Crankcase oil separation device for an internal combustion engine

Abstract

Apparatuses including coalescing filters are discussed and shown. The coalescing filter can optionally include: a filter media; a center core defining a central cavity, the center core positioned within the filter media; a first end cap; a coupling assembly attached to and extending outwardly from the first end cap, wherein the coupling assembly is configured to couple with a housing to position the coalescing filter within the housing; and a second end cap opposite the first end cap.

Description

Technical Field

[0001] This disclosure relates to a crankcase ventilation system for an internal combustion engine, such as an internal combustion engine for a vehicle or stationary power generation system. More specifically, this disclosure relates to an oil separator for a crankcase ventilation system. Background Technology

[0002] Machinery, such as agricultural, industrial, construction, or other heavy machinery, can be propelled by internal combustion engines (multiple). Internal combustion engines can also be used for other purposes, such as generating electricity. An internal combustion engine burns a mixture of air and fuel in cylinders, thereby producing driving torque and power. A portion of the combustion gases (called "blow-through gases") can escape from the combustion chamber through the piston and enter undesirable areas of the engine, such as the crankcase. Blow-through gases may contain unburned fuel, oil, and explosive gases. In rare cases, unburned fuel and / or explosive gases may accumulate within the engine, such as in the crankcase. Unburned fuel and / or explosive gases, if not properly mitigated, for example, by a safety valve, can cause an explosion. Crankcase ventilation systems are known in internal combustion engines for expelling, capturing, or diluting blow-through gases from the crankcase. Such ventilation systems may include oil separators as part of such systems. For example, U.S. Patent Application Publication No. 2008 / 0035103A1, U.S. Patent No. 10,213,715B2, and Japanese Patent No. 6,126,885B2 disclose examples of oil separators as part of a crankcase ventilation system. However, these patent applications and patents do not recognize the various features and components of this application. Summary of the Invention

[0003] In an example according to this disclosure, a coalescing filter may optionally include: a filter medium; a central core defining a central cavity, the central core being positioned within the filter medium; a first end cap; a coupling assembly attached to and extending outwardly from the first end cap, wherein the coupling assembly is configured to engage with a housing to position the coalescing filter within the housing; and a second end cap opposite the first end cap.

[0004] In another embodiment according to this disclosure, a coalescing filter optionally includes: a filter medium; a central core defining a central cavity, the central core being positioned within the filter medium; a first end cap; and a second end cap opposite the first end cap, wherein the second end cap has an orifice forming an inlet port leading to the central cavity, wherein the orifice has a non-circular shape and is configured as a prominent feature of a receiving housing for receiving a corresponding shape of the coalescing filter.

[0005] In another embodiment according to this disclosure, an apparatus for filtering oil mist from leaking gas optionally includes: a housing forming an inner cavity, an outlet manifold, and an inlet manifold, wherein the housing includes a removable and attachable cover for partially enclosing the outlet manifold; and a coalescing filter insertable into and removable from the inner cavity, the coalescing filter including: a filter medium; a central core defining a central cavity, the central core being positioned within the filter medium; a first end cap; a coupling assembly positioned within the outlet manifold, attached to and extending outwardly from the first end cap, wherein the coupling assembly receives a protrusion of the cover and is configured to position the coalescing filter within the housing; and a second end cap opposite the first end cap. Attached Figure Description

[0006] In accompanying drawings that are not necessarily drawn to scale, similar numbers may describe similar parts in different views. Similar numbers with different letter suffixes may represent different instances of similar parts. The accompanying drawings illustrate, by way of example and not limitation, the various embodiments discussed in this document.

[0007] Figure 1 This is a schematic diagram depicting an exemplary internal combustion engine having a system including a leaking gas-oil separator, according to an example of this application.

[0008] Figure 2 This is a perspective view of an oil separation device according to an example of this application.

[0009] Figure 3 yes Figure 2 An exploded view of the components of an oil separation device.

[0010] Figure 4 yes Figure 2 and Figure 3 Exploded view of the housing cover of the oil separator and components of the upper filter support assembly according to an example of this application.

[0011] Figure 5 This is based on an example from this application. Figure 2 and Figure 3 Exploded view of some components of the oil separator (including seals, coalescing filter, outlet manifold, and inner shell).

[0012] Figure 6 This is based on an example from this application. Figure 2 and Figure 3 A perspective view of the outer casing of the oil separator.

[0013] Figure 7 This is based on an example from this application. Figure 2 and Figure 3 A perspective view of the inlet manifold of the oil separator.

[0014] Figure 7A yes Figure 7 Plan view of the lower filter support of the inlet manifold.

[0015] Figure 7B yes Figure 7 Enlarged perspective view of the lower filter support of the inlet manifold.

[0016] Figure 8 This is a cross-sectional view of the connection between the lower filter support of the inlet manifold and the lower end cap of the coalescing filter according to an example of this application.

[0017] Figure 9 This is a perspective view of a portion of a coalescing filter according to an example of this application, showing the lower end cap.

[0018] Figure 10 yes Figure 2 and Figure 3 A cross-sectional view of the oil separation device.

[0019] Figure 10A yes Figure 10 An enlarged cross-sectional view of the upper part of the oil separation device.

[0020] Figure 11A-11D A method for using a coalescing filter in a maintenance oil separation apparatus according to an example of this application is shown. Detailed Implementation

[0021] Examples of this disclosure relate to an oil separator(s) for an internal combustion engine, and to systems and methods for filtering oil to separate oil and other forms of particulate matter from leaked gases. Examples of this disclosure are now described with reference to the accompanying drawings. The following description is merely exemplary in nature and is not intended to limit the disclosure, its application, or its use. The described examples illustrate specific components, apparatus, and methods to provide an understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required and that examples may be embodied in many different forms. Therefore, the examples provided should not be construed as limiting the scope of the claims.

[0022] Figure 1An exemplary schematic diagram of an engine 100 according to this disclosure is depicted. Engine 100 can be used to generate electricity, for example, for the propulsion of vehicles or other machinery. Engine 100 can include various power generation platforms, including, for example, internal combustion engines (whether gasoline, natural gas, dynamic gas mixture, or diesel type). It should be understood that this disclosure is applicable to any number of piston-cylinder arrangements and various engine configurations, including but not limited to V-type engines, inline engines, and horizontally opposed engines, as well as overhead cam and body cam configurations.

[0023] In some applications, the internal combustion engine disclosed herein is envisioned for gas compression. Therefore, in some instances, the internal combustion engine can be used in stationary applications. In other applications, the disclosed internal combustion engine can be used with vehicles and machinery, including those relevant to various industries such as oil exploration, construction, agriculture, forestry, transportation, materials handling, and waste management.

[0024] Engine 100 may include a system 102 having at least one oil separator 104 (or an array of multiple oil separators 104 as shown). System 102 may include auxiliary components 106 of engine 100, such as regulator 108, injection pump 110, and check valve 112. Check valve 112 may be positioned, for example, at the bottom of the oil drain subsystem to prevent unfiltered run-in gas from bypassing the coalescing filter of oil separator 104 and being delivered directly to compressor 114. Thus, check valve 112 can regulate oil flow.

[0025] exist Figure 1 In some examples, system 102 may be part of the original manufacture of engine 100, or it may be a retrofit system added to engine 100 during maintenance, upgrades, etc. As will be discussed in further detail later, system 102 may use multiple oil separators 104 to filter oil from leaked gases to reduce the volatile content in the leaked gases.

[0026] System 102 may be part of a purging system that may be in fluid communication with the crankcase 101 of engine 100, for example, via an inlet passage. System 102 may be configured to supply air to the crankcase and, through the engine block or through other components (not shown), to the cylinder head of engine 100. The air supplied by system 102 may be used to ventilate crankcase 101 and other components of engine 100, such as cylinder heads, rocker arm cases, etc. In addition to operating oil separator(s) 104 to separate oil from leaking gases, this ventilation may also dilute unburned fuel, explosive gases, and / or volatiles below the lower explosive limit to prevent or reduce the likelihood of an explosion within engine 100.

[0027] System 102 may include connection channels in fluid communication with various components of system 102 (some of which are specifically shown by arrows and in...). Figure 1 (Numbered in the middle). Some components of engine 100, such as engine block, crankcase 101, cylinder head, rocker arm box, valve cover, and / or breather, may be in fluid communication. The terms “one passage,” “multiple passages,” “one pathway,” “multiple pathways,” “one line,” or “multiple lines” as used herein should be interpreted broadly. These terms may be features defined by the various components of the engine shown in the figures, or may be formed by additional components known in the art (e.g., hoses, pipes, conduits, manifolds, cavities, etc.). In some instances, these additional components may be external to engine 100. The pathway may also connect regulator 108, injection pump 110, and check valve 112 to selected portions of oil separator(s) 104, as further described herein.

[0028] System 102 may include channels and other components, such as Figure 1 As shown in the diagram. Dirty fly-by gas containing oil and volatiles from system 102 can pass through a breather or other device of engine 100 along passage 103A and can be conveyed to oil separator(s) 104 for oil filtration to reduce the volatile content of the fly-by gas. After oil filtration, the fly-by gas can be conveyed from oil separator(s) 104 along passage 103B to regulator 108 (e.g., vacuum control valve, mechanical valve, or similar regulator) located between oil separator(s) 104 and injection pump 110. The fly-by gas can be conveyed from regulator 108 to the intake of injection pump 110. Regulator 108 (e.g., vacuum control valve) can be in fluid communication with the fly-by gas. Regulator 108 can be configured to regulate the flow of the fly-by gas to control the vacuum of injection pump 110.

[0029] Along with the leaking gas, system 102 can utilize pressurized air from compressor 114 (or other components such as a turbocharger) and / or air from aftercooler 116, which moves along passage 103C. This pressurized air can be mixed at a desired ratio and passed through one or more sheaths of oil separators 104. For example, this arrangement can keep the filters of each oil separator in the oil separators 104 between approximately 80°C and 120°C. The pressurized air can be mixed to achieve a temperature range above the dew point temperature of the leaking gas and below the temperature at which one or more components of the oil separators become inoperable (due to melting or other modal failure). However, other examples envision the use of alternative fluids, fluid temperatures, and / or other configurations for system 102. For example, system 102 could utilize another fluid, such as engine coolant or engine lubricating oil, which can be circulated from source 107 to the sheaths of oil separator 104 via pump 105.

[0030] After exiting the sheath(s), the pressurized air, now at a reduced pressure and temperature from leaving engine 100, can be conveyed along passage 103D to the input of injection pump 110. Injection pump 110 can use the pressurized air as motive air to draw out leaky gas through oil separator(s) 104. After exiting oil separator(s) 104, the leaky gas can be routed to the intake port of injection pump 110. The pressurized air can be routed to the inlet port of injection pump 110. The leaky gas and pressurized air can be combined in injection pump 110. In particular, injection pump 110 can be configured to allow the leaky gas and pressurized air to pass through a venturi tube of injection pump 110. Some or all of the combined motive air and leaky gas can be conveyed along passage 103E to return to engine 100, for example, as the inlet of compressor 114. Some or all of the combined motive air and leaky gas can also be routed to the environment. Air can be supplied to compressor 114, which can be configured to receive and compress air. Compressed air can be supplied from compressor 114 to aftercooler 116. Therefore, aftercooler 116 can be in fluid communication with compressor 114. Aftercooler 116 can be configured to receive and cool at least a portion of the compressed air.

[0031] In short, crankcase 101 allows leaking gas to pass through it. Multiple oil separators 104 are in fluid communication with the leaking gas and configured to separate oil from it. The mass flow rate of the booster air can be between 0.5% and 2.5% of the mass flow rate of the air received by compressor 114. The booster air can pass through the multiple oil separators 104 in a heat-exchange relationship with the leaking gas to maintain the temperature of the leaking gas within the multiple oil separators 104 within a desired temperature range. System 102 may include an ejector pump 110, which is in fluid communication with both the leaking gas exiting the multiple oil separators 104 and the booster air exiting the multiple oil separators 104. The ejector pump can be configured to combine the leaking gas and the booster air. After exiting the ejector pump, the combined leaking gas and booster air can be routed to at least one of compressor 114 or the environment.

[0032] In other words, system 102 can be configured to ratio the compressor outlet pressurized air to the aftercooler outlet air. This air ratio can be targeted at a temperature somewhere between 80°C and 120°C. Therefore, compressed air from compressor 114 and cooled air from aftercooler 116 can be mixed to achieve pressurized air with a temperature range between 80°C and 120°C (inclusive). This air mixture can be supplied to the sheath of each of the oil separators 104 to maintain the filter of each oil separator 104 at, for example, between approximately 80°C and 120°C. After passing through the sheath of the oil separators 104, the air mixture can be supplied as motive air to jet pump 110. The motive air via jet pump 110 can generate a vacuum that can be adjusted by regulator 108 (e.g., a vacuum control valve or a mechanical valve). The regulator 108 can regulate the vacuum at the outlet of the system 102 and can regulate the crankcase pressure (flow via leaking gas to the intake of the jet pump 110). In addition, pressurized air is used to heat, cool, or maintain the filters of the oil separator(s) 104 at a desired temperature.

[0033] Figure 2 An example of an oil separation device 104 that can be used with the previously described system 102 is shown. Figure 3 An exploded view of the components of the oil separator 104 is shown. (As shown...) Figure 3 As shown, the oil separator 104 may include an inlet manifold 202, an outer casing 204, an inner casing 206, a coalescing filter 207, an outlet manifold 208, and a cover 209.

[0034] Now for reference Figure 2 The inlet manifold 202 may include a body 210 and one or more ports 212. For example... Figure 2 As shown, the outlet manifold 208 may include a body 214 and one or more ports 216. According to some examples, the respective ports may be closed with a cover, plug, plate or other feature to prevent selected ports of one or more ports 212 and / or one or more ports 216 from receiving or discharging leaked gas.

[0035] like Figure 2 As shown, the inlet manifold 202 can be connected to the first end portion of the housing 204 by fasteners, welding, brazing, threaded connection, or other mechanical connections as known in the art. Similarly, the outlet manifold 208 can be connected to the second end portion of the housing 204 in a manner similar to that of the inlet manifold 202. The second end portion can generally be opposite the first end portion.

[0036] According to another example, the inlet manifold 202 and / or the outlet manifold 208 may be part of the housing 204, rather than separate components. For example, according to some examples, the housing 204, the inlet manifold 202, and / or the outlet manifold 208 may comprise a single, integrated assembly. For simplicity, the inlet manifold 202 and the outlet manifold 208, the cover, and other components may be referred to as the “housing” in this application, and it is understood that the term “housing” as used herein refers broadly not only to the inner housing 206 and the outer housing 204, but also to the inlet manifold 202, the outlet manifold 208, the cover 209, and / or other components that are not coalescing filters 207. Similarly, terms such as “upper,” “lower,” “top,” and “bottom” are relative terms rather than absolute terms. The orientation of the oil separator 104 may differ from the exemplary orientation shown.

[0037] The inlet manifold 202 and outlet manifold 208 may have cross-sections of square, rectangular, circular, pentagonal, quadrilateral, hexagonal, octagonal, or other shapes as needed, and may be constructed of any suitable material(s). The body 210 may form the outer wall, face, one or more manifolds, and other features of the inlet manifold 202. In short, the body 210 may be configured to form one or more ports 212 for conveying leaked gas into or out of the oil separator 104. Although not specifically shown, insulating material may be adjacent to or immediately adjacent to one or more sides of the body 210 (such as at its ends) and extend over one or more sides of the body. The insulating material may be held in place by mechanical fasteners, plates, and / or other features or components. According to one example, the insulating material may be a fiberglass insulation portion encapsulated within stainless steel foil, or a steel shell with an integral foam insulation pad.

[0038] For example, the outer shell 204 may have a hollow tubular shape. This shape can form an inner cavity configured to receive the inner shell 206. Therefore, the inner shell 206 can be positioned within the outer shell 204. The inner shell 206 and the outer shell 204 can be made of suitable materials (multiple types). Although the outer shell 204 and the inner shell 206 are shown as separate components in the figures, in some instances it is envisioned that these components could be integrally formed as a single piece, such as by casting or another forming technique. Reference Figure 2 The outer casing 204 may form a wall 218 having ports 220 passing through it. These ports 220 may provide multiple inlets or outlets as needed and may be in fluid communication with the sheath 222. Figure 10(As further discussed and illustrated below). Port 220 may be located at a flange 223 or other feature of a specific construction of housing 204. Flange 223 may form different faces of housing 204. For example, these faces of housing 204 may correspond to the faces of inlet manifold 202 and / or outlet manifold 208.

[0039] The body 214 may form the outer wall, surface, one or more manifolds, and other features of the outlet manifold 208. The body 214 may be configured to form one or more ports 216 for conveying leaked gas into or out of the oil separator 104. The cover 209 may be configured to engage with the body 214 and may be selectively removable from the body. The cover 209 may allow access to the inner cavity (formed by the inner housing 206) and the coalescing filter 207. The coalescing filter 207 can be removed and replaced with a new filter by selectively removing the cover 209 from the body 214. This process occurs in… Figure 11A-11D Further shown and described below. The insulating material may be adjacent to or close to one or more sides of the body 214 and the cover 209, and extends on one or more sides of the body and the cover. The insulating material may be held in place in a manner similar to that of the insulating material of the inlet manifold 202 by means of mechanical fasteners, plates and / or other features or components.

[0040] Figure 4 This is an exploded view that further details the cover 209 and a portion of the upper filter support assembly 224 of the oil separator 104. The upper filter support assembly 224 may include a STOR plug 226, a seal 228, a spring 230, and a plunger 232.

[0041] Cover 209 may be made of (a variety of) suitable materials (such as metal or (a variety of) metal alloys), similar to body 214. Figure 2 The cover 209 is made of a material that allows it to be attached to the body 214 via suitable mechanical attachments (such as fasteners). Figure 2 The cover 209 can be configured via a protrusion 234 having a receiving portion 236. Figure 4 (Only a portion of it is shown in the image) Figure 4 This refers to a portion of the upper filter support assembly 224. (As per...) Figure 10A As further discussed and shown, the STOR plug 226, seal 228, spring 230, and plunger 232 are configured to be inserted into or partially inserted into the receiving portion 236 of the protrusion 234. Thus, the receiving portion 236 receives a portion of the spring 230, plunger 232, seal 228, and STOR plug 226.

[0042] Figure 5This is an exploded view of the other components of the oil separator 104 (including the inner housing 206, coalescing filter 207, outlet manifold 208, and seal 238).

[0043] The outlet manifold 208 can be connected to the housing 204 so as to be adjacent to but spaced apart from the coalescing filter 207. The inner housing 206 can be positioned on the housing 204. Figure 2 and Figure 3 The inner housing 206 may include a sleeve with a hollow structure forming an inner cavity 240 for receiving the coalescing filter 207.

[0044] like Figure 5 As shown, the outlet manifold 208, particularly the body 214, may internally form a cavity (manifold) 242. The cavity 242 may be in fluid communication with one or more ports 216 for leakage gas to flow out after being filtered by the coalescing filter 207. The outlet manifold 208, particularly the body 214, may include a central port as part of the cavity 242, which allows access through the coalescing filter 207 into the inner cavity 240 of the inner housing 206. As further shown and discussed later, the cover 209 ( Figure 4 It can be configured to be connected to the body 214 and can be sealed to the body with a seal 238.

[0045] Figure 6 This is a perspective view of the outer casing 204. For example, the casing 204 may have a hollow tubular shape. This shape can be configured to receive the inner casing 206 ( Figure 5 The inner cavity 244 of the inner shell 206. Therefore, the inner shell 206 ( Figure 5 It can be positioned within the housing 204. The housing 204 can be made of suitable materials (a variety of materials). As previously discussed, the housing 204 may also include a wall 218, a port 220, and a flange 223.

[0046] Figure 7 This is a perspective view specifically showing the top of the inlet manifold 202. As previously discussed, the inlet manifold 202 may include a body 210 and one or more ports 212. The inlet manifold 202 may also include a lower cavity 246 and a lower filter support 248. The lower filter support 248 may include a filter inlet 250 having a port 252, a ridge 254, and a release portion such as a groove 256.

[0047] The lower cavity 246 may be defined by the body 210 and may have one or more ports 212 as inlets (or outlets) and ports 252 as its inlets or outlets. The body 210 may form the upper wall of the inlet manifold 202, and the lower filter support 248 may be positioned along the top of the inlet manifold 202. The filter interface 250 may be a centralized protrusion extending above the upper wall of the body 210. The filter interface 250 may form the port 252. A ridge 254 may project from the upper wall of the body 210. The ridge 254 may extend outwardly away from the filter interface 250 in several directions toward the outside of the inlet manifold 202. The filter interface 250 and / or the ridge 254 may include recesses 256 extending thereal.

[0048] As further discussed and shown, the inlet manifold 202 is configured to allow the lower chamber 246 to connect with the coalescing filter 207 ( Figure 5 The fluid communication between the central cavities of the body 210 and the lower cavity 246 is maintained. In particular, leaking gas can enter the lower cavity 246 from any direction via one or more ports 212 defined by the body 210. Leaking gas can pass from the lower cavity 246 through the lower filter support 248 to the coalescing filter 207 via port 252.

[0049] Figure 7A and 7B The filter interface 250 with port 252, ridge 254, and recess 256 are shown in more detail. (See attached image.) Figure 7A As shown, the filter interface 250 may have a non-circular cross-section. This non-circular shape may be oval, elliptical, oblong, square, rectangular, pentagonal, quadrilateral, hexagonal, octagonal, etc. Due to the non-circular shape of the filter interface 250, the port 252 may also be non-circular (e.g., oval, elliptical, oblong, square, rectangular, pentagonal, quadrilateral, hexagonal, octagonal, etc.).

[0050] Figure 7B A filter interface 250 is shown in perspective. The filter interface 250 may have an outer side 258 having a lip 260 and a recess 262. The lip 260 may project outwardly from the recess 262. Although the filter interface 250 is... Figure 7-7B The features shown are those of the inlet manifold 202, but according to other instances, the filter interface 250 may be a dedicated separate component (e.g., an adapter) configured to be coupled to the inlet manifold 202. According to some instances, the filter interface 250 may be attachable to the inlet manifold 202 and removable from the inlet manifold.

[0051] Figure 8The inlet manifold 202 is shown, particularly the lower filter support 248, which connects to and is coupled to the lower portion of the coalescing filter 207. A ridge 254 serves as a stop for the lower end cap 266 of the coalescing filter 207 (maintaining a distance from the rest of the inlet manifold 202). The ridge 254 positions the coalescing filter 207 at a desired distance from the rest of the inlet manifold 202, such that the filter inlet 250 is inserted into the orifice 264 of the lower end cap 266 at a desired distance. Figure 8 The filter interface 250 is shown to be inserted into and received by an orifice 264 of the lower end cap 266 of the coalescing filter 207. The orifice 264 may include an inlet port 267 communicating with the central cavity 268 of the coalescing filter 207.

[0052] The seal 270 can be received by a groove 262 at the outer side 258. For example, the seal 270 can be an O-ring or other suitable sealing construction. The seal 270 can be held in place by the lip 260 and the flange 272 of the lower end cap 266. The seal 270 can provide a sealing interface between the inlet manifold 202 (filter interface 250) and the coalescing filter 207. Figure 8 The diagram shows unfiltered leaked gas passing through port 252 of filter interface 250 and being received by inlet port 267 and central cavity 268 of coalescing filter 207. This is due to the non-circular shape of filter interface 250 and orifice 264 (see...). Figure 9 The filter interface 250 (highlighted feature) constrains the rotation of the coalescing filter 207 relative to the housing (e.g., relative to the outer housing 204, inner housing 206, outlet manifold 208, and / or cover 209, etc.) when received in the orifice 264.

[0053] Figure 9 The lower portion of the coalescing filter 207 is shown, including a lower end cap 266 with an orifice 264 forming an inlet port 267, a central cavity 268, a core 274, and a filter medium 276. (See diagram for reference.) Figure 7As shown, the orifice 264 defined by the lower end cap 266 may have a non-circular shape that generally corresponds to the shape of the filter interface 250. Therefore, the cross-section of the orifice 264 may be oval, elliptical, oblong, square, rectangular, pentagonal, quadrilateral, hexagonal, octagonal, etc. The cross-section of the central cavity 268 may be circular or non-circular. The central cavity 268 may be defined by a core 274. The coalescing filter 207 may have a generally cylindrical shape surrounding the central cavity 268 and the core 274. The core 274 may be positioned within the filter medium 276. The core 274 may comprise a thin, shaped cylindrical sheet having a plurality of orifices. These orifices communicate with the filter medium 276. The coalescing filter 207 is configured to separate a portion of the oil contained in leaked gas. The coalescing filter 207 can be constructed using single or multiple layers of synthetic microglass fibers, synthetic fibers, or other coalescing filter media types known in the industry, wherein the filter media 276 is formed in a tubular shape, wound around the core 274, or pleated and positioned around the core 274. The filter media 276 can be configured to coalesce oil mist from leaking gas. In addition to the filter media 276, the coalescing filter 207 may also include end caps, such as a lower end cap 266 and an upper end cap (not shown). The end caps may be made of a thin, rigid sheet of material that is bonded or otherwise attached to the core 274 and / or the filter media 276. The material may be a metal, (multiple) metal alloys, a suitable rigid and stable polymer, or a composite thereof. The coalescing filter 207 can be sealed to the entire housing using suitable associated seals. However, in some instances, the seals are not configured to be pre-attached to the coalescing filter 207, but are separate components inserted into the housing or components of the housing. The core 274 and filter media 276 may have an internally perforated tube structure and an externally perforated tube structure to provide the axial, torsional, and bending stiffness required for the application. This stiffness may be enhanced by end caps.

[0054] Figure 10 A cross-sectional view of the oil separator 104 is shown. Figure 10 The following are shown: inlet manifold 202, housing 204, inner housing 206, coalescing filter 207 including lower end cap 266, outlet manifold 208, cover 209, and lower filter support 248 including filter interface 250, as previously discussed. Figure 10 Also shown is the upper filter support assembly 224 and the upper end cap 278. The upper end cap 278 is generally opposite to the lower end cap 266 on the second axial end of the coalescing filter 207. Regarding Figure 10A Other components of the upper filter support assembly 224 are discussed.

[0055] refer to Figure 10The inlet manifold 202 can receive oil-containing leaked gas. As previously discussed, this leaked gas can pass through filter inlet 250 and enter coalescing filter 207. The oil-containing leaked gas can pass radially outward through coalescing filter 207 to its outer circumference. During this passage, the coalescing filter 207 is constructed to coalesce the oil from the leaked gas. This coalescing can cause the oil to separate from the leaked gas. Once coalesced, the oil can travel to the outer circumference of coalescing filter 207 and can be conveyed to the outer cavity 280 surrounding the outer circumference of coalescing filter 207. The leaked gas separated from the oil by the action of coalescing filter 207 can enter the outer cavity 280 from coalescing filter 207 and can enter the outlet manifold 208 from the outer cavity 280. The outer cavity 280 may communicate substantially all (100% or 360 degrees), most (60%-99%), majority (50%-59%), some (25%-49%), or part (5%-24%) of the outer circumference of the coalescing filter 207 with the outlet manifold 208. One or more channels may drain oil from the outer cavity 280 into the inlet manifold 202. One or more channels may be formed at least partially by the body 210 of the inlet manifold 202. One or more channels may have multiple outlet ports. The multiple outlet ports may be located on one or more faces of the body 210. One or more channels may be configured to receive oil captured by the coalescing filter 207 (separated by the action of the coalescing filter) and may discharge oil as a drain from the oil separation device 104 at the multiple outlet ports.

[0056] exist Figure 10The image shows a sleeve 222. Sleeve 222 may include a sealed cavity (separated from the internal cavity, leaking gas, oil, and coalescing filter 207) formed between the inner side of the wall 218 of the outer housing 204 and the outer surface of the inner housing 206. Therefore, sleeve 222 may be formed between the inner housing 206 and the outer housing 204. Sleeve 222 may be cylindrical in shape, having only a port 220 for fluid communication. Sleeve 222 may be configured to receive one or more of the following: an electric heater coil, insulating material, a sealing air gap, or a positive mass flow of pressurized engine air, engine coolant, or engine lubricating oil. More specifically, a resistance heating coil may be placed within sleeve 222 to provide heating for the inner housing 206 and the coalescing filter 207. This can be useful if the oil separator 104 operates in a cold environment. Alternatively or additionally, an insulating material such as foam may be placed within the sheath 222 to provide insulation of the coalescing filter 207 (and leaking gas) from harsh environments. As a supplement to or alternative to the heating coil and / or insulation, the sheath 222 may also receive a fluid that can be used to heat or cool the coalescing filter 207 (and leaking gas). For example, such a fluid may be any or a combination of a positive mass flow from a sealed air gap or pressurized engine air, engine coolant, or engine lubricating oil. However, the fluid is not limited to these examples.

[0057] Figure 10A This is an enlarged cross-sectional view of the upper portion of the oil separator 104 (including the upper portion of the coalescing filter 207 containing the upper end cap 278, the outer housing 204, and the inner housing 206). The outlet manifold 208, the cover 209, and the upper filter support assembly 224 are also shown. Figure 10A Arrows indicate an exemplary flow path of leaked gas along the upper portion of coalescing filter 207, through the coalescing filter, and through outlet manifold 208.

[0058] As previously referenced Figure 4 The discussion, and still ongoing Figure 10A As shown, the upper filter support assembly 224 may include a STOR plug 226, a seal 228, a spring 230, and a plunger 232. Additionally, the upper filter support assembly 224 may include a coupling assembly 282. The coupling assembly 282 may include a grommets 284 and a plurality of arms 286.

[0059] STOR plug 226 engages spring 230 and is downwardly secured into receiving portion 236 of protrusion 234. Seal 228 may be located between STOR plug 226 and protrusion 234. Spring 230 may be received in receiving portion 236 and engages STOR plug 226 and plunger 232. Plunger 232 may extend at least partially from receiving portion 236 and protrusion 234. Plunger 232 may be biased by spring 230.

[0060] The coupling assembly 282 may be attached to and extend outward from the upper end cap 278. As further discussed and shown, the coupling assembly 282 may be configured to connect to the cover 209 in a telescopic receiving manner and configured (e.g., relative to the outer housing 204, inner housing 206, outlet manifold 208, and / or cover 209, etc.) to position the coalescing filter 207 within the housing. This positioning of the coalescing filter 207 may be relative to the centerline axis of the housing. Thus, according to one example, the centerline axis of the coalescing filter 207 may be substantially aligned with the centerline axis of the housing via the coupling assembly 282.

[0061] The grommets 284 may have through-holes 288 configured to receive the lower portion of the protrusions 234 of the cover 209. A plurality of arms 286 may be coupled to the grommets 284 and to the upper end cap 278. The arms 286 may be spaced apart from each other (e.g., in increments of 45, 90, 135, or 180 degrees). The arms 286 may extend outward and downward from the grommets 284 to the upper end cap 278, such that the grommets 284 are spaced apart from the upper end cap 278. The shape and arrangement of the arms 286 may allow for an open-frame configuration of the coupling assembly 282, thereby allowing leaked gas to flow relatively unimpeded within the cavity 242 of the outlet manifold 208. In particular, the arms 286 may be spaced apart around the centerline axis of the coalescing filter 207 to provide multiple flow paths for filtered leaked gas through the outlet manifold 208 of the housing.

[0062] Multiple arms 286 may be stamped from metal, (multiple) metal alloys, or (multiple) other suitable materials. Multiple arms 286 may be connected to the upper end cap 278 by riveting, welding, adhesives, fasteners, or other suitable mechanical connections. Figure 10AAs shown, one or more of the plurality of arms 286 may be bent along at least two different arcs. These two arcs may have curvatures in different directions (e.g., concave and convex). Specifically, one or more of the plurality of arms 286 include a first arcuate bend 290 and a second arcuate bend 292. The first arcuate bend 290 may be attached to or adjacent to a grommets 284. The second arcuate bend 292 may be attached to or adjacent to an upper cap 278. The first arcuate bend 290 may be spaced apart from the second arcuate bend 292 by an intermediate portion 294. The intermediate portion 294 may be substantially straight (e.g., uncurved). The first arcuate bend 290 may have a first radius of curvature in a first direction, wherein the first radius of curvature has a center adjacent to the grommets 284, said center being generally spaced below the first arcuate bend 290 of at least one of the plurality of arms 286. The second arcuate bend 292 may have a second radius of curvature in a second direction, wherein the second radius of curvature has a center that is axially spaced from the upper end cap 278 at or near its outer radial portion. The center may be positioned axially spaced above the second arcuate bend 292 of at least one of the plurality of arms 286.

[0063] The upper end cap 278 may include at least one of a ridge or a recess 296 on its upper surface facing the coupling assembly 282. For example, the ridge or recess 296 may be generally aligned with and positioned below the grommets 284. The ridge or recess 296 may be contacted by the plunger 232. Figure 10A As shown, plunger 232 and spring 230 are inserted into receiving portion 236. Plunger 232 protrudes a certain distance from receiving portion 236 and is configured to engage upper end cap 278 when biased by spring 230. This configuration can induce axial compressive load on coalescing filter 207, which can reduce vibration. Therefore, when plunger 232 is biased by spring 230, the axial vibration of coalescing filter 207 relative to housing can be reduced via the engagement between plunger 232 and upper end cap 278. In addition, coupling assembly 282 can constrain radial movement of coalescing filter 207 relative to the centerline axis of housing via engagement with protrusion 234 to reduce radial vibration of coalescing filter 207. The configuration of upper filter support assembly 224 allows for a certain degree (e.g., 6 mm or less) of axial constrained movement of coalescing filter 207 relative to cover 209. The radial restraint movement of the coalescing filter 207 can be relatively smaller than the degree of axial restraint movement of the coalescing filter 207. The degree of axial restraint movement of the coalescing filter 207 can be determined by the force of the spring 230 and / or the position and / or thickness of the flanges 298A and 298B of the plunger 232 and the protrusion 234. The flanges 298A and 298B together form a stop to limit the axial travel of the plunger 232.

[0064] Figure 11A-11D A method 300 for maintaining the coalescing filter 207 from the housing (one or more parts of the oil separator 104 other than the coalescing filter 207) is shown. Figure 11A As shown, method 300 may include removing cover 209 from outlet manifold 208 to expose the top of coalescing filter 207. Additionally, as... Figure 11A As shown, the connecting assembly 282 can be configured as a handle for inserting the coalescing filter 207 and removing the coalescing filter from the housing. This is because the grommets 284 and / or the multiple arms 286 are easily accessible and gripped.

[0065] Figure 11B-11D It is a cross-sectional view. For example... Figure 11B As shown, seal 228 can be removed from the housing (here, outlet manifold 208) along with cover 209 for replacement (if needed). Figure 11C As shown, the coalescing filter 207 can be removed from the housing (removed from the inner cavity 240). Figure 11D As shown, seal 270 can be removed from filter port 250 and replaced. This replaced seal 270 can then be coupled to filter port 250, and the described process can be reversed. Therefore, as... Figure 11C As shown, a new or replacement coalescing filter 207 can be inserted into the housing (into the inner cavity 240). Figure 11B As shown, a new or replacement seal 228 can be attached to the housing. Figure 11A As shown, the cover 209 can be attached to the outlet manifold 208.

[0066] Industrial applicability

[0067] In operation, engine 100 can be configured to burn fuel to generate power. While generally efficient, a small fraction of the combustion gases may escape from the combustion chamber as blow-by gases and enter undesirable areas of engine 100, such as the crankcase. This disclosure envisions a system 102 that includes one or more oil separators 104 to filter oil and remove oil from the blow-by gases.

[0068] Oil separation devices incorporating coalescing filters are known; however, these devices have drawbacks. For example, these devices may have coalescing filters that are difficult to access for maintenance, difficult to properly align relative to the housing of the oil separator 104, and / or may be insufficiently or improperly constrained due to excessive vibration. The durability of the coalescing filter may be negatively affected by the latter two problems. Furthermore, improper alignment of the coalescing filter can lead to undesirable oil leaks.

[0069] The oil separator 104 discussed has various features that address these and other problems. For example, the connecting assembly 282 can be configured as a handle for easy gripping during maintenance for inserting and removing the coalescing filter 207 from the housing. This improves the accessibility of the coalescing filter 207 for maintenance.

[0070] The connecting assembly 282, with its multiple arms 286 and grommets 284, allows leaking gas to flow relatively unimpeded within the cavity 242 of the outlet manifold 208, even when functioning as a handle. Furthermore, the connecting assembly 282, through engagement with the protrusion 234, aligns the coalescing filter 207 relative to the housing and restricts radial movement of the coalescing filter 207 relative to the centerline axis of the housing, thereby reducing radial vibration of the coalescing filter 207. Additionally, to further reduce vibration, the oil separator 104 is configured to apply an axial compressive load to the coalescing filter 207. Specifically, the plunger 232, when biased by the spring 230, reduces axial vibration of the coalescing filter 207 relative to the housing through engagement between the plunger 232 and the upper end cap 278. On the lower portion of the coalescing filter 207 and the oil separator 104, the filter inlet 250 (a prominent feature) restricts the rotation of the coalescing filter 207 relative to the housing (e.g., relative to the outer housing 204, inner housing 206, outlet manifold 208, and / or cover 209, etc.) when received in the orifice 264. Due to these components and features, the oil separator 104, particularly the coalescing filter 207, exhibits long-term durability even under high vibration loads.

[0071] Additionally, the oil separator 104 may include an inlet manifold 202 and an outlet manifold 208, which are configured to allow leaking gas to enter and exit the manifold in any desired direction (the housing design of the inlet manifold 202 and outlet manifold 208 allows for up to 360-degree routing of leaking gas). Thus, the oil separator 104 provides configurability, versatility, scalability, and modularity not found in typical oil separators. This configurability, versatility, scalability, and modularity can meet the needs of a wide range of engine platforms with varying displacements and power densities. For example, the oil separator 104 of the present invention can be directly configured as a component, such as a multi-row parallel array, a multi-row tandem array, a U-shaped array, an L-shaped array, a T-shaped array, an H-shaped array, a single-row array, etc. This modularity (allowing for easy selection of a desired number of oil separators and implementation as an array) provides the configurability, versatility, scalability, and modularity required to address the needs of various engine platforms. The described components can be readily configured to handle various volumes of leaking gas and other fluids as needed for the requirements of various engines and / or auxiliary components. Both the inlet manifold 202 and the outlet manifold 208 may include multiple ports. These ports may be located along multiple sides / faces (e.g., corresponding to the four faces of, for example, the inlet manifold and / or the outlet manifold). This allows for various routing directions of leaking gas. Additionally, this configuration allows the oil separators to be placed as needed, in close proximity to each other (e.g., adjacent or spaced apart by a small distance).

[0072] The detailed description above is intended to be illustrative, not restrictive. Therefore, the scope of this disclosure should be determined by reference to the appended claims and the full scope of their equivalents.

Claims

1. A coalescing filter, comprising: Filter media; A central core, which defines a central cavity and is positioned within the filter medium; First end cap; A coupling assembly is attached to and extends outward from the first end cap, wherein the coupling assembly is configured to engage with a housing to position the coalescing filter within the housing; as well as A second end cap opposite to the first end cap.

2. The coalescing filter according to claim 1, wherein the coupling assembly comprises: A cable loop having a through hole configured to receive a protrusion of the housing; as well as A plurality of arms are connected to the grommets and the first end cap, wherein the plurality of arms are spaced apart and extend outward and downward from the grommets to the first end cap, such that the grommets are spaced apart from the first end cap.

3. The coalescing filter of claim 2, wherein one or more of the plurality of arms includes a first arcuate bend and a second arcuate bend, wherein the first arcuate bend is attached to the grommets and the second arcuate bend is attached to the first end cap, wherein the first arcuate bend is spaced apart from the second arcuate bend by an intermediate portion, and wherein the first arcuate bend has a first radius of curvature in a first direction and the second arcuate bend has a second radius of curvature in a second direction.

4. The coalescing filter of claim 2, wherein the plurality of arms are spaced apart around the central axis of the filter to provide multiple flow paths for leaking gas through the outlet manifold of the housing.

5. The coalescing filter according to any one of claims 1-4, wherein the coupling assembly is configured for inserting the coalescing filter and removing the coalescing filter from the housing.

6. The coalescing filter according to any one of claims 1-5, wherein the coupling assembly is configured to engage the housing to constrain radial movement of the filter relative to the centerline axis of the housing during operation.

7. The coalescing filter according to any one of claims 1-6, wherein the second end cap has an orifice forming an inlet port leading to the central cavity, wherein the orifice has a non-circular shape.

8. The coalescing filter of claim 7, wherein the orifice is configured to receive a corresponding non-circular protrusion of the housing, wherein the protrusion constrains rotation of the filter relative to the housing when received in the orifice.

9. The coalescing filter according to any one of claims 1-8, wherein the first end cap includes at least one of a ridge or a recess on its upper surface facing the coupling assembly.

10. An apparatus for filtering oil mist from leaked gas, comprising: A housing that forms an inner cavity, an outlet manifold, and an inlet manifold, wherein the housing includes a removable and attachable cover for partially enclosing the outlet manifold; as well as A coalescing filter, the coalescing filter being insertable into and removable from the cavity, the coalescing filter comprising: Filter media; A central core, which defines a central cavity and is positioned within the filter medium; First end cap; A coupling assembly, positioned within the outlet manifold, attached to and extending outward from the first end cap, wherein the coupling assembly receives a protrusion of the cover and is configured to position the coalescing filter within the housing; and A second end cap opposite to the first end cap.

11. The apparatus of claim 10, wherein the coupling component comprises: A rope ring with a through hole; as well as Multiple arms connected to the grommets and the first end cap; The cable loop having the through hole receives the protrusion of the cover; Furthermore, the engagement between the grommets and the protrusions restricts the radial movement of the coalescing filter relative to the centerline axis of the housing during operation.

12. The apparatus according to any one of claims 10-11, wherein the second end cap has an orifice forming an inlet port leading to the central cavity, wherein the orifice has a non-circular shape, wherein the inlet manifold has a protruding feature of a corresponding shape received by the orifice, wherein the non-circular shape of the orifice and the protruding feature constrain the rotation of the filter relative to the housing.

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