WO1998049440A1

WO1998049440A1 - Integrated duct and resonator for an automobile engine air induction system

Info

Publication number: WO1998049440A1
Application number: PCT/CA1998/000382
Authority: WO
Inventors: Stephen F. Bloomer; Mark W. Merritt
Original assignee: Siemens Canada Ltd
Current assignee: Siemens Canada Ltd
Priority date: 1997-04-24
Filing date: 1998-04-23
Publication date: 1998-11-05
Anticipated expiration: 1999-10-24

Abstract

An integrated duct and resonator chamber component is installed on an engine between the air cleaner and throttle body to establish a flow path for inducted air flow to the engine through a duct portion of the component. One or more resonator chambers are provided which can be of differing volumes to be tuned to different noise frequency ranges. Fluid communication between the duct portion and each resonator chamber can either be defined by a cut away region to create an expansion chamber and/or with one or more small openings to create a Helmholtz resonator. The duct portion is described as variously shaped, including single or double elbow configuration.

Description

INTEGRATED DUCT AND RESONATOR FOR AN AUTOMOBILE ENGINE AIR INDUCTION SYSTEM

BACKGROUND OF THE INVENTION This invention concerns ducting for the air induction system of an automobile engine. Due to a lack of overhead space beneath the hood, the air cleaner is typically mounted in a location in modern engines remote from the throttle body through which air is inducted into the intake manifold. Ducting is installed extending from the air cleaner to the throttle body. Expansion chambers and/or Helmholtz resonators are also commonly used to reduce engine noise connected to the ducting at a point where room is available amidst the engine components.

The installation of the ducting is labor intensive due to the need to make clamped connections between each component. The assembly together of separate pieces using clamps and fittings also increases resistance to the air induction flow.

U. S. Patent No. 5,424,494 describes the combination of an expansion chamber and Helmholtz resonator in a single molded piece, but the combination resonator must still be installed in the system using separate hoses, clamps, etc. See also U. S. Patent No. 5, 1 63,387.

Expansion chamber devices are connected in the air induction flow path and consist of a relatively large volume cavity which is open to the air flow passage. The expansion chamber is known to amplify sound waves and to dissipate sound energy in the system. A Helmholtz resonator comprises a side branch chamber which does not receive a through flow of induction air, but is in communication with the duct air flow via one or more relatively small area openings or necks.

Neither device is effective over all noise frequency ranges, but each can be tuned to a noise frequency range by selection of proper geometry, applying known principles. It is also known to vary the resonator geometry to increase the effective range thereof, as described in U. S. Patent No. 4,539,947.

It is an object of the present invention to simplify the ducting and the resonator chamber components to reduce assembly labor costs as well as the cost of the components themselves.

It is another object to provide a noise attenuating air induction system component of minimal flow resistance.

SUMMARY OF THE INVENTION

The above objects are achieved by combining the ducting connecting the air cleaner with the throttle body with one or more noise attenuating resonator chambers as an integrally constructed piece so as to eliminate the need for assembling and separately installing the ducting. The integrated ducting and resonator chambers may be blow molded as one piece or injected molded in two or more pieces which are friction welded together to form a unitary structure.

The resonator chambers are appropriately located within available space when the ducting is installed in the engine compartment. Installation of the ducting thus also installs a broad band noise attenuator at the same time.

The resonator chambers can be integrated with the ducting in various ways, each involving communication with the air flow passage without receiving a substantial volume of air flow. One or more openings allow communication therebetween to allow sound waves to enter the chamber for dissipation thereof. The geometry of the openings can be configured to establish a Helmholtz or combined Helmholtz/expansion chamber resonator attenuating selected noise frequencies. The ducting and resonator chamber can be molded to have any shape and size to be accommodated to the available space, to provide adequate flow capacity, and to provide a designed for noise attenuation frequency range.

Multiple resonator chambers of assorted shapes and sizes can be integrated with the ducting, in various arrangements.

The integrated duct-resonator component can also be formed with a cover extending over the top of the engine, overlying the components to improve the under-the-hood appearance of the engine.

DESCRIPTION OF THE DRAWINGS

Figure 1 is a diagrammatic view of an engine showing the installation of an integrated duct-resonator chamber component according to the invention. Figure 2 is an exploded perspective view of the integrated duct- resonator chamber component depicted diagrammatically in Figure 1 .

Figure 3 is a perspective view of a second embodiment of an integrated duct-resonator chamber component according to the present invention. Figure 4 is a view of the section 4-4 taken in Figure 2.

Figure 5 is a view of the section 5-5 taken in Figure 2.

Figure 6 is an alternate form of the section shown in Figure 5.

Figure 7 is another alternate form of the section shown in Figure 5. Figures 8-1 0 are sectional views taken through three other embodiments of the invention, each incorporating two resonator chambers.

Figure 1 1 is an exploded perspective view of yet another embodiment of the invention incorporating a cosmetic cover. DETAILED DESCRIPTION

In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 1 1 2, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.

Referring to Figure 1 , a plane view of an automotive engine 1 0 is depicted diagrammatically. An air cleaner 1 2 is disposed at an offset location from a throttle body 1 4, installed on an intake manifold 1 6.

According to the concept of the present invention, the necessary ducting for connecting the air cleaner 1 2 to the throttle body 1 4 is provided by a single integrated duct-resonator component 1 8. Figure 2 illustrates a first embodiment of the integrated duct and resonator component 1 8. The exploded view illustrates the construction of the component 1 8 of two-piece molded plastic, comprising an upper shell 20 and a lower shell 22, which shells are friction welded together along aligned and facing flanges 24, 26 extending about the perimeter of each shell.

In the example shown, the upper shell 20 has a right angle trough-shaped portion 28, with tubular ends 30, 32 comprising fittings for connection to the air cleaner, throttle body, or other engine components. Other angle elbows or straight sections could also be used.

A generally square, flat lid portion 34 (which may be ribbed as shown for aesthetic purposes and for stiffening) has two sides which each project from a respective side of the angled portion 28.

The bottom shell 22 is also formed with a right angle troug shaped portion 36 which is fit to the upper shell portion 28 to form a tubular air duct portion of a length and shape to enable interconnection of the air cleaner 1 2 and throttle body 1 4.

An open-topped resonator chamber portion 38 is also molded integrally with the angled portion 36, having two sides projecting from a respective inside wall of the angled position 36.

The lid portion 34 overlies and seals the open top of the resonator chamber portion 38 when the upper and lower shells are friction welded together.

The lower shell 22 is also formed with a tubular portion 40 which extends down the side of the chamber 38, its upper end having an opening 42 extending into the interior space 44 of the air flow duct formed by the two trough-shaped portions 28, 36.

A second opening 45 enters into the interior cavity 46 of the resonator chamber portion 38. The resonator is thus located at a point intermediate the length of the air flow duct passage.

The air duct passage defined by the interior space 44 is in communication with cavity 46 only via opening 45. Hence, the resonator functions as a Helmholtz device, with the size of the openings 42 and 45, the length of the tube 42 and 44, and the volume of the cavity 46, and the other geometric parameters determining the range of noise frequencies which are effectively attenuated.

The location, size, and shape of the duct and chamber portions can be variously configured to be fit to the space available for accommodating the device in the particular engine with which the component 1 8 is to be used.

For example, the duct portion need not necessarily be of a right angle elbow configuration, but could be straight and could also have a more flattened cross sectional shape. Figures 3-5 show another embodiment of the integrated duct- resonator component, in which a resonator chamber 48 is more or less centered between duct ends 52, 54.

The interior cavity 56 of the chamber 48 is in communication with an air duct region 58 by a partition region 60, which may have one or more openings, or alternatively be partially or completely cut away. The curvature of the outer wall 62 extending between the duct ends 52, 54 tends to cause the air flow to not enter the cavity 56. The shape of the outer wall 62 as seen in Figure 5 can act to confine the induction flow in the duct space 58 away from the cavity 56.

The configuration and extent of the partition region 60 controls whether cavity 56 acts as an expansion chamber, a Helmholtz resonator, or both, and the effective frequency range such that the designer can tailor the noise attenuation effect to the particular needs of the application.

Figure 6 shows a less confining outer wall 62A, while Figure 7 shows an asymmetric confining wall 62B.

Figure 8 shows a double elbow, double resonator integrated duct- resonator component 64, having parallel but offset duct ends 66, 68. Nonparallel ends could also be provided. Outer walls 70, 72 partially define a pair of resonator chambers 74, 76. Interior walls 78, 80 also define in part the chambers 74, 76, as well as air flow passages 82, 84 extending between the chambers 74, 76. Partition regions 86, 88 respectively extend between the duct air flow passages and adjacent chamber 74 or 76, respectively.

The curvature of the walls 78, 80 define a double elbow with the curvature creating outside confinement tending to keep air flow from passing through chambers 74, 76. The partition regions 86, 88 may be slotted, perforated, or completely open as necessary to achieve an expansion chamber Helmholtz resonator, or combined noise attenuation effect.

Figure 9 shows another configuration of an integrated duct- resonator 90 component in which duct ends 92, 94 are on the same side, but offset laterally.

In this case, the resonator chamber cavities 96, 98 are adjacent each other, with a solid wall 100 establishing separation.

A semicircular outer wall 102 and inner wall 104 define air flow passages 106, 108 extending past a respective chamber 96, 98.

Partition regions 110, 112 allow communication of each duct 106, 108 with a respective chamber 96, 98. Cut out partition regions 110, 112 may be cut out, slotted, perforated, etc., as desired to produce a desired noise attenuation. The chambers 96, 98 can be of equal or differing volumes to cause noise attenuation in different noise frequency bands.

Figure 10 shows aligned duct ends 114, 116 at opposite sides of another embodiment of an integrated duct resonator component 118. A pair of inner walls 120, 122 and outer walls 126, 128 create branched air flow passages 130, 132 which pass around a pair of resonator chambers 134, 136 separated by wall 138.

Cut out partition regions 140, 142 establish communication of the duct passages 130, 132 with the chambers 134, 136 which can be slotted, perforated, open, or a combination thereof, as above. Figure 11 shows another embodiment of the integrated duct- resonator component 144 which is constructed of an upper and lower injection molded shells 146, 148 friction welded together along abutting weld perimeter surfaces 150, 152.

Upper shell 146 includes a primary cover portion 154 having downwardly extending outer wall 155 and a cover extension 156 which may be used as a cosmetic or cosmetic cover for overlying other engine components.

Inner duct walls 158, 160 project downwardly from the inside of the cover. The lower shell 148 has an outer wall 162 shaped to abut the edge of the upper shell outer wall 155 to allow friction welding the same together.

Inner duct walls 164, 166 also are aligned with upper shell walls 158, 160 and welded together to define air flow duct passage 168. Ends 170, 172 are fit into semicircular contours 174, 176 in the upper shell 146.

Resonator chambers 178, 180 are defined between the outer walls 161, 162 and inner walls 164, 166, lying on either side of the duct passage 168. Cut out partition regions 182, 184 establish fluid communication between the duct passage 168 and a respective resonator chamber 180, 178. Fairing shapes 186, 188 may also be provided on either side of the cutout regions 182, 184 to smooth the air flow and avoid any sharp edges.

It can be appreciated that the invention allows multiple resonator chambers to be packaged in a minimum space by being nested together and fit to the contours of available space.

The noise attenuation device can be configured in a wide variety of ways to fit the needs of particular applications.

Claims

1 . In an automotive engine having an air induction system including an air cleaner and a throttle body for receiving air drawn into said engine, said throttle body located away from said air cleaner, the improvement comprising: an integrated duct-resonator component interconnecting said air cleaner and said throttle body; said duct-resonator component having an elongated duct portion receiving air flow and connecting said air cleaner and said throttle body, said duct-resonator component also having at least one resonator chamber forming a unitary structure with said duct portion, said duct portion having a flow passage in fluid communication with an interior space of said resonator chamber.

2. The improvement according to claim 1 wherein said duct- resonator component duct portion has said at least one resonator chamber disposed adjacent thereto at a point intermediate the length thereof, with a cutout region between the flow passage of said duct portion and the interior of said resonator chamber establishing open fluid communication therebetween.

3. The improvement according to claim 2 wherein a second resonator chamber is disposed adjacent said duct portion at a point intermediate the length thereof.

4. The improvement according to claim 3 wherein said resonator chambers have differing volumes to be tuned to different noise frequency ranges.

5. The improvement according to claim 3 wherein said resonator chambers are located on either side of said duct portion.

6. The improvement according to claim 3 wherein said duct portion includes branched sections diverging from each other at an inlet and outlet section of said duct portion, said branched sections defining an intermediate space therebetween, said resonator chambers disposed in said intermediate space.

7. The improvement according to claim 3 wherein said duct portion extends in a U shape to dispose an inlet and outlet section on the same side of said integrated duct-resonator chamber component, said resonator chambers disposed within a space defined by said U

D shape.

8. The improvement according to claim 1 further including a cosmetic cover panel integrated with said duct-resonator component and extending outward therefrom.

9. The improvement according to claim 1 wherein said duct portion includes an elbow shape, and wherein said resonator chamber lies within the space of a crook defining said elbow shape.

1 0. The improvement according to claim 9 wherein said duct portion is cut away in the crook region to establish open communication with said resonator chamber to create an expansion chamber.

1 1 . The improvement according to claim 3 wherein said duct portion has a double elbow turn shape and wherein each of said resonator chambers is disposed in a respective crook region of said double elbow shape.

1 2. The improvement according to claim 1 0 further including one or more small openings causing said resonator chamber to function as a Helmholtz resonator.

1 3. The improvement according to claim 1 wherein said fluid communication between said duct portion and said resonator chamber comprises a cut away opening causing said resonator to function as an expansion chamber.

14. The improvement according to claim 1 3 further including one or more openings causing said resonator to function as a Helmholtz resonator.

1 5. A method of providing a duct connection between an air cleaner and an intake manifold inlet of an internal combustion engine, as well as a resonator chamber for attenuating noise in an air induction system of said engine, comprising the steps of: constructing a unitary structure incorporating both a duct portion configured to direct induced air flow from said air filter to said intake manifold inlet, and a resonator chamber in fluid communication with said duct portion; and, installing said unitary structure on said engine with an inlet section of said duct portion connected to said air cleaner and an outlet section of said duct portion connected to said intake manifold inlet.