Patent Description:
A turbocharger is generally a turbine-driven, forced induction device configured to increase the efficiency and power of an engine. As compared to a naturally aspirated engine, a turbocharged engine produces greater output power because the turbine forces more air, and proportionately more fuel, into the engine's combustion chambers than atmospheric pressure alone. As will be appreciated by those skilled in the art, turbochargers were once referred to as "turbosuperchargers" when all forced induction devices were classified as "superchargers. " At present, however, the term "supercharger" typically is used in reference to only mechanically driven, forced induction devices, such as by way of a belt, gear, shaft, or chain connected to the engine's crankshaft, whereas the term "turbocharger" is used in reference to a turbine driven by the engine's exhaust gas.

Turbochargers find wide use with truck, car, train, aircraft, and construction equipment engines. Turbochargers typically are used with Otto cycle and Diesel cycle internal combustion engines; although more recently, turbochargers have also been found to be useful with automotive fuel cells. One drawback, however, is a lack of specialized or a dedicated line of air filters available for turbochargers and centrifugal superchargers. It will be appreciated that turbochargers and centrifugal superchargers tend to present severe space constraints within engine compartments, thereby limiting the sizes and shapes of potential air filters. Many users rely on short cone-shaped air filters that are designed for other engine applications. Some users resort to making their own screen covers for the turbocharger air inlet. An air filter is disclosed in <CIT>. <CIT> also discloses an air filter.

Those skilled in the art will recognize that the shape of a housing of the turbocharger or supercharger, referred to as a "snail," presents unique challenges. An inlet receiver of the air filter must be inset into a scroll of the turbocharger or supercharger, thus requiring the user to expose the base of the air filter in order to access and tighten a clamp of the air filter. This encourages the user to apply force to the air filter in an attempt to expose the base, potentially damaging the air filter in the process. Consequently, another drawback is that conventional air filters are not easily installable onto turbochargers and superchargers without potentially damaging the air filters. What is needed, therefore, is an air filter which fits tightly onto air inlets of turbochargers and superchargers without the base of the air filter having to be exposed during installation of the air filter.

An apparatus is provided for an air filter configured to be mounted onto air inlets of turbochargers and superchargers. The air filter comprises a proximal base including an inlet receiver configured to receive an air inlet, a clamp to secure the air inlet within the inlet receiver, and a first opening aligned with a screw mechanism of the clamp. A filter medium fastened to the proximal base is configured to remove particulate matter and other contaminates from an incoming air stream. In some embodiments, the filter medium comprises paper, foam, cotton, spun fiberglass, or other known filter materials, woven or non-woven material, synthetic or natural, or any combination thereof. In some embodiments, the filter medium comprises a filter oil composition to enhance air cleaning properties of the filter medium. A distal end cap fastened to the filter medium comprises a second opening aligned with the first opening. A conduit within an interior cavity of the air filter is disposed between the first opening and the second opening, facilitating tightening and loosening the clamp by extending an appropriate tool through the interior cavity so as to engage the screw mechanism of the clamp. The conduit facilitates guiding the tool through the interior cavity to the screw mechanism while also serving to prevent unfiltered air from entering through the first opening and the second opening into the air inlet.

In an exemplary embodiment, an air filter configured to be mounted onto air inlets of turbochargers and superchargers comprises a proximal base configured to support the air filter and provide an interface between the air filter and an air inlet of a turbocharger or a supercharger, the proximal base comprising an inlet receiver configured to receive the air inlet, a clamp configured to secure the air inlet within the inlet receiver, and a first opening aligned with a screw mechanism of the clamp; a filter medium fastened to the proximal base and configured to remove particulate matter and other contaminates from an incoming air stream; a distal end cap fastened to the filter medium and comprising a second opening aligned with the first opening; and a conduit within an interior cavity of the air filter and disposed between the first opening and the second opening; wherein the first opening and the second opening facilitate tightening and loosening the clamp by extending an appropriate tool through the interior cavity by way of the conduit so as to engage the screw mechanism of the clamp.

In another exemplary embodiment, the filter medium is comprised of paper, foam, cotton, spun fiberglass, or other known filter materials, woven or non-woven material, synthetic or natural, or any combination thereof. In another exemplary embodiment, the filter medium is pleated or otherwise shaped or contoured to increase a surface area for passing the air stream to be cleaned. In another exemplary embodiment, the filter medium comprises a filter oil composition to enhance air cleaning properties of the filter medium.

In another exemplary embodiment, the distal end cap is comprised of a material which is sufficiently hard so as to retain the filter medium in a desired configuration and support the air filter when coupled to the air inlet of the turbocharger or the supercharger. In another exemplary embodiment, the conduit is configured to guide an appropriate tool through the interior cavity to the screw mechanism. In another exemplary embodiment, the conduit prevents unfiltered air from entering through the first opening and the second opening into the air inlet.

In another exemplary embodiment, the clamp comprises a metal band including a perforated portion which is received by the screw mechanism, the perforated portion being configured to receive a worm gear, or other similar component within the screw mechanism capable of engaging the perforated portion, such that turning the worm gear accordingly tightens or loosens the metal band. In another exemplary embodiment, the screw mechanism is configured with a substantially perpendicular orientation with respect to the circumference of the metal band, thereby facilitating engaging the screw mechanism with an appropriate tool by way of the first opening and the second opening.

In an exemplary embodiment, an air filter configured to mount onto an air inlet of a turbocharger comprises a base comprising an inlet receiver configured to couple with the air inlet; a filter medium coupled to the base and configured to remove particle contaminates from air drawn into the air inlet; a cap coupled to the filter medium; a conduit within an interior cavity of the air filter and disposed between a first opening in the base and a second opening in the cap; and a clamp configured to secure the air inlet within the inlet receiver, the clamp being operable by way of the first opening, the conduit, and the second opening.

In another exemplary embodiment, the clamp further comprises a screw mechanism aligned with the first opening, the conduit, and the second opening so as to facilitate operation of the clamp by way of a suitable tool passed through the cap, the conduit, and the base. In another exemplary embodiment, the screw mechanism is configured to enable tightening and loosening of the clamp by way of the suitable tool. In another exemplary embodiment, the conduit is configured to guide the suitable tool through the interior cavity to the screw mechanism. In another exemplary embodiment, the conduit is configured to prevent unfiltered air from entering through the first opening and the second opening into the air inlet.

The drawings refer to embodiments of the present disclosure in which:.

In general, the present disclosure describes an apparatus and a method for an air filter configured to be mounted onto air inlets of turbochargers and superchargers. The air filter comprises a proximal base configured to support the air filter and provide an interface between the air filter and an air inlet of a turbocharger or a supercharger. The proximal base comprises an inlet receiver configured to receive the air inlet, a clamp configured to secure the air inlet within the inlet receiver, and a first opening aligned with a screw mechanism of the clamp. A filter medium is fastened to the proximal base and configured to remove particulate matter and other contaminates from an incoming air stream so as to prevent them from entering into the air inlet. A distal end cap is fastened to the filter medium and comprises a second opening aligned with the first opening. A conduit within an interior cavity of the air filter is disposed between the first opening and the second opening. The first opening and the second opening facilitate tightening and loosening the clamp by extending an appropriate tool through the interior cavity by way of the conduit so as to engage the screw mechanism of the clamp.

<FIG> illustrate an exemplary embodiment of an air filter <NUM> configured to be mounted onto an air inlet of a turbocharger or a supercharger (hereinafter "turbocharger"). As illustrated in <FIG>, the air filter <NUM> comprises a proximal base <NUM>, a filter medium <NUM>, and a distal end cap <NUM>. As best illustrated in <FIG>, the proximal base <NUM> further comprises an inlet receiver <NUM>, a clamp <NUM>, and an opening <NUM>. The air filter <NUM> preferably is comprised of materials that are sufficiently durable and temperature resistant so as to retain its configuration during installation and operation when coupled with the air inlet of the turbocharger.

The proximal base <NUM> generally is configured to support the air filter <NUM> and provide an interface between the air filter <NUM> and air inlet of the turbocharger. The inlet receiver <NUM> is configured to receive the air inlet of the turbocharger, and the clamp <NUM> is configured to secure the air inlet within the inlet receiver <NUM> such that air is drawn through the filter medium <NUM> into an interior cavity <NUM> of the air filter <NUM> and then is conducted through the opening <NUM> into the air inlet of the turbocharger. It will be appreciated that the inlet receiver <NUM> has a configuration, and the opening <NUM> has a diameter, suitable to accept the air inlet of the turbocharger. For example, the inlet receiver <NUM> may comprise any of a variety of additional ridges, or raised portions, so as to optimally engage the air inlet of the turbocharger. The specific configuration of the inlet receiver <NUM> and the diameter of the opening <NUM> depend upon the particular make and model of the turbocharger for which the air filter <NUM> is to be utilized, and thus a wide variety of configurations and diameters may be incorporated into the air filter <NUM> without straying beyond the scope of the present disclosure.

As best shown in <FIG> and <FIG>, the proximal base <NUM> comprises a ridge <NUM> and a recess <NUM> configured to receive a proximal end <NUM> of the air filter <NUM>. It is envisioned that any of a variety of fasteners (not shown) may be used to affix the proximal end <NUM> within the recess <NUM>. In some embodiments, the ridge <NUM> may be molded to a wire support of the air filter <NUM>. In some embodiments, the ridge <NUM> may be crimped such that it folds onto and retains the wire support and the filter medium <NUM> of the air filter <NUM>. It will be appreciated that by those skilled in the art that, in some embodiments, fastening the filter medium <NUM> to the proximal base <NUM> by way of the ridge <NUM> and the recess <NUM> renders the filter medium <NUM> irremovable from the air filter <NUM>.

It is envisioned that a user of the air filter <NUM> may periodically clean the filter medium <NUM> rather than replacing the air filter <NUM>, as is typically done with conventional air filter systems. In some embodiments, a method for cleaning the filter medium <NUM> comprises removing the air filter <NUM> from the air inlet of the turbocharger, inserting a water hose through the opening <NUM> into the interior cavity <NUM> of the filter, and spraying water so as to flush contaminants from the filter medium <NUM>. In some embodiments, the method for cleaning the air filter <NUM> comprises utilizing a high pressure air hose in lieu of the water hose. In some embodiments, the method for cleaning the air filter <NUM> comprises spraying water onto the exterior of the filter medium <NUM>, such that the water and contaminants drain from the exterior of the filter medium <NUM>. Other cleaning methods will be apparent to those skilled in the art without deviating from the scope of the present invention as defined by the claims.

As discussed above, the proximal end <NUM> of the filter medium <NUM> is fastened to the proximal base <NUM> by way of the ridge <NUM> and the recess <NUM>. The distal end cap <NUM> may be similarly affixed to the filter medium <NUM> by way of any of a variety of fasteners (not shown). In some embodiments, the distal end cap <NUM> may be molded to a wire support of the filter medium <NUM>, as discussed herein. In some embodiments, the distal end cap <NUM> may be crimped around its peripheral edge such that it folds onto and retains the wire support and the filter medium <NUM> of the air filter <NUM>. In some embodiments, a simple nut and bolt may be used to attach the filter medium <NUM>, the wire support, and the distal end cap <NUM> onto the proximal base <NUM> such that the proximal end <NUM> is held fixed within the recess <NUM>. Any of a variety of fastening means may be practiced for attaching the filter medium <NUM>, the wire support, and the distal end cap <NUM> onto the proximal base <NUM> without deviating from the spirit and scope of the present invention as defined by the claims. Further, the distal end cap <NUM> preferably is comprised of a material which is sufficiently hard so as to retain the filter medium <NUM> in the desired configuration and support the air filter <NUM> when coupled to the air inlet of the turbocharger. The filter medium <NUM> is also preferably durable enough to withstand repeated cleaning and use, as discussed herein.

As discussed above, the wire support may be incorporated into the filter medium <NUM> so as to provide additional strength and durability to the air filter <NUM>, thereby facilitating periodic cleaning and reusing the air filter <NUM> instead of discarding the filter after each application. In some embodiments, the filter medium <NUM> may be positioned between the wire support and one or more layers of a reinforcing material. For example, the wire support may comprise a wire screen positioned on an outer surface and an inner surface of the filter medium <NUM>. In some embodiments, the wire screens may be comprised of powder-coated aluminum screen wire that is co-pleated along with the filter medium <NUM> so as to reinforce the air filter <NUM>. In some embodiments, the inner surface of the filter medium <NUM> may comprise a stronger mesh reinforcement which is similar to those incorporated into Diesel filter applications. In some embodiments, additional or alternative reinforcements may be provided, as will be apparent to those skilled in the art.

In the embodiment of the air filter <NUM> illustrated in <FIG>, the proximal base <NUM> has a diameter substantially equal to the diameter of the distal end cap <NUM>. In some embodiments, however, the proximal base <NUM> may have a larger size than the size of the distal end cap <NUM>. It should be understood that the air filter <NUM> of the present disclosure is not limited to the exact shape illustrated in <FIG>, but rather, may include a wide variety of generally cylindrical shapes, generally circular, oval, round, curved, or other closed perimeter shapes, that provide a relatively large surface area of the filter medium <NUM>. In some embodiments, the filter medium <NUM> may comprise various heights other than as shown in <FIG>, as well as comprising inverse cone-shapes. In some embodiments, the air filter <NUM> may comprise inverted filter cones inserted so as to increase air flow through the filter medium <NUM>.

In the embodiment illustrated in <FIG>, the distal end cap <NUM> comprises a first opening <NUM> aligned with a screw mechanism <NUM> of the clamp <NUM>. A second opening <NUM> in the proximal base <NUM> is also aligned with the screw mechanism <NUM>, as shown in <FIG>. It will be appreciated that the screw mechanism <NUM> is configured to enable a user to tighten the clamp <NUM> during installation of the air filter <NUM> onto the air inlet of the turbocharger. Alternatively, the user may use the screw mechanism <NUM> to loosen the clamp during removal of the air filter <NUM> from the turbocharger.

<FIG> illustrates a perspective view of the clamp <NUM> in absence of the air filter <NUM>. The clamp <NUM> comprises a metal band <NUM> including a perforated portion <NUM> which is received by the screw mechanism <NUM>. The perforated portion <NUM> is configured to receive a worm gear, or other similar component within the screw mechanism <NUM> capable of engaging the perforated portion <NUM>, such that when the worm gear is turned the metal band <NUM> is accordingly tightened or loosed. A drive head <NUM> is configured to receive a tool suitable for turning the worm gear. The metal band <NUM> preferably comprises <NUM> stainless steel or other similar material. In some embodiments, the metal band <NUM> may be galvanized. As best illustrated in <FIG> and <FIG>, the screw mechanism <NUM> is disposed in a substantially perpendicular orientation relative to a circumference of the metal band <NUM>. The substantially perpendicular orientation facilitates engaging the screw mechanism <NUM> with an appropriate tool positioned at substantially a right angle relative to the circumference of the metal band <NUM>.

The first opening <NUM> and the second opening <NUM> facilitate tightening and loosening the clamp <NUM> by extending an appropriate tool into the first opening <NUM>, through the interior cavity <NUM>, and into the second opening <NUM> so as to engage the screw mechanism <NUM>. As best illustrated in <FIG>, a conduit <NUM> is positioned within the interior cavity <NUM> and disposed between the first opening <NUM> and the second opening <NUM>. The conduit <NUM> is configured to guide the appropriate tool through the interior cavity <NUM> to the screw mechanism <NUM>. The conduit <NUM> further serves to prevent unfiltered air from entering through the first and second openings <NUM>, <NUM> and into the air inlet of the turbocharger.

<FIG> illustrates a perspective view of an exemplary use environment <NUM> wherein a screw driver <NUM>, or other similar appropriate tool, is extended into the first opening <NUM>, through the conduit <NUM>, and through the second opening <NUM> so as to adjust the clamp <NUM> by way of turning the drive head <NUM> of the screw mechanism <NUM>. <FIG> illustrates a perspective view of an exemplary use environment <NUM> wherein a wrench <NUM> is being used to turn a driver <NUM> so as to adjust the clamp <NUM> by way of turning the screw mechanism <NUM>. In the environment <NUM> of <FIG>, the driver <NUM> extends into the first opening <NUM>, through the conduit <NUM> in the interior cavity <NUM>, through the second opening <NUM>, and engages with the drive head <NUM> of the screw mechanism <NUM>. Those skilled in the art will appreciate that accessing the screw mechanism <NUM> by way of the first opening <NUM> and the second opening <NUM> advantageously enables the inlet receiver <NUM> of the air filter <NUM> to be inset into the scroll of the turbocharger and then tightened onto the air inlet without the user having to apply force to the air filter <NUM> in an attempt expose the proximal base <NUM> and access the clamp <NUM>.

As best shown in <FIG>, the filter medium <NUM> circumferentially surrounds the interior cavity <NUM>, such that the filter medium <NUM> creates an exterior perimeter of at least a portion of the interior cavity <NUM>. As mentioned above, the exterior shape may be generally circular, oval, conical, or otherwise shaped to improve the surface area available for air flow passage for a given volume of the interior cavity <NUM>. The shape may be consistent along a longitudinal length, as illustrated in <FIG>, or may vary along the length. For example, the outer profile may taper from the proximal base <NUM> to the distal end cap <NUM> so as to resemble a cone-shape, as discussed herein.

Claim 1:
An air filter configured to be mounted onto air inlets of turbochargers and superchargers, comprising:
a proximal base (<NUM>) configured to support the air filter (<NUM>) and provide an interface between the air filter and an air inlet of a turbocharger or a supercharger, the proximal base comprising an inlet receiver (<NUM>) configured to receive the air inlet, a clamp (<NUM>) configured to secure the air inlet within the inlet receiver, and a second opening (<NUM>) aligned with a screw mechanism (<NUM>) of the clamp;
a filter medium (<NUM>) fastened to the proximal base and configured to remove particulate matter and other contaminates from an incoming air stream;
a distal end cap (<NUM>) fastened to the filter medium and comprising a first opening (<NUM>) aligned with the second opening (<NUM>); and
a conduit (<NUM>)) within an interior cavity (<NUM>) of the air filter and disposed between the first opening and the second opening;
wherein the first opening and the second opening are configured to facilitate tightening and loosening the clamp by extending an appropriate tool through the interior cavity by way of the conduit so as to engage the screw mechanism of the clamp.