Patent Publication Number: US-2021180547-A1

Title: Space optimizing air filter

Description:
PRIORITY 
     This application claims the benefit of and priority to U.S. patent application Ser. No. 15/879,304 filed on Jan. 24, 2018 and U.S. Provisional Application, entitled “Space Optimizing Air Filter,” filed on Jan. 24, 2017 and having application Ser. No. 62/449,909. 
    
    
     FIELD 
     The field of the present disclosure generally relates to air filter devices. More particularly, the field of the invention relates to an apparatus and a method for an air filter that optimizes filtration of air entering an available volume within an air cleaner cover of a small engine. 
     BACKGROUND 
     An air filter designed to remove particulate matter from an airstream generally is a device comprising fibrous materials. These fibrous materials may remove solid particulates such as dust, pollen, mold, and bacteria from the airstream. Air filters are used in applications where air quality is important, notably in building ventilation systems and with engines. 
     Air filters may be used in automobiles, trucks, tractors, locomotives, motorcycles, and other vehicles that use internal combustion engines. Air filters may be used with gasoline engines, diesel engines, or other engines that utilize fossil fuels or other combustible substances. Air filters may be used with engines in which combustion is intermittent, such as four-stroke and two-stroke piston engines, as well as other types of engines that take in air continuously such that a combustible substance may be burned. For example, air filters may be used with some gas turbines. Filters may also be used with air compressors and in other devices that relay on intake air. 
     Air filters for internal combustion engines prevent abrasive particulate matter from entering the engine&#39;s cylinders, where the particulate matter would cause mechanical wear and oil contamination. Such filters may be made from pleated paper, foam, cotton, spun fiberglass, or other known filter materials. Generally, however, air filters used with internal combustion engines and compressors are comprised of either paper, foam, or cotton filter materials. Some filters use an oil bath wherein particulate matter and contaminants are trapped in the oil. In many fuel injected engines, a flat panel pleated paper filter element may be used. A flat panel filter is usually placed inside a plastic air box connected to a throttle body of the engine by way of ductwork. Vehicles that use carburetors or throttle body fuel injection typically use a cylindrical air filter positioned above the carburetor or throttle body. 
     In many recreational applications, such as motorcycles, all-terrain vehicles, quads, quad bikes, three-wheelers, four-wheelers, quad cycles, and the like, the sizes of the engines generally are much smaller than the engines of trucks and automobiles. Consequently, free space near the relatively smaller engines of such vehicles carries a relatively higher premium, and thus the air boxes of small engines and the air filters they house generally are severely limited in size. As will be appreciated, however, an air filter generally provides a surface area through which to pass an airstream and entrap particulate matter and other contaminates so as to prevent them from entering into the air intake of the engine. Thus, a drawback to relatively small air filters is that they may become quickly clogged with debris due to their relatively small size. As the air filter becomes increasingly clogged with debris, air pressure within the air filter drops while the atmospheric air pressure outside the filter remains the same. Such a pressure differential gradually chokes the airstream through the air filter, hindering the ability of the air filter to protect the engine and degrading engine performance. 
     Another drawback to small air filters is that recreational vehicles and motorcycles frequently are operated in dirty, off-road conditions where optimal air filtration is of the utmost importance. What is needed, therefore, is an air filter that provides an optimized surface area for filtering an airstream and may be installed directly into the air boxes of small engines. 
     SUMMARY 
     An apparatus and a method are provided for a space optimizing air filter for optimizing filtration of an airstream passing through a volume within an air cleaner cover of an internal combustion engine. The air filter comprises a base plate that is configured to mount to an air inlet of the engine. The base plate comprises an inlet receiver that has an opening suitable for receiving the air inlet. A top plate is configured to receive the air cleaner cover. A receiver for the air cleaner cover is disposed in the top plate to facilitate fastening the air cleaner cover onto the air filter. A filter medium is disposed between the base plate and the top plate. Multiple countersinks in the top plate and sleeves extending through an interior cavity of the air filter are configured to facilitate fastening the air filter to the air inlet of the engine. The air filter has a height that tapers along a length of the air filter, from a maximal height at a front portion to a minimal height at a rear portion of the air filter. The degree of tapering of the height of the filter medium, as well as the values of the maximal filter height and the minimal filter height are configured to maximize the total surface area of the filter medium within the volume between the air cleaner cover and the engine to which the air filter is coupled. In some embodiments, the maximal filter height may be utilized to take advantage of a relatively greater airflow due to a ram air opening in the air cleaner cover. 
     In an exemplary embodiment, an air filter for optimizing filtration of an airstream passing through a volume within an air cleaner cover of an internal combustion engine comprises: a base plate configured to mount to an air inlet of the engine; a top plate configured to receive the air cleaner cover; and a filter medium disposed between the base plate and the top plate. 
     In another exemplary embodiment, the base plate is comprised of a recessed portion bounded by a peripheral edge that retains a lower portion of the filter medium, and wherein the top plate is comprised of a recessed portion bounded by a peripheral edge that retains a top portion of the filter medium. In another exemplary embodiment, the recessed portions are coupled with a wire support of the filter medium. 
     In another exemplary embodiment, the filter medium has a height that tapers along a length of the air filter, a maximal height being at a front portion of the air filter and a minimal height being at a rear portion of the air filter. In another exemplary embodiment, any one or more of the maximal height, the minimal height, and a degree of tapering of the height are configured to maximize the total surface area of the filter medium that is disposed between the air cleaner cover and the base plate. In another exemplary embodiment, the height of the air filter is substantially uniform along a width of the air filter. In another exemplary embodiment, the degree of tapering of the height depends upon the volume and shape of the air cleaner cover that will be fastened onto the air filter. 
     In another exemplary embodiment, the base plate comprises an inlet receiver that has an opening suitable for receiving the air inlet of the engine. In another exemplary embodiment, a curved portion comprising the inlet receiver is joined with the base plate and has a curvature configured to establish an air-tight coupling between the base plate and the air inlet. 
     In another exemplary embodiment, the inlet receiver has a configuration and a diameter that are suitable to accept the air inlet of the engine. In another exemplary embodiment, multiple countersinks are disposed in the top plate and configured to receive fasteners to mount the air filter onto the air inlet of the engine, each of the multiple countersinks being coupled with a sleeve that extends within an interior cavity of the air filter and through the base plate, the multiple countersinks and the sleeves being configured to receive fasteners suitable for mounting the air filter onto the air inlet such that an air-tight seal is established between the base plate and the air inlet. In another exemplary embodiment, the multiple countersinks and the sleeves are disposed in locations of the air filter that are aligned with existing threaded holes of the air inlet. 
     In another exemplary embodiment, a receiver for the air cleaner cover is disposed in the top plate to facilitate fastening the air cleaner cover onto the air filter. In another exemplary embodiment, the receiver extends above the top plate to a controlled height above the bottom of the base plate, the controlled height being selected to allow an interior surface of the air cleaner cover to contact a pliable seal disposed atop the recessed portion. 
     In an exemplary embodiment, a method for an air filter to optimize filtration of an airstream passing through a volume within an air cleaner cover of an internal combustion engine comprises: configuring a base plate to mount onto an air inlet of the engine; configuring a top plate to receive the air cleaner cover; and disposing a filter medium between the base plate and the top plate. 
     In another exemplary embodiment, configuring the base plate further comprises forming an inlet receiver that has an opening for receiving the air inlet of the engine. In another exemplary embodiment, configuring the top plate further comprises disposing multiple countersinks in the top plate and coupling each of the multiple countersinks with a sleeve that extends through the base plate, the multiple countersinks and sleeves being configured to receive fasteners to mount the air filter onto the air inlet of the engine. In another exemplary embodiment, the method further comprising forming a recessed portion in each of the base plate and the top plate to retain the filter medium. In another exemplary embodiment, the method further comprising tapering a height of the filter medium from a maximal height at a front portion to a minimal height at a rear portion of the air filter. In another exemplary embodiment, configuring the top plate further comprises disposing a receiver atop the top plate to facilitate fastening the air cleaner cover onto the air filter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings refer to embodiments of the present disclosure in which: 
         FIG. 1  illustrates an isometric view of an exemplary embodiment of a space optimizing air filter, in accordance with the present disclosure; 
         FIG. 2  is a side plan view of the space optimizing air filter of  FIG. 1 , illustrating a filter height that tapers from a front portion to a rear portion of the air filter; 
         FIG. 3  is a rear plan view of the space optimizing air filter shown in  FIG. 1 , illustrating a total controlled height of the air filter; 
         FIG. 4  is a top plan view of the space optimizing air filter of  FIG. 1 , showing a length and a width of the air filter; 
         FIG. 4A  is a bottom plan view of the space optimizing air filter of  FIG. 1 , showing an inlet receiver and interior cavity of the air filter; and 
         FIG. 5  is a cut-away view of the space optimizing air filter of  FIG. 1 , illustrating countersinks and sleeves extending through an interior cavity of the air filter. 
     
    
    
     While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. 
     DETAILED DESCRIPTION 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the invention disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first filter,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first filter” is different than a “second filter.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein. 
     Although embodiments of the present disclosure may be described and illustrated herein in terms of an air filter having a specific perimeter shape, it should be understood that embodiments of the present disclosure are not limited to the exact shape illustrated, but rather may include a wide variety of generally enclosed perimeter shapes, such as generally circular, cylindrical, round, curved, conical, polygonal, rhomboid, trapezoid, and the like, that provide a relatively large surface area in a given volume within an air cleaner or an air box. 
     In general, the present disclosure describes a space optimizing air filter and methods for optimizing filtration of an airstream passing through a volume within an air cleaner cover of an internal combustion engine. The air filter comprises a base plate that may be mounted to an air inlet of the engine. The base plate includes an inlet receiver that has an opening to receive the air inlet. A top plate includes a receiver configured to facilitate fastening the air cleaner cover onto the air filter. A filter medium is disposed between the base plate and the top plate. Multiple countersinks in the top plate and sleeves extending through an interior cavity of the air filter facilitate fastening the air filter onto the air inlet of the engine. The air filter has a height that tapers along a length of the air filter, from a maximal height at a front portion to a minimal height at a rear portion of the air filter. The maximal height, the minimal height, and the degree of tapering of the height may be configured to maximize the total surface area of the filter medium within the volume between the air cleaner cover and the engine to which the air filter is coupled. 
       FIG. 1  illustrates an isometric view of an exemplary embodiment of a space optimizing air filter  100  (hereinafter, “air filter  100 ”), in accordance with the present disclosure. The air filter  100  is configured to be mounted onto an internal combustion engine, so as to filter an airstream entering the engine, and receive an air cleaner cover (not shown) that directs the airstream into a filter medium  104  comprising the air filter. The filter medium  104  is retained between a base plate  108  and a top plate  112 . The base plate  108  and the top plate  112  preferably are comprised of materials that are sufficiently durable and temperature resistant to retain their configuration during installation and operation when coupled with an air inlet of the internal combustion engine. In some embodiments, the base plate  108  and the top plate  112  may be coated with a corrosion resistant material, such as zinc or other suitable material, without limitation. 
     As best illustrated in  FIG. 5 , the filter medium  104  generally surrounds an interior cavity  116  such that the filter medium  104  creates an exterior perimeter of at least a portion of the cavity. An exterior cross-sectional shape of the filter medium  104  may be suitably shaped so as to increase the surface area available for filtration of the airstream flowing into the volume within the air cleaner cover. The shape may be consistent along a height of the filter medium  104 , extending from the base plate  108  to the top plate  112 , or may vary along the height of the filter medium. In some exemplary embodiments, the outer profile may taper along the height of the filter medium  104 . 
     The filter medium  104  generally provides an area to pass the airstream and entrap particulates and other contaminates flowing with the airstream. The filter medium  104  may be comprised of paper, foam, cotton, spun fiberglass, or other known filter materials, woven or non-woven material, synthetic or natural, or any combination thereof. The filter medium  104  may be pleated, or otherwise shaped, or contoured so as to increase a surface area for passing the airstream to be cleaned. The length of the filter medium  104  in the circumferential direction may be longer than the length of the perimeter of the air filter  100  generally, such that the surface area of the filter medium  104  is greater than the profile surface area of the air filter  100 . 
     In some embodiments, the filter medium  104  may be comprised of 4 to 6 layers of cotton gauze sandwiched between two epoxy-coated aluminum wire screens. The cotton may be advantageously treated with a suitably formulated filter oil composition that causes tackiness throughout microscopic strands comprising the filter medium. The nature of the cotton allows high volumes of airflow, and when combined with the tackiness of the filter oil composition creates a powerful filtering medium that ensures a high degree of air filtration. Further details about components comprising the filter medium  104 , as well as details about the filter oil composition, are disclosed in U.S. patent application Ser. No. 14/181,678, entitled “Air Box With Integrated Filter Media,” filed on Feb. 16, 2014, and U.S. patent application Ser. No. 14/701,163, entitled “Filter Oil Formulation,” filed on Apr. 30, 2015, the entirety of each of which is incorporated herein by reference. 
     As described above, the filter medium  104  is retained between the base plate  108  and the top plate  112 . The base plate  108  is comprised of a recessed portion  120  bounded by a peripheral edge  124  that retains a lower portion of the filter medium  104 . Similarly, the top plate  112  is comprised of a recessed portion  128  bounded by a peripheral edge  132  that retains a top portion of the filter medium  104 . Any of a variety of fasteners may be used to affix the filter medium  104  within the recessed portions  120 ,  128 . In some embodiments, the recessed portions  120 ,  128  may be molded onto a wire support of the filter medium  104 . In some embodiments, the recessed portions  120 ,  128  may be crimped so as to fold onto and retain the wire support and the filter medium  104 . Further, in some embodiments, any of various suitable adhesives may be used to adhere the wire support and filter medium  104  to the recessed portions  120 ,  128 . It will be appreciated that by those skilled in the art that fastening or adhering the filter medium  104  to the base and top plates  108 ,  112  renders the filter medium  104  irremovable from the air filter  100 . 
     As best illustrated in  FIG. 2 , the air filter  100  has a height that generally tapers along a length  136  ( FIG. 4 ) of the air filter, extending from a front portion  140  to a rear portion  144  of the air filter. As such, the air filter  100  has a maximal filter height  148  at the front portion  140  and a minimal filter height at the rear portion  144 , as shown in  FIG. 3 . The degree of tapering of the height of the filter medium  104 , as well as the values of the maximal filter height  148  and the minimal filter height are configured to maximize the total surface area of the filter medium  104  that is disposed within the volume between the air cleaner cover and the engine to which the air filter  100  is coupled. It is contemplated that the maximal filter height  148  may be further utilized to take advantage of a relatively greater airflow due to a ram air opening in the air cleaner cover. 
     As best illustrated in  FIG. 3 , the height of the air filter  100  may be substantially uniform along a width  152  ( FIG. 4 ) of the air filter. In some embodiments, however, the height of the air filter  100  may be configured to taper in either direction along the width  152  of the air filter. As will be appreciated, the degree of tapering of the height of the air filter  100  along the length and width  136 ,  152  generally depends upon the volume and shape of the air cleaner cover that will be fastened onto the air filter. As such, the height of the air filter  100  may be changed along either or both of the length and width  136 ,  152  of the air filter, without limitation. 
     With reference to  FIGS. 4A and 5 , the base plate  108  comprises an inlet receiver  156  that has an opening  160  suitable for receiving an air inlet of the internal combustion engine. A curved portion  164  comprising the inlet receiver  156  joins with the base plate  108 . The curved portion  164  has a curvature that is critical for establishing an air-tight coupling between the base plate  108  and the air inlet of the engine. The inlet receiver  156  may be secured to the air inlet such that air is drawn through the filter medium  104  into the interior cavity  116  of the air filter  100  and then is conducted through the opening  160  into the air inlet of the engine. It should be appreciated that the inlet receiver  156  generally has a configuration and a diameter  168  ( FIG. 3 ) that are suitable to accept the air inlet of the engine. For example, the inlet receiver  156  may comprise any of a variety of ridges or raised portions that are found to optimally engage the air inlet of the engine. The specific configuration of the inlet receiver  156  and the diameter  168  depend upon the particular make and model of the engine for which the air filter  100  is to be utilized, and thus a wide variety of configurations and diameters may be incorporated into the air filter  100  without limitation. 
     It is contemplated that a suitable gasket may be fastened between the base plate  108  of the air filter  100  and the air inlet of the engine, and that the curved portion  164  and the inlet receiver  156  may extend into an opening of the air inlet. Multiple countersinks  172  may be disposed in the top plate  112  and configured to receive fasteners that are configured to mount the air filter  100  onto the air inlet of the engine. As best illustrated in  FIG. 5 , each countersink  172  is coupled with a sleeve  176  that extends within the interior cavity  116  and through the base plate  108 . The countersinks  172  and the sleeves  176  may be configured to receive fasteners suitable for mounting the air filter  100  onto the air inlet such that an air-tight seal is established between the base plate  108 , the gasket, and the air inlet. As such, the countersinks  172  and the sleeves  176  preferably are disposed in locations of the air filter  100  that are aligned with existing threaded holes of the air inlet. In the illustrated embodiment of  FIGS. 1-5 , three countersinks  172  and sleeves  176  are incorporated into the air filter  100  as described herein. In some embodiments, however, the air filter  100  may be comprised of either more or less than three countersinks  172  and sleeves  176  that are disposed in different locations than illustrated herein, depending on the specific configuration of the engine and the air inlet which the air filter is to be coupled. 
     As shown in  FIG. 5 , the countersinks  172  extend into the interior cavity  116  to a depth positioned at a fastener controlled height  180  above the bottom of the base plate  108 . The fastener controlled height  180  depends on the length of the particular fasteners that are intended to be used to fasten the air filter  100  onto the engine. As will be recognized, the length of the fasteners generally depends on a total height  184  ( FIG. 3 ) of the air filter  100 , and thus depends upon the configuration of the particular air cleaner cover that is intended to be fastened onto the air filter. In some embodiments, the fastener controlled height  180  may be configured to receive original manufacture equipment fasteners that are used to mount an original air filter onto the engine. In some embodiments, the fastener controlled height  180  may be configured to receive customized fasteners, without limitation. 
     Returning again to  FIG. 1 , a receiver  188  for the air cleaner cover may be centrally disposed in the top plate  112  to facilitate fastening the air cleaner cover onto the air filter  100 . In the embodiment illustrated herein, the receiver  188  is comprised of a threaded hole configured to receive a threaded fastener, such as a bolt, that may be used to mount the air cleaner cover onto the air filter  100 . In other embodiments, however, the receiver  188  may be configured to receive any of various suitable fasteners, without limitation. As shown in  FIG. 3 , the receiver  188  extends above the top plate  112  to a controlled height  192  above the bottom of the base plate  108 . The controlled height  192  may be selected to position the air cleaner cover at a specific distance above the top plate  112  once the air filter  100  is mounted onto the engine. For example, the controlled height  192  may be selected to allow an interior surface of the air cleaner cover to contact a pliable seal disposed atop the recessed portion  128 . 
     Turning, now, to  FIGS. 3, 4A, and 5 , the base plate  108  may include one or more vent receivers  196  that are configured to enable a practitioner of the air filter  100  to place any of various ventilation hoses coupled with the engine into fluid communication with the interior cavity  116  of the air filter. For example, the vent receivers  196  may be comprised of one or more flanges adapted to couple the interior cavity  116  with any of a PCV valve, a crankcase breather, and various sensors that are electrically connected with the engine. In some embodiments, the vent receivers  196  may be comprised of threaded fittings that are configured to accept threaded fittings coupled with the ventilation hoses. As will be appreciated, the number and configuration of the vent receivers  196  generally depend upon the particular engine for which the air filter  100  is to be utilized. It should be understood, therefore, that a wide variety of different configurations of the vent receivers  196  may be incorporated into various embodiments of the air filter  100  without limitation. 
     It is contemplated that a user of the air filter  100  may periodically clean the filter medium  104  rather than replacing the entire air filter  100 , as is typically done with conventional air filter systems. In some embodiments, a method for cleaning the filter medium  104  comprises removing the air cleaner cover from the air filter  100 , removing the air filter  100  from the air inlet of the engine, inserting a water hose through the opening  160  into the interior cavity  116 , and spraying water so as to flush contaminants from the filter medium  104 . In some embodiments, wherein the filter medium comprises a filter oil composition, a solvent may be used to remove the oil from the filter medium  104 . Once the filter medium  104  is completely dry, a suitably formulated filter oil composition may be uniformly applied and allowed to wick into the filter medium. Further details about suitable filter oil compositions are disclosed in above-disclosed U.S. patent application Ser. No. 14/701,163, entitled “Filter Oil Formulation,” filed on Apr. 30, 2015, which is incorporated herein by reference. Various other cleaning methods will be apparent to those skilled in the art without deviating from the spirit and scope of the present disclosure. 
     While the invention has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the invention is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. To the extent there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.