Patent Publication Number: US-2015075121-A1

Title: Multi-mode air filter for motorcycles or other vehicles

Description:
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Nos. 61/877841, filed Sep. 13, 2013, entitled “MULTI-MODE AIR FILTER FOR MOTORCYCLES OR OTHER VEHICLES,” and 61/891325, filed Oct. 15, 2013, entitled “MULTI-MODE AIR FILTER FOR MOTORCYCLES OR OTHER VEHICLES.”This application hereby incorporates by reference the above-identified applications in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to air filters for vehicles, such as motorcycles, for example. In particular, the present invention relates to dual mode air filters for such vehicles. 
     2. Description of the Related Art 
     Motorcycles and other similar vehicles incorporating internal combustion engines typically incorporate an air filter arrangement to filter particulate from air that is to be supplied to the intake system and, ultimately, the combustion chamber of the engine. The removal of particulate from the intake air reduces wear and increases the life of the engine. However, many air filters designed for regular use, while providing satisfactory filtering performance, also increase resistance to airflow and, thus, reduce the power output of the engine relative to its potential output. Therefore, for racing or other high performance applications, filter designs are often utilized that improve airflow, but provide little or no effective filtering. 
     SUMMARY OF THE INVENTION 
     An aspect of the present invention involves the realization that the same vehicle may be exposed to both normal use and high-performance or racing use and that it would be advantageous to have an air filter system that is adjustable between at least two modes of use. In some configurations, the air filter system can be adjusted between at least two modes of use quickly and/or without any or without significant disassembly or removal of the system components. 
     The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized. 
     An embodiment involves an air filter system for a vehicle includes a housing defining an opening to an intake system of the vehicle. A filter element is supported within the housing and positioned upstream from the opening relative to a flow of intake air to the intake system. A bypass channel selectively permits intake air to pass through the opening without passing through the filter element. A closure selectively closes the bypass channel. 
     In some configurations, the closure comprises a shutter. The shutter can be an iris-type shutter. The shutter can be variably adjustable between an opened position and a closed position. The intake member can surround an opening to the bypass channel. In some configurations, the intake member is movable to adjust a position of the shutter. The intake member can be rotatable. 
     In some configurations, the closure comprises a plug. The plug can be removed from an opening to the bypass channel and an intake member can be coupled to the opening. 
     In some configurations, the filter element is annular in shape and is sandwiched between a first plate and a second plate. The bypass channel can extend through the second plate and into an interior space of the filter element. 
     In some configurations, a screen element extends across the bypass channel. 
     An embodiment involves an air filter system for a vehicle. The air filter system includes a housing defining an opening to an intake system of the vehicle, a filter element supported within the housing and positioned upstream from the opening relative to a flow of intake air to the intake system, a bypass channel that selectively permits intake air to pass through the opening without passing through the filter element, the bypass channel comprising a first bypass channel portion and a second bypass channel portion parallel to the first bypass channel portion, wherein the intake air passes through only one of the first and second bypass channel portions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Throughout the drawings, reference numbers can be reused to indicate general correspondence between reference elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. 
         FIG. 1  is a front perspective view of an air filter system for a motorcycle or other vehicle having certain features, aspects and advantages of a preferred embodiment. The air filter system is illustrated in a first or normal use mode in  FIG. 1  in which all intake air is passed through a filter element. 
         FIG. 2  is a front perspective view of the dual mode air filter system of  FIG. 1  in a second mode in which a portion of the intake air is permitted to pass through a bypass channel that bypasses the filter element. 
         FIG. 3  is a front perspective view of the dual mode air filter system of  FIG. 1  in a third mode in which the bypass channel is fully open. 
         FIG. 4  is a front perspective view of a modification of the air filter system of  FIGS. 1-3 . The air filter system of  FIG. 4  includes a removable plug that selectively covers the bypass channel. 
         FIG. 5  is a front perspective view of the air filter system of  FIG. 4  with the plug removed and the bypass channel open. An optional tapered inlet or velocity stack is coupled to the inlet of the bypass channel. 
         FIG. 6  is a front perspective view of a modification of the air filter system of  FIGS. 4 and 5 . 
         FIG. 7  is a sectional view of the air filter system of  FIG. 6 . The air filter system of  FIGS. 5 and 6  includes a bypass member that defines at least a substantial entirety of the bypass channel. 
         FIG. 8  is a front perspective view of another embodiment of an air filter system for a motorcycle or other vehicle. 
         FIG. 9  is a sectional view of the air filter system of  FIG. 8  that includes a removable plug that selectively covers the bypass channel. 
         FIG. 10  is another sectional view of the air filter system of  FIG. 8  with the bypass channel fully open. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIGS. 1-3  illustrate an air filter system  10  for a motorcycle or other similar vehicle incorporating an air-using or internal combustion engine. The air filter system  10  can be a multi-mode system that includes at least two operational modes. Preferably, one mode is a first or normal use mode in which all or substantially all intake air is passed through a filter element, such as a foam or paper element, which filters a high level of particulate from the intake air. Another mode is a second, high-performance or racing mode in which at least some intake air bypasses the filter element in a path from upstream of the air filter system  10  to the combustion chamber of the associated vehicle. Preferably, in the second mode, a portion of the intake air passes through a bypass channel that includes a lower level of filtering compared to the filter element. In some configurations, intake air passing through the bypass channel may be unfiltered or substantially unfiltered (e.g., passed through a screen that filters only relatively large objects). The illustrated air filter system  10  of  FIGS. 1-3  preferably includes more than two modes of operation, which are described further herein. 
     The air filter system  10  preferably includes a housing arrangement  12 , which can include a first wall  14  and a second wall  16 . A filter element  18  (e.g., a foam or paper filter element) is positioned within the housing arrangement  12 , such as between the first wall  14  and the second wall  16 . In the illustrated arrangement, the first wall  14  is defined by a plate and the second wall  16  is defined by a second plate. The filter element  18  is sandwiched between the first plate  14  and the second plate  16 , preferably being sealed against each plate  14 ,  16 . Thus, the filter element  18  forms a side wall of the air filter system  10 . Alternatively, the filter element  18  could be contained within a housing arrangement  12  that has distinct side walls. In the illustrated arrangement, the plates  14 ,  16  are coupled to one another, such as by a plurality of fasteners  20  (e.g., bolts). Optional spacers  22  can be provided to appropriately space the first plate  14  from the second plate  16  to avoid excessive axial forces from being applied to the filter element  18 . The first plate  14  can be coupled to an intake system of an associated vehicle (not shown), such as by one or more fasteners  24  (e.g., bolts), preferably in a substantially sealed manner. 
     The illustrated filter element  18  is generally or substantially annular in shape thereby defining an interior space through which intake air can pass. Intake air can pass through a wall of the filter element  18  from the outside of the air filter system  10  to within the interior space of the filter element  18  and then through an opening in the first plate  14  to the combustion chamber of the engine of the associated vehicle. The wall of the filter element  18  can be of any suitable material(s) or construction. Preferably, the filter element  18  is the same as or similar to other filters used for normal use applications in connection with the particular vehicle with which the present air filter system  10  is intended for use. Such filter elements are often foam or paper (including paper-like materials). The filter wall may be corrugated or pleated to increase surface area. 
     The air filter system  10  also includes a bypass opening or bypass channel  30  through which intake air can pass from outside the air filter system  10  to the combustion chamber of the engine of the associated vehicle without passing through the filter element  18 . In the illustrated arrangement, the bypass channel  30  is at least partially defined by an aperture or opening  32  in the second plate  16 , which opens to the interior space of the filter element  18 . A tapered inlet or velocity stack  34  can surround the opening  32  and extend outwardly from the second plate  16  to guide intake air through the opening  32  and, preferably, increase a velocity of the intake air as it passes through the velocity stack  34 . 
     The bypass channel  30  or opening  32  can be selectively partially or fully closed by a shutter  40 . The illustrated shutter  40  is a multi-component iris or diaphragm type shutter in which multiple shutter leafs or blades move (e.g., pivot) toward or away from a center of the opening  32 . However, other suitable types of shutters could also be used (e.g., butterfly type or guillotine type). Preferably, a screen element  50  extends across the opening  32  to inhibit large objects from passing through the bypass channel  30 . However, preferably the screen element  50  does not significantly restrict air flow and provides much less “filtering” than the filter element  18 . In other words, the screen element  50  preferably is simply a large object deflector through which airflow is at least substantially unrestricted. 
     In the illustrated arrangement, the shutter  40  is manually-controlled, preferably without requiring the use of tools. For example, the components (e.g., leafs or blades) of the shutter  40  can be coupled for movement with the velocity stack  34  such that rotation of the velocity stack  34  results in movement (e.g., pivoting movement) of the components of the shutter  40  to move the shutter  40  between a closed position and an open position. Any suitable coupling arrangement can be used between the velocity stack  34  and the components of the shutter  40 , such as a pin-in-slot or groove arrangement, for example and without limitation. The velocity stack  34  can have detent positions relative to the housing  16  or can be infinitely adjustable. In some arrangements, the shutter  40  is positionable (at least securely) in only a fully opened or a fully closed position. In other arrangements, such as the illustrated arrangement, the shutter  40  is variable such that it can be positioned for use in one or more positions between fully opened and fully closed. In other arrangements, a control mechanism other than the velocity stack  34  can be used to control a position of the shutter  40 , such as a separate dial, for example and without limitation. 
       FIG. 1  illustrates the air filter system  10  in a first position, or normal use position, in which the shutter  40  is fully closed and preferably all intake air is required to pass through the filter element  18 . As a result, maximum filtering preferably is provided.  FIG. 2  illustrates the air filter system  10  in a second position in which the shutter  40  is partially open and some intake air is permitted to bypass the filter element  18  by passing through the bypass channel  30 . As discussed herein, the shutter  40  can have multiple intermediate or partially opened positions.  FIG. 3  illustrates the air filter system  10  in a third position in which the shutter  40  is in a fully opened position such that a maximum flow of intake air is permitted to bypass the filter element  18 . When the bypass channel  30  is partially or fully open, a portion of the intake air preferably also passes through the filter element  18 . However, depending on various factors, such as the amount of flow restriction provided by the filter element  18 , the relative flow areas of the filter element  18  and the bypass channel  30  and the flow volume or velocity of the intake air flow (possibly among other factors), under some circumstances flow through the filter element  18  may be limited when the bypass channel  30  is partially or fully open. 
       FIGS. 4 and 5  illustrate a modification of the air filter system  10  of  FIGS. 1-3 . In the air filter system  10  of  FIGS. 4 and 5 , the bypass channel  30  is closed by a removable plug  60 . In some configurations, the plug  60  is threadably engaged with the opening  32  of the housing  16 . The plug  60  can have a tool engagement portion, such as a nut-like structure or a tool cavity, to permit the plug  60  to be removable with a suitable tool. Alternatively, the plug  60  could be manually removable without the use of tools and could include a hand grip portion to facilitate such removal. In other arrangements, the plug  60  could be a friction fit or held in place with another component or arrangement, such as a latch, for example. 
     When the plug  60  is removed, a tapered inlet or velocity stack  34  can be coupled to the housing  16 . Alternatively, the plug  60  could be positioned within the velocity stack  34 , which could remain in place in both normal and bypass modes. The air filter system  10  of  FIGS. 4 and 5  can be simpler in construction and, thus, can provide a lower cost alternative to the system  10  of  FIGS. 1-3 , while providing similar advantages. 
       FIGS. 6 and 7  illustrate a modification of the air filter system  10  of  FIGS. 4 and 5 . The air filter system  10  of  FIGS. 5 and 6  includes a bypass member  70  that defines at least a substantial entirety of the bypass channel  30 . Preferably, the bypass member  70  includes a tubular portion  72  that extends from the opening  32  in the second plate  16  toward the first plate  14 . Preferably, the tubular portion  72  extends the entire distance between the first plate  14  and the second plate  16  such that all of the intake air that passes through the opening  74  of the first plate  14  (and to the engine of the associated vehicle) passes through the tubular portion  72  of the bypass member  70 . In other words, in some configurations, little to no intake air passes through the filter element  18  when the bypass member  70  is assembled to the air filter system  10  because the filter element  18  causes significantly greater resistance to air flow. However, in some configurations or under some circumstances, flow may be permitted to occur through both the bypass channel  30  and the filter element  18 . In other arrangements, other suitable structures for channeling all intake flow through the bypass member  70  and/or substantially preventing intake flow through the filter element  18  in the bypass mode can also be used. 
     In the illustrated arrangement, an end of the tubular portion  72  abuts against a surface portion of the first plate  14  that surrounds the opening  74 . Preferably, a diameter, cross-sectional dimension or area of the tubular portion  72  is the same as or substantially similar to the diameter, cross-sectional dimension or area of the opening  74  to provide good flow characteristics. It is contemplated that contact between the end of the tubular portion  72  and the surface of the first plate  14  sufficiently seals off the filter element  18  such that all or substantially all intake air is forced through the bypass member  70 . However, in other arrangements, a separate seal member may be provided between the tubular portion  72  and the first plate  14 . 
     In the illustrated arrangement, the bypass member  70  includes a tapered inlet or velocity stack  34 , which can be coupled to or unitarily formed with the tubular portion  72 , or a combination thereof. In the illustrated arrangement, a portion of the velocity stack  34  is unitarily formed with the tubular portion  72 . A cap  76  is coupled to the end of the unitary portion of the velocity stack  34  and, preferably, secures the screen element  50  therebetween. The cap  76  can be coupled by any suitable arrangement, such as threaded fasteners (as shown), for example. In addition, the bypass member  70  can be coupled to the air filter system  10  by any suitable arrangement, such as threaded engagement with a component (e.g., the second plate  16 ) or any other arrangement described herein. A seal member (e.g., O-Ring) can be provided between the bypass member  70  and the component (e.g., the second plate  16 ), if desired. Similar to the system of  FIGS. 4 and 5 , the bypass member  70  can be removed and a plug (e.g., plug  60 ) can be used to plug the opening  32  for a filtered mode of the system  10 . 
       FIGS. 8-10  illustrate another embodiment of the air filter system  10  shown in  FIGS. 6 and 7 . The air filter system  110  shown in  FIGS. 8-10  includes a filter mode ( FIG. 9 ) and a bypass mode ( FIG. 10 ). In the filter mode, the system  110  includes a plug or cover  160 , which can be utilized to close off the opening  132  in the second plate  116  and force air flow through the filter element  118 . In the bypass mode, the system  110  includes a bypass member  170  that defines at least a portion of the bypass channel  130 . Preferably, the bypass member  170  can cooperate with portions or components of the first plate  114  and/or other portions of the system  110  to define an entirety or a substantially entirety of the bypass channel  130 . In the illustrated arrangement, the bypass member  170  includes a singular intake channel or tubular portion  172  that communicates with one or more openings  174  of the first plate  114 . Preferably, the tubular portion  172  and tubular intake ports  174   a,    174   b  define a substantial entirety of the bypass channel  130  such that all of the intake air passing through the bypass channel  130  passes through the singular tubular portion  172  and one of the tubular intake ports  174   a,    174   b.  In other words, in some configurations, little to no intake air passes through the filter element  118  when the bypass member  170  is assembled to the air filter system  110 . In some configurations or under some circumstances, air flow may be permitted to occur through both the bypass arrangement  170  and the filter element  118 . In other arrangements, other suitable structures for channeling all intake flow through the bypass member  170  and/or substantially preventing intake flow through the filter element  118  in the bypass mode can also be used. 
     Preferably, a total cross-sectional area of the singular tubular portion  172  is the same as or substantially similar to the collective cross-sectional area of the tubular intake ports  174   a,    174   b  (or other configuration of the opening  174  in the first plate  114 ) to provide good flow characteristics. It is contemplated that contact between the end of the singular tubular portion  172  and the surface of the tubular intake ports  174   a,    174   b  or other portion of the first plate  114  sufficiently seals off the filter element  118  such that all or substantially all intake air is forced through the bypass member  170 . However, in other arrangements, a separate seal member may be provided between the singular tubular portion  172  and the tubular intake ports  174   a,    174   b  or the first plate  114 . 
     In the illustrated arrangement, the bypass member  170  includes a flange portion or flange  134 , which can be coupled to or unitarily formed with the tubular portion  172 , or a combination thereof. The flange  134  can permit the bypass member  170  to be secured to the second plate  116  by any suitable arrangement, such as one or more threaded fasteners (as shown), for example. A cap or ring  176  is coupled to the end of the flange  134  and, preferably, secures the screen element  150  therebetween. The ring  176  can be coupled to the flange  134 , the second plate  116  or another suitable component by any suitable arrangement, such as threaded fasteners (as shown), for example. A seal member (e.g., O-Ring) can be provided between the bypass member  170  and the component (e.g., the second plate  116 ), if desired. The cover  160  and the flange  134  of the bypass member can be secured to the second plate  116  using the same fastener locations. 
     It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. For instance, various components may be repositioned as desired. It is therefore intended that such changes and modifications be included within the scope of the invention. Moreover, not all of the features, aspects and advantages are necessarily required to practice the present invention. Accordingly, the scope of the present invention is intended to be defined only by the claims.