Convex Air Cleaner Element with Variable Thickness

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Solution Overview

Problem

Straddle-type vehicles face challenges in reducing the size of air cleaners while maintaining air cleaning functionality, as the thickness of the air cleaner elements is dependent on both strength and air cleaning functionality, making it difficult to minimize size without compromising performance.

Innovation Solution

The design incorporates a convex cleaner element with a support frame where the periphery has a smaller thickness than the inner portions, allowing the cleaner element to cover the opening of the lead-in duct without increasing the air cleaner's size, and using a porous material with fine and coarse element layers for enhanced air filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a convex cleaner element is used with uniform thickness, then the air cleaner functionality is improved, but the size of the air cleaner increases

Engineering Contradiction:

Improveair cleaning functionalityVSAvoidsize of air cleaner

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The cleaner element is designed with non-uniform thickness: the peripheral portion has a first thickness while the inner portion has a second thickness greater than the first. This local quality variation allows the peripheral sealing function to be maintained with minimal thickness, while the inner portion provides sufficient air cleaning functionality, thereby reducing overall air cleaner size without compromising performance.

Inventive Principle:

Principle #3Local quality

2Volume of stationary object

If the thickness of the cleaner element is reduced, then the size of the air cleaner is reduced, but the strength and air cleaning functionality are compromised

Engineering Contradiction:

Improvesize of air cleanerVSAvoidstrength of cleaner element

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The cleaner element employs different thicknesses in different regions: the peripheral portion with smaller thickness provides sealing function, while the inner portion with greater thickness ensures structural strength and air cleaning functionality. This resolves the contradiction by allocating material thickness according to functional requirements rather than using uniform thickness throughout.

Inventive Principle:

Principle #3Local quality

3Volume of stationary object

If a separate rubber member is added to reduce the thickness of the air cleaner periphery, then the size is reduced, but the air cleaning functionality is reduced due to smaller effective region

Engineering Contradiction:

Improvesize of air cleanerVSAvoidair cleaning functionality

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The cleaner element is designed to perform multiple functions: the peripheral portion with smaller thickness provides sealing function, while the inner portion with greater thickness provides air cleaning functionality. This multi-functional design eliminates the need for separate rubber members, maintaining air cleaning functionality while reducing overall size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The sealing function and air cleaning function are merged into a single cleaner element structure rather than using separate components. The peripheral portion handles sealing while the inner portion handles air cleaning, combining what were previously separate functions into one integrated component, thereby reducing the number of parts and overall size.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for a compact air cleaner size while maintaining sufficient air cleaning functionality and preventing engine performance degradation, even when the cleaner element is convex, by ensuring a large opening area and integrating the seal's function with the support frame.

Implementation Method 1

The cleaner element (60) includes a convex element body (61) and a seal (62) protruding from the periphery of the element body toward the inner side of the element body

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

a convex cleaner element with a support frame where the periphery has a smaller thickness than the inner portions, allowing the cleaner element to cover the opening of the lead-in duct

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS9267469B2Straddle-type vehicle and method of manufacturing the same

Publication Date: 2016.02.23 YAMAHA MOTOR CO LTD

AI summary

A motorcycle includes a body frame, an engine, a lead-in duct, and an air cleaner case. An air cleaner includes a convex cleaner element protruding in a direction opposite to a direction extending toward the lead-in duct, and a convex support frame that supports the inner surface of the cleaner element. The support frame includes an outer frame that supports a periphery of the cleaner element. The cleaner element includes a convex element body and a seal provided adjacent the peripheral edge of the element body to project toward the inner surface of the element body so as to work together with the periphery of the element body to hold the outer frame. The periphery of the element body has a smaller thickness than the other portions of the element body.