CLEANER: ASSEMBLY; COMPONENTS; SYSTEMS; AND, METHODS

This application is being filed on 26 January 2011, as a PCT

International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Michael Baseotto, a citizen of the Belgium, applicant for the designation of the US only, and claims priority to U.S. Provisional patent application Serial No.

61/299,410, filed January 29, 2010.

Field of the Disclosure

The present disclosure relates to techniques and equipment for separating water from air flow into an air cleaner for an engine system. The typical application would be to separate water from air for a combustion air intake system of a vehicle such as a truck or other equipment.

Background

Vehicles and other equipment which use internal combustion engines, such as diesel engines, are generally provided with an air cleaner assembly. The air cleaner assembly filters air to be directed into the combustion air intake for the engine. Typically, the air cleaner assembly includes a serviceable filter cartridge positioned therein, which is periodically removed and either serviced or replaced. Examples of such air cleaner assemblies include the ones described in the following publications, incorporated herein by reference: WO 2009/014982, published January 29, 2009; WO 2009/014986, published January 29, 2009; WO

2009/014988, published January 29, 2009; and U.S. 5,547,480, issued August 20, 1996.

The intake air to the air cleaner assembly sometimes includes water therein, for example rain water or street water that is splashed into the air. It is desirable to separate as much of the water as reasonably possible, from the intake air stream to the air cleaner. In this manner, damage to the engine, turbocharger and/or other components is minimized.

A variety of techniques have been developed for separating water from intake air. A example arrangement is described in the following publication, incorporated herein by reference: WO 2008/0157699, published December 24, 2008. Bi that arrangement, inlet louver configurations are used to facilitate water separation.

Improvements have been sought in water separators used for intake air to air cleaners, for vehicles or other equipment. In general, improvements are sought in features that allow for greater efficiency in water separation, less problematic inlet air flow restriction and or ease of assembly and use.

Summary

According to the present disclosure, an inlet air flow water separator assembly for use in separating liquid water from an inlet air flow to an air cleaner arrangement is provided. The air cleaner arrangement is typically configured for use in filtering inlet air, to an air intake of an internal combustion engine, for example as used on a vehicle or other equipment.

In general terms, the water separator assembly comprises an inlet assembly comprising (i.e. including) an inlet shell having a shell air flow inlet and a shell air flow outlet. The inlet shell defines a shell interior.

A vane assembly, including an interior vane arrangement, is positioned within the shell interior. In an example depicted, the interior vane arrangement includes: a vane interior defining a vane interior air flow conduit; a substantially closed side end surface to flow therethrough, oriented directed toward the shell air flow inlet; an interior vane arrangement air flow inlet positioned to receive air flow from an interior of the shell; and, an air flow outlet configured to direct air flow form the vane interior through the shell air flow outlet. The assembly further includes a water drain arrangement including a water drain outlet positioned to drain water from a location interiorly of the shell and exteriorly of the interior vane arrangement.

Also according to an aspect of the present disclosure, an assembly in which the interior vane arrangement has an outer flow surface with a water collection channel arrangement thereon, is described. The water collection channel

arrangement typically comprises at least one groove or channel on at least one side of the interior vane assembly. Some example water collection channel arrangements are depicted and described. The interior vane arrangement may include the features previously characterized, and can include advantageous features described in detail herein. Overall specific, preferred, advantageous features are described.

In addition, assemblies and/or systems involving the inlet air flow water separator assembly in combination with other features of a system, for air advantageous cleaner operation and/or engine air flow operation, are described.

Methods of assembly and use are also described.

There is no specific requirement that an assembly, system, component, feature or technique follow all of the detailed specifics characterized herein, in order to obtain some benefit according the present disclosure.

Brief Description of the Drawings

Fig. 1 is a schematic side elevational view of an assembly comprising a combination of an air cleaner assembly and an inlet air flow water separator assembly in accord with present disclosure.

Fig. 2 is a schematic, perspective, side view of an inlet air flow water separator assembly usable with an air cleaner assembly in accord with the present disclosure.

Fig. 3 is a second, schematic, perspective side view of the inlet air flow water separator assembly of Fig. 2.

Fig. 4 is a schematic, perspective, cross-sectional view of the inlet air flow water separator assembly of Figs. 2 and 3.

Fig. 5 is a schematic side cross-sectional view of the inlet air flow water separator assembly of Figs. 2-4.

Fig. 6 is a schematic exploded perspective view of the inlet air flow water separator assembly Figs. 2-5

Fig. 7 is a schematic side elevational view of a vane assembly of the inlet air flow water separator assembly of Figs. 2-6.

Fig. 8 is a schematic inlet end elevational view of the vane assembly of Fig.

7.

Fig. 9 is a schematic top plan view of the vane assembly of Figs. 7 and 8. Fig. 10 is a schematic side cross-sectional view of the vane assembly of Fig. Fig. 11 is a schematic side elevational view of an inlet shell of the inlet air flow water separator assembly of Figs. 2-6.

Fig. 12 is a schematic, closed end, elevational view of the inlet shell of Fig.

11.

Fig. 13 is a schematic top plan view of the inlet shell of Figs. 11 and 12.

Fig. 14 is a schematic elevational view of inlet louver arrangement of the air flow water separator assembly of Figs. 2-6.

Fig. 15 is a schematic side elevational view of the inlet louver arrangement of Fig. 14.

Fig. 16 is a schematic top plan view of the inlet louver arrangement of Figs.

14 and 15.

Fig. 17 is a schematic inlet end elevational view of an inlet screen of the air flow water separator assembly of Figs. 2-6.

Fig. 18 is a schematic side elevational view of the inlet screen of Fig. 17. Fig. 19 is a schematic top plan view of the inlet screen of Fig. 17.

Fig. 20 is a schematic plan view of a gasket component of the assembly of Figs. 2-6.

Fig. 21 is a schematic drawing of an engine and air flow inlet combination, including: an engine; an air cleaner assembly, including a serviceable filter cartridge therein; and, an inlet air flow water separator assembly or arrangement according to the present disclosure.

Fig. 22 is a schematic view of a vehicle having: a typical forward direction; an engine; an air cleaner assembly having a serviceable filter cartridge therein; and, an inlet air flow water separator assembly or arrangement according to the present disclosure.

Detailed Description

I. General Environment of Use

Reference numeral 1, Fig. 1, generally depicts an air cleaner assembly/air flow water separator assembly combination according to the present disclosure. Referring to Fig. 1, depicted are: an air cleaner assembly 3; an air cleaner inlet duct 4; and, an inlet air flow water separator assembly or arrangement 5. The air cleaner 3 maybe of any variety of types. Although alternatives are possible, some example air cleaner assemblies that can be used for the air cleaner assembly 3 are depicted and described for example in WO 2009/014982; WO 2009/014986; WO 2009/014988; and, U.S. 5,547,480, incorporated herein by reference. In general, the air cleaner assembly 3 includes an access cover 7 removably secured to a housing 8. Within the housing 8 is included a serviceable air filter cartridge, not depicted in Fig 1. The serviceable air filter cartridge is configured to be loaded with contaminant, such as dust, during use. Periodically, the service cover 7 is removed, and the cartridge is removed from the housing 8.

Typically, the serviceable cartridge is replaced with a new air filter cartridge, although it can be refurbished and be reinstalled. In some instances, the air cleaner 3 may include a secondary or safety filter cartridge therein, which may also be serviceable.

The air cleaner inlet duct 4 provides for direction of inlet air into air cleaner 3. The inlet duct 4 may comprise a variety of shapes, suitable to accomplish the desired air direction.

The inlet air flow water separator assembly 5 is shown positioned to direct inlet air into the inlet duct 4. The assembly 1 is depicted with a bellows conduit 10, providing air flow direction and communication between the inlet air flow water separator assembly 5 and the air cleaner inlet duct 4.

The assembly 1 can be mounted on a variety of types of equipment.

Typically, the assembly 1 would be positioned on a vehicle, such as a truck.

Referring to Fig. 1, a truck normal forward direction for a typical application is indicated by the arrow 11. Herein below, in association with Figs. 21 and 22, further discussion is provided of typical environments for use of an air flow water separator assembly 5 in accord with the present disclosure.

Example assemblies usable for the water separator assembly 5 and bellows conduit 10 are depicted in Figs. 2-6, with selected components depicted in Figs. 7- 20. These are discussed in the next section. II. An Example Water Separator Assembly Usable as Water Separator

Assembly 5

A. General Features

Attention is now directed to Fig. 2, in which an inlet air flow water separator assembly 20 is depicted in schematic view, with a bellows conduit 21 operably positioned thereon. The inlet air flow water separator assembly 20 and bellows conduit 21 can be used, for example, in the environment of Fig. 1, as the assembly 5 and bellows conduit 10.

Referring to Fig. 2, a schematic side perspective view is depicted. In Fig. 2, the inlet air flow water separator assembly 20 is oriented as would be typical for use, i.e. upper portions of Fig. 2 would generally be directed upwardly and flow into (and in the example shown out of) bellows conduit 21 would, as shown at arrow 2 Id, generally be directed downwardly. Alternate configurations are possible with applications of selected principles according to the present disclosure; however the orientation of Fig. 2 is typical.

Still referring to Fig. 2, the water separator assembly 20 includes: an air inlet assembly 22 comprising an inlet shell 23; the inlet shell 23 having (defining) a shell air flow inlet 25 and a shell air flow outlet 26. The inlet shell 23 has a top 23t and first and second, opposite, sides 27, 28. The shell 23 further includes a closed end 23e, opposite the inlet 25 and extending between the sides 27, 28. In use, side 27 is typically oriented in the direction of movement of a vehicle (to which assembly 20 is mounted in use) i.e. toward a typical forward direction. A typical shell 23, as depicted, has a longer dimension (axis) directed vertically, in use.

Still referring to Fig. 2, the air flow inlet water separator assembly 20 optionally includes a plurality of mounts 29. In the example depicted, each mount 29 includes an aperture 29x thereon. The mounts 29 provide locations whereby the assembly 20 can be secured by fasteners, for example bolts, to a framepiece or other structural support piece, securing the assembly 20 to the vehicle or other equipment with which it used. A typical mounting approach would be with fasteners such as bolts extending through the apertures 29x, although alternative mounting and fastening arrangements can be used. In the example depicted, selected ones 23 s of the mounts 23 are on the shell 23. The shell air flow inlet 25 defines an air flow aperture by which air flow enters the air flow water separator assembly 20. The air flow entering water separator assembly 20 through the shell air flow inlet 25 is, in due course, directed as inlet air into air cleaner 3, Fig.l, for use. Thus, the shell air flow inlet 25 defines an air flow inlet 30 to assembly 20. In a typical example assembly, such as the one depicted in Fig. 2, the shell air flow inlet 25 is oriented with a longer dimension vertically in use, and a shorter (width) dimension positioned generally horizontally. Alternatives are possible.

The particular inlet air flow water separator assembly 20 depicted includes (optionally and preferably) an inlet louver arrangement 32 positioned in the shell 23, i.e. in shell inlet 25 in extension across assembly inlet 30. The inlet louver arrangement 32 includes a plurality of spaced louvers 33 oriented in extension across inlet 30 (and shell inlet 25). The louvers 33 each include an outer or upstream (i.e. forward or front) edge 34. The louvers 33 are optionally and preferably positioned so that outer or upstream (forward or front) edges 34 extend both: horizontally across some or all of inlet 30 in a direction between sides 27, 28; and, slanted upwardly (i.e. toward top 23t and away from bellows 21) in extension from a direction toward side 27 to a direction toward side 28. Performance features associated with this direction of extension of louvers 33 are discussed herein below, in connection with Figs. 21 and 22.

In general, each louver 33 includes an upper, outer, surface 33u and an opposite lower, inner, surface 331. The upper surfaces 33u are generally directed upwardly and, in the example depicted, outwardly. The lower surfaces 331 are generally directed downwardly and in the example depicted, inwardly. Thus, louvers 33 are positioned so that the upper surfaces 33u are generally directed away from an interior 23i of the shell 23; and, so that the lower surfaces 331 are directed interiorly of the shell 23.

In operation, air passes through louver arrangement 32 at inlet 30, and is directed into an interior 20i of water separator assembly 20, i.e. interiorly of shell 23. As this occurs, a portion of water carried by the air can collect on the louvers 33 and drain exteriorly under gravity influence, away from entering into water separator assembly 20. This is, in operation, generally facilitated by the direction the individual louvers 33 extend, relative to a direction of forward motion of a vehicle on which the assembly 20 is used. In general terms, the inlet louver arrangement 32 can be characterized herein as a "water-separating inlet louver arrangement," since it does provide for some water separation. However, a significant portion of water separation by the water separator assembly 20, is conducted by structure interiorly of shell 25, as described below.

The inlet air flow water separator assembly 20 (optionally and preferably) includes an inlet screen 40 therein. The inlet screen 40 is positioned to extend across inlet 30 and shell air flow inlet 25, such that air entering into interior 20i of water separator 20 (and interior 33i of shell 23) must pass through the inlet screen 40. The inlet screen 40, discussed in more detail below in connection with Figs. 17- 19, generally comprises a structure or parcel having air flow apertures therethrough, through which air flow is directed.

In general, the inlet screen 40 inhibits large matter, such as cigarettes, leaves, insects and, floating debris, from entering interior 20i of water separator 20 (and thus interior 23i of shell 23). The inlet screen 40 is positioned interiorly of, i.e. downstream from, louver arrangement 32.

Together, the inlet shell 23, louver arrangement 32 and inlet screen 40 can be characterized herein as the air flow inlet assembly 22 for the water separator assembly 20.

In Fig. 3, a perspective view of the assembly 20 is depicted, analogous to Fig. 2, but toward side 27. Selected features previously characterized, are numbered analogously. It is again noted that in the example depicted, side 27 is configured to be positioned against an equipment frame arrangement, on which the assembly 20 is secured in use. A typical use would be with side 27 mounted against a rear of a cab of a vehicle, although alternatives are possible. To facilitate mounting, in the example depicted side 27 is relatively flat.

Attention is now directed to Fig. 4. Fig. 4 is a schematic, perspective, cross- sectional view of water separator assembly 20 and bellows conduit 21, depicted oriented analogously to Fig. 2. In Fig. 4, inlet assembly 22 comprising: inlet shell 23, louver arrangement 32 and inlet screen 40 can be seen. Positioned interiorly of inlet assembly 22 is provided an inlet volume or space 48 positioned inside of (i.e. between) sidewalls 27 and 28 and in interior 23i of shell 23. Inlet volume or space 48 is defined exteriorly of vane assembly 50, discussed below. The inlet volume or space 48 includes, in a bottom 48x thereof, a water drain arrangement 52. Water drain arrangement 52 includes water drain outlet 52a through bottom 48x, in the example depicted having an evacuator valve assembly 53 mounted thereover. The evacuator valve assembly 53 can have a variety of configurations known for water evacuator assemblies in the prior art. The particular water evacuator valve 53 depicted, comprises a duck billed valve 53v having a slit 53x in a lower end portion thereof. In general, water in interior volume or space 48 will drain to bottom 48x under gravity influence and then through drain outlet 52a, to valve member 53, by which it can be ejected from assembly 20. In the assembly depicted, valve member 53 is mounted on a lower, downwardly projecting, drain tube 52t.

Attention is now directed to Fig. 5, a schematic cross-sectional view generally analogous to Fig. 4, in which components previously described can be observed. Again, drain 52 and evacuation valve 53 are viewable.

Attention is now directed to Fig. 6, a schematic, exploded perspective view of the assembly 20 and the bellows conduit 21. In Fig. 6, inlet assembly 22 can be seen comprising: inlet shell 23; louver arrangement 32; and inlet screen 40.

As explained above, shell 23 defines an open inlet 25, for air flow into shell interior 23i. Over (across) inlet 25, louver arrangement 32 and screen 40 are positioned. Referring to Fig. 6, a gasket 60 is depicted. The gasket 60 provides for a weather seal and vibration dampening between adjacent components, i.e. between the screen 40 and shell 23. In Fig. 6 selected fasteners 61 are viewable.

Still referring to Fig. 6, shell 23 also includes a bottom opening 26, opposite top 23t. The bottom opening 26 is sized, positioned and configured, to receive projecting therein, vane assembly 50 when water separator assembly 20 is assembled.

In general, it is noted that the bottom opening 26, when fit over internal structures described below, surrounds and defines an air flow outlet from shell 23. In general terms, the shell 23 can be characterized as having the inlet 25 and outlet 26 oriented laterally with respect to one another. The term "laterally" when used in this manner, is meant broadly to indicate that the air flow direction through the inlet 25 and the outlet 26 is not generally in the same direction. Typically, in general, air flow through the outlet 26 will be at approximately 90° relative to the inlet. Also, typically, the air flow through the outlet 26 will be directed downwardly.

Referring to Fig. 6, vane assembly 50 is positioned on lower duct member 62. The duct member 62 surrounds and defines a conduit having an open interior for air flow passage therethrough. The duct member 62 includes an air flow exit end 63. In assembly, bellows conduit 21 is mounted over air flow exit end 61, to receive, from duct member 62, air to be directed into inlet duct 4, Fig. 1. Thus, duct member 62, via vane assembly 50, receives air flow passing through outlet end 26 of shell 23 and directs the air flow into bellows conduit 21.

It is noted, referring to Fig. 6, that lower duct member 62 includes selected ones 29z of mounts 29 thereon.

Still referring to Fig. 6, vane assembly 50 includes an interior vane arrangement 65 having a front (or side) end 65 e with a surface 65 s generally directed toward the shell air flow inlet 25, when water separator assembly 20 is assembled. In addition, interior vane arrangement 65 includes an interior arrangement air flow inlet 65z.

In general, the interior vane arrangement 65 defines an interior 65i, configured to receive air flow therein, from interior 23 i of shell 23. Further, interior vane arrangement 65 is configured to direct air within interior 23i to exit end 63 of duct arrangement 62. The particular interior vane arrangement 65 depicted, is positioned with interior vane arrangement air flow inlet 65z generally directed in a direction opposite from (i.e. away from) side end 65e and shell inlet 25. Typically, the closest part of inlet 65z to inlet 25 is spaced at least 40 mm therefrom, typically at least 60 mm and often further.

In general terms, the interior vane arrangement 65 depicted includes first and second, opposite, sides or side sections 65x, 65y, which generally extend in a direction away from front (or side) end 65e and also in a direction away from shell inlet 25.

Typically, surface 65s, i.e. end 65e, is substantially closed to air flow therethrough. By the term "substantially closed" in this and similar context, it is meant that the referenced or feature surface is either completely imperforate, or if it includes any aperture therein, the aperture is sufficiently small so that little, if any, air passage therethrough occurs in use. In a typical preferred application, end 65e, i.e. surface 65s, is completely closed to passage of air therethrough. Also, typically surface 65s, i.e. end 65e, is curved, for example around a horizontal radius within the range of 20-60 mm, inclusive, although alternatives are possible. The radius of curvature of surface 65s (i.e. of end 65e) can taper downwardly, as it extends upwardly. Opposite sides 65x, 65y are also typically closed with respect to entry of air therethrough, into interior 65i of vane 65 (by which the air can pass into lower duct arrangement 62). Typically, surfaces 65x, 65y are completely closed to such passage.

Referring to Fig. 6, for the particular example arrangement depicted, the air flow inlet 65z of the interior vane arrangement 65 is defined by: rear edges 65o of side sections 65x, 65y and rear edge 65tr of top end 65t. Further, lower end 65zl of inlet 65z is defined by a portion of base 65b of interior vane arrangement 65. Top 65t is typically substantially closed, usually completely closed.

Typically, the top 65 e has a perimeter which defines an area of at least 5 sq. cm, typically at least 10 sq. cm and often within the range of 10 to 50 sq. cm, although alternatives are possible.

In general terms, air flow inlet 65z can be characterized as defined directed upwardly and rearwardly away from both of and 65e and shell inlet 25. There is no specific requirement that a perimeter 65p of inlet 65y define a generally planar definition. However, when perimeter 65p is approximately planar, its planar extension can be said to be typically at an angle X, Fig. 7, relative to the horizontal, of at least 45°, typically not more than 85°, and often within the range of 60° to 80°, inclusive.

Still referring to Fig. 6, it is noted that perimeter 65p around inlet 65z is defined in part by a collar 65c, which projects radially outwardly, i.e. away from sides 65x, 65y, base 65b and top 65t in extension around inlet 65z. Alternately stated, the collar 65c projects in a direction generally perpendicular to air flow from (and through) inlet 25. The collar 65c inhibits water which collects on sides 65x, 65y, top 65t or elsewhere on vane 65, from being drawn by air flow into inlet 65z. Thus, the collar 65c is typically closed and continuous. The collar will typically extend outwardly relative to adjacent portions of vane arrangement at least 2 mm, often more.

Referring again to Fig. 6, side 65x includes artifact grooves or channels 70 therein. The channels or grooves 70 are artifacts, from formation of preferred interior flow directors discussed below. It can be understood there can be analogous channels or grooves, typically, in the opposite side 65y. It is also noted that the channels or grooves 70 operate as water collection channels, for a water collection channel arrangement discussed below. Still referring to Fig. 6, side 65x includes an optional spacer 71 thereon, to provide for spacing against a portion of shell 23, during assembly.

From a review of Figs. 2-6, general operation of inlet air flow water separator assembly 20 will be understood. In operation, air flow will enter shell inlet 25 and pass through louver arrangement 32. A portion of any liquid water carried in the air, will be collected on the louvers 33 of louver arrangement 32, and drain outwardly from the assembly 20. The air will be directed generally into, and through, inlet screen 40. Having passed through the inlet screen 40, the air and any carried water, will enter shell interior 23i. The air will be directed by the interior vane arrangement 65 around sides 65x, 65y (and to some extent over top 65t), over collar 65c and into inlet 65z at edge 65p. Water collecting on an exterior surface of interior vane arrangement 65 and/or on inner surface 25x of the shell 25 can drain downwardly to water flow trough arrangement 75, Fig 4. This water can drain then to water drain arrangement 52, through outlet 52a and valve 53, and then outwardly from separator assembly 20.

In general terms, the water flow trough arrangement 75, Fig. 4, is a trough surrounding at least partially around the vane 65 adjacent a base 65b thereof, between the vane 65 and the shell 23. The trough 75, in the example depicted, completely surrounds the vane 65, in water flow communication with the water drain arrangement 52.

Referring again to Fig. 6, at edge 65p, and upon passing into inlet 65i, the air will pass into interior 65 i of interior vane arrangement 65. From there, the air is directed into duct section 60.

Thus, some general observations about air flow through air flow water separator assembly 20 can be observed. First, air flow into the inlet interior of shell 23 is generally directed outwardly from the shell 23 in a lateral direction relative to inlet flow, and typically at about a 90° direction to the inlet 25 of shell 23. Further, the air flow into interior 65i of inlet vane arrangement 65 is generally in a direction opposite to air flow entrance into shell inlet 25. By this it is not meant that the air necessarily makes a full 180° turn, but rather that the general direction entrance 65z face is 180° opposite inlet 25. The air, of course, may make less than a 180° turn relative to the inlet direction, given the example arrangement where the perimeter 65p of inlet 65z, is slanted upwardly. Referring to Fig. 4, internal vane arrangement 65 includes within interior 65i a director vane arrangement including a plurality of air flow director vanes 80 configured to help direct air flow interiorly and downwardly. In general terms, the air flow director vanes 80 can be characterized as positioned in interior 65i of the interior vane arrangement 65 in extension between the first and second, opposite, sides 65x, 65y. Typically, the director vane arrangement includes at least first and second director vanes 80, but can include more than that. Also, at least a selected one, typically at least two, of the director vanes 80 include an arcuate section 80r directing air flow within the interior 65i of the inlet vane arrangement 65, from an inlet direction toward an outlet direction. Referring to Fig. 10, a cross-sectional view of the interior vane arrangement 65, vanes 80 can be seen, each having an arcuate section 80r.

B. A Water Collection Channel Arrangement

It is noted that in preferred applications, according to the present disclosure, the water separator assembly includes a water collection channel arrangement, as described herein. Referring to Fig. 6, in general terms, the water collection channel arrangement is positioned on an outer flow surface of the vane arrangement 65. In particular, the inlet vane arrangement 65 as characterized, has as opposite sides 65x, 65y. Outer surfaces of the sides 65x, 65y, comprise flow surfaces or air flow surfaces, of the inlet vane arrangement 65.

At least one of the sides, for example 65x, includes a water collection channel arrangement thereon. Typically, a water collection channel arrangement is provided on each of the sides 65x, 65y.

The water collection channel arrangement comprises at least one groove or channel in the flow surface, typically a plurality of grooves or channels in the flow surface, and in the example shown, a plurality of collection grooves or channels in each of the sides 65x, 65y, in communication with the flow surface thereof. The channels, indicated at 70, Fig. 6, are grooves in the flow surface. As water is collected on the flow surface, and is pushed toward the inlet 65z by air flow over the surface, the collected water will tend to be pushed into the grooves 70.

The grooves 70 each have a substantial extent of vertical extension. At least one of the grooves 70, for example, typically has a total vertical extension, i.e. total vertical distance from the upper most end to lower most end, of at least 300 mm, typically at least 350 mm, for example 400-700 mm; and, overall length which can be somewhat more, for example on the order of at least 320 mm, typically at least 370 mm, and often 420-720 mm, although alternatives are possible. In the example depicted, at least one, and typically a plurality, the channels 70 includes an arcuate section therein. Also, typically the channels 70 are continuous in extension between opposite ends.

Typically, at least two of the grooves are at least 250 mm long, and have a total vertical extension of at least 200 mm.

Typically, at least three of the grooves are at least 100 mm long, and have a total vertical extension of at least 150 mm.

Typically, at least two, and typically at least three, of the grooves 70 are at least partially in flow alignment, in direction across a surface of 65 of end 65e toward inlet 65z, in a direction parallel to base 65b. By this, it is meant that preferably at least two, and typically at least three of the grooves 70 are aligned so that a line can be drawn through two of them and typically at least three of them, which line is perpendicular to a vertical extension of vane 65, in use. In the example depicted in Fig. 6, three such grooves 70, i.e. the lower three, are positioned in this manner.

In the example depicted, a lower most three of the channels 70, Fig. 6, are depicted extending from a location adjacent the inlet 65z to a location adjacent the base 65b. Further, the upper most end of these three areas of channel 70 can be said to begin adjacent the collar 65c, on the side of the collar 65c away from the inlet 65z. (Similarly, an uppermost one of channel or groove 70 terminate adjacent collar 65c).

It has been found that the groove or channels 70 facilitate water collection and drainage. Again, as air flows across the associated flow surface, water will tend to collect and drain into the channels 70. The channels are closed, and thus the water cannot pass into interior 65i. Under gravity influence, water within the channels 70, tends to drain downwardly toward a lower end of the channels, from which it can flow into the trough arrangement 75, Fig. 4, to eventually drain to the water drain outlet 48.

When the inlet vane 65 is implemented with opposite flow sides 65x, 65y, it will typically be preferred that there is at least one water collection channel, and typically a plurality of water collection channels, in each of the opposite sides, i.e. in a flow surface of each side. Typically each groove is continuous, and is at least 3 mm deep, although it may be substantially deeper, for example 5 mm or more. Typically, each side includes at least one channel that is at least 320 mm long and extends over a vertical distance of the 300 mm. Typically, each side includes at least three channels that are at least 150 mm long and extend over a vertical distance of 100 mm.

C. Example Component Features 1. Example Detail of the Interior Vane Arrangement 65, Figs. 7-10

In Figs. 7-10, the interior vane arrangement 65 is depicted, separated from shell 23, and bellows conduit 21. Referring first to Fig. 7, a side elevational view directed towards side 65x is provided. Groove artifacts 70 can be seen. Also, viewable in base conduit 60 is a groove artifact 85 discussed below.

In Fig. 8, an end (or edge) elevational view of interior vane arrangement 65 is provided, taken toward air flow inlet 65z. Interior 65i is viewable. Within interior 65 are viewable director vanes 80. Referring to Figs. 7 and 8, the vanes 80, in the example arrangement depicted, are selected and positioned to divide air flow through interior 65i into four (about equal) fractions. Alternatives are possible.

The interior vane arrangement 65 can be formed in a variety of mariners. An example typical arrangement, would be to have formed shell 65 in two side pieces, indicated generally in Fig. 8 at A and B, which can be secured to one another. The bottom conduit 62 can also be formed in halves, as parts of the side pieces A and B. An example would be to mold the two sides A, B from plastic of appropriate structural integrity for the use intended, and then to secure the two sides together with adhesive, sonic welding, etc.

Still referring to Figs. 7 and 8, it is noted that the bottom conduit or duct member 62 includes, adjacent end 63, an adapter 89 including groove 89g. The adapter 89 is configured to facilitate attachment of bellows conduit 21, Fig. 6. Referring to Fig. 6, a gasket ring 90 is depicted oriented and positioned between duct 60 and bellows conduit 21. It is noted that a snap-fit connection can be used between bellows 21 and adapter 89. However, if desired, a band or clamp can be provided at this location. In Fig. 9, a top plan view of vane arrangement 50 is provided. It can be seen that side 65x is (optionally) designed at least in part to aerodynamic principles.

More specifically, in extension away from first end or edge 65e and toward upper end 65t, side 65x tapers toward side 65y. In general, surface 65x is a flow surface which will have a large amount of air passing thereover. Contoured shaping to surface 65x is selected to facilitate air flow. Side 65y, on the other hand is relatively flat, and is configured to match a shaping of an analogous surface in shell 23.

In general terms, the example interior vane 63 depicted, can, in part, be viewed as a wing, for example an airplane wing, directed upwardly. It has a relatively blunt front end 65e first engaged by air flow. One surface 65x is contoured similarly to an upper surface of wing, tapering downwardly toward a tip corresponding to end 65t. An opposite surface 65x however, is more generally planar. Of course, unlike a wing, collar 65c to provided around an end of the structure, adjacent inlet 65z and grooves 70 are provided.

Bi Fig. 10, a cross-sectional view of vane arrangement 65 is depicted. Here, internal flow directors 80, are shown in cross-section, each with its arcuate section 80r. Also depicted is flow director vane 85x which directs flow in base conduit 62.

Again, vanes 80 and 85x are flow directors, to facilitate air flow entering inlet 65y to be turned and directed downwardly through duct 62 to end 63.

2. Shell 23; Figs. 11-13

In Figs. 11-13, shell 23 is viewable. The shell 23 can be molded plastic, as a single piece. It can also be formed in halves, secured to one another appropriately.

In Fig. 11, a side elevational view of shell 23 is viewable. The view is generally taken toward side 28. In Fig. 12, a view taken toward end 23e is viewable. In Fig. 13, a top plan taken toward top 23t is viewable.

3. Louvre Arrangement 32, Figs. 14-16

Attention is now directed to Figs. 14-16, in which the inlet 30 and louver arrangement 32 are depicted as a single assembly 100. It is noted that that the assembly 100 can be formed as a single molded plastic piece. The assembly 100 depicted comprises a peripheral frame 101 across which individual louvers 33 of the louver assembly 32 extend. The frame 100 also includes an edge lip 102 which surrounds and defines inlet 30. Arrangement 100 includes a plurality of mounting members 105 thereon, to which fasteners can be connected in order: to secure screen 40 in place, Fig. 6; and, to secure the assembly 100 to shell 23 4. Screen Arrangement 40, Figs. 17-19; Gasket, Fig. 20

In Figs. 17-19 inlet screen 40 is shown depicted. Referring to Fig. 17, the inlet screen 40 comprises an outer rim 40r surrounding an interior 40i. Within interior 40i, the screen arrangement 40 comprises screen sections 40s. The screen sections 40s, for the example depicted, are perforate (perforated) plastic sections. The screen 40 can be a single, integral, plastic molded piece. In Fig. 17, only one section 40t is depicted drawn with perforations, for simplicity. The others of sections 40s would typically be similar.

In Fig. 17, a view of inlet screen 40 is taken generally toward an inlet side 40x thereof. This is the side that would face incoming air to assembly 20.

In Fig. 18, a side elevational view of inlet screen 40 is viewable. In Fig. 19, a top plan perspective view of inlet screen 40 is viewable.

From the following example dimensions of the screen 40, a general understanding of a typical embodiment is facilitated. Typically, the screen will be on the order of 950 mm high and about 130 mm wide. (Typically, the shell 23 will be about 500 mm deep in direction inwardly from shell inlet 25).

The example dimensions serve to indicate that typically the vertical dimension of the inlet 25 and shell 23 will be at least 2 times as high as the width dimension of the inlet 25, often at least 3 times as high and sometimes 4-10 times as high.

In Fig. 20, optional gasket member 60 is viewable. The gasket member 60 can be, for example an EPDM gasket. It can be understood by reference to Fig. 6, to assemble inlet assembly 45, screen 40 is placed against, and partially projecting into, member 100. Fasteners can provide for secure connections. This assembly, along with gasket 60, can then be positioned on shell 23, again with fasteners. III. Some General Features and Characteristics of Assembly Use and

Operations

A. An Example Engine Air Flow Inlet Arrangement, Fig. 21.

In Fig. 21 , a schematic depiction of a typical engine air flow inlet arrangement which uses an inlet air flow separator assembly in accord with the descriptions above is indicated schematically. Referring to Fig. 21, at 200 an engine system is depicted. The engine system 200 can generally comprise, for example, an internal combustion engine, such as a diesel engine. The engine system 200 includes an air flow inlet 201 through which combustion air is directed into the engine system 200.

Referring to Fig. 21, the system depicted includes an air cleaner arrangement 205 having an interior 205i with a serviceable filter cartridge 206 positioned therein. Typically in operation, the air cleaner 205 is configured so that air directed to inlet 207 thereof is directed through air filter cartridge 206 before it leaves the air cleaner 205 through outlet 208; the filtered air from outlet 208 being directed to inlet 201 for engine system 200.

Air direction to the inlet 207 for the air cleaner 205 is shown at line 210. This line 210 can, for example, comprise bellows conduit 10 and duct 4, Fig. 1. The air is directed from an air flow water separator assembly 220 which can be generally in accord with the descriptions herein. Air inlet flow to water separator assembly 220 is depicted at arrow 221. In general, the described lateral relationship between air inlet flow 221 to separator assembly 220 and air outlet flow 210 from separator assembly 220 can be seen. At 223, water drainage from separator assembly 220 is shown.

B. Example Environment of Use, Fig. 22

Air flow inlet water separator assemblies in accord with the present disclosure, are typically configured to be used on vehicles. In Fig. 22,

schematically, a typical environment of use is depicted. Referring to Fig. 22, a vehicle 300 is depicted having a cab 301 and a cargo section 302. The vehicle 300 would typically include an engine system 200, for example under the cab 301.

Behind the cab 301 is positioned: air cleaner assembly 305 and an inlet air flow water separator 306. The air cleaner 305 and air flow inlet water separator assembly 306 are generally positioned analogously to air cleaner 3 and water separator assembly 5, Fig. 1. The particular water separator assembly 306 depicted can be analogous to water separator assembly 20, Fig. 2. When such is the case, the louvers 32 are generally configured to extend upwardly and rearwardly in a direction from the cab 301 toward the cargo section 302, i.e. upwardly and rearwardly with respect to a general direction 310 of vehicle movement forward, in typical use.

Direction of the louver upwardly and away from the general direction of vehicle movement forward, is to select for performance advantage. In particular, air draw into the separator assembly 306 is generally laterally with respect to truck movement, and due to the louver position, upwardly and forwardly with respect to vehicle movement. Thus, the vehicle movement does not cause a "ram" of air into the water separator assembly 306. Rather, the water separator assembly 306 is generally operated under air draw provided by operation of the engine 200. C. Some General Features and Principles of Typical, Preferred, System in Accord with the Present Disclosure

An air flow inlet water separator arrangement in accord with the present disclosure is typically used on a vehicle such a truck. Such a vehicle would, typically have a diesel engine system, having a rated air flow within the range of about 300 cu. ft. per minute (8.5 cu. meters/min) to 1500 cu.ft./minute (42.5 cu. meters/minute), although alternatives are possible. In this context, the term "rated air flow" is meant to refer to inlet air flow to the engine, under conditions of operating rpm at full load.

The inlet air flow separator arrangement depicted in Figs. 2-6, is configured, when specific preferred features depicted are used, so that in operation the forward motion of the vehicle is not directly used to facilitate a water separation. In this manner, the air flow separator arrangement 20 differs from some arrangements that are common, that use air/water flow momentum and vehicle movement, to facilitate separation. In particular, some air inlet flow water separators are oriented to receive air directed to an inlet face therein; which inlet face is toward the direction of vehicle movement. Thus, as the vehicle moves forwardly air is pushed (rammed) into the inlet. When this air carries water, the water is forced against a back wall of the separator, where it collects and drains downwardly and typically through an outlet provided in the back wall. Such arrangements require vehicle movement, for efficient water separation. The preferred air inlet water separator arrangement according to the present disclosure does not rely, in this manner, on vehicle movement, to accomplish water separation.

Rather, water separator arrangement in accord with the preferred features characterized herein above, as depicted in Figs. 1-6 relies on engine draw of air, for operation and separation. The air flow inlet direction into the air inlet water separator arrangement is generally laterally to, or at least not facing the direction of, vehicle movement, when in the forward direction. Indeed, when configured as described, the inlet louver arrangement 32 actually directs the inlet air not only laterally, but upwardly and somewhat forwardly in the direction of vehicle movement.

It is also noted that the arrangement described does not rely on exotic louver definitions, with catchers or other features, to facilitate separation. While such features can be used, there is not a reliance upon such features with the present disclosure, as there is with arrangements in accord with WO 2008/157659.

IV. Summary of Features and Principles

According to the present disclosure, an inlet air flow water separator assembly is provided. The inlet air flow water separator assembly is configured for use in separating liquid water from an inlet air flow to an air cleaner arrangement, for example for inlet combustion air. The inlet air flow water separator assembly (sometimes "water separator assembly") generally comprises an inlet assembly comprising an inlet shell having a shell air flow inlet and a shell air flow outlet. The shell defines a shell interior. In a typical application, the shell is configured so that a lateral flow relationship is provided between the shell air flow inlet and share air flow outlet. By "lateral flow relationship" and similar terms used herein, it is meant that the shell air flow inlet and shell air flow outlet are not oriented for direction of air therethrough, in the same direction. Rather, the air must make a turn within the interior of shell, in moving from the shell air flow inlet to the shell air flow outlet. Typically, the turn is configured so that the inlet direction and outlet direction of air flow, with respect to the shell, are about 90° to one another. In a typical

arrangement, in use, the outlet flow direction is generally downwardly. The typical inlet air flow water separator assembly includes a vane assembly including an interior vane arrangement positioned within an interior of the shell. Typically the interior vane arrangement includes: a vane interior defining an interior vane arrangement air flow conduit; and, a substantially closed side end (or edge) surface, oriented directed toward the shell air flow inlet. By the term "substantially closed" in this context, it is meant that the identified surface is configured not to allow a substantial amount of air flow therethrough, but rather is closed to such flow. In a typical application, such a surface will be completely closed to air flow therethrough.

In general terms, the interior vane arrangement includes an air flow inlet, positioned to receive air flow from an interior of the shell and to direct it into the vane interior. Further, the interior vane arrangement includes an air flow outlet configured to direct air flow from the vane interior through the shell air flow outlet.

In an example arrangement described, the air flow inlet of the interior vane arrangement is surrounded by the radially outwardly projecting collar, which inhibits water collected on an exterior of the vane arrangement, from reaching the vane interior.

In general terms, a typical inlet air flow water separator assembly in accord with the present disclosure, includes a water drain arrangement. The water drain arrangement includes a water drain outlet positioned to drain water from a location interiorly of the shell (i.e. from the shell interior) and exteriorly of the interior vane arrangement. The water drain outlet, then, serves to drain water that enters the shell, but does not enter the inlet vane arrangement, from the air flow water separator assembly. The water drain outlet is typically covered by an ejector valve or valve arrangement.

In general operation, then, a typical preferred air flow inlet water separator arrangement according to the present disclosure operates with air flow entering an outer shell, through an outer shell air flow inlet. The air is directed around an exterior of an inlet vane arrangement, to then enter an interior of the inlet vane arrangement, (typically with air flow over a collar around an entrance to the interior) which interior has an inlet directed in a direction generally opposite to the air flow inlet to the shell (i.e. generally away from the shell air flow inlet). Within the interior of the vane arrangement, the air is then directed downwardly and outwardly from the air flow water separation arrangement. Water collects within the shell and exteriorly to the interior vane arrangement. This water drains to a water drain arrangement, by which it is removed form an interior of an air flow water separator arrangement.

There is no requirement that an air flow water separator arrangement to include all of the features characterized herein. However, advantageous features are characterized in the figures and description.

Typically, the inlet air flow water separator assembly or arrangement includes, as the interior vane arrangement, a vane arrangement configured with the interior vane arrangement air flow inlet facing a direction opposite the shell air flow inlet. Further, the interior vane arrangement depicted has an inlet thereof directed slanted upwardly, when the air flow inlet water separator assembly is configured and positioned for use. Typically, an inlet plane defined by the inlet to the interior vane arrangement is directed upwardly at an angle, to the horizontal, of at least 45° and not more than 85°, and often within the range of 60°-80°, inclusive, in use, i.e. when the flow separator arrangement is positioned for use.

In a typical arrangement, the interior vane arrangement includes first and second opposite side sections (surfaces or sides) with a substantially closed front end surface extending therebetween. Typically, the front end surface is completely closed. The first and second, opposite, side sections each direct away from the front end surface in a direction also away from the shell air flow inlet; and, the first and second, opposite, side sections define an air flow conduit therebetween, in the interior vane arrangement. The side sections are preferably substantially closed to air flow therethrough, typically completely closed. A water channel collection arrangement, for example channels or grooves, can be positioned on one or more of the side sections.

The inlet air flow water separator assembly depicted, includes a director vane arrangement positioned in the interior vane arrangement air flow conduit. The director vane arrangement includes a plurality of director vanes, typically at least first and second director vanes positioned in the interior vane arrangement air flow conduit and in extension between the first and second, opposite side sections. Each one of the first and second director vanes includes an arcuate section directing air flow within the inlet vane arrangement air flow conduit section, from an inlet duration toward an outlet direction; the outlet direction typically being downwardly. In an example arrangement depicted, the interior vane arrangement includes a substantially closed top end. In the specific example depicted, the top end is completely closed to air flow therethrough.

In an example arrangement depicted, the interior vane assembly is positioned to define air flow passage therearound, i.e. around opposite sides thereof, within the shell interior.

In the example depicted, the interior vane assembly includes a base portion within the shell interior and the water drain arrangement includes a water flow trough arrangement adjacent the base portion of the interior vane assembly (and exterior to the interior vane assembly) in an interior of the shell. Water flow trough arrangement is configured and positioned to direct collected water to flow between the interior vane arrangement and the shell to the water drain outlet. Typically, the water flow through arrangement extends completely, or at least nearly completely, around the interior vane arrangement.

In an example depicted, an air flow inlet screen is positioned across the shell air flow inlet. The screen, for example, can comprise a perforate panel.

In an example depicted, a louver arrangement is positioned across the shell air flow inlet. The example louver arrangement depicted comprises a plurality of spaced louvers extending across the shell air flow inlet; the shell air flow inlet having first and second, opposite, sides and top; and, each louver having a forward (front) edge extending between the opposite sides. In an example depicted, each louver not only extends between the opposite sides, but has a forward (front) edge extending generally upwardly in extension between the first and second, opposite, sides of the shell air flow inlet.

In an example assembly depicted, the louver arrangement comprises a plurality of spaced louvers extending across a louver frame. The louver frame is sized and configured to be secured the shell, at an inlet thereof.

A typical assembly includes both an air flow inlet screen and a louver arrangement, as characterized, with the air flow inlet screen being positioned interiorly of, i.e. downstream from, the louver arrangement. By the term

"downstream" in this (typical) context, reference is meant to a direction of airflow through the componentry referenced, in typical use.

Also, according to the present disclosure, inlet air flow water separator assembly is described, which includes an inlet shell having a shell air flow inlet and an shell air flow outlet, the inlet shell defining a shell interior; and, a vane assembly including an interior vane arrangement positioned within the shell interior and including an outer flow surface with the water collection channel arrangement thereon. A water drain arrangement including water drain outlet is positioned to drain water from a location interiorly of the shell and exteriorly of the interior vane arrangement. The features of the vane arrangement and inlet shell, can be generally as characterized above.

Typically, the interior vane assembly has at least a first side with a portion of the air flow surface thereon; and, the water collection channel comprises at least one channel on the first side. The interior vane assembly may have first and second sides, and the water collection channel arrangement may include at least one channel in each of the first and second sides. In an example depicted, at least two channels are positioned on each side, typically, 2-5 channels on each side.

The water collection channel arrangement generally includes at least one channel having: a total length of at least 320 mm; and, a total vertical extension of at least 300.

Typically, the channels are closed and each has a depth of at least 5 mm, typically greater than 10 mm, although alternatives are possible.

Typically the at least one channel having a length of at least 320 mm and a total vertical extension of at least 300 mm, also includes an arcuate section therein. Typically at least two channels in each side have an arcuate section.

Also according to the present disclosure, an engine air flow inlet

arrangement is provided. The inlet arrangement includes an inlet air water separator assembly, generally in accord with the characterizations above; and, an air cleaner. Further, an air flow conduit is included, providing air flow from the inlet air flow water separator assembly to the air cleaner. The air cleaner typically includes a housing with a serviceable air filter cartridge positioned therein. In a typical arrangement, the air cleaner housing is positioned lower on equipment with which the inlet air flow water separator assembly is used, than the inlet air flow water separator assembly. Typically it is at least 6 inches (15.2 cm) lower than an inlet to the air flow water separator assembly, for example 1-6 feet (30.5-183 cm) lower, although alternatives are possible.

Also according to the present disclosure, a vehicle including an engine and an engine air flow inlet arrangement generally is characterized as described. A conduit arrangement is characterized as positioned to direct filtered from the air cleaner to the engine.

As described, the vehicle has a typical forward direction, and the engine air flow inlet arrangement includes a louver arrangement positioned across the shell air flow inlet, which has louvers that extend upwardly and rearwardly relative the forward direction of the vehicle.

In a typical system, the engine of the vehicle has a rated flow within the range of 300-1500 cfm, (8.5-42.5 cu/ meters/min) although alternatives are possible.

In general terms, methods of separating water from an inlet flow to an air cleaner are provided. The methods typically include:

(a) directing air through a shell inlet and into a shell interior, in a in flow direction;

(b) directing air in the shell interior toward a closed end of an interior vane, and eventually into an open face of the interior vane, which open face is directed generally away from the shell inlet, and typically at least partially upwardly; and,

(c) collecting water in the shell interior, and exteriorly of the interior vane, and draining the water from the shell.

The method can be practiced by directing air in accord with separator assembly features described in detail herein above.

It is, again, noted that (in general) arrangements, assemblies; features and components thereof, as well as techniques in accord with the present description, do not need to include all of the features and details characterized herein, in order to obtain some advantage. Further, there is no specific requirement that the features be configured in the precise manner exemplified in the figures.