Air box for a two-wheeler

Abstract

A two-wheeled vehicle can include a frame, a plurality of ground-engaging members for supporting the frame, and an engine supported by the frame and operably coupled to the ground-engaging members. Additionally, the two-wheeled vehicle can include an air box including an inlet pipe and a filter. The air box can include a first housing portion, a second housing portion, and a vertical seam coupling the first housing portion and the second housing portion.

Description

Background Art

[0001] [Related Applications]

[0002]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 349,819, filed on June 7, 2022, the entire disclosure of which is hereby expressly incorporated by reference herein. [Field of the Disclosure]

[0003]

[0002] The present invention relates to an air box for a vehicle, and more particularly, to an air box for a two-wheeled vehicle that improves ease of manufacture. [Background of the Disclosure]

[0004]

[0003] Conventional two-wheeled vehicles include a frame for supporting an operator. The frame may also support a passenger behind the operator. The engine is typically located under the driver and is coupled to the frame. The front portion of the vehicle may include a panel or cover located in front of the driver to support additional vehicle components such as lights. The rear portion of the vehicle may include a luggage area such as saddle bags that extend laterally outward from the frame.

[0005]

[0004] Such vehicles typically include an air box as part of an air intake assembly that is fluidly coupled to the engine. The air box can include a filter, a tray, an inlet tube, an oil separator, and various other components. Since the space on such vehicles can be restricted, it is necessary to support the air box on the two-wheeled vehicle without interfering with other vehicle components. Summary of the Disclosure

[0006]

[0005] In an exemplary embodiment of the present disclosure, a two-wheeled vehicle includes a frame and a plurality of ground engaging members for supporting the frame. In addition, the two-wheeled vehicle includes an air box that includes a left housing, a right housing separate from the left housing, and a vertical seam that separates the left housing and the right housing.

[0007]

[0006] A further exemplary embodiment of the present invention includes a two-wheeled vehicle having a frame and a plurality of ground engaging members for supporting the frame. Additionally, the two-wheeled vehicle includes an air box that includes a first housing portion, a second housing portion separate from the first housing portion, and a filter located inside one of the first housing portion and the second housing portion.

[0008]

[0007] This summary is provided to introduce, in a simplified form, a selection of concepts that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

Brief Description of the Drawings

[0009]

Figure 1

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[0010]

[0021] Corresponding reference numerals indicate corresponding parts throughout several views. Unless otherwise specified, the drawings are not to scale.

[0011] Detailed Description of the Drawings

[0012]

[0022] The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are selected and described so that those skilled in the art can utilize their teachings. The invention mainly includes standard motorcycles, but it should be understood that the invention is also applicable to other types of vehicles such as all-terrain vehicles, motorcycles, ships, multi-purpose vehicles, scooters, golf carts, and mopeds.

[0013]

[0023] First, referring to FIGS. 1-2, an exemplary embodiment of a motorcycle 2 is shown. The illustrated vehicle 2 is a motorcycle and can be configured for cruising, touring, sports, dirt bike, or other various driving applications as described herein.

[0014]

[0024] Vehicle 2 includes a grounding engagement member, i.e., a front grounding engagement member such as front wheel 6 and a rear grounding engagement member such as rear wheel 8, which support a frame 4. Vehicle 2 travels on the ground on front wheel 6 and rear wheel 8. Front wheel 6 and rear wheel 8 are substantially aligned along the center line L of vehicle 2. Although vehicle 2 is a two-wheeler, various embodiments of the present disclosure can include three-wheelers, four-wheelers, five-wheelers, or six-wheelers. A front fender (not shown) may be partially positioned around front wheel 6 and may include a light or a reflector. Similarly, a rear fender (not shown) may be positioned around rear wheel 8. In addition, a brake assembly (not shown) is operably coupled to front wheel 6 and / or rear wheel 8.

[0015]

[0025] The frame 4 of vehicle 2 can include an intermediate frame assembly 10 for supporting a fuel tank 12, an air box 14, and an engine 16. Other portions of frame 4 such as intermediate frame assembly 10 or a front frame portion or a rear frame portion can support a cooling assembly, a transmission, a rear suspension assembly, and an operator seat. Front wheel 6 and / or rear wheel 8 are operably coupled to engine 16 to propel vehicle 2 along the ground. Engine 16 can be a spark-ignition gasoline engine, an electric motor, or other suitable torque generators operable in various embodiments of the present teachings.

[0016]

[0026] Vehicle 2 also includes a front suspension assembly, a steering assembly 18, operator controls, and other systems. Steering assembly 38 includes a handlebar that can be moved by an operator to rotate front wheel 6 left or right. Steering assembly 38 is coupled to vehicle 2 via a triple clamp assembly. The triple clamp assembly may be operably coupled to the front suspension assembly via a down tube 22.

[0017]

[0027] Next, referring to FIGS. 3 - 13, the air box 14 is supported within a portion of the frame 4 and is generally positioned below the fuel tank 12 (FIG. 1), above the engine 16 (FIG. 1), and between the side frame arms 20. At least a portion of the air box 14 is behind the down tube 22 and the head tube 38 and is positioned generally along the longitudinal centerline L (FIG. 1). In one embodiment, the air box 14 is directly coupled to the engine 16 via a throttle body assembly 46 as further disclosed herein. Referring to FIGS. 4, 6, and 7, the air box 14 is coupled to the frame 4 at a recessed mounting portion 44 by pins 26 and bushings 28. The bushings 28 provide the advantage of additional friction and lateral damping to stabilize the air box 14 and isolate it from vibrations of the frame 4. The pins 26 may be welded to the frame 4 and, in one embodiment, the pins 26 may have a diameter of approximately 8 millimeters. As shown in FIG. 7, the air box 14 can be installed or removed as a single unit without tools or clamps by rotating the air box 14 about the centerline of the pins 26 and bushings 28. The installation and removal procedure allows for the air box 14 to be quickly exchanged with another air box 14 having different performance characteristics, as described below.

[0018]

[0028] At least as shown in FIG. 8, the air box 14 includes a left housing 32 and a right housing 34 that are coupled to each other along a vertical seam 36. In one embodiment, the left housing 32 and the right housing 34 may be fixedly coupled to each other along the vertical seam 36 via vibration welding, rivets, adhesives, etc. However, in other embodiments, the left housing 32 and the right housing 34 are removably coupled to each other by removable fasteners (e.g., nuts) along the seam 36. The vertical seam 36 extends vertically along at least the front and rear surfaces of the air box 14 and extends longitudinally along the front and rear surfaces of the air box 14 to form a continuous seam 36. In this way, the vertical seam 36 is different from the horizontal seam that extends horizontally and longitudinally in embodiments of the air box with an upper housing and a lower housing. Coupling the left housing 32 and the right housing 34 by the vertical seam 36 provides the advantages of simpler tool requirements in the manufacturing process and increased space available between the frame 4, the engine 16, and the fuel tank 12.

[0019]

[0029] The interior of the left housing 32 (FIG. 12) and the right housing (FIG. 13) may be defined by a rib structure 68. The rib structure 68 gives rigidity to the air box 14 and mitigates the radiated acoustic response from the air box 14 panel mode excited by the intake pressure dynamics. The left housing 32 has a mounting portion for coupling the radiator filling neck 58 (FIG. 3) to the air box 14. This provides the advantage of placing the radiator filling neck 58 at the highest point of the cooling system. As shown in FIG. 12, the internal space at the rear of the air box 14 may be configured to support the oil separator 74, capture oil, and prevent the oil from entering the throttle body assembly 46 or being recirculated through the throttle body assembly 46. The oil separator 74 can be removably or fixedly coupled to at least a portion of the air box 14, such as the left housing 32. In one embodiment, the oil separator 74 can be vibration welded to the vertical seam 36 to prevent air leakage and maintain the pressure within the air box 14. The oil separator 74 returns the captured oil to an oil system (not shown) via at least one of the coupling 72 and the hose 66.

[0020]

[0030] As shown in FIGS. 5, 9, 10, and 12, the air box 14 includes an inlet pipe 50. The inlet pipe 50 can be fixedly or removably supported within the air box 14. In one embodiment, the inlet pipe 50 may be vibration welded to the vertical seam 36. Vibration welding mechanically and fixedly fastens the inlet pipe 50 to at least a portion of the air box 14, such as the left housing 32, so as to prevent air leakage and maintain the pressure within the air box 14 and cannot be removed. The opening 30 of the inlet pipe 50 is located in the front lower portion of the air box 14 within the pocket 64 between the down tubes 22. The opening 30 of the inlet pipe 50 captures the air flow and guides it through the inlet pipe 50 and the outlet 52 into the air volume 86 of the air box 14. Referring to FIGS. 10 and 12, the inlet pipe 50 has a Venturi design with a smaller diameter opening 30 and a larger diameter outlet 52, and the outlet 52 gives the inlet pipe 50 a tapered configuration to minimize the total cross-sectional area at the opening 30. The diameter of the inlet opening 30 can range from 20 to 35 mm. The diameter of the outlet 52 can range from 25 to 70 millimeters. The length of the inlet pipe 50 from the opening 30 to the outlet 52 can range from 100 to 200 millimeters. The Venturi design creates a pressure differential within the inlet pipe 50 to maximize the capture of the air flow. The inlet pipe 50 is angled within the air box 14, and the spacing between the outlet 52 and the opening 30 of the inlet pipe 50 is designed to maximize the space for the air volume 86 within the air box 14 while saving space for other components on the vehicle 2. In some embodiments, the inlet pipe 50 can have a smaller or larger opening 30 based on the desired performance characteristics of the vehicle 2. A larger diameter opening 30 has higher performance characteristics than a smaller diameter opening 30.

[0021]

[0031] The air box 14 further includes a filter 76 for filtering the incoming air before it flows into the engine 16. The filter 76 is coupled to the air box 14 by a tray 78 that seats on rails 56 of both the left housing 32 and the right housing 34 inside the air box 14. As shown in FIG. 11, the tray 78 is coupled to a cover 70 that defines a portion of the top of the left housing 32 when the opening 42 of the tray 78 is aligned with the opening 80 of the left housing 32. The tray 78 is inserted through an opening 82 and positioned within or on the rails 56. When the tray 78 is installed, a fastener 40 can be inserted through the opening 42 of the cover 70. A recess 84 on the left housing 32 aids in the removal of the tray 78. The tray 78 facilitates the installation, removal, and replacement of the filter 76. The filter 76 and the tray 78 separate the interior of the air box 14 into two parts, one part being a pre-filtered or dirty air volume 86 that is in front of the air box 14 and upstream or forward of the filter 76, and the other part being a clean air volume 88 that is behind the air box 14 and downstream or rearward of the filter 76. The rails 56 receive the tray 78 and maintain its position at an angle of about 30 to 60 degrees (e.g., 43 degrees) from the ground within the air box 14. This angle maximizes the surface area of the filter 76 and the total clean air volume 88.

[0022]

[0032] During operation, the air box 14 is configured to receive ambient air at the opening 30 of the inlet pipe 50, flow the air through the filter 76 via the air volume 86, provide the filtered air from the clean air volume 88 to the throttle body assembly 46, and allow it to flow into and be combusted in the engine 16. Additionally, referring to FIG. 12, in some examples, the air box 14 is coupled to a second air outlet 24 on the left housing 32 to provide the filtered air to a secondary air injection system (not shown) for combustion therein. Referring to FIG. 6, the second body air outlet 24 can be coupled to a solenoid valve 62 via a hose 60 for fluid coupling to an exhaust port (not shown). The secondary air injection system can provide the filtered air to an exhaust port (not shown) during startup of the engine 16 to warm up the catalyst more rapidly and reduce the emissions of the engine 16.

[0023]

[0033] Embodiment

[0024]

[0034] Embodiment 1: A two-wheeled vehicle comprising a frame, a plurality of ground engaging members for supporting the frame, and an air box. The air box can include a left housing, a right housing separate from the left housing, and a vertical seam separating the left housing and the right housing.

[0025]

[0035] Embodiment 2: The two-wheeled vehicle according to Embodiment 1, wherein the left housing is welded to the right housing at the vertical seam.

[0026]

[0036] Embodiment 3: The two-wheeled vehicle according to Embodiment 1, wherein at least one of the left housing and the right housing can have an internal rib structure.

[0027]

[0037] Embodiment 4: The two-wheeled vehicle according to Embodiment 1, wherein a radiator filling neck is mounted outside one of the left housing and the right housing.

[0028]

[0038] Embodiment 5: The air box can include an inlet pipe having an outlet opening and an inlet opening, and the inlet opening is smaller than the outlet opening. The two-wheeled vehicle according to Embodiment 1.

[0029]

[0039] Embodiment 6: The inlet pipe may be angled between the inlet opening and the outlet opening. The two-wheeled vehicle according to Embodiment 5.

[0030]

[0040] Embodiment 7: The air box can include a second air outlet. The two-wheeled vehicle according to Embodiment 1.

[0031]

[0041] Embodiment 8: A two-wheeled vehicle comprising a frame, a plurality of ground engaging members for supporting the frame, and an air box. The air box can include a first housing portion, a second housing portion different from the first housing portion, and a filter. The filter may be located in one of the first housing portion and the second housing portion.

[0032]

[0042] Embodiment 9: The filter can be angled with respect to the ground plane within the air box. The two-wheeled vehicle according to Embodiment 8.

[0033]

[0043] Embodiment 10: The two-wheeled vehicle according to Embodiment 8, wherein the filter can be coupled to the air box by a tray.

[0034]

[0044] Embodiment 11: The two-wheeled vehicle according to Embodiment 10, wherein the tray can be supported within the air box by rails.

[0035]

[0045] The present invention has been described as having an exemplary design, but the present invention may be further modified within the spirit and scope of the present disclosure. Accordingly, this application is intended to cover any variations, uses, or adaptations of the present invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which the present invention pertains.

Claims

1. A frame, A plurality of ground engaging members for supporting the frame, An air box including a left housing, a right housing separate from the left housing, and a vertical seam separating the left housing and the right housing, A two-wheeled vehicle comprising the same.

2. The two-wheeled vehicle according to claim 1, wherein the left housing is welded to the right housing at the vertical seam.

3. The two-wheeled vehicle according to claim 1, wherein at least one of the left housing and the right housing has an internal rib structure.

4. The two-wheeled vehicle according to claim 1, wherein a radiator filling neck can be mounted outside one of the left housing and the right housing.

5. The two-wheeled vehicle according to claim 1, wherein the air box includes an inlet pipe having an outlet opening and an inlet opening, and the inlet opening is smaller than the outlet opening.

6. The two-wheeled vehicle according to claim 5, wherein the inlet pipe is angled between the inlet opening and the outlet opening.

7. The two-wheeled vehicle according to claim 1, wherein the air box includes a second air outlet.

8. A frame, A plurality of ground engaging members for supporting the frame, An air box including a first housing portion, a second housing portion separate from the first housing portion, and a filter located inside one of the first housing portion and the second housing portion, A two-wheeled vehicle comprising the same.

9. The two-wheeled vehicle according to claim 8, wherein the filter is angled with respect to a ground plane within the air box.

10. The two-wheeled vehicle according to claim 8, wherein the filter is coupled to the air box by a tray.

11. The two-wheeled vehicle according to claim 10, wherein the tray is supported in the air box by rails.

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