Integrated Cowl Module Air Intake Duct Design
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Solution Overview
Problem
The existing air intake devices for vehicles are not optimally configured, leading to inefficient design, complex installation, and high costs due to non-standardized positioning and complex duct shapes, which complicates assembly and maintenance.
Innovation Solution
A cowl module is introduced, positioned between the engine and passenger compartments, featuring a compact air intake duct with peripheral air intake ports and integrated filtration assemblies, allowing for standardized design, reduced parts, and simplified assembly, using semi-cylindrical pipes and thermoplastic materials for weight reduction and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air filter elements are placed in the engine compartment according to remaining space, then the air intake device can be installed, but the geometry and configuration become non-optimized and complex
Solution Approach 1:
The patent merges the air intake duct with the cowl module into a single integrated component. The duct is formed as an integral part of the cowl module's lower shell, eliminating the need for separate duct components and complex assembly procedures. This integration simplifies the overall device configuration while maintaining manufacturing feasibility.
Solution Approach 2:
The cowl module is designed to serve multiple functions: it provides structural protection for the windshield, manages water drainage through integrated channels, and incorporates the air intake duct as an integral component. This multi-functionality reduces the number of separate parts needed and simplifies the overall air intake device configuration.
2Ease of operation
If air intake ducts use complex non-slender shapes to connect elements, then all elements can be connected, but the pipes extend over great lengths increasing cost and difficulty of installation and maintenance
Solution Approach 1:
By integrating the air intake duct directly into the cowl module structure, the patent eliminates the need for long external ducts. The duct becomes a built-in feature of the cowl module, significantly reducing its length and improving accessibility for installation and maintenance operations.
Solution Approach 2:
The air intake duct is pre-formed as an integral part of the cowl module during manufacturing, rather than being assembled separately. This preliminary integration reduces installation complexity and improves accessibility, as the duct is already in its final position and configuration when the vehicle is assembled.
3Volume of stationary object
If air filter is integrated into the guard ply on the bonnet, then space is utilized, but the filter design requires minimized crushing stiffness requiring special materials and artifices increasing design and installation cost
Solution Approach 1:
The patent integrates the air filter elements directly into the cowl module structure, combining the filtration function with the existing structural component. This eliminates the need for separate filter housings and complex mounting mechanisms, reducing design and manufacturing costs while effectively utilizing the space available in the cowl module.
Solution Approach 2:
The cowl module serves as both a structural protective element and a housing for the air filter elements. This multi-functional design eliminates the need for specialized filter integration techniques and reduces overall design complexity and cost.
4Productivity
If multiple separate air intake elements are positioned according to remaining space, then all components can be installed, but assembly becomes less optimal and more time-consuming
Solution Approach 1:
The patent combines multiple air intake elements (duct, filter elements, cowl module) into a single integrated assembly. This reduces the number of separate parts that need to be handled and assembled, significantly improving assembly speed and productivity.
Solution Approach 2:
The air intake elements are pre-assembled into the cowl module structure during manufacturing. This preliminary integration means that fewer components need to be assembled on the production line, reducing assembly time and improving productivity.
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 results in a more compact, cost-effective, and easier-to-assemble air intake system, facilitating engine access, reducing development costs, and improving maintenance efficiency while providing clean air for both the engine and passenger compartment.
Implementation Method 1
a primary filter element located in a chamber primary from which the filtered air is channeled
Implementation Method 2
a secondary filter element located in a secondary chamber from which the Filtered air is channeled
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The module (100) has a front face (3) that is arranged with regard to an engine compartment (1), and a posterior face (4) that is placed with regard to a passenger compartment (2). An air inlet pipe includes an air intake port (5) that is placed on a periphery of the module. A primary filtering element is located in a primary chamber, and filtered air is channeled towards a primary connection opening (14) placed on the periphery of the module. The connection opening is connected to an air intake system of an engine. An independent claim is also included for a vehicle.