Integrated Headlight-Air Intake System

The Integrated Headlight-Air Intake System is a dual-purpose assembly that merges a functional headlight with an air intake pathway within one housing. This design optimizes cold air delivery to the engine’s intake manifold or turbocharger, boosting performance through enhanced cooling and air density, while maintaining the headlight’s beam function and alignment to meet road legality standards. The housing incorporates air channels or ducts that facilitate airflow without compromising light projection or regulatory requirements.

Detailed Description of the Invention

• Structure:      
  • The Integrated Headlight-Air Intake System features a modified headlight housing with a hollowed central or inner section forming an air intake duct. 
  • A compact LED or projector light source is positioned along the outer perimeter or upper segment to preserve lighting functionality.
• Airflow System: 
  • Air enters via a front-facing intake opening integrated into the housing or lens. 
  • A smooth internal duct directs air to the intake manifold or intercooler, with an embedded high-flow air filter ensuring clean airflow. 
  • Optional velocity stacks or scoops improve airflow efficiency.
• Lighting System: 
  • The light source (e.g., LED or HID) is mounted along the duct’s edge or in a partitioned section, with reflectors and lenses maintaining a DOT-compliant beam pattern. 
  • The intake duct does not interfere with light output.
• Mounting:      
  • The system installs in the factory headlight location using existing brackets or minor adaptations. 
  • Modular designs support left- or right-side vehicle applications.
• Materials:      
  • Housing: Lightweight carbon fiber composite for strength and vehicle weight reduction. 
  • Lens: Polycarbonate or tempered glass for durability. 
  • Intake Duct: Composite, aluminum, or thermoplastic for heat resistance. 
  • Air Filter: Washable cotton or foam, accessible for maintenance.

Manufacturing

• Fabricate a headlight housing with integrated intake channels using molding or CNC machining. 
• Install a compact light assembly with reflectors and a protective lens along the housing’s edge. 
• Incorporate an air filter within the intake pathway, sealing with heat-resistant gaskets and clamps. 
• Connect the intake duct to the engine’s airbox or piping with silicone couplers.

Usage

• Install the Integrated Headlight-Air Intake System in place of the factory headlight. 
• During operation, ambient air enters the intake, is filtered, and flows to the engine, while the integrated light provides compliant illumination for safe driving.

Applications 

• Performance street cars requiring enhanced airflow and legal headlights. 
• Track vehicles needing regulatory-compliant lighting. 
• Turbocharged or supercharged vehicles benefiting from cooler intake air. 
• Custom or OEM automotive applications seeking innovative, space-efficient designs.