Vehicle Air Cleaner Filter Assembly Segmentation
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Solution Overview
Problem
The existing air cleaners for straddle-type vehicles have a complex structure that increases manufacturing costs and weight, and complicates the replacement of the cleaner element, while also compromising air-tightness due to the integral metal unit design.
Innovation Solution
The air cleaner features a filter assembly with a cylindrical cleaner element supported by a separate element supporting member and a detachable plate-shaped top cover, allowing for simplified assembly and replacement, along with a separately housed flame arrester for improved air-tightness and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the top cover, upper holder, and wire gauze are formed as an integral metal unit, then the air-tightness is secured, but the manufacturing cost increases and the weight increases
Solution Approach 1:
The integral metal unit is divided into separate components: the top cover, the upper holder, and the wire gauze flame arrester. The top cover is made of resin and detachably fastened to the upper holder, while the wire gauze is separately disposed within the holder. This segmentation reduces manufacturing complexity and weight while maintaining air-tightness through proper sealing design at the attachment interface.
2Reliability
If the top cover, upper holder, and wire gauze are formed as an integral metal unit, then the air-tightness is secured, but the manufacturing cost increases
Solution Approach 1:
The filter assembly is segmented into separate components that can be manufactured independently and assembled. The top cover is detachably fastened to the upper holder, allowing each part to be produced separately at lower cost. The wire gauze flame arrester is also separately disposed, avoiding the need for expensive integral metal fabrication while maintaining sealing effectiveness.
Solution Approach 2:
The top cover is made of resin instead of metal, using a cheaper material that can be easily replaced if needed. This material substitution significantly reduces manufacturing cost while the detachable fastening design ensures that air-tightness is maintained through proper sealing at the connection interface.
3Reliability
If the integral metal unit including top cover, upper holder, and wire gauze is removed to replace the cleaner element, then the air-tightness is maintained, but the replacement work becomes much more difficult
Solution Approach 1:
The filter assembly is divided into separable components where the top cover can be detachably removed from the upper holder. This allows the cleaner element to be accessed and replaced by simply removing the top cover, without needing to remove the entire upper holder assembly. The air-tightness is maintained through sealing design at the detachable interface, enabling easy maintenance while preserving reliability.
4Reliability
If the top cover is made of metal as an integral unit, then the air-tightness is secured, but the weight of the filter assembly increases
Solution Approach 1:
The top cover is made of resin instead of metal, significantly reducing the weight of the filter assembly. The resin material is sufficient for the application requirements and can be easily replaced if needed. Air-tightness is maintained through proper sealing design at the detachable fastening interface between the resin top cover and the upper holder, eliminating the need for heavy metal construction.
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 reduces the number of assembly steps, facilitates easier replacement of the cleaner element, and enhances air-tightness by using a single sealing member, while also reducing the overall weight and manufacturing costs.
Implementation Method 1
The induced air passes through the filter assembly 105 from the outside to the inside so as to be filtered
Implementation Method 2
A wire gauze 141 as a flame arrester is integrally attached to the inner surface of the upper holder 121
Data Source
AI summary
The present air cleaner for an engine of a vehicle, includes: a cleaner case; and a filter assembly disposed in the cleaner case. The filter assembly includes a cylindrical cleaner element, an element supporting member supporting a lower end of the cleaner element and an inner circumferential surface of the cleaner element so that the cleaner element is kept in a predetermined cylindrical shape, and a plate-shaped top cover detachably fastened on an upper surface of the element supporting member so as to press an upper end of the cleaner element downward.