INTAKE SYSTEM FOR A MOTORCYCLE

FIELD OF THE INVENTION

[0001] The subject matter as described herein, relates generally to an intake system and more particularly, to an air cleaning device for a straddle type vehicle with a swinging power unit.

BACKGROUND OF THE INVENTION

[0002] A straddle type vehicle with a swinging power unit is generally propelled by an internal combustion engine provided at a lower portion of the vehicle. The engine has a combustion chamber which receives combustible mixture (air-fuel mixture) through an air-fuel mixing chamber via an intake pipe. The air in the air-fuel mixture is filtered through an intake system comprising an air cleaning device drawing in the environmental air and supplying it to the air-fuel mixing chamber after filtering through a filter element. In this way, the air cleaning device removes undeirable impurities like moisture, dirt, dust, chaff and the like from the environmental air which have the potential to damage the engine and the fuel system. However, there are a few problems faced in the air cleaning device.

[0003] In a typical air cleaning device layout for a straddle type vehicle, there is an inlet through which the environmental air is sucked in. During rain, the air cleaning device is prone to undesirable entry of water as well as air laden with water during suction and absence of a suitable draining provision may exacerbate the problem. Secondly, the air cleaning device in such straddle type vehicle is usually compactly located below a utlity box. Obtaining maximum flow area utilizing the entire surface area of the filter element in a compact layout is always a challenge. Thirdly, a PCV (positive crankcase ventilation) chamber integrated with the air cleaning device is connected to the engine crankcase through a pipe to absorb any oil mist (or oil vapour) or any blow-by gas arising out of the crankcase. A portion of the oil mist from the crankcase gets accumulated in the PCV chamber and a draining provision is required to expel it. Another portion of the oil mist may escape into the body of air cleaning device and need effective draining. Fourtly, an outlet pipe which carries the filtered air to the air-fuel mixing chamber is usually glued to the outer surface of the air cleaning device. The glue spreads out and is difficult to confine to a particle portion on the outer surface of the cleaning device. The present invention intends to solve all or any of the above problems and obviate any lacunae in the prior art.

[0004] Hence, the present subject matter is directed to overcome one or more problems as set forth above. It is therefore an object of the present invention to develop an improved intake system comprising an air cleaning device with suitable intake, filtering and draining provisions for filtering and supplying the environmental air to the air-fuel mixing chamber without the aforesaid problems. It is another object of the present invention to disclose an improved air cleaning device for a straddle type vehicle with swinging power unit having the capability of effectively draining the accidentally entered water or oil out of the device.

SUMMARY OF THE INVENTION

[0005] To this end, the present subject matter discloses an air cleaning device comprising of a pre filter member comprising an air inlet opening, a post filter member, a filter element comprising a filtering component disposed between the pre filter member and the post filter member, the pre filter member, the post filter member and the filter element secured together to develop into the said air cleaning device. The said air cleaning device is characterised in that, an air inlet tube comprising a plurality of air channels is connected to the pre filter member at the air inlet opening to avoid water entry to the air cleaning device, the filtering component in the filter element is disposed angularly with respect to the ground plane to maximise the air flow area for increased filtration, a PCV chamber is integrated formed with and connected to the post filter member through an orifice and separated from the post filter member by a wall, the PCV chamber further comprising a plurality of horizontally and vertically disposed compartments to stop the flow of oil and water, and a PCV cover mechanically connected to the PCV chamber and having a breather hose for connecting the PCV chamber to an engine crankcase.

[0006] The air cleaning device is further characterised in that the post filter member further comprises at least two drains for effective draining of water and oil (including any oil vapour or oil mist) wherein a first drain is provided inside the PCV chamber to drain oil and a second drain is provided inside the post filter member to drain water as well as oil, and a cylindrical projection is provided on the outer surface of the post filter member for effective gluing between an air outlet pipe and the post filter member.

[0007] According to an embodiment of the present invention, the air inlet opening of the pre filter member is inclined toward the ground at a lower portion of the pre filter member for draining the water entering the air cleaning device through the air inlet opening, and the air inlet tube is located inwardly of the pre filter member. According to another embodiment of the present invention, the air inlet opening of the pre filter member is located toward an upper portion of the pre filter member and the air inlet tube is located outwardly of and supported on the pre filter member, the air inlet tube positioned between the left frame member and pillion foot rest so that the air channels face toward a side panel of the vehicle.

[0008] The foregoing objectives and summary provide only a brief introduction to the present subject matter. To fully appreciate these and other objects of the present subject matter as well as the subject matter itself, all of which will become apparent to those skilled in the art, the ensuing detailed description of the subject matter and the claims should be read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above and other features, aspects, and advantages of the subject matter will be better understood with regard to the following description, appended claims and accompanying drawings where:

FIG. 1 shows a side view of a typical straddle type vehicle.

FIG. 2 shows a side view of a straddle type vehicle incorporating a first embodiment of the air cleaning device according to the present invention.

FIG. 3 shows a side view of the air cleaning device according to the first embodiment of the present invention.

FIG. 4 shows an exploded view of the air cleaning device of FIG. 3.

FIG. 5(a) shows an inner perspective view of a pre filter member of the air cleaning device of FIG. 3.

FIG. 5(b) shows a perspective view of an air inlet tube assembled with the pre filter member of the air cleaning device of FIG. 3.

FIG. 6(a) and 6(b) respectively show inner and outer views of the pre filter member according to the present invention.

FIG. 7 shows a perspective view of a filter element of the air cleaning device of FIG. 3.

FIG. 8(a) and 8(b) respectively show inner and outer views of a post filter member of the air cleaning device of FIG. 3.

FIG. 9 shows a perspective view of the post filter member with a PCV chamber in the air cleaning device of FIG. 3.

FIG. 10 shows another implementation of the PCV chamber in the air cleaning device.

FIG. 11(a) shows a perspective view of a pre filter member according to a second embodiment of the air cleaning device.

FIG. 11(b) shows an air inlet tube connected to the pre filter member according to the second embodiment of the air cleaning device of FIG. 11(a).

DETAILED DESCRIPTION OF THE INVENTION

[00010] The present invention is now briefly explained with the help of rendered FIGs. 1-11. The subject matter disclosed herein relates to an improved intake system comprising an air cleaning device to provide maximum air flow area for air Alteration and to prevent entry of undesirable impurities like oil (including oil vapours or oil mist) and water into the device, and if they enter, to provide adequate draining provisions for expelling the oil and water in order to prevent them from getting accumulated and affect the intake system's performance. Various other features and embodiments of the improved intake system according to the present invention here will be discernible from the following further description thereof, set out hereunder. The brief description is to be understood as an exemplary embodiment and reading of the invention is not intended to be taken restrictively. In the ensuing exemplary embodiments, the vehicle is a straddle ride type vehicle. However it is contemplated that the proposed air cleaning device may be applied to other types of vehicles within the spirit and scope of this invention including a scooter type motorcycle.

[00011] FIG. 1 illustrates a side view of an embodied straddle type vehicle with a swinging power unit. Typically such a vehicle includes a body frame assembly made up of several tubes welded together which usually supports the body of the said vehicle. The vehicle has a steerable anterior wheel 110 and a driven rear wheel 111 driven by driving force generated by the power unit. The body frame assembly 101 of the vehicle is an elongated structure, which typically extends from a forward end to a rearward end of the vehicle. It is generally convex in shape, as viewed from a side elevational view. The body frame assembly 101 includes a head pipe and a down pipe that extends downward from the head pipe, and is covered by a plurality of vehicle body covers including a front panel 115, a leg shield 116, an under seat cover 117 and a side panel 112. The head pipe is provided at the anterior end of the body frame 101.

[00012] A handlebar assembly 105 and a seat assembly 106 are supported at opposing ends of the frame assembly and a generally open area is defined there between known as floorboard 107 which functions as a step through space. A fuel tank (not shown) that stores fuel supplied to the engine is disposed at the rear end of the vehicle above the rear wheel 111. It is present on the upper side of the power unit along with a fuel tank cap. The seat for a driver and a pillion is placed forward to the fuel tank and rearwardly of the floorboard 107. A muffler is provided to the right side of the rear wheel, and connects to the engine. A side stand fixed to the left side of the body frame supports the vehicle such that vehicle inclines to the left side without falling.

[00013] Typically, a front suspension assembly 103 is operatively positioned between the anterior wheel 110 and the frame assembly. Similarly a rear suspension assembly 114 is operatively positioned between the rear wheel 111 and the frame assembly. The front suspension assembly 103 commonly is a telescopic fork arrangement while the rear suspension assembly 114 is a hydraulic damped arrangement.

[00014] In the said vehicle, the rear suspension swing arm typically supports the power unit which is configured to drive the rear wheel 111 of the vehicle. The power unit is structured such that an engine 102 and a swing case 108, which are well known for this form of straddle type vehicle, are integrally constructed. In an embodiment of the present invention, the engine is a four stroke single cylinder internal combustion engine and the swing case 108 is connected to a left side surface of a crankcase of the engine 102 so as to extend forward.

[00015] It is disposed on the vehicle frame with one end of the swing case 108 attached to the rear wheel hub in such a way that the power unit is substantially angularly disposed to the ground. The engine 102 is arranged horizontally, that is, its crankshaft is placed perpendicularly to the longitudinal direction of the vehicle body. Since the basic construction of an engine is known to those versed in the art, the details have been omitted. The said power unit is surrounded by a shroud (not shown) with a fan to enhance forced cooling of the power unit. The shroud present over the power unit is also known as cooling cowl and may be made of plastic resin or the likes.

[00016] FIG. 2 shows a side view of the straddle type vehicle incorporating a first embodiment of the air cleaning device according to the present invention. The figure shows the mounting position of the air cleaning device 200 disposed just below a utility box 118 and above the swing case 108 with the help of a mounting provision 201 connected to the swing case 108. The air cleaning device 200 is mounted on a left side of the longitudinal axis of the straddle type vehicle and laterally to the rear wheel 111. An outlet pipe 202 supplies the filtered air from the air cleaning device 200 to the air-fuel mixing chamber.

[00017] FIG. 3 shows a side view of the air cleaning device 200 according to the first embodiment of the present invention whereas FIG. 4 shows an exploded view of the same. The air cleaning device 200 comprises a pre filter member 300 comprising an air inlet opening 303, a post filter member 500 and a filter element 400 comprising a filtering component 401 disposed between the pre filter member and the post filter member. During air cleaning device assembly, the pre filter member 300, the filter element 400 and post filter member 500 are secured to each other through fasteners 204 disposed in the openings 203 provided, to develop into the said air cleaning device. The profile of the pre filter member 300 and post filter member 500 is substantially similar so as to provide an overall similar profile to the air cleaning device 200. The individual members making up the air cleaning device are further described in detail in the subsequent figures.

[00018] FIG. 5(a) shows a perspective view of the pre filter member of the air cleaning device of FIG. 3. An outer surface 301 of the pre filter member 300 is visible to an onlooker from a left side of the vehicle with the styling parts of the straddle type vehicle removed whereas an inner surface 302 is invisible to him. The environmental air enters the pre filter member 300 through the air inlet opening 303. The air inlet opening 303 forms a rectangular recess and is provided at a lower portion of the outer surface 301 of the pre filter member 300 as shown in FIG. 6(b). The location of the air inlet opening 303 reduces the chance of water entry during rain due to being located at a lower portion of the pre filter member 300. It also facilitates ease of draining of water if it enters the pre filter member as the water (or impurities) drain out naturally towards the ground.

[00019] FIG. 5(b) shows a perspective view of an air inlet tube 304 assembled with the pre filter member 300 according to a first embodiment of FIG. 3. It is connected to the pre filter member 300 at the air inlet opening 303. The air inlet tube 304 comprises a plurality of air channels, jointly referred by the numeral 305, for channelizing the incoming air towards the filter element 400 separately provided. In the first embodiment, it is supported and located inwardly of the pre filter member 300 in such a way that it is either integrated with or secured to the inner surface 302 of the the pre filter member 300. The air inlet tube 304 has recesses 306b through which it is secured to the corresponding recesses 306a on the inner surface 302 of the pre filter member 300. It is to be noted that the air inlet tube 304 and pre filter member 300 are individual, separate and mechanically connectable components. In an embodiment, the air inlet tube 304 is joined and formed integral with the inner surface 302 of the pre filter member 300 by hot melting process.

[00020] Further, the air inlet opening 303 of the pre filter member and the said air channels 305 of the air inlet tube 304 are substantially planar and angularly disposed to each other as shown in FIG. 6(a). The air inlet tube 304 is inclined towards the ground for easy draining of water (or other impurities) entered in the air cleaning device 200 through the air inlet opening 303. Therefore, when the environmental air is sucked in by the air cleaning device 200, it does not directly goes into the filter element 400. It enters the pre filter member 300, passes through the air channels 305 of the air inlet 1tube 304 and thereafter flows towards the filter element 400. The orientation of the air inlet tube 304 and presence of air channels 305 ensure that the probability of entry of water or water contained in moist air to enter the air cleaning device is least. Even if the water enters the air inlet opening 303 along with the environmental air, it will strike the inner surface 302 of the pre filter member 300 and will drain out from the air inlet itself.

[00021] FIG. 7 shows a perspective view of the filter element 400 of the air cleaning device 200 according to the present invention. The filtering component 401 filters the air received after passing through the air channels 305 of the air inlet cover 304. In the given profile, if the filtering component is placed perfectly horizontal or perfectly vertical, it leads to area loss. Hence, within the profile of the air cleaning device 200, the filtering component 401 in the said filter element 400 is disposed angularly with respect to the ground plane to maximize the air flow area for increased air filtration. The angle is shown by the alphabet A. In an embodiment of the present invention, the said filtering component 401 is oriented 45 degrees to the ground plane. In this way the filter element has maximum area due to which more air may pass through the filtering component 401. A wall at the lower portion of filtering component may be included to support it.

[00022] FIG. 8(a) shows an inner view of the post filter member 500 of the air cleaning device 200. A PCV chamber (positive crankcase ventilation chamber) 600 is located outwardly from an outer surface 501 of the post filter member 500.

The PCV chamber 600 is separated from an inner surface 502 of the post filter member 600 by a wall 604 integrated with the inner surface 502. The wall 604 has ' an orifice 603 connecting the PCV chamber 600 and post filter member 500.

[00023] FIG. 9 shows a perspective view of post filter member 500 with the PCV chamber 600 according to an implementation. The PCV chamber 600 further comprises of a plurality of horizontally and vertically disposed walls 606, and a separate PCV cover 601 present outwardly to and mechanically connected with the PCV chamber 600. In an embodiment of the present invention, the PCV cover 601 is welded on the PCV chamber 600. The PCV cover 601 has a breather hose 605 on its outer surface for connecting for connecting the PCV chamber to the engine crankcase. The walls 606 in the PCV chamber do not allow the oil mist (or oil vapour) received from the engine crankcase via breather hose 605 to directly enter the post filter member 500. FIG. 10 shows another implementation of the walls of the PCV chamber 600 wherein it has at least one horizontally oriented and at least two vertically oriented walls. The walls in the respective embodiments act as a barrier preventing the oil mist from escaping into the post filter member. The oil mist hits the walls 606 and is collected in the PCV chamber 600 itself due to which it is partially blocked from going directly inside the post filter member 500 through the orifice 603. The collected oil mist is drained out by a first drain 602. Similarly water if collected can be drained out from the first drain 602. Further, if the oil mist escapes into the post filter member through the orifice 603, a drain path 504 connecting to a second drain 505 for guiding the oil to the second drain 505 is provided for the oil and water to go out of the post filter member 500.

In this way, the post filter member 500 has at least two drains provided to prevent accumulation of oil and water. The first drain 602 has a higher collection volume while the second drain 505 has a low collection volume. Th'e drain path 504 follows the profile of the post filter member.
[00024] FIG. 8(b) shows the outer view of the post filter member 500 of the air cleaning device 200. The filtered air exits from the air cleaning device 200 through the outlet pipe 202 glued to the outer surface 501 of the post filter member 500. For the glue to hold, to be retained and for proper gluing between the outlet pipe 202 and the outer surface 501 of the post filter member 500, a cylindrical projection 503 is provided on the outer surface of the post filter member around the connecting area. Due to the cylindrical projection 503, the applied glue remains confined to the connecting area and hence leads to better gluing.

[00025] Another implementation of the air cleaning device is described below with the help of FIGs. 11(a) and 11(b). FIG. 11 (a) shows a perspective view of a pre filter member according to a second embodiment of the air cleaning device. Here, the air inlet opening 303 of the pre filter member 300 is located toward an upper portion of the pre filter member 300. The air inlet tube 304 is located outwardly of and supported on the pre filter member unlike the first embodiment. The air channels now project out of the pre filter member 300 and help reduce the induction noise. Here, the air inlet tube positioned between the left frame member and pillion foot rest and is bent or curved so that the air channels face toward a side panel of the vehicle.

[00026] According to an aspect, the air inlet tube is made of any material including plastic resin or rubber. Specially, the use of rubber significantly reduces induction noise.

[00027] The present subject matter is thus described. The description is not intended to be exhaustive nor is it intended to limit the invention to the precise form disclosed. It will be apparent to those skilled in the art that the disclosed embodiments may be modified in light of the above description. The embodiments described are chosen to provide an illustration of principles of the invention and its practical application to enable thereby one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore the forgoing description is to be considered exemplary, rather than limiting, and the true scope of the invention is that described in the appended claims.

We claim:

1. An air cleaning device connected to an air-fuel mixing chamber in a straddle type vehicle with a swinging power unit, the air cleaning device comprising of:

(a) a pre filter member comprising an air inlet opening,

(b) a post filter member,

(c) a filter element comprising a filtering component disposed between the pre filter member and the post filter member, the pre filter member, the post filter member and the filter element secured together to develop into the said air cleaning device, characterised in that, an air inlet tube is connected to the pre filter member at the air inlet opening to avoid water entry to the air cleaning device, the air inlet tube further comprising a plurality of air channels for channelizing the incoming air towards the said filter element, the filtering component in the said filter element is disposed angularly with respect to the ground plane to maximise the air flow area for increased filtration, a PCV chamber is integrally formed with and connected to the said post filter member through an orifice and separated from the post filter member by a wall, the PCV chamber further comprising a plurality of horizontally and vertically disposed walls to stop the flow of oil and water, and a PCV cover mechanically connected with the PCV chamber and having a breather hose on the outer surface of the PCV cover for connecting the PCV chamber to an engine crankcase, the PCV cover made of any material including plastic resin,' the post filter member further comprises at least two drains for effective draining of water and oil mist (or oil vapour) wherein a first drain is provided inside the PCV chamber to drain oil and a second drain is provided inside the post filter member to drain water as well as oil, and wherein further a cylindrical projection is provided on the outer surface of the post filter member for effective gluing between an air outlet pipe and the post filter member.

2. The air cleaning device as claimed in claim 1, wherein the air inlet opening of the pre filter member is inclined toward the ground at a lower portion of the pre filter member for draining the water entering the air cleaning device through the air inlet opening.

3. The air cleaning device as claimed in claim 2, wherein the air inlet tube is supported and located inwardly of the pre filter member.

4. The air cleaning device as claimed in claim 1, wherein air inlet opening of the pre filter member is located toward an upper portion of the pre filter member.

5. The air cleaning device as claimed in claim 4, wherein the air inlet tube is located outwardly of and supported on the pre filter member, the air inlet tube positioned between the left frame member and pillion foot rest so that the air channels face toward a side panel of the vehicle.

6. The air cleaning device as claimed in claim 1, wherein the said air inlet opening of the pre filter member and the said air channels of the air inlet tube are substantially planar and angularly' disposed to each other.

7. The air cleaning device as claimed in claim 1, wherein the air inlet tube and the pre filter member are individual, separate and mechanically connectable components.

8. The air cleaning device as claimed in claim 7, wherein the air inlet tube is joined and made integral to the pre filter member by hot melting process.

9. The air cleaning device as claimed in claim 1, wherein the air inlet tube is made of any material including plastic resin or rubber.

10. An intake system for a straddle type vehicle with a swinging power unit comprising of the air cleaning device as claimed in any of the preceding claims.