Air box with integrated filter media

Abstract

An apparatus and a method are provided for an air box with an integrated air filter to communicate air flow from an exterior of the air filter to an air intake of an automobile engine. The air filter comprises a filter material that surrounds at least a portion of an interior cavity of the air filter. An end cap is affixed to a distal end of the filter material, and a wire support extends along at least a portion of the exterior surface of the filter material. The air box comprises a housing portion and a mount portion. The housing portion is configured to direct air drawn through the filter material into the interior cavity of the air filter and then into the air intake of the automobile engine. The mount portion is configured to support the air box and the air filter once installed within an automobile engine bay.

1 . An apparatus for an air box with an integrated air filter, the apparatus comprising:
 the air filter comprising a filter material circumferentially extending such that the filter material surrounds at least a portion of an interior cavity of the air filter, a distal end cap affixed to a distal end of the filter material, and a wire support extending along at least a portion of an exterior surface of the filter material; and   a housing portion and a mount portion of the air box, where a front surface of the housing portion comprises a conduit with an opening and a transition that are configured to receive an air intake conduit extending from an intake portion of an automobile engine, and a back surface of the housing portion comprises a ridge and a recess configured to fixedly receive a proximal end of the filter material, such that air drawn through the filter material into the interior cavity is drawn through the opening of the conduit into the intake portion of the automobile engine;   wherein the mount portion is configured to be installed within an interior of an automobile engine bay, and wherein the housing portion is configured to support the air filter and provide a communicative air flow from an exterior of the air filter to the intake portion of the automobile engine.   
     
     
         2 . The apparatus of  claim 1 , wherein the air filter is fastened to the housing portion such that the air filter is irremovable from the air box. 
     
     
         3 . The apparatus of  claim 1 , wherein the air box is comprised of a material which is sufficiently durable and temperature resistant to retain its configuration during installation and operation. 
     
     
         4 . The apparatus of  claim 1 , wherein the mount portion includes a suitable fastening means to facilitate installing the air box into the automobile engine bay. 
     
     
         5 . The apparatus of  claim 4 , wherein the fastening means is dependent on the specific make and model of the automobile with which the air box is to be used. 
     
     
         6 . The apparatus of  claim 1 , wherein the transition provides a connection between the conduit and the housing portion. 
     
     
         7 . The apparatus of  claim 6 , wherein the transition comprises a molded portion between the conduit and the housing portion. 
     
     
         8 . The apparatus of  claim 6 , wherein the transition positions a longitudinal dimension of the conduit at an angle relative to the housing portion. 
     
     
         9 . The apparatus of  claim 8 , wherein the angle between the conduit and the housing portion depends upon the particular automobile for which the air box is to be utilized. 
     
     
         10 . The apparatus of  claim 1 , wherein the opening has a diameter suitable to accept the air intake conduit of the automobile engine. 
     
     
         11 . The apparatus of  claim 1 , wherein the flange has a configuration suitable to accept the air intake conduit of the automobile engine. 
     
     
         12 . The apparatus of  claim 1 , wherein fasteners are used to affix the proximal end within the recess. 
     
     
         13 . The apparatus of  claim 1 , wherein the ridge is crimped such that it folds onto and retains the wire support and the filter material of the air filter. 
     
     
         14 . The apparatus of  claim 1 , wherein the air box and the air filter are configured such that the air filter may be periodically cleaned without removing the air filter from the air box. 
     
     
         15 . The apparatus of  claim 1 , wherein the mount portion further comprises a plurality of structural supports. 
     
     
         16 . The apparatus of  claim 15 , wherein the structural supports are ribs configured to increase the rigidity of the mount portion. 
     
     
         17 . The apparatus of  claim 1 , wherein the housing portion comprises a plurality of structural members. 
     
     
         18 . The apparatus of  claim 17 , wherein the structural members are ribs configured to increase the rigidity of the housing portion. 
     
     
         19 . The apparatus of  claim 1 , wherein the distal end cap is comprised of a material which is sufficiently hard to retain the filter material in a desired configuration and support the air filter when coupled to the housing portion. 
     
     
         20 . The apparatus of  claim 1 , wherein the distal end cap is crimped around its peripheral edge such that it folds onto and retains the wire support and the filter material. 
     
     
         21 . The apparatus of  claim 1 , wherein the filter material is positioned between the wire support and one or more layers of a reinforcing material. 
     
     
         22 . The apparatus of  claim 21 , wherein the wire support comprises a first wire screen positioned on an outer surface and a second wire screen positioned on an inner surface of the filter material. 
     
     
         23 . The apparatus of  claim 1 , wherein the filter material provides a surface area through which to pass an air stream and trap particulate matter and other contaminates so as to prevent them from entering into the air intake of the automobile engine. 
     
     
         24 . The apparatus of  claim 1 , wherein the filter material is comprised of paper, foam, cotton, spun fiberglass, or other known filter materials, woven or non-woven material, synthetic or natural, or any combination thereof 
     
     
         25 . The apparatus of  claim 1 , wherein the filter material is pleated or otherwise shaped or contoured to increase the surface area for passing the air stream to be cleaned. 
     
     
         26 . The apparatus of  claim 1 , wherein the filter material comprises oil to enhance the air cleaning properties of the filter material. 
     
     
         27 . A method for cleaning an air box with an integrated air filter which is installed within an engine bay of an automobile, the method comprising:
 removing an air intake conduit of an automobile engine from a conduit of the air box, where the conduit comprises a flange and an opening into an interior cavity of the air filter, and where the interior cavity is bounded by a circumferentially extending filter material and a distal end cap;   inserting a water hose through the opening into the interior cavity of the air filter; and   spraying water so as to flush contaminants from the filter material, such that the water and contaminants drain from a bottom of the air filter and exit the engine bay.   
     
     
         28 . A method for providing an air box with an integrated air filter to communicate air flow from an exterior of the air filter to an air intake portion of an automobile engine, the method comprising:
 extending a filter material circumferentially so as to form at least a portion of an interior cavity of the air filter;   extending a wire support along at least a portion of the filter material;   affixing a distal end cap to a distal end of the filter material, such that the wire support is retained along the at least a portion of the filter material and the air filter retains its shape during operation and cleaning;   forming a housing portion and a mount portion of the air box, such that a front surface of the housing portion comprises a conduit with an opening and a transition to receive an air intake conduit extending from the air intake portion of the automobile engine, and such that a back surface of the housing portion comprises a ridge and a recess to fixedly receive a proximal end of the filter material; and   configuring the mount portion to be installed within an interior of an automobile engine bay.