Abstract:
An air intake apparatus for a vehicle powered by an internal combustion engine. There is disclosed an air intake apparatus including ducting members for fluidly communicating cleaned intake air, for combustion, in the direction of the internal combustion engine. The apparatus also features an air filter element arranged on the duct members, as well as a case for housing the air filter element. The communicating duct members are engineered such that the air filter element can be pivoted from the case to an open position, such as for cleaning, while nevertheless remaining upon on the air communicating duct members.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to German Patent Application No. DE 10 2007 021 756.2, filed on May 9, 2007, the entirety of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to air intake apparatuses for vehicles powered by an internal combustion engine, and more specifically to an air intake apparatus including elements for fluidly communicating cleaned intake air in the direction of the engine for combustion therein, an air filter element, and a case housing the air filter element. 
     2. Background Art 
     Any vehicle comprising an internal combustion engine usually features an air intake apparatus for supplying air to the engine for combustion. The air intake apparatus typically includes an air filter element serving to clean the intake air to remove debris in the form of dirt, water, sand, grit and the like from the intake air in passing through the air filter element which can build up therein, forming there a filter cake. 
     Such an efficient cleaning of intake air is especially needed on vehicles negotiating rough terrain, such as, for example, off-road competition motorcycles or so-called all-terrain vehicles (ATV). On such a vehicle, to maintain high engine performance, it is necessary to clean frequently the air filter element to remove the particles collected thereon. The cleaning is essential so that the pressure drop in communicating the flow of intake air through the air filter element is not substantially increased. 
     Known air intake assemblies employed on ATVs commonly include an air filter element arranged in a case located beneath the rider saddle of the ATV. The air filter element takes the form of an elongated cylinder having a coupling at the face side of the cylinder, for engagement with at a complementary-configured coupling on the case, the engagement often by means of a screw clip, whereby the known air filter element is screwed to the coupling of the case. When this known air filter element needs to be cleaned, first the lid of the case has to be removed. For this purpose the bolts securing the lid to the case have to be loosened by means of a tool, or fasteners clamping the lid to the case must be opened. Then, again by means of a tool, a screw coupling of the clip needs to be opened so that ultimately the air filter element can be withdrawn from the coupling in the case, and through the opening in the case formerly closed off by the lid. 
     A further known air intake apparatus features a cylindrically-shaped foam plastics member arranged on a support and disposed in a case housing the air filter element. Connection is by means of a screw extending along the longitudinal centerline of the cylindrical air filter element push-mounted in the region of a case on the air filter element via a correspondingly-configured coupling before being bolted by means of a tool. To remove the air filter element from this type of known air intake apparatus, a tool must be used to first unbolt the air filter element before it can be withdrawn from the case. Once cleaned, the air filter element then has to be reinserted into the case in the reverse sequence, and again by means of a tool the bolted fastener between the air filter element and the case coupling retightened. 
     The case in both instances is arranged beneath the rider saddle and a gap is provided between the case and the mudguards covering the rear wheels of the cited ATV. This gap results in debris such as dirt, sand and/or grit thrown up by the rear wheels gaining access to the case through the gap, quickly fouling up the air filter element. 
     Cleaning the air filter element on the cited known air intake assemblies is impossible without the aid a tool. Moreover, cleaning is time-consuming because every time bolts must first be loosened before, in a next step, the air filter element can be removed from its case. After the air filter element has been cleaned, it must be reinserted in the case in the reverse sequence and then the bolt fastener retightened. 
     It is on the basis of this that the present invention has the object of eliminating the above drawbacks. According to the new disclosure hereafter, there is provided an air intake apparatus for a vehicle powered by an internal combustion engine which apparatus makes it possible to remove the air filter element from the case without having to use a tool, thus expediting cleaning of the air filter element. 
     SUMMARY OF THE INVENTION 
     There is described an air intake apparatus for a vehicle powered by an internal combustion engine, comprising a means fluidly communicating cleaned intake air for combustion in the direction of the internal combustion engine and an air filter element arranged on the means as well as a case housing the air filter element, the means being engineered such that the air filter element can be hinged open from the case whilst remaining located on the means. 
     The air intake apparatus in accordance with the present disclosure thus is characterized in that, among other things, the air filter element can be removed out of the case without the aid of a tool, in thereby performing a movement that is guided by apparatus elements and whereby the filter element remains located on the overall apparatus. During filter cleaning the apparatus is hinged open from the case, meaning that together with being hinged open, or by a rotating movement, the air filter element can be moved out of the case housing it, without requiring the assistance of a tool. 
     The air filter element hinged open from the case can then be separated from the apparatus, again without requiring the assistance of a tool—i.e., removed for cleaning, for example. Afterwards the air filter element is releasably reattached, and hinged back into the case. 
     For this purpose it is provided for in accordance with one aspect of the disclosed apparatus that the fluid communication elements include a section at which the air filter element can be releasably attached, and the section can be mounted on the case to thereby form a lid of the case. 
     In other words, a section of the fluid communication elements can be engineered so that the air filter element can be releasably attached thereto, this filter attachment section also forming a lid of the case. Hinging open the communication components removes the section from the case, whilst simultaneously hinging open the air filter element from the case. Similarly, the air filter element is hinged back into the case by a return hinging motion, and the section defined at the case to simultaneously form the lid of the case in protecting the case from debris such as dirt, water, sand, grit and the like. 
     In accordance with another aspect of the disclosed apparatus, it is provided that the fluid communication means includes a duct fluidly communicating intake air, the duct featuring a closed profile cross-section, and engineered to be integrally formed with a curved element opening towards the filter attachment section, which can be attached at the section. The duct is formed at the end portion opposite the element for arrangement at a throttle member or a carburetor member of the internal combustion engine. 
     The duct configured by a closed profile cross-section may have, for example, a circular cross-section or a cross-section similar in form to an ellipsis. It preferably features at its end portion, directed towards the aforementioned section, an open curved member (for example a member configured similar to a dome) for passage of the intake air which is engineered integrally with the duct. This, for example, domed member can then be attached to the section, for example by detents configured at the member and latching in corresponding holes of the section simultaneously forming the lid of the case. 
     To fluidly communicate the intake air cleaned by the air filter element to the internal combustion engine, it is directed through the duct which at its end portion opposite the domed member is configured so that it can be defined at a throttle member or carburetor member of the internal combustion engine. 
     To attain the hinging action of the communication means, it is provided for in accordance with another aspect of the disclosed apparatus that the fluid communication elements are configured flexible in the region of a duct which conveys cleaned intake air in the direction of the engine. The communication element can be hinged open from the plane of a lid of the case. Thus, the duct may be made of an elastomer such as, for example, nitrile butyl rubber, so that the air filter element releasably attached at the section can be hinged open from the case by hinging open the section together with the open curved member. When the air filter element is in the fitted position on the vehicle, for example, oriented in a direction upwards, the flexible duct thereby provides a hinge so that, as compared to its fitted position in the case, the air filter element can be hinged open by an angle of (for example) approximately 60 to 120 degrees to be freely accessible. 
     In this position, the air filter element can be released from the section without the aid of a tool, for instance, for cleaning it. After cleaning, the air filter element can be releasably reattached at the section and hingeably moved back into the case, simply by moving the flexible duct back in the opposite direction. The air filter element, together with the section and the curved member, accordingly are hinged back into their initial position. This makes it possible to remove the air filter element practically instantly without having to use a tool as is the case with known air intake assemblies. 
     To avoid pulsation of the flexible duct due to the pulsating flow in the air column, in another aspect of the disclosed apparatus the duct is provided within its closed profile with at least one longitudinal bracing rib, extending, for example, approximately from one end portion to approximately the other end portion of the duct. The rigidity of the duct can be influenced by the number of bracing ribs provided. Thus, four such bracing ribs may be provided along the inner circumference of the duct, so that despite its flexible configuration it does not tend to pulsate because of the pulsating gas flow. 
     In accordance with yet another aspect, to increase the surface area of the air filter element through which the intake air can flow, the air filter element is a dome-shaped foam plastic element with a sealing edge arranged at a ported retainer, and featuring a spring clip for bringing the sealing edge into contact with a section of the communication elements. It is this dome-shaped configuration that achieves an increase in the surface area of the air filter element through which the intake air can flow. The air filter element can be made of a foam plastics material for forming a scrubber. This foam plastics material can be arranged at a complementary-shaped retainer ported for passage of intake air. It may be attached with a spring clip; the sealing edge of the thus-tensioned air filter element is urged by the spring clip into contact by the lid section of the fluid communication elements which, for example, may be the aforementioned lid of the case. The spring clip ensures that the air filter element is urged by its sealing edge against the lid, thus preventing the ingress of entrained debris into the air intake duct. When the air filter element needs to be cleaned, all that needs to be done is to release the spring clip so that the air filter element can be removed. To fit the air filter element to the section or lid, it is located by its sealing edge on the lid and then urged tight against the lid by the spring bias of the spring clip. 
     To achieve a self-cleaning effect of the foam plastic element, it is provided for in accordance with still another aspect of the disclosed apparatus that the foam plastic element can be brought into contact by the sealing edge with the section, so that the foam plastic element is suspended in the case. This makes it possible that the jolts occurring in operation of the vehicle cause any debris that has collected on the shell surface of the foam plastic element to drop down in the case. 
     As explained above, in known air intake assemblies there is a gap between the mudguards of the vehicle and the case housing the air filter element. This causes the drawback that debris thrown up by the vehicle may access, via the air intake portion, the interior of case. 
     To reduce contamination of the air filter element by debris thrown up by the wheels of the vehicle, it is provided for in another aspect of the disclosed apparatus that the case is engineered integrally with mudguards. In such an option, the mudguards extend in the longitudinal direction of the case, and away therefrom on both sides thereof. Because the mudguards are arranged above the wheels of the vehicle, this means that the configuration of the case with the mudguards extending away therefrom on both sides of the case ensures that there is no gap between the mudguards and the case. Elimination of the gap results in an elimination of debris directly gaining access to the region of the air intake ports of the case. 
     The case for mounting the air filter element thus forms with the mudguards an integral configuration which ensures that debris or water thrown up by the wheels can no longer gain access to the region of the air intake ports of the case. In addition, this configuration ensures that forming a case and mudguard no longer involves a plurality of components, each of which needs to be assembled in production of the vehicle. This reduces the tool-up time in vehicle production. 
     The case as engineered in accordance with this disclosure also ensures that no additional fairing items are needed to, for instance, prevent debris or water ingress into the region of the air intake ports in the case. In accordance with still another aspect of the disclosed apparatus, it may also be provided for that the case is fully preassembled with the complete air intake apparatus. Thus in production of the vehicle fitted as such, the integral assembly fully preassembled merely needs to be mounted on the frame structure of the vehicle. 
     It also is provided that the case has, at an end portion opposite a duct fluidly communicating in the longitudinal direction of the case, an air intake snorkel for fluidly communicating ambient air into the case. To reduce debris being entrained into the case it is provided for in yet another aspect of the disclosed apparatus that the air intake snorkel is configured for arrangement in the region below a rider saddle of the vehicle. Although ambient air to be cleaned gains access to the case via this air intake snorkel, because the air intake snorkel is arranged below the rider saddle of the vehicle, it is ensured that the ambient air passing through the air intake snorkel entrains less debris than would be the case, for example, were the air intake snorkel to be located fully exposed uncovered without protection. 
     In accordance with another aspect of the disclosed apparatus, it is provided for that the case has side walls integrally formed with a case floor, and configured in a region transversely to the longitudinal direction of the case similar to an inverted saddle roof, and featuring at its lowest point a drain port. This configuration promotes that any debris or moisture entering the case settles on the floor of the case. From there it progresses in the direction of the lowest point of the case floor, the floor being configured similar to an inverted saddle roof provided with a drain port (from which the debris is discharged from the case). 
     The air intake apparatus may be pre-fitted as a unit together with the case comprising the vehicle mudguards. In this arrangement, the air intake apparatus is adapted to be located beneath the rider saddle of the vehicle, so that the air intake snorkel is beneath the saddle. The vehicle concerned may be, for example, a two-track vehicle featuring a saddle for the rider and/or passenger and steered by means of a handle bar. The vehicle may be an all-terrain vehicle (ATV). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and form a part of the specification, are for the purpose of illustrating a preferred embodiment of the apparatus, and are not to be construed as limiting the invention. The present disclosure will now be detailed with reference to the drawings, in which: 
         FIG. 1  is a section view of an air intake apparatus arranged at a frame structure of an ATV as shown in one embodiment in accordance with the present disclosure; 
         FIG. 2  is a view similar to that as shown in  FIG. 1  with the rider saddle removed and in a position hinged open from a case; 
         FIG. 3  is a view similar to that as shown in FIG. frame structure  2  but in a view in perspective; 
         FIG. 4  is a cross-sectional view of the embodiment as shown in  FIG. 1  in a view from the rear; and 
         FIG. 5  is an exploded view of an air intake apparatus in accordance with the present disclosure. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Best Mode for Practicing the Invention 
     Referring now to  FIG. 1  of the drawings, there is illustrated a section view of an air intake apparatus  1  in accordance with one embodiment of the present disclosure arranged on a frame structure  2  of an ATV. 
     Located at the frame structure  2  is a rider saddle  3  for a rider of the ATV. As is directly evident, the air intake apparatus  1  in the embodiment as shown is arranged beneath the saddle  3 , so that the air intake apparatus  1  is already located where it is protected from dirt and water splash. For fluidly communicating cleaned intake air in the direction of the internal combustion engine (not shown), the air intake apparatus  1  comprises a communicating means  4  including a flexibly configured duct  5  via which cleaned intake air can be transported. At its end portion  6  facing the internal combustion engine, the duct  5  is engineered with a coupling  7  which is connectable to a throttle member or carburetor member of the internal combustion engine. 
     As viewed in the plane of the drawing as shown in  FIG. 1 , the duct  5  portion of the communicating means extends, aftwards in the longitudinal direction of the vehicle, from the coupling  7  and in the direction of an air filter element  8 . 
     As shown in more detail in  FIG. 5 , the duct  5  is engineered, for example, cross-sectionally oval or elliptical and features a closed profile. In this embodiment, the duct  5  is integrally formed, preferably integrally, with an openly curved element  9 . Curved element  9  is configured domed, and may be made of an elastomer such as, for example, nitrile butyl rubber. This achieves a wanted elasticity or flexibility of the duct  5 , so that the duct may serve as a hinge whereby the air filter element  8  can be pivotally moved away from a case  10  (particularly the top of the case) to an open position. In the open position shown in more detail in  FIG. 3 , the filter element  8  is freely accessible for cleaning. 
     Ambiently originating intake air can enter the case  10  via an air intake snorkel  11  arranged beneath the rider saddle  3 , and can flow from there via the air filter element  8  where it is cleaned, and into the flexible duct  5 . From the duct  5 , the cleaned air flows via the coupling  7  to the internal combustion engine (not shown). On intake of the intake air for combustion, a pulsating air flow materializes in the duct  5 . To prevent the duct  5  from negatively pulsating in sympathy, four longitudinal bracing ribs  5   a  ( FIGS. 1 and 4 ) are provided along the inner circumference within the duct  5 . Ribs  5   a  extend approximately from the end portion  6  of the duct  5  to approximately the opposite end portion, near the element  9 . 
     When housing an air filter element  8 , the case  10  is closed off by a lid section  12  ( FIGS. 1-3 ) of the air intake apparatus  1 , which section  12  simultaneously forms the lid of the case  10 . During engine operation backfiring may occur, resulting in ignition of an air/fuel mixture flowing into the combustion chamber. This may cause a deflagration which is propagated as a pressure wave in the intake air portion, forcing the lid section  12  to the side walls  16  ( FIG. 4 ) in engine operation, due to the negative pressure formed in the case  10 . To ensure that the section  12  is not blown out from the side walls  16  on such a backfire, a flexible member made, for example, of foam plastic may be disposed between a protuberance  3   a  at the rider saddle  3  and the section  12 . Such foam plastic member comes into contact with the protuberance  3   a  as soon as the lid section  12  is slightly lifted from the case  10 , thus preventing any further lift-off of the section  12  from the top of the case  10 . 
     So as to move the air filter element  8  from the top of the case  10  into the hinged open position as shown in  FIGS. 2 and 3 , the rider saddle  3  is removed or hinged open, for example at a joint located in a front end portion of the rider saddle. This provides access to the air intake apparatus  1 . The air filter element  8  can then hingeably pivot, together with the lid section  12  and the domed open curved element  9 , to the open position, with the flexible duct  5  simultaneously serving as a flexible joint. 
     No tool is needed to pivotally move open the air filter element  8  from the top of the case  10  as shown in  FIGS. 2 and 3 , resulting in the filter being instantly achieved as soon as the rider saddle  3  has been removed or likewise hinged open, providing immediate access to the air filter element  8 , for example, for cleaning. For this purpose, the air filter element  8  formed by a domed foam plastics member can simply be removed from the lid  12  by releasing a spring clip  13  from its detent position with the lid section  12  ( FIGS. 2 and 5 ). After this, the air filter element  8  can be removed and, for example, washed or otherwise cleaned. In the reverse sequence, the air filter element  8  is placed flush against the lid  12  by a the filter element&#39;s sealing edge  14  (as shown in detail in  FIG. 5  of the drawing) before the spring clip  13  is engaged with the lid section  12 . For this purpose, a sleeve  29  is provided at the underside of the lid  12 , for rotatably engaging the spring clip  13  at one end  25 . The other end  24  of the spring clip  13  can be engaged with a hook retainer  28  at the underside of the lid  12 , so that the clip  13  urges the air filter element  8  against the lid  12 . 
     After this, the air filter element  8  can be moved back into the case  10  by a pivoting down motion (in the direction of the arrow B in the plane of the drawing of  FIG. 2 ) of the duct  5  together with the curved element  9 , lid section  12 , air filter element  8  together and the spring clip  13 , resulting in the air filter element  8  being repositioned in the case  10 . With the communicating means, including the duct  5  in the closed position shown in  FIG. 1 , the lid  12  and the case  10  close off the inner space  18  of the case  10 . In this position, the air filter element  8  is located suspended within the case  10 . In other words, the sealing edge  14  is located at the top in the yaw axis direction of the air filter element  8 ; when jolted in operation of the ATV, any debris having collected on the air filter element  8  falls by the force of gravity from the filter element, thus achieving a certain self-cleaning effect. 
     Referring now to  FIG. 3  and  FIG. 4 , there is illustrated how the case  10  is engineered integrally with the mudguards  15 . The mudguards extend laterally away from both sides of the case  10 , and thus away from the wheels of the vehicle (not shown) located below the mudguards  15 . Accordingly, any debris and/or water and the like thrown up in vehicle operation cannot gain access to the interior space  18  of the case  10 , as is possible with known air intake apparatuses due to the gap between the mudguards  15  and the case  10 . 
       FIG. 4  illustrates how the case  10  has side walls  16  engineered integrally formed with a case floor  17 . In a preferred embodiment such as that shown, the case floor  17  is configured to have a trough-like shape, at least in a section transversely to the longitudinal direction of the case  10 , approximating the shape of an inverted saddle roof. A “saddle roof” is one which follows a convex curve about one axis and a concave curve about the other. Reference also is made to  FIGS. 1 and 2 , showing that the inverted saddle-roof shape of the floor  17  leads down to a drain port at a lower portion thereof. It is this configuration which ensures that any debris having gained access to an inner space  18  of the case  10  flows in the direction of a drain port  19  located at the lowest point in the case floor  17 , from where it can be discharged from the inner space  18  of the case  10 . 
     Referring now to  FIG. 5  of the drawings, there is illustrated, as an exploded view in perspective, an embodiment of the air intake assembly  1  in accordance with the present disclosure. The duct  5  preferably is engineered integrally with the domed or curved element  9 , which latch locks into detent holes  20  of the lid  12  by detents (not shown because of the view in perspective). 
     The lid section  12  features a downswept circumferential edge  21  which contacts and clasps the side walls  16  when the lid  12  is arranged on the tops of the side walls  16  of the case  10 . The domed air filter element  8  features, at a surface facing the lid  12 , a sealing edge  14  which, when the air filter element  8  is positioned at the lid  12 , ensures that the air filter element  8  can be contactably sealed against the lid  12 . For this purpose, the air filter element  8  made of a foam plastics material can be drawn over a retainer  23  to endow the air filter element  8  with the necessary dimensional stability. 
     Locating the air filter element  8  on the lid  12  results in it being held to the lid by the engagement of the two ends  24 ,  25  of the spring clip  13  at the lid. A retaining pin  26  arranged at the spring clip  13  engages a hole in a socket  27  of the retainer  23 , thus ensuring that due to the spring-loading of the element  8 , its sealing edge  14  is in reliable contact with the underside of the lid section  12 . 
     The air intake apparatus in accordance with the present disclosure ensures that the filter element (cleaner) may be quickly and easily accessed, removed and, for example, cleaned without requiring the use of any tools. For this purpose the user of the vehicle fitted therewith, for example someone riding an ATV, merely needs to remove or hinge open the rider saddle on the vehicle to gain free access to the air intake apparatus beneath the rider saddle. Since the duct of the air intake apparatus is flexible, the air intake apparatus can be hingeably opened away from the case, with the air filter element yet remaining joined to the air intake apparatus. Configuring the case of the air intake apparatus in accordance with the present disclosure integrally with the mudguards significantly diminishes contamination by the flow of ambient air into the case entraining debris such as dirt, sand, water and the like, as compared to known air intake assemblies. 
     It is understood that as regards all features of the invention not explained above in detail reference is expressly made to the claims and the drawing. 
     LIST OF REFERENCE NUMERALS 
     
         
           1  air intake assembly 
           2  frame structure 
           3  rider saddle 
           3   a  protuberance 
           4  means 
           5  duct 
           5   a  bracing rib 
           6  end portion 
           7  coupling 
           8  air filter element 
           9  curved element 
           10  case 
           11  air intake snorkel 
           12  section, lid 
           13  spring clip 
           14  sealing edge 
           15  mudguard 
           16  side wall 
           17  case floor 
           18  inner space 
           19  drain port 
           20  detent hole 
           21  circumferential edge 
           22  face 
           23  retainer 
           24  end 
           25  end 
           26  retaining pin 
           27  socket 
           26  retainer 
           29  sleeve 
         B arrow 
       
    
     Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.