Air Cleaner Adsorption Element Frame Support
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Solution Overview
Problem
Existing air-cleaners for internal combustion engines face challenges in preventing adsorbent flexing while maintaining low air-flow resistance, as adsorption materials like granular activated carbon and nonwoven fabrics increase air-flow resistance and are difficult to integrate effectively.
Innovation Solution
The air-cleaner design includes a housing with a filter element and an adsorption element supported by a frame and a support member, where the adsorption element is vibration welded or pinned to the mounting portion, preventing flexing and maintaining low air-flow resistance through a two-step flange structure and through-holes for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the adsorption sheet is thickened to prevent flexing, then the adsorbent stability is improved, but the air-flow resistance is increased
Solution Approach 1:
The adsorption element is divided into a frame portion and an adsorption portion. The frame portion provides structural support to prevent flexing, while the adsorption portion contains the actual adsorbent material. This segmentation allows the support function and adsorption function to be separated, enabling thin adsorption material without compromising stability.
Solution Approach 2:
The frame acts as an intermediary structure between the housing and the adsorption portion. It transfers and distributes air flow around the adsorption material, providing mechanical support while minimizing resistance to the actual adsorption process. The frame's rigid structure prevents flexing without requiring thick adsorbent layers.
2Reliability
If granular activated carbon and nonwoven fabrics are used as adsorbents, then the vaporized fuel adsorption capability is improved, but the air-flow resistance is increased
Solution Approach 1:
The patent employs granular activated carbon as the adsorbent material, which is a porous material with high surface area and adsorption capacity. The porous structure allows vaporized fuel molecules to be trapped effectively while maintaining relatively low resistance to air flow compared to dense nonwoven fabric structures.
Solution Approach 2:
The adsorption capability is concentrated in specific regions where the granular activated carbon is positioned within the frame structure. This localized placement of high-performance adsorbent material ensures effective vaporized fuel adsorption while minimizing the overall volume and air-flow resistance of the adsorption element.
3Reliability
If multiple materials (granular activated carbon, nonwoven fabrics, heat resistant nets) are integrated, then the adsorption performance and structural stability are improved, but the manufacturing difficulty is increased
Solution Approach 1:
The adsorption element is segmented into distinct functional components: a frame portion for structural support and an adsorption portion for vaporized fuel adsorption. This segmentation simplifies manufacturing by allowing each component to be produced separately using appropriate materials and processes, then assembled together, rather than attempting to integrate multiple materials into a single complex structure.
Solution Approach 2:
The patent uses a composite structure combining a rigid frame material (providing structural stability) with granular activated carbon (providing adsorption performance). This composite approach allows each material to be selected and processed independently for its optimal properties, then combined in a simple assembly process, reducing overall manufacturing complexity compared to creating a fully integrated multi-material component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively adsorbs vaporized fuel without increasing air-flow resistance, ensuring efficient filtration and preventing adsorbent flexing, thus enhancing the performance of the air-cleaner in internal combustion engines.
Implementation Method 1
an adsorption element (30) for adsorbing a vaporized fuel flowing into the housing (2)
Implementation Method 2
the support member (40) supports the adsorption portion (31) so as to prevent the adsorption portion (31) from being flexed
Implementation Method 3
The adsorption element and the support member may be vibration welded to the mounting portion, being formed integrally with each other
Data Source
AI summary
The air-cleaner includes a housing. The air-cleaner includes a filter element located in the housing to filter air taken into the housing. The air-cleaner includes an adsorption element for adsorbing vaporized fuel flowing into the housing. The housing includes first and second housing components having open ends put on each other. The filter element is held between the first and second housing components, separating the housing into a clean side and a dust side. The adsorption element includes a frame at the periphery; and an adsorption portion located inside the frame. One of the first and second housing components as the clean side has an inner side back in the open end, the inner side having a mounting portion having the adsorption element mounted thereto. The mounting portion includes the adsorption element; and a support member placed thereon.