FIELD

The field of the present disclosure generally relates to filtration devices. More particularly, the field of the present disclosure relates to an apparatus and a method for an air box that exhibits a reduced resistance to an intake airstream and may be coupled with an engine control unit so as to cool the engine control unit by way of the intake airstream.

BACKGROUND

An engine control unit (ECU) is a type of electronic control unit that controls a series of actuators on an internal combustion engine to ensure optimal engine performance. The ECU receives data from a multiplicity of sensors within the engine bay, interprets the data by way of multidimensional performance maps referred to as “lookup tables,” and adjusts the engine actuators accordingly. Typically, the ECU controls the fuel mixture, ignition timing, variable cam timing, and emissions of the vehicle. In many instances, the ECU also interacts with a transmission controller, as well as many systems that are essential to operation of the engine, including an anti-lock braking system, a traction system, a stability control system, a climate control module, and an anti-theft system.

Although the electronic components inside the ECU generally are fairly robust, malfunctions may occur. For example, shorts in sensor circuits may overload and damage the ECU. In some instances, problems with voltages supplied to the ECU by a power supply or damaged ground connections may cause the ECU to malfunction. Further, corrosion, excessive heat, and vibration may also can cause harm to the ECU.

An ECU mounted within an engine by of the vehicle operates in a particularly hot and hostile environment, necessitating cooling of the ECU so as to avoid malfunction of the internal electronic components due to overheating. In addition, any heat generated within the ECU may further shorten the life of the ECU if the heat is not transferred away. Cooling of ECUs typically is achieved by way of liquid cooling, air cooling, or conduction of heat away from the ECU.

Heat conduction cooled ECUs may include a heat exchanger, commonly referred to as a “chill plate,” that is configured to support and cool the ECU. The chill plate may be comprised of a coolant chamber that receives fuel flowing from a fuel tank to the engine. The chill plate conducts heat from the ECU to the fuel flowing through the coolant chamber before the fuel is routed to the engine.

Air-cooled ECUs typically include a multiplicity of cooling fins disposed on an exterior of the ECU and configured to transfer heat from the ECU to a passing airstream. For example,FIG. 1illustrates an exemplary ECU100that is configured to be air-cooled. The ECU100is comprised of a housing104that encloses and protects electronic components within the housing. Typically, the housing104is comprised of a rigid material, such as metal, that is suitable to withstand the operating conditions within the engine bay. Sockets108facilitate electrically coupling the electronic components within the ECU100with the actuators, sensors, and systems of the vehicle. Feet112may be coupled with the housing104and configured to support the ECU100within the engine bay. In the illustrated embodiment ofFIG. 1, the feet112are disposed on a bottom surface of the ECU100. In other embodiments, however, the feet112may be disposed on any suitable surface of the ECU100, as needed. Further, multiple holes116may be disposed in the feet112, as well other locations of the housing104, to facilitate mounting the ECU100within the engine bay. As will be recognized, the holes116are configured to receive hardware fasteners for fastening the ECU100within the engine bay.

In the illustrated embodiment ofFIG. 1, the ECU100comprises a multiplicity of cooling fins120disposed on opposite side surfaces of the housing104. Thus, the ECU100may be situated in any suitable location within the engine bay whereby the airstream is directed through the multiplicity of cooling fins120and removes heat from the ECU100. Frequently, the ECU100is coupled with the engine such that the multiplicity of cooling fins120are exposed to a cooling airstream within the engine bay.

What is desired, however, is an air box that exhibits a reduced resistance to the intake airstream and may be coupled with an ECU so as to provide cooling to the ECU by way of the intake airstream.

SUMMARY

An apparatus and a method are provided for an air box configured to cool an engine control unit (ECU) by way of an airstream being communicated through an air filter to an air intake system of an internal combustion engine of a vehicle. The air box is comprised of a housing configured to support the air filter within an interior of the housing. An opening in the housing is configured to fixedly receive at least one surface of the ECU so as to place the surface into direct contact with the airstream. A mount portion is disposed within the housing and configured to receive a base of the air filter. In some embodiments, the air filter may be of a flangeless variety, and thus the mount portion may be comprised of a flat surface that receives a compressible seal disposed on the base of the air filter. A conduit comprising an opening to an interior of the air filter is configured to be coupled with the air intake system. An inlet to the housing is configured to direct the airstream from an air inlet duct of the vehicle to the interior of the housing and the air filter.

In an exemplary embodiment, an air box configured to cool an engine control unit (ECU) by way of an airstream being communicated through an air filter to an air intake system of an internal combustion engine of a vehicle comprises a housing configured to support the air filter within an interior of the housing; an opening in the housing configured to fixedly receive at least one surface of the ECU; a mount portion disposed within the housing and configured to receive an air filter; a conduit comprised of an opening to a clean side of the air filter and configured to be coupled with the air intake system; and an inlet to the housing that is configured to couple with an air inlet duct of the vehicle so as to direct the airstream into the interior of the housing.

In another exemplary embodiment, the mount portion is comprised of a flat surface that is configured to receive a seal disposed at a base of the air filter, a multiplicity of suitable fasteners being used to compress the seal and establish an airtight connection between an interior of the air filter and the mount portion. In another exemplary embodiment, the mount portion is comprised of a flange that extends into the interior of the housing and is configured to be received into an opening in a base of the air filter.

In another exemplary embodiment, the conduit is comprised of a transition and a flange that is configured to receive the air intake system, the transition comprising a molded connection between the flange and the housing. In another exemplary embodiment, the transition positions a longitudinal dimension of the flange at an offset relative to the housing, a value of the offset depending upon the particular vehicle, as well as the specific configuration of the engine, for which the ECU cooling air box is to be utilized. In another exemplary embodiment, the transition positions a longitudinal dimension of the flange at an angle relative to the housing, a value of the angle depending upon the particular vehicle, as well as the specific configuration of the engine, for which the ECU cooling air box is to be utilized.

In another exemplary embodiment, the opening comprises an edge portion that is configured to receive and place the at least one surface into direct contact with the airstream. In another exemplary embodiment, the edge portion is configured to receive a multiplicity of fasteners so as to fixedly attach the ECU to the housing. In another exemplary embodiment, a multiplicity of threaded holes are disposed in suitable locations within the edge portion to receive the multiplicity of fasteners. In another exemplary embodiment, the edge portion is configured to receive feet of the ECU, such that a portion of the at least one surface between the feet effectively encloses the interior of the housing. In another exemplary embodiment, a gasket is disposed between the at least one surface and the edge portion so as to provide an airtight coupling between housing and the ECU.

In an exemplary embodiment, a method for an air box configured to cool an engine control unit (ECU) by way of an airstream being communicated through an air filter to an air intake system of an internal combustion engine of a vehicle comprises configuring a housing that is comprised of a mount portion to support the air filter within an interior of the housing; extending a conduit from the mount portion to couple with the air intake system, the conduit comprising an opening to an interior of the air filter; forming an inlet to the interior of the housing to couple with an air inlet duct of the vehicle; and forming an opening in the housing to receive at least one surface of the ECU, such that the at least one surface substantially encloses the interior of the housing.

In another exemplary embodiment, forming an opening further comprises configuring an edge portion of the opening to receive the at least one surface, such that the at least one surface is placed into direct contact with the airstream. In another exemplary embodiment, configuring the edge portion further comprises disposing a multiplicity of threaded holes in suitable locations within the edge portion to receive a multiplicity of fasteners to fixedly attach the ECU to the housing. In another exemplary embodiment, configuring the edge portion further comprises fabricating a gasket to be disposed between the at least one surface and the edge portion to provide an airtight coupling between housing and the ECU.

