Integrated frame and air box method and apparatus

• US 20080190683A1
• Filed: 05/02/2005
• Published: 08/14/2008
• Est. Priority Date: 05/02/2005
• Status: Active Grant

• Current Assignee: Polaris Industries Incorporated (Polaris Inc.)
• Original Assignee: Polaris Industries Incorporated (Polaris Inc.)
• Inventors: Hoeve, Jason W. B.
• Granted Patent: US 7,779,950 B2
• Time in Patent Office: Days
• US Class Current: 180/229
• CPC Class Codes: B60K 13/06 using structural parts of the vehicle as ducts, e.g. frame parts
• CPC Class Codes: B60Y 2200/12 Motorcycles, Trikes; Quads; Scooters
• CPC Class Codes: B62K 11/08 the beam being fabricated from sheet metal, e.g. forming fuel tank walls
• CPC Class Codes: B62K 19/12 having cast members
• CPC Class Codes: B62K 19/30 Frame parts shaped to receive other cycle parts or accessories axle suspensions B62K25/00
• CPC Class Codes: F02D 29/02 peculiar to engines driving vehicles; peculiar to engines driving variable pitch propellers
• CPC Class Codes: F02D 9/02 concerning induction conduits throttle valves, or arrangements thereof in conduits F02D9/08
• CPC Class Codes: F02M 35/02 Air cleaners
• CPC Class Codes: F02M 35/10052 special shapes or arrangements of plenum chambers; Constructional details
• CPC Class Codes: F02M 35/10255 Arrangements of valves; Multi-way valves F02M35/10032 takes precedence; valves in the plenum chamber F02M35/10065; check valves F02M35/10275
• CPC Class Codes: F02M 35/116 for engines with cylinders in V-arrangement or arranged oppositely relative to the main shaft
• CPC Class Codes: F02M 35/162 Motorcycles; All-terrain vehicles, e.g. quads, snowmobiles; Small vehicles, e.g. forklifts

Abstract

The present teachings generally include a motorcycle having an engine with at least two cylinders. A first cylinder head has a first top portion and a first side portion. A second cylinder head has a second top portion and a second side portion. The first cylinder head and the second cylinder head are associated with the engine. A frame member defines an integral air box that communicates air into the engine. The frame member couples to the first side portion of the first cylinder head and the second side portion of the second cylinder head.

Claims

1. A motorcycle having an engine with at least two cylinders, the motorcycle comprising:

a first cylinder head having a first top portion and a first side portion;

a second cylinder head having a second top portion and a second side portion, said first cylinder head and said second cylinder head associated with the engine; and

a frame member defining an integral air box communicating air into the engine, wherein said frame member couples to said first side portion of said first cylinder head and said second side portion of said second cylinder head.

2. The motorcycle of claim 1 further comprising a front fork journal formed in said frame member, wherein a position of said front fork journal is based on a first mounting location associated with said first side portion and a second mounting location associated with said second side portion.

3. The motorcycle of claim 1 wherein said integral air box defines an intake aperture and output aperture.

4. The motorcycle of claim 3 further comprising a filter assembly releaseably connected to a portion of said frame member that defines said intake aperture.

5. The motorcycle of claim 4 further comprising a fuel tank coupled to at least a portion of said frame member, said fuel tank spaced from said intake aperture such that said filter assembly is removable from said intake aperture without removing said fuel tank from said frame member.

6. The motorcycle of claim 4 further comprising a valve coupled to said filter assembly, said valve moveable to an open condition, a closed condition and a plurality of positions therebetween.

7. The motorcycle of claim 6 wherein said valve coupled to said air box reduces noise from said air box when in said closed position relative to said open position.

8. The motorcycle of claim 6 further comprising a control module that detects an engine load and controls said valve to one of said open condition, said closed condition and said positions therebetween based on said detection of said engine load.

9. The motorcycle of claim 8 wherein said detection of said engine load includes determining at least one of an ignition speed, an intake air pressure, a throttle position, a mass airflow and combinations thereof.

10. The motorcycle of claim 6 wherein said valve is located on a side of the motorcycle having an exhaust pipe.

11. The motorcycle of claim 1 wherein said air box defined by said frame member has a unitary construction.

12. A motorcycle having an engine, the motorcycle comprising:

a frame member defining an integral air box, said integral air box defining an intake aperture and an output aperture;

said output aperture coupled to an intake system that is coupled to the engine;

a filter assembly releaseably connected to a portion of said frame member and received by said intake aperture; and

a fuel tank coupled to at least a portion of said frame member, said fuel tank spaced from said intake aperture such that said filter assembly is removable from said intake aperture without removing said fuel tank from said frame member.

13. The motorcycle of claim 12 further comprising a valve coupled to said filter assembly, said valve moveable to an open condition, a closed condition and a plurality of positions therebetween.

14. The motorcycle of claim 13 wherein said valve coupled to said air box reduces noise from said air box when in said closed position relative to said open position.

15. The motorcycle of claim 13 further comprising a control module that detects an engine load and controls said valve to one of said open condition, said closed condition and said positions therebetween based on said detection of said engine load.

16. The motorcycle of claim 15 wherein said detection of said engine load includes determining at least one of an ignition speed, an intake air pressure, a throttle position, a mass airflow and combinations thereof.

17. The motorcycle of claim 13 wherein said valve is located on a side of the motorcycle having an exhaust pipe.

18. A motorcycle having an engine, the motorcycle comprising:

an air box integrally formed from a frame member, said air box defining an intake aperture and an output aperture;

a valve assembly in communication with said intake aperture selectively moveable between an about open position, an about closed position and a plurality of positions therebetween; and

a control module that detects a load on the engine and that controls said valve to one of said open conditions, said closed condition and said positions therebetween based on said detection of said load on said engine.

19. The motorcycle of claim 18 wherein said detection of said engine load includes determining at least one of an ignition speed, an intake air pressure, a throttle position, a mass airflow and combinations thereof.

20. The motorcycle of claim 18 wherein said air box communicates air into the engine.

21. The motorcycle of claim 18 further wherein said valve is located on a side of the motorcycle having an exhaust pipe.

22. The motorcycle of claim 18 further comprising a filter assembly coupled to said valve assembly.

23. A motorcycle having an engine, the motorcycle comprising:

a unitary frame member defining an integral air box, said integral air box defining an intake aperture and an output aperture;

a flexible member disposed in said output aperture and coupled to said air box; and

an intake system having an intake member sealingly engaged to said flexible member;

said intake system connected to the engine.

24. A frame member defining an air box that couples to an engine, the air box comprising:

a plurality of walls having a unitary construction, said walls defining a space within said walls;

at least one intake aperture and a single output aperture defined by said walls, said output aperture coupling to the engine and

a journal at least partially defined by said walls.

25. The air box of claim 24 further comprising an internal plate defined by said walls within said space.

26. The air box of claim 25 wherein said plate further defines at least one hole formed therein.

27. The air box of claim 25 wherein said plate reduced noise from the air box relative to the air box without said plate.

28. The air box of claim 24 wherein said walls further define a lip and wherein said lip defines a periphery of said single output aperture.

29. The air box of claim 24 wherein said air box includes two intake apertures and wherein said two intake apertures are about coaxial.

32. The motorcycle of claim 24, further comprising by an internal plate defined by said walls within said space.

30. A method of aligning an air box integral to a frame to an engine, the method comprising:

providing the air box having a front mounting boss and rear mounting boss;

providing an intake manifold connected to the engine;

coupling the air box to the engine; and

sealing the air box to the intake manifold by coupling the air box to the engine.

31. A motorcycle comprising a frame member having a front journal portion and a rear mounting portion, and an air box associated with said frame member, said air box comprising a plurality of walls having a unitary construction with at least one output aperture coupled to the engine, the motorcycle further comprising a filtration system filtering air entering said air box and having at least one intake opening and a filter member, the filter member being positioned adjacent to said at least one intake opening and internally of said air box, whereby said air flow is through said at least one intake opening into said air box, through said filter and to said engine.