Crushable air duct for motor vehicle air intake system

Abstract

The present invention provides a crushable air duct having a series of cleverly positioned and patterned crack-inducing grooves formed thereon. These grooves allow the air duct to be crushed in the event of an impact or a specified impact force, thereby protecting adjacent, more expensive under-hood components from damage. In the event of an impact, this series of grooves allows cracks in the air duct to easily propagate throughout the entire pattern in a controlled and predictable manner. The crushable air duct is formed of a rigid polymeric material. The air duct includes an inlet and an outlet. The grooves are formed on one or both of the outer surface and the inner surface of the air duct. Typically some of the grooves extend between the inlet and the outlet. The grooves are preferably parallel. Other grooves are formed circumferentially around the air duct. At least some of the parallel grooves intersect with the circumferential grooves.

Description

Technical Field

[0001] The present invention generally relates to air intake systems for internal combustion engines of vehicles. More specifically, the present invention relates to a crushable or collapsible air duct or air channel having strategically located and patterned crack-inducing grooves that provide a thickness designed to fail at a specified load to prevent subsequent damage to higher cost under-hood components. Background Art

[0002] Internal combustion engines typically include an air intake system (AIS) for delivering ambient air to the throttle body and ultimately into the combustion chamber as part of the air-fuel mixture. The air intake system includes an air duct that first draws in ambient air and delivers the input air to and through the air filter box. A typical air duct is generally a low-cost unit that is often located adjacent to higher-cost under-hood components such as the air conditioning (A / C) condenser, radiator, and radiator-related components including the fan unit (or units) and fan shroud.

[0003] In the event of a collision, the radiator and the associated fan unit and fan cover are pushed to the rear of the vehicle into the engine compartment. This problem also occurs even in the case of a low-speed collision, where the assembly of the "cooling assembly (pack)" (A / C condenser, radiator, fan unit and fan cover) and the support member is pushed to the rear of the vehicle by about 100mm. In order to minimize the additional damage to the radiator, fan unit and fan cover, there is an industry requirement of "low-speed damage (LSD)" for the car and the industry requirement is applicable to the AIS air duct. These rules require that the rear area of ​​the vehicle of the radiator is empty or only included in the parts that will apply the minimum resistance to the movement of the radiator, fan unit and fan cover in the event of a collision. The force from the AIS air duct to resist the movement of the radiator, fan unit and fan cover must be low enough so that the A / C condenser, radiator, fan unit and fan cover are not damaged during the collision event, so as to minimize the maintenance cost.

[0004] Given the concerns about possible crash events, existing AIS dirty side ducts (DSD) are at risk of failing to meet the safety LSD cascade target. The cascade target for vehicle safety sought by automotive designers is to have DSD destruction when subjected to a predetermined acceptable force (e.g., 500N) in a crash event to meet the LSD requirement. A "successful" crash event outcome is the absence of post-crash damage to components such as the A / C condenser, radiator, fan unit, fan shroud, battery, or battery cover.

[0005] Among the components at risk in a crash event, the air intake duct is usually the component with the lowest cost to sacrifice and replace. In response to LSD requirements, automakers want to provide a duct that is strong enough to perform under all engine conditions, but still fragile enough to be destroyed in a low-speed collision and make room for more complex and expensive components so that these components can be moved into the space without damage. To meet this demand, manufacturers use soft elastomer / rubber materials on AIS ducts and hoses. However, elastic components can be more expensive and heavier than molded rigid plastic components. These components also tend to be heavier than molded rigid plastic components, thus adding undesirable extra weight to the vehicle.

[0006] Thus, known methods of reducing damage to expensive under-hood components in the event of a crash do not always produce satisfactory results.As in most areas of automotive technology, there are always numerous opportunities for improvement involving the design of AIS components. Summary of the invention

[0007] The present invention provides a crushable or foldable air intake duct having a series of cleverly positioned and patterned crack-causing grooves formed thereon. These grooves allow the duct to be crushed in an impact event, thereby protecting adjacent, more expensive under-hood components from damage. These components include, but are not limited to, radiators, cooling fans, cooling fan covers, and air conditioning components. In an impact event, this series of grooves allows cracks in the duct to easily spread throughout the entire pattern in a controlled and predictable manner. The crushable duct disclosed in the present invention exhibits at least the same or better performance than known elastomeric versions in an impact event. The crushable duct disclosed in the present invention is preferably, but not absolutely, crushed under a predetermined acceptable force (e.g., 500N).

[0008] The crushable air duct disclosed in the present invention comprises a main body having an air inlet and an air outlet. A series of grooves are formed on the outside of the main body, but these grooves may also or alternatively be formed on the inside of the main body. The pattern of these grooves may be regular, such as square, triangle or hexagon. Alternatively, the pattern of the grooves may be irregular. Although only one set of grooves may be provided, two sets of grooves are preferably provided but not absolutely. One set of grooves extends roughly between the air inlet and the air outlet. This set of grooves is parallel. Another set of grooves (if any) is formed around the main body of the crushable air duct in the circumferential direction. If two sets of grooves are provided at the same time, at least some of the two sets of grooves intersect each other.

[0009] To enhance the crushability of the crushable air duct, the body is formed of a brittle rigid polymeric material. Non-limiting examples of usable polymeric materials include polypropylene, high density polyethylene, and acrylonitrile-styrene-acrylate.

[0010] The crushable air duct disclosed herein may be formed from a single piece of rigid polymeric material, or may be formed from multiple pieces of rigid polymeric material, such as multiple shells attached together. Attachment of one shell to another may be performed by any number of methods including, but not limited to, clasps, snap-fit ​​assemblies, and plastic welding.

[0011] The above advantages and other advantages and features will become more apparent from the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of the present invention, reference should now be made to the embodiments shown in more detail in the accompanying drawings and described below by way of example of the invention, in which:

[0013] Figure 1 is an environmental view of a crushable air duct according to the present invention, wherein the air duct is located in an engine compartment according to a perspective view;

[0014] Figure 2 is based on Figure 1 An alternative view of the environment view;

[0015] Figure 3 is with Figure 1 A similar view of the environment but from above;

[0016] Figure 4 is with Figure 1 A similar view of the environment but from the side;

[0017] Figure 5 is a front view of the crushable air duct disclosed in the present invention;

[0018] Figure 6 is a first side view of the crushable air duct disclosed in the present invention;

[0019] Figure 7 is a rear view of the crushable air duct disclosed in the present invention;

[0020] Figure 8 is a second side view of the crushable air duct disclosed in the present invention;

[0021] Fig. 9 is a top view of the crushable air duct disclosed in the present invention;

[0022] Fig.10 is a bottom view of the crushable air duct disclosed in the present invention;

[0023] Fig.11 yes Figure 5 A cross-sectional view of the crushable air duct disclosed in the present invention taken along line 11-11; and

[0024] Fig.12 is similar to Figure 1 , but shows the environmental condition of the crushable air duct after experiencing an impact event. DETAILED DESCRIPTION

[0025] In the following drawings, the same reference numerals will be used to represent the same components. In the following description, different operating parameters and components are described for different embodiments of the present invention. These specific parameters and components are included in the embodiments, but are not meant to be restrictive.

[0026] The accompanying drawings and the related description illustrate an intake manifold according to the present disclosure. In particular, Figures 1 to 4 The crushable air duct of the air intake system is shown as being in its position in the engine compartment of a vehicle under normal operating conditions. The crushable air duct itself is in Figures 5 to 11 are shown separately in various views. Fig.12 , the crushable air duct is shown in its crushed state within the engine compartment after an impact event.

[0027] It should be understood that the underhood features and their arrangement may be varied without departing from the spirit or scope of the present invention. Figures 1 to 4 as well as Fig.12 It should also be understood that additional configurations of the crushable air ducts disclosed herein may be employed without departing from the spirit or scope of the disclosed inventive concepts.

[0028] refer to Figures 1 to 4 , which shows the engine compartment of the vehicle. The engine compartment (generally indicated as 10) contains a crushable air duct 12, an air cleaner box 14 shown partially in dotted lines, and a radiator 16. A fan cover 17 is fixed to the side of the radiator 16 facing the rear of the vehicle. A replaceable air filter (not shown in the figure) is usually provided in the air cleaner box 14.

[0029] The crushable air duct 12 is a dirty side duct (DSD) having a Figures 1 to 3 ) receives input air and passes through its outlet end 20 (as shown) Figure 1 , Figure 2 and Figure 4 An air inlet (not shown) is typically attached to the inlet end 18 of the crushable air duct 12. The outlet end 20 of the crushable air duct 12 is fluidly associated with the air cleaner box 14. The air cleaner box 14 delivers the now filtered input air to the engine intake duct (not shown).

[0030] Crushing air duct 12 Figures 5 to 111 and 2. The air inlet end 18 is shown separately in various views in the drawings. With reference to these figures, a front view of the crushable air duct 12 is shown. The air inlet end 18 preferably, but not necessarily, includes a circumferential stop flange 22 against which the air inlet rests when inserted. The air inlet end 18 also includes a locking device for locking the attachment to the air inlet. Such a locking device may include, for example, attachment tabs 24 and 24'.

[0031] The air outlet end 20 preferably, but not necessarily, includes a circumferential stop flange 26 against which the air inlet stops when inserted. The air inlet end 18 also includes a locking device for locking attachment to the air cleaner box 14. Such a locking device may include, for example, attachment tabs 28, 28', 28", and 28'".

[0032] The crushable air duct 12 can be formed of any of several rigid polymer materials that have good strength but can be cracked along the designed grooves. Non-limiting examples of such rigid materials include polypropylene (PP), high-density polyethylene (HDPE), and acrylonitrile-styrene-acrylate (ASA) or any combination thereof.

[0033] The crushable air duct 12 is preferably but not necessarily molded from multiple pieces. The multi-piece structure helps to reduce manufacturing costs. Preferably but not necessarily, the crushable air duct 12 is formed by two connected shells (a first shell 30 and a second shell 32). The first shell 30 and the second shell 32 can be attached to each other. The attachment of the first shell 30 to the second shell 32 can be achieved by any number of methods, including mechanical fasteners or as shown in the figure by a series of attachment fasteners including a tab 34 and a snap-fit ​​assembly 36 (independently or in combination). Fig.11 As shown, each snap-fit ​​assembly 36 includes a cantilevered snap portion 38 and a latch portion 40 .

[0034] As previously mentioned, the crushable air duct 12 is made to fold and crush through a series of cleverly positioned and patterned grooves that cause cracking. These grooves provide a concentrated area with reduced wall thickness, which is designed to fail under a specified load. This designed and adjustable failure allows the crushable air duct 12 to be crushed and usually flattened to prevent subsequent damage to the components under the hood of higher costs. The designed groove pattern and the orientation of the grooves allow cracks to be controlled and easily spread throughout the entire crushable air duct 12 when impacted. Preferably, the crushable air duct 12 must be crushed under a predetermined impact force less than acceptable.

[0035] The first shell 30 and the second shell 32 each include a series of grooves that define a pattern. Figures 5 to 11As shown, these grooves are shown as being formed on the outside of the housing 30 and the housing 32, but it should be understood that these grooves can also be formed as shown. Fig.11 That is formed on the inner side of one or both of the housing 30 and the housing 32 .

[0036] A first series of grooves are formed on the first housing 30. As shown, the first set of parallel grooves includes grooves 42, 42', 42", 42'" and 42". Parallel grooves 42, 42', 42", 42'" and 42"" are generally formed between the air inlet end 18 and the outlet end 20, although these grooves may be shorter. The width and depth of the parallel grooves 42, 42', 42", 42'" and 42"" can be adjusted as needed to produce the desired crushing results.

[0037] Substantially perpendicular to the parallel grooves 42, 42', 42", 42'", 42"" is a set of circumferential grooves 44, 44' and 44". It should be understood that a greater or lesser number of parallel grooves 42, 42', 42", 42'" and 42"" and circumferential grooves 44, 44' and 44" may be formed on the first shell 30.

[0038] A second series of grooves is formed on the second housing 32. As shown, the first set of parallel grooves includes grooves 46, 46', 46", 46'" and 46". Parallel grooves 46, 46', 46", 46'" and 46"" are also generally formed between the air inlet end 18 and the outlet end 20, although these grooves may be shorter. The width and depth of parallel grooves 46, 46', 46", 46'" and 46"" can be adjusted as needed to produce the desired crushing results.

[0039] Substantially perpendicular to the parallel grooves 46, 46', 46", 46"' and 46"" is a set of circumferential grooves 48, 48', 48", 48"', 48"" and 48""'. It should be understood that a greater or lesser number of parallel grooves 46, 46', 46", 46"' and 46"" and circumferential grooves 48, 48', 48", 48"', 48"" and 48""' may be formed on the second shell 32.

[0040] As previously described, these grooves may be formed internally and externally on the first shell 30 and the second shell 32. Figures 5 to 10 The parallel grooves and circumferential grooves formed on the exterior are shown, but Fig.11 A set of grooves formed inside are shown. For reference, the first housing 30 includes a set of parallel grooves 50 and 50' inside, and the second housing 32 includes a set of parallel grooves 52 and 52' inside. A greater or lesser number of grooves 50, 50', 52 and 52' may be formed.

[0041] Figures 1 to 11 shows the performance of the crushable air duct 12 before the impact event, and Fig.12 The crushable air duct 12 after the impact event is shown. As shown, the vehicle has been impacted as shown by the arrow. After the impact event, the radiator 16 has been pushed toward the interior of the vehicle in the direction of the air cleaner box 14. However, after the impact event, the air cleaner box 14, the fan cover 17 and all the air conditioning components remain intact. This is possible because the crushable air duct 12 has absorbed the energy of the impact and has therefore been crushed between the radiator 16 and the air cleaner box 14, thereby substantially freeing up the space it previously occupied.

[0042] As previously described, whether formed on the outside or inside of the crushable air duct, the number, path, layout and depth of each groove can be modified as needed to provide optimal performance in an impact event. Although these grooves have been shown as being elongated and circumferential, it should be understood that many variations of groove patterns are possible, including both regular and irregular patterns. It should also be understood that, although grooves have been specified, the concave areas shown as grooves in the figures can also be channels, and their shapes (alternatively or in combination) are polygonal, circular or oval or a mixture of these shapes. The thickness of the first shell 30 and the second shell 32 can be constant or variable.

[0043] The air duct disclosed in the present invention is highly tunable and can be designed and produced to meet a wide variety of requirements. Variables include the geometry of the grooves, the choice of material, the thickness of the material, and the groove pattern. Multiple variations of the air duct have been produced, and subsequent analysis and physical testing have determined the tunability of the air duct under its multiple variations.

[0044] Given the variables described, the disclosed crushable duct 12 provides maximum flexibility to the engine designer and enables specific adjustments to the under-hood arrangement. In this way, the cost of repairing an impact event can be reduced by reducing or eliminating damage to high-cost components without adding weight, cost or complexity to the vehicle's air intake system.

[0045] One skilled in the art will readily recognize from the foregoing discussion and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the appended claims.

Claims

1. An air duct for an air intake system of a vehicle, the air duct comprising: a body having a length, an inlet, an outlet, an outer surface, and an inner surface; a first set of grooves formed on the outer surface comprising a set of parallel grooves; a second set of grooves including a set of circumferential grooves formed on the outer surface, at least some of the grooves in the second set of grooves intersecting at least some of the grooves in the first set of grooves, the first set of grooves and the second set of grooves defining separable segments; as well as A third set of grooves including a set of parallel grooves is formed on the inner surface. 2 . The air duct of the air intake system for a vehicle according to claim 1 , wherein the parallel grooves on the outer surface extend from the inlet to the outlet. 3 . The air duct of claim 1 , wherein the body is formed of a rigid polymer material. 4 . The air duct of the air intake system for a vehicle according to claim 1 , wherein the main body is formed of a first shell and a second shell. 5 . The air duct of the air intake system for a vehicle according to claim 4 , wherein the first housing is attached to the second housing by mechanical fasteners, adhesives, or welding. 6 . The air duct of the air intake system for a vehicle according to claim 4 , wherein the first housing is attached to the second housing by a clasp.

7. An air intake system for a vehicle, the system comprising: an air filter box having an input air side; and An air duct formed of a rigid polymeric material, the air duct being attached to the input air side of the box, the air duct having a long axis, an outer surface, an inner surface, an inlet and an outlet, the air duct having a first set of grooves formed on the outer surface comprising a set of parallel grooves, a second set of grooves formed on the outer surface comprising a set of circumferential grooves, and a third set of grooves formed on the inner surface comprising a set of parallel grooves, at least some of the grooves in the second set of grooves intersecting at least some of the grooves in the first set of grooves, the first set of grooves extending generally along the long axis between the inlet and the outlet. 8 . The air intake system for a vehicle according to claim 7 , wherein the circumferential groove is formed around the air duct in a circumferential direction. 9 . The air intake system for a vehicle according to claim 7 , wherein the rigid polymer material is polypropylene, high density polyethylene, or acrylonitrile-styrene-acrylate. 10 . The air intake system for a vehicle according to claim 7 , wherein the air duct is formed by a first housing and a second housing.

11. An air intake system for a vehicle, the system comprising: an air filter box having an input air side; and an air duct formed of a rigid polymeric material, the air duct being attached to the input air side of the box, the air duct having an outer surface, an inner surface, a major axis, an inlet and an outlet, the air duct having a first set of parallel grooves and a set of circumferential grooves formed on the outer surface of the air duct and a second set of parallel grooves formed on the inner surface, the first set of parallel grooves and the circumferential grooves intersecting, Each set of grooves provides a concentrated area of ​​reduced wall thickness in the duct that is designed to fail at a specified load. 12 . The air intake system for a vehicle of claim 11 , wherein the first set of parallel grooves extend along the long axis between the inlet and the outlet. 13 . The air intake system for a vehicle according to claim 12 , wherein the set of circumferential grooves includes grooves formed circumferentially around the air duct.

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