Reusable Air Filter for Engine Intake Systems
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Solution Overview
Problem
Enclosed air boxes with paper filters in engines suffer from restricted airflow as particulates build up, leading to decreased engine performance, increased fuel consumption, and potential contamination, with discarded filters contributing to landfill waste.
Innovation Solution
An aircharger air intake system featuring an open air box with a filter medium that can be cleaned and reused, comprising an air filter supported by an air box with a mount wall and an intake tube configured to conduct filtered air directly to the engine intake, reducing air resistance and incorporating adapters for sensors and ventilation hoses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an enclosed air box with a paper filter is used, then the engine is protected from particulate contamination, but air flow becomes restricted as particulates build up in the filter
Solution Approach 1:
The patent enables the air filter to be recovered and reused through cleaning instead of being discarded. The filter medium is designed to withstand repeated cleaning cycles, allowing it to be restored to its original filtering capability. This resolves the contradiction by maintaining engine protection while eliminating the progressive air flow restriction that occurs with single-use filters.
Solution Approach 2:
The patent transforms the static, single-use filter into a dynamic, reusable component. The filter medium can transition between a contaminated state and a cleaned state, allowing it to dynamically restore its air flow properties while maintaining its protective function. This dynamic capability resolves the contradiction between continuous protection and sustained air flow.
2Object-affected harmful factors
If a paper filter is used in an enclosed air box, then particulates are removed from the air, but the filter must be discarded and replaced when clogged, contributing to landfill waste
Solution Approach 1:
The patent implements a recovery system for the air filter by enabling it to be cleaned and reused multiple times. The filter medium is specifically designed to withstand repeated cleaning without degrading its filtering capability. This eliminates the need to discard the filter after single use, thereby preventing filter material from entering landfills while maintaining effective particulate removal.
Solution Approach 2:
The filter system is designed to be self-regenerating through cleaning processes that restore its filtering capability. Rather than requiring replacement, the filter serves itself by being cleaned and reused, converting a consumable waste product into a sustainable, reusable component that continuously provides particulate removal without contributing to landfill waste.
3Reliability
If an enclosed air box with ductwork is used, then the air filter is protected, but the air box and ductwork create additional air restriction that decreases engine performance
Solution Approach 1:
The patent extracts the filter from the enclosed air box configuration and positions it in an open, exposed location. This eliminates the need for complex ductwork and air box structures, removing the source of additional air restriction. The filter remains protected through its mounting design while allowing direct, unrestricted air flow to the engine, thereby resolving the contradiction between protection and performance.
Solution Approach 2:
The patent separates the filtering function from the air delivery function. Rather than using an enclosed box that combines both functions with associated restrictions, the filter is positioned independently to perform its protective function while allowing free air flow through separate, unrestricted pathways to the engine intake. This segmentation resolves the contradiction by eliminating the air restriction caused by enclosed structures.
4Strength
If a flat panel pleated paper filter is placed inside an enclosed plastic box, then the filter is protected from damage, but the enclosed box creates a tortuous air path that restricts airflow
Solution Approach 1:
The patent extracts the filter from the enclosed plastic box configuration and installs it in an open location directly accessible to air flow. The filter is mounted using a design that provides necessary protection and support without requiring enclosing walls and ductwork. This extraction eliminates the tortuous air path created by the enclosed box while maintaining filter integrity through alternative mounting protection.
Solution Approach 2:
The patent separates the protective mounting structure from the air flow pathway. The filter is secured using a mounting system that provides structural support and protection independent of the air delivery path. This allows air to flow directly to the filter and through to the engine without navigating around enclosed structures, resolving the contradiction between protected mounting and free air flow.
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
Improves engine performance by maintaining airflow, reducing fuel consumption, and minimizing waste through the use of a reusable air filter system that can be periodically cleaned, thereby extending the filter's lifespan and reducing environmental impact.
Implementation Method 1
an air filter comprising a filter medium configured to entrap particulates flowing within the airstream
Data Source
AI summary
An apparatus and a method are provided for an aircharger air intake system for filtering and conducting an airstream to an air intake of an engine. The aircharger air intake system includes an air filter comprising a filter medium configured to entrap particulates flowing within the airstream. An air box comprising one or more sidewalls and a mount wall is configured to support the air filter within an engine bay. The air box is configured to be mounted, or fastened, onto the engine. An intake tube is coupled with the air filter and configured to conduct the airstream to the air intake of the engine. The intake tube is configured to be coupled with an air temperature sensor or a mass air sensor of the engine. An adapter is configured to couple the intake tube with the air intake.