Sealed Intake Air System With Captive Fasteners
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Solution Overview
Problem
Conventional air filter systems for internal combustion engines often require complex geometries and additional components to secure the air filter and isolate it from engine heat, leading to inefficiencies and increased complexity.
Innovation Solution
A sealed intake air system with a positive connection seal interface between the air filter and a one-piece airbox using captive fasteners, featuring a rigid molded air filter base with a flange and a bellows coupler made of silicone or similar materials, providing a secure and simplified attachment method without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air filter systems use complicated geometry and additional components to secure the air filter, then the air filter can be isolated from engine heat and secured in place, but the device complexity increases and weight increases
Solution Approach 1:
The air filter base is merged with the airbox into a single integrated component. The base includes an integrated seal that directly engages with the airbox, eliminating the need for separate mounting brackets, clips, or additional fastening hardware. This integration maintains reliable isolation from engine heat while significantly reducing device complexity.
Solution Approach 2:
The air filter base serves multiple functions simultaneously: it supports the air filter element, provides sealing against the airbox, structurally connects to the airbox, and isolates the air filter from engine heat. This multi-functionality eliminates the need for multiple separate components, reducing overall system complexity while maintaining reliability.
2Strength
If conventional air filter systems use additional hardware to secure the air filter, then the air filter can be firmly attached, but the weight of the system increases
Solution Approach 1:
The mounting structure is merged into the air filter base itself. The base includes integrated attachment features such as ribs, lugs, or direct engagement surfaces that are molded as part of the base structure. This eliminates the need for separate metal brackets, clips, or fasteners, maintaining strong attachment while significantly reducing weight.
3Reliability
If conventional air filter systems use complicated geometry to trap the air filter element, then the air filter can be secured and isolated, but the manufacturing complexity increases
Solution Approach 1:
The air filter base and airbox are designed as integrated components that can be manufactured using injection molding or similar processes. The seal and mounting features are incorporated into the base structure as a single molded part, eliminating the need for complex assembly operations, multiple machining steps, or intricate geometries. This integration maintains reliable air filter securing while significantly improving ease of manufacture.
Data Source
AI summary
A sealed intake air system incorporates a positive connection seal interface between the air filter and the airbox with captive fasteners to provide a positive connection between the air filter and the one-piece airbox.