Air Intake Noise Reducing Device With Mechanical Interlocking Gasket
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Solution Overview
Problem
Conventional air intake noise reduction devices suffer from deteriorated sealing effects and require adhesive treatment, leading to increased assembly time and manufacturing costs.
Innovation Solution
An air intake noise reducing device featuring a seal member with protrusion holding portions and a noise reducing net with connecting protrusions that are securely held within these portions, eliminating the need for adhesives and ensuring uniform surface pressure for effective sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the net and gasket are connected by inserting protruded portions into the gasket and fixed with adhesive, then the net is securely attached, but the sealing effect of the gasket deteriorates and assembly time increases
Solution Approach 1:
The gasket is divided into multiple protrusion holding portions that separately engage with connecting protrusions on the net. This segmentation allows the net to be securely attached through multiple discrete attachment points while maintaining uniform pressure distribution across the gasket's sealing surface, preventing deterioration of the sealing effect.
Solution Approach 2:
The adhesive bonding system is replaced with a mechanical interlocking system consisting of protrusion holding portions and connecting protrusions. This mechanical connection provides secure attachment of the net to the gasket without requiring adhesive materials, thereby maintaining the gasket's sealing properties and reducing assembly complexity.
2Strength
If adhesive is used to fix the net to the gasket, then secure attachment is achieved, but assembly time and manufacturing cost increase
Solution Approach 1:
The chemical bonding process using adhesive is replaced with a purely mechanical interlocking mechanism. The protrusion holding portions and connecting protrusions provide immediate mechanical attachment without requiring adhesive application, curing time, or specialized bonding equipment, thereby significantly reducing assembly time and manufacturing cost.
Solution Approach 2:
The gasket structure itself provides the attachment mechanism through its integrated protrusion holding portions. This self-service design eliminates the need for separate adhesive materials and application processes, allowing the net to be securely attached through simple mechanical engagement that reduces assembly time and complexity.
3Strength
If protruded portions are inserted into the gasket, then the net is held in position, but uniform surface pressure is compromised
Solution Approach 1:
The gasket is segmented into multiple protrusion holding portions distributed across its surface. This segmentation allows the net to be held securely at multiple discrete locations while maintaining uniform pressure distribution across the entire sealing surface, as the protrusions are strategically positioned to avoid concentrating stress in one area.
Solution Approach 2:
The protrusion holding portions are strategically positioned at specific locations on the gasket where local attachment is needed for holding the net, while the remaining surface areas maintain uniform pressure for sealing. This local quality approach ensures that the holding function and sealing function are both optimized without interfering with each other.
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
The solution reduces air intake noise while minimizing assembly time and costs, maintaining sealing properties without the use of adhesives, and allowing for easier recycling and material selection.
Implementation Method 1
Air flowing through the air intake passage is dispersed and rectified by the net, so that the air intake noise is reduced
Implementation Method 2
the connecting protrusions are held in the protruding holding portions such that the air intake noise reducing member is firmly secured to the seal member
Implementation Method 3
surface pressure of the gasket differs from portions of the gasket whether the protruded portions and the outer rim are contained or not. As a result, there arises a problem that sealing effects of the gasket are deteriorated
Data Source
AI summary
The present invention provides an air intake noise reducing device, an internal combustion engine fitted with the air intake noise reducing device and a structure for fitting the air intake noise reducing device to the internal combustion engine. The air intake noise reducing device comprises a gasket (2) comprising a ring member (2a) held by connecting surfaces of an air intake passage (100) and protrusion holding portions (2b) extending from the ring member (2a) toward a center of the air intake passage (100); and a net member (3) comprising a net (3a) for rectifying intake air and connecting protrusions (3b) extending outward from the net (3). The connecting protrusions (3b) are held in the protruding holding portions (2b) such that the ring member (3) is firmly secured to the gasket (3). The air intake noise reducing device constituted by in the above-mentioned manner can reduce assembly man-hours without deteriorating a sealing property of the air passage.