Crankcase pressure regulator with umbrella-type 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 consists of a movable member that cooperates with a seat to provide a variable orifice for maintaining substantially constant 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, after - cooler, and engine internal components. The pressure regulator maintains the crankcase pressure at an acceptable level.

[0004] In one example of the prior art, a pressure control assembly uses diaphragm and spring biasing means to maintain a constant vacuum within the system. The spring cooperates with the diaphragm, and the 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 movable parts. The spring wears over time and needs to be replaced before failure.

[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 maintain a set negative pressure in the crankcase. In the partially open position, the pressure decreases from the upstream point of the valve to the downstream point of the valve compared to the fully open position. A regulator chamber and an atmospheric chamber are formed within the housing. A diaphragm coupled to the housing defines the regulator chamber and the atmospheric chamber. The diaphragm and housing also define the atmospheric chamber, which is opposite to and below the regulator chamber. During operation, the positive atmospheric pressure in the atmospheric chamber can move the plate, diaphragm, and weight upward, which moves the valve member upward, thereby positioning the valve from an open or partially open position to a partially open or closed position.

[0006] U.S. Patent No. 1,0352209, “Pressure Regulator Assembly,” filed July 16, 2019, by Solberg, discloses a filter in combination with a pressure regulator. This combination includes a primary housing that houses an air / oil separation element. A valve member extends into the throat of the element. A secondary housing forms a regulator chamber and an atmospheric chamber. A partition in the secondary housing separates the atmospheric chamber from the regulator chamber and provides a fluid seal. The partition is movable in opposite directions in response to changes in the pressure difference between the atmospheric chamber and the regulator chamber, without the use of a spring. A valve opens into the regulator chamber and provides fluid communication with the regulator chamber. The secondary housing is held by the primary housing. Alternatively, a fluid port may open from the secondary housing, and the valve may not open into the regulator chamber. The applicant incorporates the entirety of U.S. Patent No. 1,0352209, “Pressure Regulator Assembly,” filed July 16, 2019, by reference herein. [Overview of the Initiative]

[0007] One embodiment of the present invention includes a crankcase pressure regulator integrated with a filter assembly having an internal cavity having a first portion and a second portion defined by a filter element housing. The filter element is located within the housing. The regulator housing partitions an atmospheric chamber. The pressure regulator chamber is partitioned by the regulator housing. A partition within the regulator housing fluid-seals the pressure regulator chamber from the atmospheric chamber. A valve assembly having a valve head and a valve orifice in the internal cavity defined by the filter housing, wherein the valve head is connected to the partition and the valve orifice has 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. The intake orifice is defined by the filter housing opening into the first portion of the cavity. The exhaust orifice is defined by the opening in the filter housing into the second portion of the cavity. The 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 to the first axial direction in response to changes in the pressure difference between the pressure in the pressure regulating chamber and the pressure in the atmospheric 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 the second axial direction opposite to 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, positioning 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, positioning the valve assembly orifice from a first partially open orientation to a second partially open orientation.The first axial movement of the valve head moves the valve head relative to the valve assembly orifice, orienting the orifice from the second partially open position to the fully open position. When the valve orifice is in the partially open position or the fully open position, the fluid before passing through the exhaust orifice passes through the valve orifice and then through the sidewall of the filter element.

[0008] Another embodiment of the present invention includes a pressure regulator having a main cavity defined by a portion of the pressure regulator. An intake orifice opens into the main cavity. An exhaust orifice opens out of the main cavity. A regulator housing is connected to the portion of the pressure regulator assembly that defines the main cavity, and the regulator housing defines an atmospheric chamber and a pressure regulator chamber. A partition separates the atmospheric chamber and the pressure regulator chamber. A valve head is connected to a valve stem. The stem is connected to a partition. A valve orifice provides a passage through which a 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 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 to the first axial direction. The first axial movement of the valve head moves the head relative to the valve orifice, positioning the orifice from the closed direction to the first partially open orientation. The first axial movement of the valve head 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 first axial movement of the valve head moves the valve head relative to the valve orifice, positioning the orifice from the second partially open position to the open position.

[0009] Naturally, further objects and embodiments of the present invention are disclosed through the specification, drawings, and other areas of the claims. [Brief explanation of the drawing]

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

[0011] [Figure 1] Figure 1 is a cross-sectional view of a pressure regulator integrated with a filter element located in a filter element housing downstream of the engine crankcase and upstream of the vacuum source, which embodies the features of the present invention. [Figure 2] Figure 2 is an exploded view of the pressure regulator integrated with the filter element within the filter element housing shown in Figure 1. [Figure 3] Figure 3 is a cross-sectional view of a pressure regulator integrated with a filter element located in a filter element housing downstream of the engine crankcase and upstream of the vacuum source, similar to the assembly shown in Figure 1. The assembly in Figure 3 uses a sensing tube to sense the reference pressure, in contrast to a sensing orifice in a tube extending from the regulator chamber into the filter housing assembly, and this assembly embodies the features of the present invention. [Figure 4] Figure 4 is a cross-sectional view of an independent pressure regulator located downstream of the crankcase and filter, and upstream of a vacuum source such as a turbocharger, which embodies the features of the present invention.

[0012] Before describing embodiments of the present invention in detail, it should be understood that the present invention is not limited in its application to the details of the structure and arrangement of components described in the following description or illustrated in the drawings. Other embodiments of the present invention are possible and can be carried out or implemented in a variety of ways. It should also be understood that the expressions and terms used herein are for illustrative purposes only and should not be considered limiting. The use of “comprising,” “comprising,” or “having” and their variations herein means that they encompass the items listed thereafter and their equivalents, as well as additional items. Unless otherwise specified or limited, the terms “attached,” “connected,” “supported,” and “joined,” and their variations, are used broadly and include both direct and indirect attachment, connection, support, and joining. Furthermore, “connected” and “joined” are not limited to physical or mechanical connection or joining. [Modes for carrying out the invention]

[0013] Figures 1 to 3 show embodiments of a crankcase pressure regulator integrated with a filter assembly (100) that embodies the features of the present invention. This integrated assembly filters the air drawn into the assembly from the engine crankcase (102) and exhausts the filtered air, while maintaining a desired pressure (usually negative pressure) within the crankcase. The exhaust gas can be forcibly returned to the engine by a turbocharger.

[0014] The integrated assembly includes a primary housing (104), also referred to as the filter element housing (104). The primary housing defines an internal cavity (106a, 106b). An air / oil separation element (108) is located within the housing cavity. The housing (104) mounts the filter element (108). A partition wall (110) is located within a secondary housing (112), also referred to as the regulator housing (112). The partition wall (110) isolates the atmospheric chamber (114) from the pressure regulator chamber (116). The partition wall (110) is movable in a first axial direction (118) and a second axial direction (120) opposite to the first axial direction. The partition wall moves without the help of a spring in response to changes in pressure in the regulator chamber relative to atmospheric pressure in the atmospheric chamber. Springless valve assemblies (122a, 122b, 122c) are located within the housing cavity. The valve assemblies (122a, 122b, 122c) change from a closed configuration to a partially open configuration and then to a fully open configuration in response to the movement of the bulkhead (110). They also change from an open configuration to a closed configuration and an intermediate configuration in response to the movement of the bulkhead (110). The bracket (370) is located between the primary housing (104) and the secondary housing (112) and facilitates their connection.

[0015] More specifically, a portion of the primary housing (104) forms an intake orifice (126) that opens into the housing cavity (106a, 106b). An exhaust orifice (128) formed by a portion of the housing (104) opens to the outside of the housing cavity (106a, 106b). The secondary housing (112) is located at the end of the primary housing (104) and covers 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 atmospheric chamber (114) that is fluidically sealed away from the pressure regulator chamber (116). The first side partition (110) has a first side surface (110a) facing in the first axial direction, which forms the interface of the regulator chamber (116). The partition wall on the second side opposite the first side has a second side surface (110b) opposite the first side that forms the interface of the atmospheric chamber. The partition wall includes a flexible and resilient diaphragm (110c) that isolates the pressure regulator chamber (116) from the atmospheric chamber (114). Axial movement of the partition wall (110) in the first axial direction (118) and the second axial direction (120) causes the valves (122a, 122b) of the valve assembly to move 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 gases from the crankcase (102) into a downstream intake orifice (124). From the intake orifice (124), the exhaust gases move downstream through a first portion (106a) of the cavity. The first portion forms a defined flow path that opens to or above the throat (108a) of the filter element. An orifice (122c) of the valve assembly may overlap the opening end of the filter throat, be positioned above it, be positioned below it, be in the same position, or be in the vicinity. An orifice (112) provides exclusive access to the throat (108a) of the filter element (108). When the valve assembly is open or partially open, the exhaust gas (132) from the crankcase flows out through a defined passage (106a), through the orifice (122c) of the valve assembly, into the throat (108a) of the filter element, and over the valves (122a, 122b) of the valve assembly. The exhaust gas (132) enters the orifice (122c) through a first access port (122c') and exits the orifice (122c) through a second access port (122c''). The valve may include a valve head (122a) and a valve stem (122b). The exhaust gas (132) flows over the valve head (122a) and around the valve stem (122b). The exhaust gas from the throat (108a) passes through the continuous circumferential filter walls of the filter element. The walls may be side walls. The filter is located in the second part (106b) of the cavity. The exhaust gas (132) passes through the filter wall of the second part of the cavity. From the second part (106b), the exhaust gas flows out through the exhaust orifice (128). All of the exhaust gas passing from the first cavity (106a) to the second cavity (106b) passes through the orifice (122c) of the valve assembly. The exhaust gas can be injected back into the engine (102) by a vacuum source (130), such as a turbocharger. The exhaust gas (132) travels through a path from the intake orifice (126) to the exhaust orifice (128) without entering the atmospheric pressure chamber (114). The chamber (114) is sealed off from the flow path.

[0017] More specifically, the valves (122a, 122b) are fixedly connected to the bulkhead (110). The pressure in the pressure regulating chamber (116) can be made negative. When the pressure in the pressure regulating chamber (116) increases by a negative magnitude to a certain negative pressure, the atmospheric pressure at the bulkhead in the atmospheric chamber (114) overcomes forces acting on the bulkhead (110), such as the weight of the bulkhead, causing the bulkhead (110) to move along its axis (110d) in a second axial direction (120) opposite to the first axial direction. The movement of the bulkhead (110) in the second axial direction (120) causes the valve head (122a) of the valve assembly to move along its axis (122d) in the second axial direction (120). When the valve assembly is open or partially open, the valve head (122a) moves toward a 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 in the second direction (120), the valve head (122a) moves further 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 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), for example, the weight of the partition wall including the multiple weights on it, becomes stronger than the atmospheric pressure in the atmospheric pressure chamber (114) acting on the partition wall (110) in the second direction (120), thereby causing the partition wall (110) to begin moving 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'). As the valve begins to move in the first direction (118) away from the first access (122'), a portion of the valve head (122a) moves away from the orifice. As the valve head (122a) moves further away from the first access portion (122c') in the first axial direction (118), the valve head (122a) moves further away from the orifice (122c). When the valve head (122a) is completely detached from the orifice (122c) of the valve assembly, the orifice (122c) opens completely, and the valve assembly becomes an open configuration.

[0019] The pressure in the regulator chamber changes with the change in reference pressure. The reference inlet (134) is located in 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) in order to detect the reference pressure. The inlet (134) is also located upstream of the first access (122c') that opens to the orifice (122c). The inlet opens into the tube (136). The inner surface of the tube defines a channel and a cavity. The tube extends through the atmospheric chamber (114) and opens into the pressure regulator chamber (116). The tube (136) and its cavity and the inlet (134) are fluid-sealed from the atmospheric chamber (114) so ​​as not to pass fluid from the atmospheric chamber (114) into the tube (136) or its cavity. Furthermore, the fluid from the pipe (136) and its cavity does not pass through the atmospheric chamber (114). The inlet (134) represents a surrogate pressure for the pressure (negative, positive) inside the crankcase (102).

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

[0021] More specifically, the valve head (122a) has a second end that is axially opposite to the first end. The second end includes an end face (122a'') enclosed by the outer circumference. The outer circumference is a circle with a diameter having a length. The outer circumference encloses a region. The valve has a surface (122a') of the first end that is enclosed by the outer circumference. The outer circumference is a circle with a diameter having a length and encloses a region. The diameter of the first surface (122a') is shorter than the diameter of the second surface (122a''). The first surface and the second surface are opposite to each other. The first surface faces the second direction (120). The second surface faces 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''), which connects the first end face (122a') and the second end face (122a''). The side surface (122a''') tapers radially inward as it approaches the first surface (122a') from the second surface (122a''). The outer surface of the valve defines a conical shape. The valve head (122a) is considered to be 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 pipe (136) at the pipe end opposite to the open end (136a) that opens into the pressure regulating chamber (116). The stem extends through a projection on the first surface (122a') of the valve head. The tube (136) interconnects the valve head (122a) and the stem (122b) to the partition (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 inward 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 in the first wall (140) of the regulator housing. This wall is a flat plane and 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 circular. The opening (146) is continuous except for the part that opens through the side wall. The opening fluidly connects the atmosphere chamber (114) to the atmosphere or the external environment of the regulator housing.

[0025] The atmospheric 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 elastomeric surface (110c’) formed from the diaphragm (110c). It also consists of a rigid surface (110e’) that overlaps a part of the elastomeric 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 elastomeric 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 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 enclosed by the atmospheric chamber (114) increases and decreases as the valve head (122a) moves axially.

[0026] The regulator chamber (116) at the first end has a sectional 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 formed integrally 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 elastomeric 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 elastomeric 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) seats over the end (104a') of the canister and defines access to the cavity of the canister in which the filter element (108) is seated.

[0028] The pressure regulator assemblies (114, 116, 122a, 122b, 122c) are responsible for maintaining the crankcase (102) at a desired pressure, usually negative pressure, while the 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 varying degrees so that the negative pressure in the crankcase (102) is maintained at a set predetermined pressure, for example, minus 3 inches. The unit of measurement may also be mercury inches. 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 in the negative pressure source (130) is minus 10 inches. The drop in the valve assembly orifice (122c) before and after is minus 2 in the first partially open orientation. Therefore, if the valve assembly orifice (122c) is left in this first open orientation, it means that the negative pressure in the crankcase will increase above the desired pressure. This increase is undesirable because it removes too much fouling 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, partially filling the orifice (122c) more than when the valve was filling the orifice when the orifice (122c) was in the first open orientation. The orifice is now in the 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 closed position. Atmospheric pressure overcomes the axial force applied from the partition wall (110), causing the partition wall to move in the second axial direction (120), which in turn draws the valve head (122a) into the orifice (122c) in the second axial direction more than in the previous orientation, thus moving the valve head in the second axial direction (120). The valve assembly is oriented from a more partially open orientation to a more partially closed orientation, which is within a given range of open positions.Compared to a more open orientation, a less partially open orientation provides increased drop before and after the valve assembly orifice to ensure that the crankcase pressure referenced by the regulator chamber inlet orifice (134) remains within a 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, if the filter becomes clogged, the drop before and after the filter (108) increases. Consequently, the negative pressure in the crankcase (102) changes to less than minus 3 inches relative to the orifice (122c) if the valve head (122a) remains in its original position. It could even be as low as minus 1 inch. To prevent this change, the valve forward (122a) moves in a first direction (118), orienting the valve head (122a) further outward from the orifice (122c) than it was previously positioned. The valve moves in the first axial direction (118) because the axial force increased by the bulkhead (110) overcomes the atmospheric force in the atmospheric chamber (114) that moves the bulkhead (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 that the orifice (122c) is more open than in its previous orientation. By orienting the orifice (122c) to a more open orientation, the drop before and after the valve orifice (122c) is reduced to a smaller 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 bulkhead (110), the atmospheric chamber (114), and the valve assemblies (122a, 122b, 122c), interacts and operates without the help of springs. Those skilled in the art often refer to the 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 atmospheric chamber (114) to the first portion (106a) of the cavity. The inlet (152) opens into the tube (154), which has a first end (154a) that opens into the pressure regulator chamber (116) through its end wall (148). The tube (154) extends from the first end (154a) to the outside of the regulator housing (112) and the filter housing (104), orienting the inlet (152) away from the first portion (106a) of the cavity. In this embodiment, the inlet (152) is located at the access port to the intake orifice (126). The tube (136) is not in fluid communication with the pressure regulating chamber.

[0031] In a further alternative embodiment, the pressure regulator assembly exists independently. 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 (310) of the regulator assembly. The stem, which is a rod, extends through the atmospheric chamber (312) into the main cavity (300). The valve stem (308) extends to a valve head (309) and connects to the valve head (309). A 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 located close to the end of the exhaust orifice (308) and distal to the opposite end 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 projection, similar to the end face (122a') without a projection. The head has a second end face (309b) and a tapered side (309c) similar to the head (122a). A partition (314), functioning similarly to the partition (110), isolates the atmospheric chamber (312) from the pressure regulator chamber (318). The partition (314) includes a diaphragm (321) that separates the atmospheric chamber (312) from the pressure regulator chamber (318). The pressure regulating chamber (318) and atmospheric chamber (312) perform the same function as the pressure regulator (116) and atmospheric chamber (114). Chambers (312) and (318) are defined by a conventional housing above the main cavity. In summary, the partition wall (310) moves up and down due to changes in the pressure difference between the regulator chamber (318) and the atmospheric chamber (312). The movement of the partition wall (310) moves the valve head (309) relative to the valve orifice (311). This movement positions the orifice (311) into different orientations, which can be called operating states. The orifice (311) can be in a closed orientation, an open orientation, and different partially open orientations.The change in the orientation of the orifice alters the pressure drop before and after the orifice (311). This change, like the change in pressure drop before and after the orifice (122c), helps maintain the crankcase pressure at a constant level.

[0032] During operation, the intake (304) and exhaust (306) ports of the regulator assembly are upstream of the vacuum source (130). The orifices of the intake (304) and exhaust (306) ports 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 tube (328) forming the inlet (326) opens into the crankcase (102) at one end (328a) having the tube inlet (326) and opens into the pressure regulator chamber (328b) at the other end. The vacuum source draws exhaust gas from the crankcase (102) through the filter (324). The filtered exhaust gas is drawn into the cavity (300) through the intake orifice (304). Exhaust gas is drawn out of the cavity (300) through the exhaust orifice (306). As exhaust gas is drawn in through the intake port (304) and exhaust port (306), the pressure change at the reference intake port (326) causes the partition wall (310) to move up and down. The movement of the partition wall (310) causes the valve head (309) to move up and down in the first axial direction (118) and the second axial direction (120). The movement of the valve head (309) changes the descent of the orifice (311) in front of and behind it. This change keeps the pressure inside 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 and second portion that are defined by a filter element housing and are fluidly separable, A filter element disposed within the aforementioned filter element housing, An atmospheric chamber defined by a regulator housing and communicating with the atmosphere, The pressure regulator chamber defined by the regulator housing, A partition wall separates the atmospheric chamber and the pressure regulator chamber, and fluidly seals the space between the atmospheric chamber and the pressure regulator chamber, A valve assembly comprising a valve head, a valve orifice formed in a plate separating the first portion and the second portion, a valve stem and a tube connecting the valve head to the partition wall, wherein the valve orifice has a first open access portion opening toward the first portion and a second open access portion opening toward the opposite side of the first open access portion, An intake orifice opening into the first portion, An exhaust orifice opening into the second portion, It comprises an inlet that communicates with the pressure regulator chamber, The valve orifice may take one of the following states depending on its relative position to the valve head: a closed open state, a first partially open state, a second partially open state that is more open than the first partially open state, or an open state. The partition wall is movable in a first direction along the longitudinal axis of the valve stem and in a second direction opposite to the first direction in response to a change in the pressure difference between the pressure in the pressure regulator chamber and the pressure in the atmospheric chamber. The valve head is configured to move in the first direction when the partition wall moves in the first direction, and to move in the second direction when the partition wall moves in the second direction. As the valve head moves in the first direction, the valve head moves relative to the valve orifice, causing the valve orifice to transition from the closed state to the first partially open state, then from the first partially open state to the second partially open state, and then from the second partially open state to the fully open state. When the valve orifice is in the first partially open state, the second partially open state, or the fully open state, the fluid passes through the valve orifice, then through the wall of the filter element, and then through the exhaust orifice. A crankcase pressure regulator integrated with the filter assembly.

2. When the valve orifice is in the first partially open state, the fluid flows through the valve orifice more freely than when the valve orifice is in the closed state. A crankcase pressure regulator integrated with the filter assembly according to claim 1.

3. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein when the valve orifice is in the second partially open state, the fluid flows through the valve orifice more freely than when the valve orifice is in the first partially open state.

4. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein when the valve orifice is in the open position, the fluid flows through the valve orifice more freely than when the valve orifice is in the second partially open position.

5. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein when the valve orifice is in the first partially open state, the valve head does not enter the valve orifice as much as when it is in the closed state.

6. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein when the valve orifice is in the second partially open state, the valve head does not enter the valve orifice as far as when it is in the first partially open state.

7. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein when the valve orifice is in the open state, the valve head does not enter the valve orifice as much as when it is in the second partially open state.

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

9. A crankcase pressure regulator integrated with the filter assembly according to claim 1, further comprising a tapered continuous surface located between the first and second surfaces of the plate and defining the valve orifice.

10. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein the tube extends into the atmospheric chamber, the inlet opens into the tube, and the tube opens into the pressure regulator chamber.

11. A crankcase pressure regulator integrated with a filter assembly according to claim 1, wherein the tube extends through the end wall of the regulator housing, the tube has a first end that opens into the pressure regulator chamber, and the tube extends from the first end toward the inlet that opens into the tube at an access port to the intake orifice, between the outside of the regulator housing and the outside of the filter element housing.

12. A pressure regulator assembly, A main cavity defined by a portion of the pressure regulator assembly, An intake orifice opening into the main cavity, An exhaust orifice opening from the main cavity, A regulator housing is connected to the portion defining the main cavity of the pressure regulator assembly, and defines the atmospheric chamber and the pressure regulator chamber. A partition wall separating the atmospheric chamber and the pressure regulator chamber, Valve head and A valve stem connected to the partition wall via a pipe, The valve head connected to the valve stem, Equipped with a valve orifice, The valve head moves in the first direction when the partition wall moves in a first direction along the longitudinal axis of the valve stem, and the valve head moves in the second direction when the partition wall moves in a second direction opposite to the first direction. The valve orifice may take one of the following states depending on its relative position to the valve head: a closed open state, a first partially open state, a second partially open state that is more open than the first partially open state, or an open state. As the valve head moves in the first direction, the valve head moves relative to the valve orifice, causing the valve orifice to transition from the closed state to the first partially open state, then from the first partially open state to the second partially open state, and then from the second partially open state to the fully open state. A pressure regulator assembly in which the fluid passes through the valve orifice and then through the exhaust orifice.

13. The pressure regulator assembly according to claim 12, wherein the valve head has a surface that prevents the fluid from passing through the valve head.

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