Compact Air Cleaner Integrating Cyclone and Filter Units
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Solution Overview
Problem
Existing air cleaners for internal combustion engines with cyclone and filter dust collection units are bulky due to separate and complex structures, increasing the lateral dimension and component count, which is detrimental for installation in limited spaces.
Innovation Solution
A compact air cleaner design integrating cyclone and filter dust collection units with shared components, featuring a base member, cover member, filter element, passage member, and case member, which simplifies assembly and reduces the number of parts, using guide vanes inclined at 30-37 degrees to maximize dust removal without increasing flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cyclone dust collection unit and filter dust collection unit are constructed as mutually independent devices connected in series, then dust removal effectiveness is improved, but the number of component parts increases and the overall structure becomes complex
Solution Approach 1:
The patent merges the cyclone dust collection unit and filter dust collection unit into a single integrated housing structure. The cyclone chambers and filter element are arranged within the same housing, sharing common walls and support structures. This integration reduces the number of separate components while maintaining the series connection functionality for effective dust removal.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it contains both the cyclone dust collection chambers and the filter element, provides structural support for all components, and facilitates the series connection of dust collection stages. This multi-functionality reduces overall device complexity while preserving dust removal effectiveness.
2Reliability
If the cyclone dust collection unit is designed with relatively large size for effective dust separation, then dust removal capability is improved, but the lateral dimension of the air cleaner increases
Solution Approach 1:
The patent transitions from a lateral arrangement to a vertical arrangement of dust collection components. The cyclone chambers are positioned above the filter element within the housing, utilizing the vertical dimension for dust separation. This dimensional reorganization maintains effective dust separation capability while minimizing the lateral footprint of the air cleaner.
Solution Approach 2:
The filter element is nested within the housing structure that also contains the cyclone chambers. The components are arranged concentrically and vertically to maximize space utilization. This nesting arrangement allows the larger cyclone units to be positioned above the filter without increasing lateral dimensions, as the filter element fits within the vertical space of the housing.
3Reliability
If multiple independent cyclone dust collection units are provided for improved dust removal, then dust separation effectiveness is enhanced, but the overall size and number of components increase
Solution Approach 1:
Multiple cyclone dust collection units are merged into a single housing structure, sharing common walls, support ribs, and the filter element. The cyclone chambers are arranged adjacently within the housing, eliminating the need for separate housings for each unit. This merging reduces the overall volume while maintaining enhanced dust separation effectiveness through multiple cyclone stages.
Solution Approach 2:
The housing is segmented into multiple functional zones containing individual cyclone chambers and a filter section. Each segment performs a specific dust separation function, but all segments are integrated within a single compact housing. This segmentation allows for efficient space utilization and reduced overall size compared to completely independent units.
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 design results in a highly compact and efficient air cleaner with improved dust removal capabilities and reduced flow resistance, allowing for efficient air intake while maintaining a compact rectangular profile, thus optimizing engine design for space-constrained applications.
Implementation Method 1
a plurality of guide vanes (44D) extending radially between an outer circumferential surface of each air ejection pipe and an inner circumferential surface of the corresponding circular hole
Implementation Method 2
a substantially annular filter element (43) positioned on the base wall inside the filter chamber and having an internal space communicating with the outlet passage
Data Source
AI summary
An air cleaner includes a base member including a base wall extending substantially horizontally, and a cover member attached to an upper side of the base wall to jointly define a filter chamber for receiving a filter element therein. The air cleaner further includes a passage member communicating with the filter chamber and incorporated with a plurality of air ejection pipes each surrounded by an annular air inlet passage fitted with guide vanes for rotating the air flow, and a case member defining separation chambers for separating dust from the rotating air flow. The passage member is interposed between the cover member and the case member.