Sealed Air Intake Assembly With Tool-Free Filter Tube Coupling
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Solution Overview
Problem
Existing air intake assemblies for internal combustion engines either lack efficiency in separating intake air from other air in the engine compartment or complicate installation and maintenance, with open-element filter housings being easy to install but inefficient and sealed filter housings being difficult to maintain.
Innovation Solution
An air intake assembly featuring a sealed filter housing with a multi-component coupling interface that securely connects the air filter and intake tube without fastening hardware, using a clearance engineering fit to simplify installation and maintenance, and includes features like a hump coupler and clamps for easy integration with engine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an open-element filter housing is used, then ease of installation and maintenance is improved, but efficiency in separating intake air from other air in the engine compartment deteriorates
Solution Approach 1:
The filter housing is divided into a sealed housing structure and a separate access cover, allowing the housing to remain sealed for efficient air separation while the cover can be easily removed for maintenance. This segmentation resolves the contradiction by separating the functions of air isolation and maintenance access.
Solution Approach 2:
A multi-component coupling interface acts as an intermediary between the filter element and the sealed housing, providing both secure sealing and easy installation. The coupling interface includes features like clips or snap-fits that enable tool-free installation while maintaining the sealed environment required for effective air separation.
2Reliability
If a sealed filter housing is used, then efficiency in separating intake air from other air in the engine compartment is improved, but ease of installation and maintenance deteriorates
Solution Approach 1:
The sealed housing is segmented with a removable cover or access panel that can be easily opened for maintenance while the main housing remains sealed. This allows the housing to provide efficient air separation when closed while enabling easy access to the filter element for replacement.
Solution Approach 2:
The coupling interface is designed with self-aligning or self-latching features that automatically guide and secure the filter element during installation, eliminating the need for complex fastening procedures. This self-service mechanism maintains the sealed environment while simplifying the installation process.
3Reliability
If fastening hardware is used to secure the air filter and intake tube, then connection reliability is improved, but device complexity and part count increase
Solution Approach 1:
The coupling interface merges multiple functions into a single integrated component that simultaneously provides sealing, mechanical attachment, and alignment features. This eliminates the need for separate fasteners, gaskets, and mounting brackets, reducing part count while maintaining connection reliability through the combined design.
Solution Approach 2:
The coupling interface employs self-latching or snap-fit mechanisms that automatically secure the filter element and intake tube without requiring additional fastening hardware. The design uses elastic deformation or geometric interlocking to create reliable connections that are both simple and secure.
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 solution provides an efficient air intake system that effectively separates intake air, offers easy installation and maintenance, and reduces the part count by eliminating the need for fastening hardware, while ensuring a secure and airtight seal.
Implementation Method 1
using a clearance engineering fit to simplify installation and maintenance
Data Source
AI summary
Disclosed herein are air intake assemblies for internal combustion engines. In some embodiments, an air intake assembly includes an air filter configured to produce filtered air, a sealed filter housing configured to house the air filter therein, and an intake tube configured to convey the filtered air to an internal combustion engine. The filter housing includes an air intake port configured to provide intake air to the air filter. The air filter is configured to remove particulate matter from the intake air and produce the filtered air. The air filter includes a multi-component coupling interface configured to accept an intake-end portion of the intake tube in the coupling interface. The filter housing includes an aperture configured to accept the coupling interlace of the air filter in the aperture. Also disclosed herein are methods of the air intake assemblies.