Lubricant manifold for an internal combustion engine

Abstract

A lubricant manifold includes a lubricant filter head, a pump inlet pipe, an inlet transfer pipe, and a lubricant cooler. The lubricant filter head is configured to be coupled to a lubricant filter. The pump inlet pipe is fluidly coupled to the lubricant filter head and is integrally formed with the lubricant filter head. The pump inlet pipe is configured to receive lubricant and supply the lubricant to the lubricant filter head. The inlet transfer pipe is fluidly coupled to the lubricant filter head and is integrally formed with the lubricant filter head and the pump inlet pipe. The inlet transfer pipe is configured to receive the lubricant from the pump inlet pipe. The lubricant cooler is fluidly coupled to the inlet transfer pipe and is integrally formed with the lubricant filter head, the pump inlet pipe, and the inlet transfer pipe.

Description

[0001] Cross - reference to related patent applications

[0002] This application claims the priority of U.S. Provisional Patent Application No. 63 / 021,926, filed on May 8, 2020, entitled "LUBRICANT MANIFOLD FOR INTERNAL COMBUSTION ENGINE", the content of which is incorporated herein by reference. Technical Field

[0003] This application generally relates to a lubricant manifold for an internal combustion engine. Background Art

[0004] For internal combustion engines such as diesel engines, lubricants are used to reduce friction between moving parts, such as the friction between the piston and the cylinder. Particles such as soot mix with the lubricant over time. Therefore, it may be desirable to remove the particles from the lubricant without removing the lubricant. Many systems remove the particles by passing the lubricant through a filter. Additionally, it is often desirable to cool the lubricant. For example, cooling the lubricant can ensure that the lubricant maintains its desired performance in applications such as high - performance or high - horsepower engines, where the lubricant is subjected to relatively high temperatures. Summary of the Invention

[0005] In a set of embodiments, the lubricant manifold includes a lubricant filter head, a pump inlet pipe, an inlet transfer pipe, and a lubricant cooler. The lubricant filter head is configured to be coupled to a lubricant filter. The pump inlet pipe is fluidly coupled to the lubricant filter head and is integrally formed with the lubricant filter head. The pump inlet pipe is configured to receive lubricant and supply the lubricant to the lubricant filter head. The inlet transfer pipe is fluidly coupled to the lubricant filter head and is integrally formed with the lubricant filter head and the pump inlet pipe. The inlet transfer pipe is configured to receive the lubricant from the pump inlet pipe. The lubricant cooler is fluidly coupled to the inlet transfer pipe and is integrally formed with the lubricant filter head, the pump inlet pipe, and the inlet transfer pipe. The lubricant cooler is configured to receive the lubricant from the inlet transfer pipe.

[0006] In another set of embodiments, an internal combustion engine system includes an engine block - head assembly and a lubricant manifold. The engine block - head assembly includes a lubricant manifold recess and a mounting surface. The mounting surface extends around the lubricant manifold recess. The lubricant manifold includes a body. The body is at least partially received within the lubricant manifold recess. The body includes a lubricant filter head, a lubricant cooler, and a flange. The lubricant filter head is configured to be coupled to a lubricant filter. The lubricant cooler is fluidly coupled to the lubricant filter head and is integrally formed with the lubricant filter head. The lubricant cooler supplies lubricant to the lubricant filter head. The flange is integrally formed with the lubricant filter head and the lubricant cooler. The flange is coupled to the mounting surface such that the lubricant cooler is at least partially received within the lubricant manifold recess.

[0007] In yet another set of embodiments, a lubricant manifold includes a lubricant cooler, an outlet transfer conduit, and a lubricant filter head. The lubricant cooler is configured to receive lubricant. The outlet transfer conduit is fluidly coupled to the lubricant cooler and is integrally formed with the lubricant cooler. The outlet transfer conduit is configured to receive the lubricant from the lubricant cooler. The lubricant filter head is configured to be coupled to the lubricant filter. The lubricant filter head is fluidly coupled to the outlet transfer conduit and is integrally formed with the lubricant cooler and the outlet transfer conduit. The lubricant filter head is configured to receive the lubricant from the lubricant cooler. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the present disclosure will become apparent from the description, the drawings, and the claims, in which:

[0009] Figure 1 is a schematic block diagram of an exemplary internal combustion engine system having a lubricant manifold and an engine block - head assembly;

[0010] Figure 2 is Figure 1 an exploded perspective view of the lubricant manifold and the engine block - head assembly;

[0011] Figure 3 is Figure 1 a perspective view of the lubricant manifold;

[0012] Figure 4 is Figure 3 a cross - sectional view of the lubricant manifold taken along plane A - A;

[0013] Figure 5 is Figure 1Another exploded perspective view of the lubricant manifold and engine block - head assembly; and

[0014] Figure 6 is another perspective view of a lubricant manifold for an internal combustion engine system.

[0015] It will be recognized that these drawings are schematic representations for illustrative purposes. The drawings are provided to illustrate one or more implementations, and it is to be clearly understood that the drawings are not intended to limit the scope or meaning of the claims. DETAILED DESCRIPTION

[0016] The following is a more detailed description of various concepts and their implementations related to methods and devices for providing a lubricant manifold for an internal combustion engine. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways, as the concepts described are not limited to any particular implementation. For illustrative purposes, examples of specific implementations and applications are provided primarily.

[0017] I. OVERVIEW

[0018] Many oil systems utilize oil coolers manufactured using multiple components. These components are brazed together using materials such as copper and nickel. In addition to the oil cooler being composed of multiple components, the oil filter housing often is also assembled from multiple components. In addition to being composed of multiple components, these components are often attached together using fasteners. These fasteners increase the complexity of assembling the filter housing and the oil cooler. These fasteners may also create leak paths through the filter housing and the oil cooler. Although gaskets can be included to slow these leak paths, the gaskets may deteriorate over time, resulting in potential leaks.

[0019] In addition to being undesirable from a performance and engine reliability perspective, leaks can also cause aesthetic and cleanliness issues. For example, when copper in components brazed together using copper leaches into the oil consumed by the engine, the copper may deposit on the surfaces within the engine. These deposits may slow the heat transfer between the pistons and the oil in the engine. Additionally, the copper can increase the temperature of the pistons within the engine and thus increase the oil temperature within the engine, as the copper reduces the transfer of heat from the pistons. Higher oil temperatures increase the rate of oxidation of the oil and thus result in increased degradation of the oil, which requires more frequent oil changes, which is undesirable.

[0020] The implementations described herein relate to an internal combustion engine system that includes a lubricant manifold having a body formed by additive manufacturing. The body includes a lubricant filter head configured to couple with a lubricant filter. The body also includes a lubricant cooler configured to cool the lubricant. The lubricant filter head and the lubricant cooler are integrally formed by additive manufacturing. Thus, there is no leak path between the lubricant filter head and the lubricant cooler. By eliminating the leak paths present in other systems assembled from multiple separate components (e.g., a filter head bolted to a cooler), the lubricant manifold described herein is able to protect the lubricant from leaking onto other components of the engine. Additionally, the lubricant manifold described herein does not use external brazing (soldering) materials. In this way, the lubricant manifold described herein does not include copper that could leach into the lubricant, thus maintaining the desired heat transfer between the piston and the lubricant.

[0021] II. Embodiments of the Lubricant Manifold

[0022] Figure 1 An internal combustion engine system 100 (e.g., a diesel internal combustion engine system, a gasoline internal combustion engine system, a dual-fuel internal combustion engine system, a hybrid internal combustion engine system, etc.) is depicted. The internal combustion engine system 100 includes an engine block-head assembly 102 (e.g., a cylinder block and a cylinder head, etc.).

[0023] The engine block-head assembly 102 defines at least one cylinder 104 (e.g., a combustion chamber, etc.). Each cylinder 104 receives air and fuel and provides exhaust after the air and fuel combust within the cylinder 104. The internal combustion engine system 100 also includes a piston 106 for each cylinder 104 and a connecting rod 108 for each cylinder 104. For example, if the engine block-head assembly 102 defines four cylinders 104, the internal combustion engine system 100 includes four pistons 106 and four connecting rods 108.

[0024] Each piston 106 is received within a cylinder 104 and is selectively repositioned (e.g., translated, slid, etc.) within the cylinder 104 during the combustion cycle that occurs within the cylinder 104. The connecting rod 108 is coupled to the piston 106 and receives the energy of the movement from the piston 106 through the combustion within the cylinder 104. The energy received from each connecting rod 108 is utilized by the internal combustion engine system 100 (e.g., using a crankshaft, etc.) and provided to an output (e.g., a drive shaft, etc.).

[0025] The cylinder 104 and the piston 106 are sized such that their diameters are within a relatively small percentage of each other (e.g., less than 1%, less than 0.5%, etc.). This difference facilitates the movement of the piston 106 within the cylinder 104. Additionally, it is desirable for this difference to be as small as possible in order to increase the energy provided to the connecting rod 108.

[0026] To make the difference between the diameter of the cylinder 104 and the diameter of the piston 106 as small as possible, the internal combustion engine system 100 circulates a lubricant (e.g., oil, etc.) between the cylinder 104 and the piston 106. The lubricant provides both a fluid seal between the cylinder 104 and the piston 106 and a mechanism to minimize the friction between the cylinder 104 and the piston 106.

[0027] The internal combustion engine system 100 includes a lubricant system 110 (e.g., an oil system, etc.) that circulates the lubricant. The engine block - head assembly 102 includes lubricant passages 112 (e.g., galleries, flow channels, etc.) through which the lubricant is routed. The lubricant passages 112 convey the lubricant between the piston 106 and the cylinder 104. Additionally, the lubricant passages 112 can convey the lubricant to other components of the engine block - head assembly 102 (e.g., valves, tappets, etc.).

[0028] The lubricant system 110 includes a lubricant pump 114 (e.g., an oil pump, etc.). The lubricant pump 114 is configured (e.g., structurally designed, capable, etc.) to be controlled (e.g., by an engine control unit (ECU), crank gear drive, etc.) such that the lubricant circulates within the lubricant system 110. The lubricant pump 114 is fluidly coupled (e.g., in fluid communication with, connected to, etc.) to an inlet conduit 116 of the lubricant system 110. The inlet conduit 116 is configured to receive the lubricant from the lubricant pump 114.

[0029] The inlet conduit 116 is in fluid communication with a lubricant inlet conduit 117 (e.g., an inlet passage, etc.) in the engine block - head assembly 102. For example, the inlet conduit 116 can be coupled to the lubricant inlet conduit 117 via a hose clamp (e.g., a ring clamp, etc.) such that the inlet conduit 116 is in fluid communication with the lubricant inlet conduit 117. The lubricant inlet conduit 117 is configured to receive lubricant from the inlet conduit 116. The lubricant inlet conduit 117 is in fluid communication with a lubricant manifold 118 (e.g., an integrated cooler, etc.). The lubricant manifold 118 is configured to receive lubricant from the lubricant inlet conduit 117. As explained in detail herein, the lubricant manifold 118 is received within a lubricant manifold recess 120 (e.g., a bore, etc.) formed within the engine block - head assembly 102. The lubricant manifold recess 120 is in communication with a lubricant passage 112 such that the lubricant passage 112 is configured to receive lubricant from the lubricant manifold 118 when the lubricant manifold 118 is received within the lubricant manifold recess 120.

[0030] The lubricant manifold 118 includes a body 121 (e.g., a frame, a housing, etc.). As explained in more detail herein, the body 121 is a one - piece construction. Thus, there are no gaps between the components of the body 121. By eliminating the gaps between the components of the body 121, the lubricant manifold 118 is not prone to lubricant leakage between the components of the body 121. In this way, the lubricant manifold 118 represents an improvement over other conventional systems that include multiple components attached together (e.g., using fasteners, using brazing, etc.) because the joints between these components of the conventional systems facilitate leakage.

[0031] In addition, eliminating the joints between multiple components also eliminates the use of joining materials (e.g., brazing materials, copper brazing, etc.). By avoiding the use of joining materials between the components of the body 121, the lubricant manifold 118 can eliminate or significantly reduce the leaching of contaminants (e.g., copper) into the oil compared to other systems that may immerse contaminants (e.g., copper) into the oil. This also results in less oxidation of the lubricant circulating within the lubricant manifold 118, and thus the lubricant has a higher quality than other conventional systems that include multiple components attached together using joining materials. Therefore, the lubricant manifold 118 can ensure the desired operation of the internal combustion engine system 100, thereby increasing the interval between lubricant replenishment events (e.g., oil changes, etc.) compared to other systems that include multiple components attached together.

[0032] The body 121 includes a flange 122 (e.g., an edge, a boss, etc.). The flange 122 is formed integrally or monolithically with the body 121 (e.g., the flange 122 and the body 121 are of an integral construction, etc.). As used herein, when two or more elements are formed as part of a single manufacturing step and joined together to construct an integral or monolithic structure that cannot be disassembled without at least partially destroying the overall component, these two or more elements are "formed integrally" with each other. The flange 122 is coupled to a mounting surface 123 (e.g., a surface, etc.) of the engine block - cylinder head assembly 102. The mounting surface 123 extends around the lubricant manifold recess 120. In some embodiments, the mounting surface 123 is arranged in a first plane, and the flange 122 is arranged in a second plane that is configured to be parallel to the first plane along which the mounting surface 123 is arranged (e.g., when the flange 122 rotates relative to the mounting surface 123, etc.).

[0033] The flange 122 is coupled to the mounting surface 123 using at least one fastener 124 (e.g., a bolt, etc.). The fastener 124 extends through an aperture 125 (e.g., a hole, a slot, an opening, etc.) in the flange 122. After being inserted through one of the apertures 125, the fastener 124 is coupled to a receiver 126 (e.g., a threaded receiver, a threaded connection hole, etc.) in the engine block - cylinder head assembly 102. For example, the fastener 124 can be inserted through one of the apertures 125 and threaded into one of the receivers 126.

[0034] The lubricant manifold 118 includes a gasket 128 (e.g., an O - ring, a seal, etc.). When the flange 122 is coupled to the engine block - cylinder head assembly 102, the gasket 128 is positioned between the mounting surface 123 and the flange 122. The gasket 128 is not formed integrally with the body 121. Additionally, the gasket 128 is formed of a first material (e.g., polytetrafluoroethylene, a compressible material, etc.), and the body 121 is formed of a second material different from the first material (e.g., a metal, an incompressible material, etc.). The gasket 128 is configured to extend around the lubricant manifold recess 120. In some embodiments, the gasket 128 includes an aperture through which the fastener 124 extends between the flange 122 and the receiver 126.

[0035] As Figure 2As shown in FIG. 0, the body 121 includes a pump inlet conduit 130 (e.g., a passage, a channel, a flow path, etc.). The pump inlet conduit 130 is integrally formed with the body 121 (e.g., the body 121 and the pump inlet conduit 130 are of an integral construction, etc.). The pump inlet conduit 130 is configured to be in fluid communication with the lubricant inlet conduit 117 when the flange 122 is coupled to the engine block - cylinder head assembly 102. The pump inlet conduit 130 is configured to receive lubricant from the lubricant inlet conduit 117 when the flange 122 is coupled to the engine block - cylinder head assembly 102.

[0036] The body 121 further includes an inlet bypass conduit 131 (e.g., a passage, a channel, a flow path, etc.). The inlet bypass conduit 131 is integrally formed with the body 121 (e.g., the body 121 and the inlet bypass conduit 131 are of an integral construction, etc.). The inlet bypass conduit 131 is in fluid communication with the pump inlet conduit 130 and is configured to receive lubricant from the pump inlet conduit 130 when the pump inlet conduit 130 is in fluid communication with the lubricant inlet conduit 117.

[0037] The body 121 further includes a high - pressure relief valve port 132 (e.g., an orifice, an opening, etc.). The high - pressure relief valve port 132 is integrally formed with the body 121 (e.g., the body 121 and the high - pressure relief valve port 132 are of an integral construction, etc.). The high - pressure relief valve port 132 is in fluid communication with the inlet bypass conduit 131 and is configured to receive lubricant from the inlet bypass conduit 131 when the pump inlet conduit 130 is in fluid communication with the lubricant inlet conduit 117.

[0038] The lubricant manifold 118 further includes a high - pressure relief valve 133 (e.g., a pressure - relief valve, a pressure regulator, etc.). The high - pressure relief valve 133 is disposed within the high - pressure relief valve port 132, and the high - pressure relief valve port 132 is sealed (e.g., using a plug, etc.) such that lubricant can flow into the high - pressure relief valve 133 but cannot flow out of the high - pressure relief valve port 132. For example, the high - pressure relief valve 133 can be inserted into the high - pressure relief valve port 132 after the body 121 is manufactured, and then the high - pressure relief valve port 132 can be plugged before using the lubricant manifold 118 (e.g., during subsequent manufacturing steps, etc.).

[0039] The body 121 further includes a high-pressure relief valve conduit 134 (e.g., a passageway, a channel, a flow path, etc.). The high-pressure relief valve conduit 134 is integrally formed with the body 121 (e.g., the body 121 and the high-pressure relief valve conduit 134 are of an integral structure, etc.). The high-pressure relief valve conduit 134 is in fluid communication with the high-pressure relief valve 133 and is configured to selectively receive lubricant from the high-pressure relief valve 133. Specifically, the high-pressure relief valve 133 is configured to open and supply lubricant from the inlet bypass conduit 131 to the high-pressure relief valve conduit 134 when the lubricant pressure in the inlet bypass conduit 131 exceeds a threshold pressure. The high-pressure relief valve 133 is further configured not to supply lubricant from the inlet bypass conduit 131 to the high-pressure relief valve conduit 134 unless the pressure of the lubricant in the inlet bypass conduit 131 exceeds the threshold pressure.

[0040] The engine block - cylinder head assembly 102 further includes a lubricant bypass conduit 135 (e.g., a bypass channel, etc.). When the flange 122 is coupled to the engine block - cylinder head assembly 102, the lubricant bypass conduit 135 is in fluid communication with the high-pressure relief valve conduit 134. The lubricant bypass conduit 135 is configured to receive lubricant from the high-pressure relief valve conduit 134 (e.g., when the lubricant pressure in the inlet bypass conduit 131 exceeds the threshold pressure).

[0041] The engine block - cylinder head assembly 102 further includes a lubricant pan 136 (e.g., an oil pan, a tray, etc.). The lubricant pan 136 is in fluid communication with the lubricant bypass conduit 135. The lubricant pan 136 is configured to receive lubricant from the lubricant bypass conduit 135 when the flange 122 is coupled to the engine block - cylinder head assembly 102. In some embodiments, the lubricant pan 136 may also be in fluid communication with the lubricant passage 112 and is configured to receive lubricant from the lubricant passage 112. Thus, when the lubricant pressure in the inlet bypass conduit 131 exceeds the threshold pressure, the lubricant can be supplied into the high-pressure relief valve conduit 134, from the high-pressure relief valve conduit 134 to the lubricant bypass conduit 135, and from the lubricant bypass conduit 135 to the lubricant pan 136. As explained in more detail herein, the lubricant in the lubricant pan 136 can then be recycled within the lubricant system 110.

[0042] The body 121 further includes an inlet transfer conduit 138 (e.g., a passageway, a channel, a flow path, etc.). The inlet transfer conduit 138 is integrally formed with the body 121 (e.g., the body 121 and the inlet transfer conduit 138 are of an integral structure, etc.). The inlet transfer conduit 138 is in fluid communication with the pump inlet conduit 130. The inlet transfer conduit 138 is configured to receive lubricant from the pump inlet conduit 130 when the flange 122 is coupled to the engine block - cylinder head assembly 102.

[0043] The body 121 further includes a lubricant cooler 140 (e.g., an oil cooler, a heat exchanger, etc.). The lubricant cooler 140 is integrally formed with the body 121 (e.g., the body 121 and the lubricant cooler 140 are of an integral structure, etc.). The lubricant cooler 140 is fluidly coupled to the inlet transfer conduit 138 and is configured to receive lubricant from the inlet transfer conduit 138. As explained in more detail herein, the lubricant cooler 140 is configured to provide cooling to the lubricant within the lubricant cooler 140.

[0044] As Figure 3 and Figure 4 shown, the lubricant cooler 140 includes a plurality of lubricant channels 141 (e.g., pipes, tubes, etc.). The lubricant cooler 140 circulates the lubricant through the lubricant channels 141 to cool the lubricant. A liquid coolant flow can be generated through the lubricant channels 141 to provide cooling to the lubricant channels 141 that provide cooling to the lubricant.

[0045] The body 121 further includes an outlet transfer conduit 142 (e.g., a passage, a pathway, a flow channel, etc.). The outlet transfer conduit 142 is integrally formed with the body 121 (e.g., the body 121 and the outlet transfer conduit 142 are of an integral structure, etc.). The outlet transfer conduit 142 is fluidly coupled to the lubricant cooler 140, and the outlet transfer conduit 142 is configured to receive lubricant from the lubricant cooler 140.

[0046] The body 121 further includes a thermostat port 143 (e.g., an orifice, an opening, etc.). The thermostat port 143 is integrally formed with the body 121 (e.g., the body 121 and the thermostat port 143 are of an integral structure, etc.). The thermostat port 143 is fluidly coupled to the inlet transfer conduit 138, and the thermostat port 143 is configured to receive lubricant from the inlet transfer conduit 138.

[0047] The lubricant manifold 118 further includes a thermostat 144 (e.g., a temperature regulator, etc.). The thermostat 144 is disposed within the thermostat port 143, and the thermostat port 143 is sealed (e.g., using a plug, etc.) such that lubricant can flow into the thermostat 144 but cannot flow out of the thermostat port 143. For example, the thermostat 144 can be inserted into the thermostat port 143 after the body 121 is manufactured, and then the thermostat port 143 can be plugged (e.g., during subsequent manufacturing steps, etc.) before using the lubricant manifold 118.

[0048] The body 121 further includes a thermostat conduit 145 (e.g., a passage, a channel, a flow path, etc.). The thermostat conduit 145 is integrally formed with the body 121 (e.g., the body 121 and the thermostat conduit 145 are of an integral structure, etc.). The thermostat conduit 145 is fluidly coupled to the thermostat 144, and the thermostat conduit 145 is configured to selectively receive lubricant from the thermostat 144. In addition, the thermostat conduit 145 is fluidly coupled to the outlet transfer conduit 142, and the thermostat conduit 145 is configured to selectively supply lubricant to the outlet transfer conduit 142. Specifically, the thermostat 144 is configured to open and supply lubricant from the inlet transfer conduit 138 to the thermostat conduit 145 when the temperature of the lubricant in the inlet transfer conduit 138 is lower than a threshold temperature. The thermostat 144 is further configured not to supply lubricant from the inlet transfer conduit 138 to the thermostat conduit 145 unless the temperature of the lubricant in the inlet transfer conduit 138 is lower than the threshold temperature. Thus, when the cooling provided by the lubricant cooler 140 is not required (e.g., when the temperature of the lubricant in the inlet transfer conduit 138 is lower than the temperature threshold), the lubricant in the inlet transfer conduit 138 can bypass the lubricant cooler 140. In this way, the back pressure of the lubricant can be reduced.

[0049] The body 121 further includes a lubricant filter head 146 (e.g., a receiver, etc.). The lubricant filter head 146 is integrally formed with the body 121 (e.g., the body 121 and the lubricant filter head 146 are of an integral structure, etc.). The lubricant filter head 146 is fluidly coupled to the outlet transfer conduit 142, and the lubricant filter head 146 is configured to receive lubricant from the outlet transfer conduit 142.

[0050] The lubricant filter head 146 is configured to be coupled to a lubricant filter 148 (e.g., an oil filter, etc.) such that the lubricant filter 148 is fluidly coupled to the lubricant filter head 146. In different embodiments, the lubricant filter head 146 includes a threaded post 149 that is configured to be threadedly coupled to the lubricant filter 148. In other embodiments, the lubricant filter head 146 may include a threaded orifice to which the lubricant filter 148 is configured to be threadedly connected.

[0051] The lubricant filter head 146 is configured to supply lubricant from the outlet transfer conduit 142 to the lubricant filter 148 when the lubricant filter 148 is fluidly coupled to the lubricant filter head 146. In addition, the lubricant filter head 146 is configured such that the lubricant filter 148 can be fluidly coupled to and fluidly decoupled from the lubricant filter head 146 without decoupling the lubricant manifold 118 from the engine block - cylinder head assembly 102.

[0052] The lubricant filter 148 is configured to filter particles (such as soot, metal particles, etc.) from the lubricant such that the lubricant flowing out of the lubricant filter 148 contains fewer particles than the lubricant entering the lubricant filter 148 (such as the lubricant flowing from the outlet transfer pipe 142).

[0053] The lubricant filter head 146 is further configured to receive lubricant from the lubricant filter 148 when the lubricant filter 148 is in fluid communication with the lubricant filter head 146. The lubricant received by the lubricant filter head 146 from the lubricant filter 148 has been filtered by the lubricant filter 148. In this way, the lubricant filter head 146 is configured to supply lubricant to and receive lubricant from the lubricant filter 148, respectively.

[0054] The body 121 further includes a main outlet pipe 150 (such as a passage, a channel, a flow path, etc.). The main outlet pipe 150 is integrally formed with the body 121 (such as the body 121 and the main outlet pipe 150 being of an integral structure, etc.). The main outlet pipe 150 is in fluid communication with the lubricant filter head 146, and the main outlet pipe 150 is configured to receive lubricant from the lubricant filter head 146 (such as after the lubricant has passed through the lubricant filter 148).

[0055] The engine block - cylinder head assembly 102 further includes an engine inlet orifice 152 (such as an opening, a hole, etc.) formed in the mounting surface 123 and / or the lubricant manifold recess 120. The engine inlet orifice 152 is configured to receive lubricant from the main outlet pipe 150 when the flange 122 is coupled to the engine block - cylinder head assembly 102. The engine inlet orifice 152 is in fluid communication with the lubricant passage 112, and the engine inlet orifice 152 is configured to receive lubricant from the main outlet pipe 150 and supply lubricant to the lubricant passage 112 when the flange 122 is coupled to the engine block - cylinder head assembly 102.

[0056] The body 121 further includes a filter bypass pipe 154 (such as a passage, a channel, a flow path, etc.). The filter bypass pipe 154 is integrally formed with the body 121 (such as the body 121 and the filter bypass pipe 154 being of an integral structure, etc.). The filter bypass pipe 154 is in fluid communication with the lubricant filter head 146, and the filter bypass pipe 154 is configured to receive lubricant from the lubricant filter 148 and / or the outlet transfer pipe 142. Specifically, the filter bypass pipe 154 is configured to receive lubricant from the outlet transfer pipe 142 without passing the lubricant through the entire lubricant filter 148. Instead, the filter bypass pipe 154 can receive lubricant from the outlet transfer pipe 142 without the lubricant flowing through the lubricant filter 148, or the lubricant only flows through a part of the lubricant filter 148 (such as the edge, the end cap, etc.).

[0057] The body 121 further includes a bypass valve port 155 (e.g., an orifice, an opening, etc.). The bypass valve port 155 is integrally formed with the body 121 (e.g., the body 121 and the bypass valve port 155 are of an integral structure, etc.). The bypass valve port 155 is fluidly coupled to the filter bypass conduit 154 and the main outlet conduit 150. As explained in more detail herein, the bypass valve port 155 is configured to receive lubricant from the filter bypass conduit 154 and selectively supply the lubricant to the main outlet conduit 150.

[0058] The lubricant manifold 118 further includes a bypass valve 156 (e.g., a pressure regulator, a pressure reducing valve, etc.). The bypass valve 156 is disposed within the bypass valve port 155, and the bypass valve port 155 is sealed (e.g., using a plug, etc.) such that lubricant can flow into the bypass valve 156 but cannot flow out of the bypass valve port 155. For example, the bypass valve 156 can be inserted into the bypass valve port 155 after the body 121 is manufactured, and then the bypass valve port 155 is plugged before using the lubricant manifold 118 (e.g., in subsequent manufacturing steps, etc.).

[0059] The bypass valve 156 is configured to open when the pressure of the lubricant within the filter bypass conduit 154 exceeds a threshold pressure and supply the lubricant from the filter bypass conduit 154 to the main outlet conduit 150 (e.g., via the bypass valve port 155). The bypass valve 156 is further configured such that the lubricant is not supplied from the filter bypass conduit 154 to the main outlet conduit 150 unless the pressure of the lubricant within the bypass valve 156 exceeds the threshold pressure. Thus, the lubricant within the filter bypass conduit 154 can bypass the lubricant filter 148. This can facilitate the use of the lubricant manifold 118 when, for example, the lubricant filter 148 is clogged.

[0060] The body 121 further includes an auxiliary outlet conduit 158 (e.g., a passage, a channel, a flow path, etc.). The auxiliary outlet conduit 158 is integrally formed with the body 121 (e.g., the body 121 and the auxiliary outlet conduit 158 are of an integral structure, etc.). The auxiliary outlet conduit 158 is fluidly coupled to the main outlet conduit 150, and the auxiliary outlet conduit 158 is configured to receive lubricant from the main outlet conduit 150.

[0061] The lubricant system 110 further includes a transfer conduit 160 (e.g., an oil pipeline, etc.). The auxiliary outlet conduit 158 is configured to be fluidly coupled to the transfer conduit 160. For example, the transfer conduit 160 can be coupled to the body 121 via a hose clamp such that the transfer conduit 160 is fluidly coupled to the auxiliary outlet conduit 158. The auxiliary outlet conduit 158 is configured to supply lubricant to the transfer conduit 160 when the auxiliary outlet conduit 158 is fluidly coupled to the transfer conduit 160.

[0062] The internal combustion engine system 100 also includes a turbocharger 162. The turbocharger 162 is fluidly coupled to the transfer conduit 160, and the turbocharger 162 is configured to receive lubricant from the transfer conduit 160 and supply lubricant to the transfer conduit 160. The lubricant can be utilized by the turbocharger 162 to lubricate internal components (e.g., bearings, main shafts, etc.). In this manner, the lubricant manifold 118 can be utilized to cool the lubricant supplied to both the engine block - head assembly 102 and the turbocharger 162.

[0063] The lubricant system 110 also includes an outlet conduit 164 (e.g., an oil line, etc.). The outlet conduit 164 is fluidly coupled to the lubricant passage 112 and the transfer conduit 160. The outlet conduit 164 receives lubricant from the engine block - head assembly 102 (e.g., via the lubricant passage 112) and from the turbocharger 162 (e.g., via the transfer conduit 160). The outlet conduit 164 is also fluidly coupled to the lubricant pump 114, and the outlet conduit 164 is configured to supply lubricant to the lubricant pump 114.

[0064] Figure 6 The lubricant manifold 118 is shown in accordance with various embodiments. In these embodiments, the filter bypass conduit 154 and the bypass valve 156 are integrally formed within the body 121. In some embodiments, the bypass valve port 155 is omitted. In some embodiments, the auxiliary outlet conduit 158 is omitted (e.g., depending on the requirements of the lubricant system 110, etc.).

[0065] III. Manufacture of the Body of the Lubricant Manifold

[0066] The body 121 is assembled by additive manufacturing. For example, three-dimensional (3D) printing, selective laser sintering, or other similar processes can be used to assemble the body 121. As described above, the body 121 is configured such that all components of the body 121 are integrally formed. As described above, the components of the body 121 are "integrally formed" when the components of the body 121 are formed and joined together as part of a single manufacturing step to construct a one-piece or monolithic structure and the body 121 cannot be disassembled without at least partially destroying the body 121. For example, the components of the body 121: (i) cannot be separated from each other (e.g., a component of the body 121 cannot be separated from the body 121 without destroying the body 121, etc.); (ii) are not formed separately from each other (e.g., the components of the body 121 are formed simultaneously, the components of the body 121 are formed as a single component in a single process, etc.); and (iii) have no gaps or joints along the boundaries between the abutting components of the body 121 (e.g., components sharing a boundary, etc.). In some embodiments, the body 121 is constructed entirely of stainless steel (e.g., stainless steel 316, etc.). In other embodiments, the body 121 is constructed entirely of aluminum or steel.

[0067] Compared with various traditional systems, the body 121 does not contain any copper because the body 121 is assembled by additive manufacturing. Specifically, the copper brazing materials utilized in other systems are not included in the body 121 because the body 121 is assembled by additive manufacturing and all components of the body 121 are integrally formed. In other words, brazing materials are not required to construct the body 121 because the components of the body 121 are not joined together by brazing. Therefore, brazing materials are not included in the body 121. As a result, copper and other brazing materials cannot leach from the body 121 into the lubricant because the body 121 does not include copper. By protecting the lubricant from copper, the body 121 is beneficial for extending the desired operation of the internal combustion engine system 100.

[0068] In addition, the body 121 does not have any internal joints (e.g., between components of the body 121, etc.) that create leakage paths for the lubricant. For example, there is no internal joint between the lubricant filter head 146 and the lubricant cooler 140. Therefore, the lubricant cannot leak from the body 121. Compared with other systems having multiple internal joints that create leakage paths, this can reduce the warranty costs associated with the internal combustion engine system 100. These leakage paths can cause oil leakage over time, making these other systems undesirable.

[0069] In addition, the number of components of the internal combustion engine system 100 (e.g., the number of items in a bill of materials, the number of inventory items, etc.) is lower than that of other conventional systems because the main body 121 is configured such that all components of the main body 121 are integrally formed. In other words, rather than having a separate lubricant cooler and a filter head (the separate lubricant cooler and filter head would constitute two components that would have to be stored separately and then assembled), the main body 121 is a single component that includes the lubricant filter head 146 and the lubricant cooler 140.

[0070] The lubricant channels 141 can be configured such that each has a target geometry because the main body 121 is assembled by additive manufacturing. For example, one lubricant channel 141 can have a first cross-sectional shape (e.g., wing-shaped, water droplet-shaped, etc.), and another lubricant channel 141 can have a second cross-sectional shape different from the first cross-sectional shape (e.g., square, triangular, circular, oval, etc.). By selecting a suitable cross-sectional shape for each lubricant channel 141 according to predetermined design and / or performance parameters, a target heat transfer curve of the lubricant cooler 140 can be obtained. In addition, by selecting a suitable cross-sectional shape for each lubricant channel 141 according to predetermined design and / or performance parameters, a target flow rate through the lubricant cooler 140 can be provided. In addition, the mass of the lubricant manifold 118 can be significantly lower than the sum of the mass of the lubricant cooler of another system and the mass of the filter head of another system. This reduction in mass is due to the main body 121 being configured such that all components of the main body 121 are integrally formed and due to the main body 121 being assembled by additive manufacturing. Specifically, since the main body 121 is configured such that all components of the main body 121 are integrally formed, the mass of bolts for attaching various components used in other systems is not included in the lubricant manifold 118. In addition, since the main body 121 is assembled by additive manufacturing, the wall thickness of the main body 121 can be smaller than the wall thickness of the lubricant cooler and / or filter head in other systems. Specifically, by using the additive manufacturing process described herein, the main body 121 can be made to have structural characteristics that are not possible in components joined together. For example, components manufactured separately and then joined together would need to be thicker than additively manufactured components (such as the main body 121) because components joined together are affected by stress due to fasteners, adhesives, and / or welds along the joints between the joined components. By eliminating these joints, additively manufactured components (such as the main body 121) do not need to be as thick in similar locations.

[0071] Construction of the exemplary embodiment

[0072] Although this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of specific features of particular implementations. Certain features described in the context of separate implementations in this specification may also be implemented in combination in a single implementation. Conversely, the various features described in the context of a single implementation may also be implemented separately in multiple implementations or in any suitable sub-combination. Additionally, although features may be described as acting in certain combinations and even initially claimed as such, in some cases, one or more features of the claimed combination may be deleted from the claimed combination, and the claimed combination may cover sub-combinations or variations of sub-combinations.

[0073] As used herein, terms such as "substantially", "generally", and similar terms are intended to have a broad meaning that is consistent with the common and accepted usage of those skilled in the art to which the subject matter of this disclosure pertains. Those skilled in the art reviewing this disclosure should understand that these terms are intended to allow the description of certain features being described and claimed without restricting the scope of these features to the exact numerical ranges provided. Thus, these terms should be interpreted to indicate that non-substantive or immaterial modifications or alterations to the subject matter being described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0074] As used herein, terms such as "coupled" refer to two components being joined to each other either directly or indirectly. Such joining can be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining can be accomplished by the two components or the two components and any additional intermediate component being integrally formed as a single unitary body with each other; or the two components or the two components and any additional intermediate component being attached to each other.

[0075] As used herein, terms such as "fluidly coupled" refer to two components or objects having a passage formed between the two components or objects, with or without intervening components or objects, through which a fluid (e.g., lubricant, liquid lubricant, gaseous lubricant, etc.) can flow. Examples of fluid couplings or configurations for achieving fluid communication can include pipe fittings, tubes, or any other suitable components for enabling fluid to flow from one component or object to another component or object.

[0076] It is important to note that the construction and arrangement of the various systems shown in the various exemplary implementations are illustrative only and not restrictive. It is desired that all changes and variations falling within the spirit and scope of the described implementations be protected. It should be understood that some features may not be necessary, and implementations lacking various features may be considered to be within the scope of the present disclosure as defined by the appended claims. When the language "a part" is used, an item may include a partial item and / or the whole item, unless there is an express contrary statement.

[0077] Additionally, the term "or" is used in its inclusive sense (rather than its exclusive sense) in the context of a series of elements, so when used to connect a series of elements, the term "or" means one, some, or all of the elements in the series. Connective language such as the phrase "at least one of X, Y, and Z", unless specifically stated otherwise, can generally be understood in context to mean that an item, term, etc. can be X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, unless otherwise stated, such connective language generally is not intended to imply that certain implementations require the presence of at least one X, at least one Y, and at least one Z.

[0078] Furthermore, numerical ranges used herein (e.g., W1 to W2, etc.) include their maximum and minimum values (e.g., W1 to W2 includes W1 and includes W2, etc.), unless otherwise stated. Additionally, numerical ranges (e.g., W1 to W2, etc.) do not necessarily require the inclusion of intermediate values within the numerical range (e.g., W1 to W2 may only include W1 and W2, etc.), unless otherwise stated.

Claims

1. A lubricant manifold, the lubricant manifold comprising: A lubricant filter head configured to be coupled to a lubricant filter; A pump inlet pipe fluidly coupled to the lubricant filter head and integrally formed with the lubricant filter head, the pump inlet pipe being configured to receive lubricant and supply the lubricant to the lubricant filter head; An inlet transfer pipe fluidly coupled to the lubricant filter head and integrally formed with the lubricant filter head and the pump inlet pipe, the inlet transfer pipe being configured to receive the lubricant from the pump inlet pipe; and A lubricant cooler fluidly coupled to the inlet transfer pipe and integrally formed with the lubricant filter head, the pump inlet pipe, and the inlet transfer pipe, the lubricant cooler being configured to receive the lubricant from the inlet transfer pipe.

2. The lubricant manifold according to claim 1, wherein, The lubricant filter head, the pump inlet pipe, the inlet transfer pipe, and the lubricant cooler are produced as a single component in a single additive manufacturing process.

3. The lubricant manifold according to claim 1, the lubricant manifold further comprising an outlet transfer pipe fluidly coupled to the lubricant cooler and integrally formed with the lubricant filter head, the pump inlet pipe, the inlet transfer pipe, and the lubricant cooler, the outlet transfer pipe being configured to receive the lubricant from the lubricant cooler and supply the lubricant to the lubricant filter head.

4. The lubricant manifold according to claim 3, the lubricant manifold further comprising a main outlet pipe fluidly coupled to the outlet transfer pipe and integrally formed with the lubricant filter head, the pump inlet pipe, the inlet transfer pipe, the lubricant cooler, and the outlet transfer pipe, the main outlet pipe being configured to receive the lubricant from the lubricant filter head and supply the lubricant from the lubricant manifold.

5. The lubricant manifold according to claim 3, the lubricant manifold further comprising a thermostat pipe fluidly coupled to the inlet transfer pipe and the outlet transfer pipe, the thermostat pipe being integrally formed with the lubricant filter head, the pump inlet pipe, the inlet transfer pipe, the lubricant cooler, and the outlet transfer pipe, the thermostat pipe being configured to receive the lubricant from the inlet transfer pipe and supply the lubricant to the outlet transfer pipe.

6. The lubricant manifold according to claim 3, the lubricant manifold further comprising: A filter bypass pipe fluidly coupled to the lubricant filter head and integrally formed with the lubricant filter head, the pump inlet pipe, the inlet transfer pipe, the lubricant cooler, and the outlet transfer pipe, the filter bypass pipe being configured to receive the lubricant from the lubricant filter head; A bypass valve port that is fluidly coupled to the outlet transfer conduit and is integrally formed with the lubricant filter head, the pump inlet conduit, the inlet transfer conduit, the lubricant cooler, the outlet transfer conduit, and the filter bypass conduit, the bypass valve port being configured to selectively receive the lubricant from the filter bypass conduit; and A bypass valve disposed within the bypass valve port, the bypass valve being configured to receive the lubricant from the filter bypass conduit and selectively provide the lubricant to the bypass valve port.

7. The lubricant manifold according to claim 1, the lubricant manifold further comprising: A high-pressure relief valve port that is fluidly coupled to the pump inlet conduit and is integrally formed with the lubricant filter head, the pump inlet conduit, the inlet transfer conduit, and the lubricant cooler, the high-pressure relief valve port being configured to receive the lubricant from the pump inlet conduit; and A high-pressure relief valve disposed within the high-pressure relief valve port, the high-pressure relief valve being configured to receive the lubricant from the pump inlet conduit and selectively provide the lubricant from the lubricant manifold.

8. The lubricant manifold according to claim 1, wherein, The lubricant cooler includes: A first lubricant passage having a first cross-sectional shape; and A second lubricant passage having a second cross-sectional shape different from the first cross-sectional shape.

9. The lubricant manifold according to claim 8, wherein, The first cross-sectional shape is airfoil-shaped.

10. An internal combustion engine system, the internal combustion engine system comprising: An engine block-head assembly, the engine block-head assembly comprising: A lubricant manifold recess; and A mounting surface extending around the lubricant manifold recess; and A lubricant manifold including a body at least partially received within the lubricant manifold recess, the body comprising: A lubricant filter head configured to be coupled to a lubricant filter; A lubricant cooler fluidly coupled to the lubricant filter head and integrally formed with the lubricant filter head, the lubricant cooler providing lubricant to the lubricant filter head; and A flange integrally formed with the lubricant filter head and the lubricant cooler, the flange being coupled to the mounting surface such that the lubricant cooler is at least partially received within the lubricant manifold recess.

11. The internal combustion engine system according to claim 10, wherein: The lubricant filter head is not separately formed from the lubricant cooler or the flange; The lubricant cooler is not separately formed from the lubricant filter head or the flange; and The flange is not separately formed from the lubricant filter head or the lubricant cooler.

12. The internal combustion engine system according to claim 10, wherein: The lubricant cooler meets the flange along a boundary; and The lubricant cooler is not separated from the flange along the boundary.

13. The internal combustion engine system according to claim 10, wherein: The engine block-head assembly further includes a lubricant inlet conduit; The body further includes a pump inlet conduit fluidly coupled to the lubricant filter head and the lubricant inlet conduit, the pump inlet conduit being integrally formed with the lubricant filter head, the lubricant cooler, and the flange, the pump inlet conduit receiving the lubricant from the lubricant inlet conduit and providing the lubricant to the lubricant filter head.

14. The internal combustion engine system according to claim 10, wherein: the engine block - head assembly further includes an engine inlet orifice; and the body further includes a main outlet conduit fluidly coupled to the engine inlet orifice and integrally formed with the lubricant filter head, the lubricant cooler, and the flange, the main outlet conduit receiving the lubricant from the lubricant filter head and providing the lubricant to the engine inlet orifice.

15. A lubricant manifold, comprising: a lubricant cooler configured to receive lubricant; an outlet transfer conduit fluidly coupled to the lubricant cooler and integrally formed with the lubricant cooler, the outlet transfer conduit being configured to receive the lubricant from the lubricant cooler; and a lubricant filter head configured to be coupled to a lubricant filter, the lubricant filter head being fluidly coupled to the outlet transfer conduit and integrally formed with the lubricant cooler and the outlet transfer conduit, the lubricant filter head being configured to receive the lubricant from the lubricant cooler.

16. The lubricant manifold according to claim 15, wherein, The lubricant cooler, the outlet transfer conduit, and the lubricant filter head are produced as a single component in a single additive manufacturing process.

17. The lubricant manifold according to claim 16, the lubricant manifold further including a main outlet conduit fluidly coupled to the outlet transfer conduit and integrally formed with the lubricant cooler, the outlet transfer conduit, and the lubricant filter head, the main outlet conduit being configured to receive the lubricant from the lubricant filter head and provide the lubricant from the lubricant manifold.

18. The lubricant manifold according to claim 16, the lubricant manifold further including a thermostat conduit fluidly coupled to the outlet transfer conduit, the thermostat conduit being integrally formed with the lubricant cooler, the outlet transfer conduit, and the lubricant filter head, the thermostat conduit being configured to provide the lubricant to the outlet transfer conduit.

19. The lubricant manifold according to claim 15, the lubricant manifold further including: a high - pressure relief valve port integrally formed with the lubricant cooler, the outlet transfer conduit, and the lubricant filter head; and a high - pressure relief valve disposed within the high - pressure relief valve port and configured to selectively provide the lubricant from the lubricant manifold.

20. The lubricant manifold according to claim 15, wherein, The lubricant cooler includes: a first lubricant passage having a first cross - sectional shape; and a second lubricant passage having a second cross - sectional shape different from the first cross - sectional shape.

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