Air-intake duct with segmented coupling and guide members
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Solution Overview
Problem
Conventional air-intake ducts face challenges in balancing coupling and air guiding functions, leading to increased weight, reduced fuel efficiency, and complex manufacturing processes, which hinder precise control of air-intake performance.
Innovation Solution
The air-intake duct is designed with a tubular coupling member made of elastic rubber and an air guide member made of lightweight, high-stiffness materials like synthetic resin or metal, allowing for separate manufacturing and easy adjustment of the air guide member to control air-intake performance without detaching the coupling member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both the coupling member and the air guiding member are formed of elastic rubber material, then air-tightness is ensured, but the wall thickness must be increased which narrows the air passage and degrades the air guiding function
Solution Approach 1:
The air-intake duct is divided into two separate members: a coupling member made of elastic rubber material for air-tight sealing, and an air guiding member made of lightweight material with small wall thickness for efficient air passage. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
Different parts of the air-intake duct system use different materials with appropriate properties: the coupling member uses elastic rubber material where air-tightness is critical, while the air guiding member uses lightweight material where air passage efficiency is critical. This local quality optimization resolves the contradiction between sealing and airflow.
2Reliability
If both the coupling member and the air guiding member are formed of elastic rubber material, then air-tightness is ensured, but the weight increases which reduces fuel efficiency
Solution Approach 1:
The air-intake duct is segmented into a coupling member (elastic rubber) and an air guiding member (lightweight material). This allows the majority of the duct structure to use lightweight materials for reduced weight, while only the critical sealing portions use elastic rubber material.
Solution Approach 2:
The air-intake duct system uses composite material construction, combining elastic rubber material for sealing functions with lightweight materials (such as plastic or composite materials) for the air guiding structure, achieving both air-tightness and weight reduction.
3Weight of moving object
If both the coupling member and the air guiding member are formed of material other than elastic rubber material, then weight is reduced, but a seal member such as an O-ring is needed which reduces mounting efficiency
Solution Approach 1:
The coupling member integrates multiple functions: it provides air-tight sealing through its elastic rubber material properties, structural coupling between components, and positioning features. This merging of sealing and coupling functions into one component eliminates the need for separate seal members like O-rings, improving mounting efficiency.
4Ease of manufacture
If the coupling member and the air guiding member are molded integrally using a die, then manufacturing is simplified, but the shape becomes complex causing undercut which increases die complexity and manufacturing cost
Solution Approach 1:
The air-intake duct is segmented into two separately moldable components: a coupling member and an air guiding member. This segmentation allows each component to have simpler, more easily moldable shapes without undercut issues, while still achieving the overall complex functional requirements when assembled together.
5Manufacturing precision
If the entire air-intake duct is replaced to control air-intake performance, then precise control is achieved, but the task is burdensome and time-consuming
Solution Approach 1:
The air-intake duct is segmented such that the air guiding member can be independently adjusted or replaced without affecting the coupling member. This allows precise control of air-intake performance by modifying only the air guiding member (such as changing its length or internal geometry) while keeping the sealing coupling member in place, significantly reducing adjustment time and complexity.
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 configuration enables well-balanced coupling and air guiding functions, reducing weight and manufacturing costs while allowing for flexible design and easy control of air-intake performance, thereby improving fuel efficiency and design flexibility.
Implementation Method 1
a coupling member for performing the coupling function and an air guiding member for performing the air guiding function are integrally formed of the same material... the coupling member being entirely formed of an elastic rubber material
Data Source
AI summary
An air-intake duct, which is disposed between an air outlet of an air cleaner box constituting an air cleaner and an air inlet of a throttle body constituting a throttle device, is configured to guide air cleaned by the air cleaner to the throttle device. The air-intake duct includes a tubular coupling member including an upstream coupling portion coupled in an air tight manner to the air outlet of the air cleaner box and a downstream coupling portion air-tightly coupled to the air inlet of the throttle body, the coupling member being entirely formed of an elastic rubber material. The air-intake duct also includes an air guide member including a first air inlet configured to take in air therethrough from inside the air cleaner box, a first air outlet configured to discharge the air therethrough toward the throttle body, and a fitting portion fitted to the coupling member.