection tube  118  to prevent raw air  62  from leading around seal  56 . According to an alternative embodiment, an indexing system may be provided with the twist lock system to inhibit further rotation of the cap relative to the housing (i.e., such rotation may cause a disconnection between the fingers of the cap and the wall of the housing). 
     Referring to FIG. 1, engine  98  has a V-style configuration, such as a V-8 vehicular engine as is known in the automotive arts. Engine  98  includes a crankshaft (not shown) which, among other things, drives belt driven accessories  150 . An manifold and throttle assembly  130  are positioned between a left cylinder bank  180  and a right cylinder bank  184  of engine  98 . Throttle assembly  130  regulates the amount of purified air  48  directed from filter assembly  40  to a left valve cover  186  of left cylinder bank  180  and a right valve cover  188  of right cylinder bank  184 . Throttle assembly  130  is generally coaxial with canister  42  of filter assembly  40 . (According to a preferred embodiment as shown in FIG. 3, canister  42  and throttle valve  142  have axes parallel to the rotational axis of the crankshaft.) A fastener (shown as a capture clamp  82 ) connects throttle valve  142  of throttle assembly  130  to an extension tube  80  of housing  20 . (The diameter of extension tube  80  is greater than the diameter of throttle valve  142 , such that throttle valve  142  may be inserted into extension tube  80  and secured by capture clamp  82 .) Throttle assembly  130  includes a choke assembly  134  providing a controller (shown as a lever  132 ) mounted to a generally semi-circular shaped cam  136 . To regulate the amount of purified air  48  that passes through choke assembly  134 , cam  136  rotates a shaft  138 , which in turn rotates a flat throttle plate (shown as a flap  140 ) disposed within throttle valve  142 . After passing through throttle assembly  130 , purified air  48  is directed into valve covers  186  and  188  of engine  98 . Throttle valve  142  may be Y-shaped so that a left outlet or discharge  146  of throttle valve  142  is mounted to left valve cover  186  and a right discharge (not shown) of throttle valve  142  is mounted to right valve cover  188 , respectively. According to an alternative embodiment, the lever of the choke assembly may be controlled by a computer system. 
     Referring to FIG. 3, a channel  90  to direct air from left and right valve covers  186  and  188  to extension tube  80  may be mounted to housing  20 . A positive crankshaft ventilation valve (shown as a PCV valve  92 ) may be disposed within channel  90  to regulate the ventilation of purified air  48  from valve covers  186  and  188  to throttle assembly  130 . Channel  90  may also include a protrusion  94  for mounting housing  20  to valve covers  186  and  188 . A grommet  190  may strengthen and protect a mounting portion  192  of valve covers  186  and  188 . Thus, housing  20  may be removed with ease from engine  98  by disconnecting all mounting points (such as the mounting point between throttle assembly  130  and housing  20  and valve covers  186  and  188  and channel  90 ), all tubes (such as inlet  68 ) and lifting housing  20  away from the front of engine  98  and upwards over the top of engine  98 . 
     A housing system  210 , an alternative embodiment of system  10 , is shown in FIG.  6 . System  210  includes a housing  220  and an in-line style engine  298  (e.g., an in-line four cylinder engine as is known in the automotive arts). Housing  220  includes a shroud  238  having a peripheral wall  236  defining a recess cavity  234  (see FIG.  7 ). Recess cavity  234 , similar to recess  34 , surrounds belt driven accessories  250 . An air induction cavity  224  is provided within housing  220 . A fastener (shown as a capture clamp  272 ) attaches a dirty air tube  268  of housing  220  to an intake (shown as an inlet  270 ) of housing  220 . Dirty air tube  268  is shown off center and on the side of housing  220 , although the dirty air tube and the intake may be provided anywhere on the housing. A filter assembly  240  having a canister-style filter  242  secured by a twist lock mechanism  284  (similar to twist lock system  120  shown in FIG. 3) may be provided within housing  220 . Engine  298 , similar to engine  98 , includes a throttle assembly  230  that connects a filter assembly  240  to a valve cover  286 . A serpentine belt  256  interconnects a number of belt driven accessories (shown as an alternator  264 , a crank  260 , a water pump  262 , and an idler  266 ). According to any alternative or preferred embodiments, the belt driven accessories may include air conditioning condensers, air pumps, power steering pumps, superchargers, etc. 
     According to a particularly preferred embodiment, the housing system purifies raw air before the raw air is routed to the valve cover of an automotive or vehicular engine. The housing is preferably constructed of injection-molded plastic. The peripheral wall of the housing preferably covers or surrounds the entire surface of the belt system and preferably at least a part of the belt driven accessories. The cover of the filter assembly is preferably constructed of aluminum and is encapsulated in urethane. 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 seal of the filter assembly is preferably generally “V”-shaped and constructed of urethane rubber. Preferably, the covers of the cavity accessories are vibration welded to the storage area at about 120 hertz. The grip of the twist lock is molded plastic having a cross-type structure. Preferably, the grommet is constructed of 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, a mass air flow meter may be mounted between the air filter and the throttle assembly. In addition, the housing may be mounted to one or more of the valve covers, the engine block or the manifold. 
     According to other alternative embodiments, a variety of accessories may be associated with in the housing. Such accessories may be cavity accessories for storing or containing a variety of items such as liquid, spare parts, cleaning components, etc. Such cavity accessories may include a power steering fluid reservoir molded in the housing, a transmission fluid reservoir mounted to the exterior of the housing, a liquid overflow reservoir, etc. Further, the housing may include a compartment for supporting a battery. The accessories may also include a variety of mechanical accessories. The mechanical accessories may be provided in the housing (e.g., ignition system components and an engine control unit may be molded into the housing given any engine platform, and the engine control unit may be mounted in the housing, such that the airflow can function to cool the engine control unit). The mechanical accessories may be mounted to the exterior or the interior of the housing. Such mechanical accessories may include a fan mounted to the exterior of the housing for blowing air on a radiator, which may or may not be attached to the housing. Moreover, various sensors and solenoid mounting flanges (such as manifold temperature sensors and exhaust gas recirculation valves) can be molded or snapped to the housing. In addition, a charcoal canister for a canister purge solenoid may be mounted to the exterior of the housing. 
     According to other alternative embodiments associated with housing, the shape of the housing may be easily modified to conform to the style of the internal combustion engine (e.g., two and four cycle reciprocating piston engines, gas turbines, free piston, and rotary combustion type engines) and may be generally semi-circular shaped, bread-board shaped, angular shaped, etc. The underhood packaging or components (e.g., radiator, shock towers, cross members, belt driven accessories, etc.) may further influence the shape of the housing. The shroud may circumscribe and surround all of the belt driven accessories or a portions of individual belt driven accessories. A hole or space may be provided in the shroud such that the belt driven accessories may be accessible even when the housing is mounted to the engine. The shroud may abut the engine or may be spaced a distance from the engine. 
     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 filter assembly and the housing 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 housing. The filter may be a pan, box or drawer-style filter that is selectively removable from the housing. 
     It should be noted that the use of the term “channel” is not meant as a term of limitation, insofar as any valve, hose, tube, conduit, passage, passageway or like means or structure for providing a path 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 air into, through and out of the housing 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 and air 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 housing 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.