Pressure regulator for crankcase with umbrella valve

Abstract

The one-piece assembly includes a primary housing carrying a filter element. A secondary housing has a partition wall that seals an atmospheric chamber from a pressure regulator chamber. The partition wall is movable in a first axial direction and in a second axial direction opposite the first axial direction in response to changes in pressure drop across the filter element. A valve assembly responds to movement of a partition plate to change from a closed configuration to a partially open configuration to a fully open configuration. Movement of the valve maintains pressure in the crankcase downstream of the filter.

Description

Technical Field

[0001] This international application claims the benefit of U.S. Provisional Application No. 63 / 335,179, filed Apr. 26, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to an engine, and more particularly to regulating the pressure within the crankcase of an internal combustion engine by a pressure regulator assembly for the crankcase. More particularly, the regulator comprises a movable member that cooperates with a seat to provide a variable orifice for maintaining substantially constant the vacuum (negative pressure) within the crankcase.

Background Art

[0003] Closed-crankcase emission control systems require a high-efficiency filter and a crankcase pressure regulator. The high-efficiency filter needs to filter small-sized particles to prevent contamination of air, turbocharger, aftercooler, and engine internal components. The pressure regulator maintains the crankcase pressure at an acceptable level.

[0004] In one example of the prior art, the pressure control assembly uses a diaphragm and spring biasing means to maintain a constant vacuum within the system. The spring cooperates with the diaphragm, and a valve within the diaphragm moves a variable orifice to keep the pressure constant. The problem with using a diaphragm and spring is that this type of system requires many small moving parts. The spring wears over time and needs to be replaced before it fails.

[0005] In another example of the prior art, a valve member moves between at least a fully closed position, a partially open position, and a fully open position to keep the vacuum in the crankcase at a set negative pressure. In the partially open position, the pressure drops from a point upstream of the valve to a point downstream of the valve as compared to the fully open position. A regulator chamber and an atmosphere chamber are formed within the housing. A diaphragm coupled to the housing defines the regulator chamber and the atmosphere chamber. The diaphragm and the housing also define an atmosphere chamber that faces the regulator chamber and is below the regulator chamber. During operation, the positive atmospheric pressure in the atmosphere chamber can move the plate, diaphragm, and weight upward, and that movement moves the valve member upward, thereby positioning the valve from the open position or the partially open position to the partially open position or the closed position.

[0006] U.S. Patent No. 10,352,209, "Pressure Regulator Assembly" by Solberg, filed on July 16, 2019, discloses a filter combined with a pressure regulator. This combination includes a primary housing carrying an air / oil separation element. A valve member extends into the throat of the element. A secondary housing forms a regulator chamber and an atmosphere chamber. A partition of the secondary housing separates and fluid-seals the regulator chamber from the atmosphere chamber. The partition is movable in the opposite axial direction in response to a change in the pressure difference between the atmosphere chamber and the regulator chamber without using a spring. The valve opens into the regulator chamber and is in fluid communication with the regulator chamber. The secondary housing is held by the primary housing. Alternatively, it is also possible to have a fluid port opening from the secondary housing such that the valve does not open into the regulator chamber. The applicant incorporates herein by reference the entirety of U.S. Patent No. 10,352,209, "Pressure Regulator Assembly" by Solberg et al., filed on July 16, 2019. SUMMARY OF THE INVENTION

[0007] One embodiment of the present invention includes a pressure regulator for a crankcase integrated with a filter assembly including an internal cavity having a first portion and a second portion defined by a filter element housing. The filter element is within the housing. An atmosphere chamber is defined by a regulator housing. A pressure regulator chamber is defined by the regulator housing. A partition wall within the regulator housing fluid-seals the pressure regulator chamber from the atmosphere chamber. A valve assembly having a valve head and a valve orifice is within the internal cavity defined by the filter housing, the valve head being connected to the partition wall, the valve orifice having a first open access and a second open access. The assembly is adjustable to position the valve orifice in a valve orifice closed orientation, a first partially open orientation, a second partially open orientation, and an open orientation. An intake orifice is defined by the filter housing opening into the first portion of the cavity. An exhaust orifice is defined by an opening of the filter housing into the second portion of the cavity. A reference inlet is in fluid communication with the pressure regulator chamber. The valve orifice provides fluid access to the filter element. The partition wall is movable in a first axial direction and a second axial direction opposite the first axial direction in response to a change in the pressure differential between the pressure in the pressure regulating chamber and the pressure in the atmosphere chamber. Movement of the partition wall in the first axial direction moves the valve head in the first axial direction, and movement of the partition wall in the second axial direction moves the valve head in a second axial direction opposite the first axial direction of the first valve head. Movement of the valve head in the first axial direction moves the head relative to the valve orifice and positions the orifice from a closed direction to a first partially open orientation. Movement of the valve head in the first axial direction moves the valve head relative to the valve orifice and positions the valve assembly orifice from a first partially open orientation to a second partially open orientation.The movement of the valve head in the first axial direction causes the valve head to move relative to the valve assembly orifice, directing the orifice from the second partially open position to the open position. When the valve orifice is in the partially open position or the open position, the fluid before passing through the exhaust orifice passes through the valve orifice and then through the side wall of the filter element.

[0008] Another embodiment of the present invention includes a pressure regulator having a main cavity defined in part by the pressure regulator. The intake orifice opens into the main cavity. The exhaust orifice opens from the main cavity. A regulator housing is connected to the portion of the pressure regulator assembly that defines the main cavity of the pressure regulator, and the regulator housing defines an atmosphere chamber and a pressure regulator chamber. A partition wall blocks the atmosphere chamber and the pressure regulator chamber. The valve head is connected to a valve stem. The stem is connected to the partition wall. The valve orifice provides a passage through which fluid must pass before being discharged from the exhaust port. The valve orifice is arranged in a closed orientation, a first partially open orientation, a second partially open orientation, and an open orientation. Movement of the partition wall in a first axial direction moves the valve head in the first axial direction, and movement of the partition wall in a second axial direction moves the valve head in a second axial direction opposite the first axial direction. The movement of the valve head in the first axial direction moves the head relative to the valve orifice, positioning the orifice from the closed direction to the first partially open orientation. The movement of the valve head in the first axial direction moves the valve head relative to the valve orifice, positioning the valve orifice from the first partially open orientation to the second partially open orientation. The movement of the valve head in the first axial direction moves the valve head relative to the valve orifice, positioning the orifice from the second partially open position to the open position.

[0009] Of course, further objects and embodiments of the present invention are disclosed throughout other areas of the specification, drawings, and claims.

Brief Description of the Drawings

[0010] The present invention will be described with reference to the following figures.

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

[0012] Before describing embodiments of the present invention in detail, it should be understood that the present invention is not limited to the details of the structure and arrangement of the components described in the following description or illustrated in the drawings in its application. The present invention is capable of other embodiments and can be implemented or carried out in various ways. Also, it should be understood that the phrases and terms used herein are for the purpose of description and should not be regarded as limiting. The use of "comprising", "including" or "having" and variations thereof herein means including the items listed thereafter and their equivalents as well as additional items. Unless otherwise specified or limited, the terms "attached", "connected", "supported" and "coupled" and variations thereof are used broadly and include both direct and indirect attachment, connection, support and coupling. Further, "connection" and "coupling" are not limited to physical or mechanical connection or coupling.

Embodiments for Carrying Out the Invention

[0013] Figures 1 to 3 show embodiments of a pressure regulator for a crankcase integrated with a filter assembly (100) embodying the features of the present invention. This integrated assembly serves to filter the air inhaled into the assembly from the engine's crankcase (102) and exhaust the filtered air, while maintaining a desired pressure (usually negative pressure) within the crankcase. The exhausted exhaust gas can be forced back into the engine by a turbocharger.

[0014] The unitary assembly includes a primary housing (104), also referred to as a filter element housing (104). The primary housing defines internal cavities (106a, 106b). An air / oil separation element (108) is present in the housing cavities. The housing (104) mounts the filter element (108). A partition wall (110) is present within a secondary housing (112), also referred to as a regulator housing (112). The partition wall (110) separates an atmosphere chamber (114) from a pressure regulator chamber (116). The partition wall (110) is movable in a first axial direction (118) and a second axial direction (120) opposite the first axial direction. The partition wall moves in response to a change in pressure in the regulator chamber relative to the atmospheric pressure in the atmosphere chamber without the aid of a spring. A valve assembly (122a, 122b, 122c) without a spring is present within the housing cavities. The valve assembly (122a, 122b, 122c) changes from a closed configuration to a partially open configuration and a fully open configuration in response to movement of the partition wall (110). Also, in response to movement of the partition wall (110), it changes from an open configuration to a closed configuration and intermediate configurations therebetween. A bracket (370) is present between the primary housing (104) and the secondary housing (112) to facilitate their connection.

[0015] More specifically, a portion of the primary housing (104) forms an intake orifice (126) that opens into the housing cavities (106a, 106b). The exhaust orifice (128) formed by a portion of the housing (104) opens outside the housing cavities (106a, 106b). The secondary housing (112) is present at the end of the primary housing (104) covering the primary housing (104). The secondary housing (112) is connected to the primary housing (104). The secondary housing (112) defines a pressure regulator chamber (116) and an atmosphere chamber (114) that is fluid-tightly sealed from the pressure regulator chamber (116). The partition wall (110) on the first side has a first side surface (110a) facing in the first axial direction, and this side surface forms the boundary surface of the regulator chamber (116). The partition wall on the second side opposite the first side has a second side surface (110b) on the opposite side of the first side that forms the boundary surface of the atmosphere chamber. The partition wall includes a flexible and elastic diaphragm (110c) that blocks the pressure regulator chamber (116) from the atmosphere chamber (114). Axial movement of the partition wall (110) in the first axial direction (118) and the second axial direction (120) moves the valves (122a, 122b) of the valve assembly in the first axial direction (118) and the opposite second axial direction (120).

[0016] During operation, a vacuum source (130), such as a turbocharger, draws crankcase exhaust gas from the crankcase (102) into the downstream intake orifice (124). From the intake orifice (124), the exhaust gas moves downstream through the first portion (106a) of the cavity. The first portion forms a defined flow path that provides access to or opens onto the throat (108a) of the filter element. The orifice (122c) of the valve assembly can overlap, be disposed above, be disposed below, be in the same position as, or be in the vicinity of the open end of the filter throat. The orifice (112) provides exclusive access to the throat (108a) of the filter element (108). When the valve assembly is in the open or partially open state, the crankcase exhaust gas (132) flows out of the defined flow path (106a), through the orifice (122c) of the valve assembly, into the throat (108a) of the filter element, and past the valves (122a, 122b) of the valve assembly. The exhaust gas (132) enters the orifice (122c) from the first access port (122c') and exits the orifice (122c) via the second access port (122c''). The valve can include a valve head (122a) and a valve stem (122b). The exhaust gas (132) flows past the valve head (122a) and around the valve stem (122b). The exhaust gas from the throat (108a) passes through the continuous circumferential filter wall of the filter element. The wall can be a side wall. The filter is present in the second portion (106b) of the cavity. The exhaust gas (132) passes through the filter wall of the second portion of the cavity. From the second portion (106b), the exhaust gas flows out via the exhaust orifice (128). All of the exhaust gas passing from the first cavity portion (106a) to the second cavity portion (106b) passes through the orifice (122c) of the valve assembly. The exhaust gas can be re-injected into the engine (102) by a vacuum source (130), such as a turbocharger. The exhaust gas (132) moves along a path from the intake orifice (126) to the exhaust orifice (128) without entering the atmospheric pressure chamber (114). The chamber (114) is sealed from the flow path.

[0017] More specifically, the valves (122a, 122b) are fixedly connected to the partition wall (110). The pressure in the pressure adjustment chamber (116) can be a negative pressure. When the pressure in the pressure adjustment chamber (116) increases in a negative magnitude to a certain negative pressure, the atmospheric pressure at the partition wall in the atmosphere chamber (114) overcomes the forces such as the weight of the partition wall acting on the partition wall (110), and moves the partition wall (110) along the axis (110d) of the partition wall in the second axial direction opposite to the first axial direction (120). The movement of the partition wall (110) in the second axial direction (120) moves the valve head (122a) of the valve assembly in the second axial direction (120) along the axis (122d) of the valve head (122a). When the valve assembly is in an open state or a partially open state, the valve head (122a) moves toward the first access (122’) that opens into the orifice (122c) of the valve assembly. Depending on the magnitude (in units of distance) of the movement of the partition wall in the second direction (120), the valve head (122a) further moves into the valve assembly orifice (122c) in the second direction (120). When the valve head (122a) moves into the orifice (122c) and completely closes the orifice (122c), the valve head prevents the exhaust gas from passing through the orifice (122c) and entering the throat (108a) of the filter.

[0018] As the magnitude of the negative pressure decreases, the force acting on the partition wall (110) in the first direction (118), e.g., the weight of the partition wall including a plurality of weights thereon, becomes greater than the atmospheric pressure in the atmospheric pressure chamber (114) acting on the partition wall (110) in the second direction (120), whereby the partition wall (110) begins to move in the first direction (118) along the longitudinal axis (110d) of the partition wall (110). The valve moves in the first direction (118) away from the first access (122'). When the valve begins to move in the first direction (118) away from the first access portion (122'), a part of the valve head (122a) moves out of the orifice. The more the valve head (122a) moves away from the first access portion (122c') in the first axial direction (118), the more the valve head (122a) moves further out of the orifice (122c). When the valve head (122a) completely disengages from the orifice (122c) of the valve assembly, the orifice (122c) fully opens and the valve assembly assumes an open configuration.

[0019] The pressure in the regulator chamber changes with the change in the reference pressure. The reference inlet (134) is located at the central first portion (106a) of the cavity upstream of the second access (122c') that opens from the orifice (122c) downstream of the intake orifice (126) for detecting the reference pressure. The inlet (134) is also upstream of the first access (122c') that opens into the orifice (122c). The inlet opens into a pipe (136). The inner surface of the pipe defines a channel and a cavity. The pipe extends through the atmospheric chamber (114) and opens into the pressure regulator chamber (116). The pipe (136) and its cavity and the inlet (134) are fluid-sealed from the atmospheric chamber (114) so that fluid does not pass from the atmospheric chamber (114) into the pipe (136) or its cavity. Also, fluid from the pipe (136) and its cavity does not pass into the atmospheric chamber (114). The inlet (134) represents a proxy pressure of the pressure (negative, positive) in the crankcase (102).

[0020] The valve head (122a) of the valve is oriented relative to the valve orifice (122c) so as to close the orifice (122c), partially open the orifice (122c), further partially open the orifice (122c), and fully open the orifice (122c). When the orifice (122c) is closed, the valve head (122a) is present within the orifice (122c) and seals the orifice (122c) to prevent the exhaust gas from passing through the orifice (122c). When partially open, the valve head (122a) is present within the orifice (122c) and partially restricts the exhaust gas from passing through the orifice (122c). When partially open, the first end of the head (122a) where the valve stem (122b) extends is axially spaced from the first access portion (122c’) in the second axial direction (120) more than when the orifice (122c) is closed. When the orifice (122c) is further partially open, the first end of the valve head (122a) is further away from the first access (122c’) in the second axial direction (120) than when the orifice (122c) is less partially open. The flow of exhaust gas through the orifice (122c) becomes less restricted as the opening degree of the orifice decreases. When in the fully open position, the head (122a) at the first end is at the maximum distance from the first access portion (122c’) in the second axial direction (120). The flow of exhaust gas through the orifice (122c) becomes less restricted further.

[0021] More specifically, the valve head (122a) has a second end that axially opposes the first end. The second end includes an end face (122a'') encompassed by an outer periphery. The outer periphery is a circumference of a diameter having a length. The outer periphery surrounds a region. The valve has a surface (122a') of the first end surrounded by the outer periphery. The outer periphery is a circumference with a diameter having a length and surrounds a region. The diameter of the first surface (122a') is smaller in length than the diameter of the second surface (122a''). The first surface and the second surface face each other. The first surface faces in the second direction (120). The second surface faces in the first direction (118). The valve head (122a) includes a continuous side surface (122a''') between the first end face (122a') and the second end face (122a''), connecting the first end face (122a') and the second end face (122a'') to each other. The side surface (122a''') tapers radially inward as it approaches the first surface (122a') from the second surface (122a''). The valve outer surface defines a frustoconical shape. The valve head (122a) is considered umbrella-shaped. The valve stem (122b) extends axially along its longitudinal axis in the second axial direction (120) from the first end of the valve head and is connected to the tube (136) at the tube end opposite the open end (136a) that opens into the pressure regulating chamber (116). The stem extends through a protrusion of the first surface (122a') of the valve head. The tube (136) interconnects the valve head (122a) and the stem (122b) to the partition wall (110).

[0022] A plate (138) is formed in the orifice (122c) of the valve assembly. The orifice (122c) opens through the plate (138). The first access (122’) of the orifice opens through the first end face of the plate. The second access (122c’’) of the orifice opens through the second end face of the plate. The continuous side surface (138a) of the plate extends axially from the second open access (122c’) to the first open access (122c’). The side surface (138a) tapers radially inwards as it approaches the surface of the first open access from the second open access. The side surface (138a) defines the orifice (122c). The orifice is a flow path through which the exhaust gas can pass.

[0023] When the orifice (122c) is closed, the first access (122c’) of the orifice is close to the first surface (122a’) of the valve head and distal to the second surface (122a’’) of the valve head. The second access (122c’’) of the orifice is distal to the first surface (122a’’) of the head and proximal to the second surface (122a’’) of the head. When the orifice (122c) is fully open, the second access (122c’’) of the orifice is close to the first surface (122a’) of the valve head and the first access (122c’) of the orifice is distal from the first surface (122a’) of the valve head.

[0024] More specifically, the atmosphere chamber (114) at the first end has a first surface of a section that defines the first end of the atmosphere chamber. The first surface is formed on the first wall (140) of the regulator housing. This wall is a flat plane and is rigid. The continuous side surface defines the side surface of the atmosphere chamber. The side surface is rigid, formed on the side wall (144) of the regulator housing, and is curved and circumferential. The opening (146) is continuous except for the part that opens through the side wall. The opening puts the atmosphere chamber (114) in fluid communication with the atmosphere or the external environment of the regulator housing.

[0025] The atmosphere chamber (114) at the second end has a second end face (110b) that defines the chamber at its second end. The second end face is formed from the partition wall (110). The second end face consists of an elastomer surface (110c’) formed from the diaphragm (110c). It also consists of a rigid surface (110e’) that overlaps a part of the elastomer surface. The rigid surface is formed on the rigid wall (110e). The rigid wall defines an open void space where the elastic surface overlaps. The elastomer surface (110e) formed on the diaphragm extends between the rigid side wall (144) and the second end face (110a). The spokes formed by the wall (110e) define a void space overlapped by the diaphragm surface (110c’) defined by the spokes formed by the wall. The diaphragm (110c) and the rigid wall (110e) form part of the partition wall (110). The void volume surrounded by the atmosphere chamber (114) increases and decreases as the valve head (122a) moves axially.

[0026] The regulator chamber (116) at the first end has a compartment end face that defines the first end of the chamber. The end face is formed on the second wall (148). The second wall (148) is rigid and is formed from the regulator housing. The regulator chamber (116) is also defined by the side surface. The side surface is integrally formed with the side wall (150) of the regulator housing. The surface is curved and continuous circumferentially. The second end face (110a) defines the regulator chamber (116). The surface (110b) consists of an elastomer surface (110c’’) formed from the diaphragm (110c). It also consists of a rigid surface (110f’). The rigid surface is formed on the rigid wall (110f). The rigid wall defines an open void space where the elastic surface (110c’’) overlaps. The elastomer surface (110c’’) formed on the diaphragm extends between the rigid side wall (150) and the second end face (110a). The spokes formed by the wall define a void space defined by the spokes formed by the wall.

[0027] More specifically, the filter housing (104) includes a canister (104a) that houses the filter (108). The housing (104) includes a cover (104b). The cover (104b) defines an intake orifice (126) and an exhaust orifice (128). The cover (104b) seats over the canister (104a). The cover (104b) is seated on an end portion (104a') of the canister and defines access to a cavity of the canister where the filter element (108) is seated.

[0028] The pressure regulators (114, 116, 122a, 122b, 122c) serve to maintain the crankcase (102) at a desired pressure, usually a negative pressure, while a negative pressure source (130) draws exhaust gas from the crankcase (102) through the filter element (108). To maintain the pressure, the valve head (122a) moves in and out of the valve assembly orifice (122c) to various degrees so that the negative pressure in the crankcase (102) is maintained at a set predetermined pressure, for example, a pressure of minus 3 inches. The unit of measurement can also be inches of mercury. In one example of operation, the desired pressure in the crankcase (102) is minus 3 inches. The drop across the filter (108) is minus 2 inches, and the negative pressure of the negative pressure source (130) is minus 10 inches. The drop across the valve assembly orifice (122c) is minus 2 in the first partially open orientation. Thus, leaving the valve assembly orifice (122c) in this first open orientation means that the negative pressure in the crankcase increases beyond the desired pressure. This increase is undesirable because it removes too much of the dirty exhaust gas. To prevent the increase in negative pressure, the valve head (122a) moves into the valve assembly orifice (122c) in a second axial direction and partially fills the orifice (122c) more than when the valve filled the orifice when the orifice (122c) was in the first open orientation. The orifice is in a second partially open position. The valve assembly is oriented from a more fully open position when the orifice (122c) is oriented in the first open position to a non-open position. The valve head moves in the second axial direction (120) because atmospheric pressure overcomes the axial force applied from the partition wall (110) and moves the partition wall in the second axial direction (120), thereby drawing the valve head (122a) further into the orifice (122c) in the second axial direction than in the previous orientation. The valve assembly is oriented from a more partially open orientation within a range of predetermined open positions to a less partially open orientation.Compared to a more open orientation, a less partially open orientation provides an increased drop across the valve assembly orifice to ensure that the crankcase pressure, as referenced by the regulator chamber inlet orifice (134), remains within the desired negative pressure or a certain range. The valve head (122a) is oriented such that its longitudinal axis (122d) extends through the first access portion (122c’) and the second access portion (122c’’) of the orifice.

[0029] In another scenario, when the filter clogs, the drop across the filter (108) increases. Thus, the negative pressure within the crankcase (102) changes to less than minus 3 inches if the valve head (122a) remains in a fixed position relative to the orifice (122c), for example, it could become minus 1 inch. To prevent this change, the front of the valve (122a) moves in a first direction (118) to orient the valve head (122a) outside of the orifice (122c) more than when it was previously positioned. The valve moves in the first axial direction (118) because the axial force is increased by the partition wall (110) and overrides the atmospheric force within the atmosphere chamber (114) that moves the partition wall (110) in the first axial direction. This movement causes the valve head (122a) to move in the first direction (118) and away from the first access portion (122c’), so the orifice (122c) is more open than its previous orientation. By directing the orifice (122c) towards a more open orientation, the drop across the valve orifice (122c) is reduced to a less negative pressure to ensure that the crankcase pressure, referenced by the inlet (134), remains at the desired negative pressure. The pressure regulator assembly, including the pressure regulator chamber (116), the partition wall (110), the atmosphere chamber (114), and the valve assembly (122a, 122b, 122c), interacts and operates without the assistance of a spring. Those skilled in the art often refer to a negative pressure source as a vacuum source.

[0030] In an alternative embodiment, the pressure reference point is not present at the inlet (134) of the tube (136) that extends through the atmosphere chamber (114) into the first portion (106a) of the cavity. The inlet (152) opens into a tube (154) having a first end (154a) that opens through the end wall (148) into the pressure regulator chamber (116). The tube (154) extends from the first end (154a) outside of the regulator housing (112) and outside of the filter housing (104) and directs the inlet (152) away from the first portion (106a) of the cavity. In this embodiment, the inlet (152) is present at the access port to the suction orifice (126). The tube (136) is not in fluid communication with the pressure regulation chamber.

[0031] In a further alternative embodiment, the pressure regulator assembly exists alone. In this embodiment, the regulator assembly defines a main cavity (300). An intake orifice (304) opens into the main cavity (300), and an exhaust orifice (306) opens outside the main cavity (300). The valve assembly of the pressure regulator assembly includes a valve stem (308) connected to a partition wall (310) of the regulator assembly. The stem, which is a rod, extends through the atmosphere chamber (312) into the main cavity (300). The valve stem (308) extends to a valve head (309) and is connected to the valve head (309). The valve assembly orifice (311) overlaps the cavity of the exhaust orifice (308). The orifice (311) restricts access to the exhaust orifice (308). The orifice (311) is close to the end of the exhaust orifice (308) and is distal to the end on the opposite side of the exhaust orifice (308). The valve orifice (311) has the same shape as the orifice (122c). The valve head (309) has a first end face (309a) without a protrusion, similar to the end face (122a’) without a protrusion. The head has a second end face (309b) and a tapered side face (309c) the same as the head (122a). A partition wall (314) that functions similarly to the partition wall (110) isolates the atmosphere chamber (312) from the pressure regulator chamber (318). The partition wall (314) includes a diaphragm (321) that blocks the atmosphere chamber (312) from the pressure regulator chamber (318). The pressure adjustment chamber (318) and the atmosphere chamber (312) perform the same functions as the pressure regulator (116) and the atmosphere chamber (114). The chamber (312) and the chamber (318) are defined by a normal housing above the main cavity. In summary, the partition wall (310) moves up and down due to a change in the pressure difference between the regulator chamber (318) and the atmosphere chamber (312). The movement of the partition wall (310) moves the valve head (309) relative to the valve orifice (311). Due to this movement, the orifice (311) is arranged in different orientations that can be referred to as operating states. The orifice (311) can exist in a closed orientation, an open orientation, and different partially open orientations.The change in the orientation of the orifice changes the drop before and after the orifice (311). This change helps to maintain the crankcase pressure at a constant pressure, such as the change in the pressure drop before and after the orifice (122c).

[0032] During operation, the intake port (304) and the exhaust port (306) of the regulator assembly are upstream of the vacuum source (130). The orifices of the intake port (304) and the exhaust port (306) are downstream of the crankcase (102) and the filter element (324). The reference inlet (326) of the reference pressure is in fluid communication with the pressure regulating chamber (318) and the crankcase (102). The pipe (328) forming the inlet (326) opens into the crankcase (102) at one end (328a) having the pipe inlet (326) and into the pressure regulator chamber (328b) at the other end. The vacuum source sucks the exhaust gas from the crankcase (102) through the filter (324). The filtered exhaust gas is sucked into the cavity (300) through the intake orifice (304). From the cavity (300), the exhaust gas is drawn out from the exhaust orifice (306). When the exhaust gas is sucked from the intake port (304) and the exhaust port (306), the partition wall (310) moves up and down due to the pressure change of the reference intake port (326). Due to the movement of the partition wall (310), the valve head (309) moves up and down in the first axial direction (118) and the second axial direction (120). Due to the movement of the valve head (309), the drop before and after the orifice (311) changes. This change keeps the pressure in the crankcase (102) constant or within a certain range. This occurs without the help of a spring.

Claims

1. An internal cavity having a first portion and a second portion defined by a filter element housing, A filter element within the housing, An atmosphere chamber defined by a regulator housing, A pressure regulator chamber defined by the regulator housing, A partition within the regulator housing that fluid-tightly seals the pressure regulator chamber from the atmosphere chamber, A valve assembly having a valve head and a valve orifice within the internal cavity defined by the filter housing, the valve head being connected to the partition, and the valve orifice having a first open access and a second open access, A valve orifice closed orientation, a first partially open orientation, a second partially open orientation, and an open orientation, An intake orifice defined by the filter housing and opening into the first portion of the cavity, An exhaust orifice defined by the filter housing and opening into the second portion of the cavity, A reference inlet in fluid communication with the pressure regulating chamber, The valve orifice provides fluid access to the filter element, The partition is movable in a first axial direction and a second axial direction opposite the first axial direction in response to a change in the pressure difference between the pressure in the regulator chamber and the pressure in the atmosphere chamber, Movement of the partition in the first axial direction moves the valve head in the first axial direction, and movement of the partition in the second axial direction moves the valve head in the second axial direction opposite the first axial direction of the valve head, Movement of the valve head in the first axial direction moves the head relative to the valve orifice and positions the orifice from the closed orientation to the first partially open orientation, Movement of the valve head in the first axial direction moves the valve head relative to the valve orifice and positions the valve assembly orifice from the first partially open orientation to the second partially open orientation, Movement of the valve head in the first axial direction moves the valve head relative to the valve assembly orifice and positions the orifice from the second partially open orientation to the open orientation, When the valve orifice is in the partial opening position or the opening position, the fluid before passing through the exhaust orifice passes through the valve orifice and then through the wall of the filter element. A pressure regulator for a crankcase integrated with a filter assembly. **Claim 2** When the valve orifice is in the first partial opening orientation, the fluid flows through the valve orifice less restrictedly than when the valve orifice is in the closed orientation. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 3** When the valve orifice is in the second partial opening orientation, the fluid flows through the valve orifice less restrictedly than when the valve orifice is in the first partial opening orientation. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 4** When the valve orifice is in the open orientation, the fluid flows through the valve orifice less restrictedly than when the valve orifice is in the second partial opening orientation. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 5** The valve head fills the valve orifice less when the orifice is in the first partial opening orientation compared to when the valve orifice is in the closed direction. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 6** The valve head fills the valve orifice less when the orifice is in the first partial opening orientation compared to when the valve orifice is in the closed direction. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 7** The valve head fills the valve orifice less when the valve orifice is in the second partial opening orientation compared to when the valve orifice is in the first partial opening orientation. A pressure regulator for a crankcase integrated with the filter assembly according to claim 1. **Claim 8** The pressure regulator for a crankcase integrated with the filter assembly according to claim 1, wherein the valve head fills the valve head orifice less when the orifice is in the open orientation than when the orifice is in the second partially open orientation.

9. The pressure regulator for a crankcase integrated with the filter assembly according to claim 1, wherein the valve head comprises a tapered continuous surface between a first end face and a second end face of the valve head.

10. The pressure regulator for a crankcase integrated with the filter assembly according to claim 1, further comprising a tapered continuous side surface that is between the first end face and the second end face and defines the valve orifice.

11. The pressure regulator for a crankcase integrated with the filter assembly according to claim 1, further comprising a tube extending into the atmosphere chamber, wherein the reference inlet opens into the tube, and the tube opens into the pressure regulator chamber.

12. The pressure regulator for a crankcase integrated with the filter assembly according to claim 1, further comprising a tube opening into the pressure regulator chamber, wherein the reference inlet opens into the tube, and the tube extends outside the regulator housing and the filter housing and opens into the pressure regulator chamber.

13. A pressure regulator assembly, a main cavity defined by a part of the pressure regulator, an intake orifice opening into the main cavity, an exhaust orifice opening from the main cavity, a regulator housing connected to a part defining the main cavity portion of the pressure regulator assembly and defining an atmosphere chamber and a pressure regulator chamber, a partition wall blocking the atmosphere chamber and the regulator chamber, a valve head, a valve stem connected to the partition wall, the valve head connected to the stem, a valve orifice providing access to pass through before passing through the exhaust, comprising a valve orifice closed orientation, a first partially open orientation, a second partially open orientation, and an open orientation, wherein a first axial movement of the partition wall moves the valve head in a first axial direction, and a second axial movement of the partition wall moves the valve head in a second axial direction opposite to the first axial direction of the valve head. The first axial movement of the valve head moves the head relative to the valve orifice and positions the orifice from the closed orientation to the first partially open orientation, The first axial movement of the valve head moves the valve head relative to the valve orifice and positions the valve assembly orifice from the first partially open orientation to the second partially open orientation, The first axial movement of the valve head moves the valve head relative to the valve assembly orifice and orients the orifice from the second partially open position to the open position, a pressure regulator assembly. **Claim 14** The pressure regulator assembly according to claim 13, wherein the valve head has a surface that prevents fluid from passing through the valve head.

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