Rotating crankcase ventilation system

Abstract

A rotating crankcase ventilation system includes a housing, a fluid inlet, a shaft disposed along a longitudinal axis and extending between a first shaft end positioned within the fluid inlet and a second shaft end, and a filter element positioned within the interior of the housing. The filter element includes a first endcap, a second endcap, media extending between the first endcap and the second endcap, a first bearing, and a second bearing. The first and the second bearing are disposed along the longitudinal axis. The first bearing is positioned closer to the first shaft end than the second shaft end and the second bearing is positioned closer to the second shaft end than the first shaft end. At least one of the first bearing and the second bearing allow entry of blowby gas provided through the fluid inlet so as to be lubricated by the blowby gas.

Description

ROTATING CRANKCASE VENTILATION SYSTEMCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] The present application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 651,631, filed on May 24, 2024, the entire contents of which are incorporated herein by reference.TECHNICAL FIELD|0002] The present disclosure relates generally to a rotating crankcase ventilation system for use with internal combustion engine systems.BACKGROUND

[0003] During operation of an internal combustion engine, a fraction of combustion gases can flow out of the combustion cylinder and into the crankcase of the engine. These gases are often called “blowby” gases. The blowby gases include a mixture of aerosols, oils, and air. If vented directly to the ambient, the aerosols contained in the blowby gases can harm the environment. Accordingly, the blowby gases are often routed out of the crankcase via a crankcase ventilation system. The crankcase ventilation system may pass the blowby gases through a coalescer (i.e., a coalescing filter element) to remove a majority of the aerosols and oils contained in the blowby gases. The filtered blowby gases (“clean” gases) are then either vented to the ambient (in open crankcase ventilation systems) or routed back to the air intake for the internal combustion engine for further combustion (in closed crankcase ventilation systems).[0004 | Some crankcase ventilation systems utilize rotating crankcase ventilation filter elements, for example, rotating coalescer elements that increase the filter efficiency of crankcase ventilation systems by rotating the coalescer element during filtering. In rotating coalescer elements, the contaminants (e.g., oil droplets suspended and transported by blowby gases) are separated at least in part by centrifugal separation techniques. Additionally, therotation of the coalescer element can create a pumping effect, which reduces the pressure drop through the crankcase ventilation system.(0005] In various rotating crankcase ventilation filters, multiple parts are generally used for enabling filter element service operation. For example, metallic bushings, inserts and other components may be used to transmit rotational torque from a motor to the filter element for rotating the filter element and withstand vibrations. Such additional components may have tighter tolerances and may have to be heat treated to prevent premature wear. Moreover, a motor shaft, bushings, inserts, and other parts used to transfer the torque to the filter element may have to be hardened to withstand vibration loads through the life of the crankcase ventilation systems.SUMMARY[0006| In one embodiment, a rotating crankcase ventilation system comprises a housing, a fluid inlet, a shaft, and a filter element. The fluid inlet is in fluid providing communication with an interior of the housing. The shaft is disposed along a longitudinal axis and extends between a first shaft end positioned within the fluid inlet and a second shaft end positioned away from the first shaft end. The filter element is positioned within the interior of the housing and comprises a first endcap, a second endcap, media, a first bearing, and a second bearing. The media extends between the first endcap and the second endcap. The first bearing is disposed along the longitudinal axis and interfaces with a first portion of the shaft. The first bearing is positioned closer to the first shaft end than the second shaft end. The second bearing is disposed along the longitudinal axis and interfaces with a second portion of the shaft. The second bearing is positioned closer to the second shaft end than the first shaft end. At least one of the first bearing and the second bearing allow entry of blowby gas provided through the fluid inlet so as to be lubricated by the blowby gas.|0007] In another embodiment, a rotating crankcase ventilation system comprises a housing, a fluid inlet, a shaft, and a filter element. The fluid inlet is in fluid providing communication with an interior of the housing. The shaft is disposed along a longitudinal axis and extends between a first shaft end positioned within the fluid inlet and a second shaft endpositioned away from the first shaft end. The shaft is coupled to the housing and the shaft is stationary. The shaft comprises an axial channel and a lateral channel. The axial channel extends within the shaft along the longitudinal axis. The axial channel is configured to receive a lubricant. The lateral channel is in fluid receiving communication with the axial channel. The filter element is positioned within the interior of the housing and comprises a first bearing and a second bearing. The first bearing is disposed along the longitudinal axis and interfaces with a first portion of the shaft. The first bearing is positioned closer to the first shaft end than the second shaft end. The second bearing is disposed along the longitudinal axis and interfaces with a second portion of the shaft. The second bearing is positioned closer to the second shaft end than the first shaft end. At least one of the first bearing and the second bearing allow entry of blowby gases as provided through the fluid inlet so as to be lubricated by oil and aerosol in the blowby gas. The lateral channel is positioned adjacent the second bearing and configured to lubricate the second bearing.[00 8| In yet another embodiment, a rotating crankcase ventilation system comprises a housing, a fluid inlet, a shaft, a walled channel, and a filter element. The fluid inlet is in fluid providing communication with an interior of the housing. The shaft is disposed along a longitudinal axis and extends between a first shaft end positioned within the fluid inlet and a second shaft end positioned away from the first shaft end. The walled channel surrounds a portion of the shaft. The walled channel and the second endcap define an aperture therebetween. The filter element is positioned within the interior of the housing and comprising a first bearing and a second bearing. The first bearing is disposed along the longitudinal axis and interfaces with a first portion of the shaft. The first bearing is positioned closer to the first shaft end than the second shaft end. The second bearing is disposed along the longitudinal axis and interfaces with a second portion of the shaft. The second bearing is positioned closer to the second shaft end than the first shaft end. The first bearing and the second bearing allow entry of blowby gas provided through the fluid inlet so as to be lubricated by oil and aerosol in the blowby gas. The aperture is configured to alter a flow direction of the blowby gas. The blowby gas is configured to move through the walled channel towards the second bearing, contact thesecond bearing, and the oil and the aerosol in the blowby gas is configured to lubricate the second bearing.BRIEF DESCRIPTION OF THE DRAWINGS|0009] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying Figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

[0010] Figure 1 is a front view of a rotating crankcase ventilation system, in an example embodiment;[00111 Figure 2 is a front cross-section view of a rotating crankcase ventilation system of Figure 1, in an example embodiment;

[0012] Figure 3 is a right cross-section view of the rotating crankcase ventilation system of Figure 2;10013] Figure 4 is a cross-section view of a rotating crankcase ventilation system according to another example embodiment;|0014] Figure 5 is a cross-section view of a rotating crankcase ventilation system according to still another example embodiment;

[0015] Figure 6 is a cross-section view of a rotating crankcase ventilation system according to still another example embodiment;

[0016] Figure 7 is a cross-section view of a rotating crankcase ventilation system according to still another example embodiment;

[0017] Figure 8 is a cross-sectional view of a rotating crankcase ventilation system according to still another example embodiment;|0018[ Figure 9 is a graph representing separation efficiency of the rotating crankcase ventilation system of Figure 1;

[0019] Figure 10 is a graph representing pressure restriction results for the rotating crankcase ventilation system of Figure 1;|0O2O] Figure 11 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;

[0021] Figure 12 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;

[0022] Figure 13 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;

[0023] Figure 14 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;

[0024] Figure 15 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;

[0025] Figure 16 is cross-sectional view of a portion of a shaft of a rotating crankcase ventilation system, according to still another example embodiment;|0026] Figure 17 is a perspective view of a bypass lubrication system for the rotating crankcase ventilation system, according to an example embodiment;]0027] Figure 18 is a block diagram of the bypass lubrication system of Figure 17; and

[0028] Figure 19 is a perspective view of a portion of the bypass lubrication system ofFigure 17.[00291 It will be recognized that the Figures are the schematic representations for purposes of illustration. The Figures are provided for the purpose of illustrating one or more implementations with the explicit understanding that the Figures will not be used to limit the scope of the meaning of the claims.DETAILED DESCRIPTION

[0030] Following below are more detailed descriptions of various concepts related to, and implementations for providing a rotating crankcase ventilation system for an internal combustion engine system. The various concepts introduced above and discussed in greater detail below may be implemented in a number of ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.I. Overview

[0031] A rotating crankcase ventilation system may be used to filter blowby gases in an internal combustion engine system. While the rotating crankcase ventilation system filters the blowby gases, bearings within the rotating crankcase ventilation system may be lubricated to allow for operation of the rotating crankcase ventilation system. One approach for aligning the bearings includes mounting the bearings on a rotating shaft and using complex housing positional tolerances. One approach for lubrication includes using a greased seal bearing. However, using a greased sealed motor side bearing means the system must use a multiphase motor to overcome the greased sealed bearing drag, especially under cold start conditions. Both approaches to aligning the bearings and lubrication can be costly.

[0032] The present disclosure relates to a rotating crankcase ventilations system including a stationary shaft, blowby flow lubrication, and / or active lubrication. Using a stationary shaft eliminates tight and complex housing positional tolerance requirements and may allow for the housing to be manufactured out of cost cutting materials (e.g., plastic, nylon, etc.), further reducing production costs. The stationary shaft may also allow for easier bearing alignment and less chance of bearing misalignment.

[0033] Utilizing blow by flow lubrication and / or active lubrication in the system also allows for the elimination of the greased sealed motor side bearing, which improves reliability in the system and allows for enhance bearing lubrication, which extends the useful life of the bearing. Eliminating the greased sealed motor side bearing also allows the motor design to besimplified to a single-phase motor, since the bearings in a blowby flow lubrication system produce lower bearing drag and require less torque than greased seal bearing. In this way, the present embodiments of a rotating crankcase ventilation system may be more desirable than previous rotating crankcase ventilation systems, which are difficult to maintain and costly to produce.II. Overview of Example Rotating Crankcase Ventilation System[0034| Figure 1 depicts an example rotating crankcase ventilation system 100 (e.g., filter assembly, etc.) configured to process blowby gases received from an internal combustion engine to remove aerosols, oils, and other particulate contained in the crankcase blowby gases. The rotating crankcase ventilation system 100 includes a housing 102 (e.g., casing, container, enclosure, etc.). The housing 102 includes a housing main body 104 (e.g., body portion, etc.) and a housing base 106 (e.g., base, etc.). The housing main body 104 includes a housing body flange 108 (e.g., rim, lip, etc.) extending way from a portion of the housing main body 104. The housing base 106 includes a housing base flange 110 (e.g., rim, lip, etc.) extending away from a portion of the housing base 106. The housing body flange 108 and the housing base flange 110 are coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, bonded, pinned, etc.) together to form the housing 102.10035] Figures 2-3 depict a front and a right cross-sectional view of the rotating crankcase ventilation system 100 of Figure 1. The housing base 106 includes a fluid inlet 112 (e.g., entrance, conduit, etc.). The fluid inlet 112 is located in fluid communication with an interior of the housing 102. The fluid inlet 112 includes a conduit configured to deliver crankcase blowy gases to be filtered (e.g., from a crankcase of an internal combustion engine, etc.) into the housing main body 104. The fluid inlet 112 also includes a shaft mounting flange 114 (e.g., rim, lip, attachment piece, etc.) extending axially from an inner rim of the fluid inlet 112 and into a volume defined by the fluid inlet 112.

[0036] The rotating crankcase ventilation system 100 includes a shaft 116 (e.g., rod, etc ). The shaft 116 includes a first shaft end 118 and a second shaft end 120. The first shaft end 118 is positioned within the fluid inlet 112 and the second shaft end 120 is positioned away fromthe first shaft end 118. The shaft 116 is disposed along a longitudinal axis 122 and extends between the first shaft end 118 and the second shaft end 120. The first shaft end 118 is coupled to the shaft mounting flange 114. The shaft 116 stationary and fixed to the housing 102, i.e., not rotatable. The stationary shaft 116 aids in eliminating tight housing positioning tolerance requirements and allows for easier bearing alignment and less chance of bearing misalignment. In some embodiments, the shaft 116 is fixed to the housing 102 at only one end. In some embodiments, the shaft 116 is fixed the housing 102 at both ends of the shaft 116. In some embodiments, the shaft 116 is fixed on two separate housings. In some embodiments, the shaft 116 is configured to be hollow and used as a manifold to carry aerosol or pressurized lubricant.[0037| The rotating crankcase ventilation system 100 includes a filter element 124 (e.g., rotating coalescer, etc.) positioned within the interior of the housing 102. The filter element 124 includes a first endcap 126 (e.g., enclosure, etc.), a second endcap 128 (e.g., enclosure, etc.), and a media 130 (e.g., filter media, axial flow channels, inside-out fibrous media, stacked discs, depth filter, corrugated, wound, etc ). The first endcap 126 is located closer to the housing base 106 than the second endcap 128. The first endcap 126 and the second endcap 128 define an inner volume within which the media 130 is secured. The media 130 includes a media first end 132 that is proximate to the housing base 106 and a media second end 134 that that is opposite the media first end 132. The media 130 extends between the first endcap 126 and the second endcap 128. The first endcap 126 is disposed on the media first end 132 and the second endcap 128 is disposed on the media second end 134.

[0038] The first endcap 126 includes a first bearing mount flange 136. The first bearing mount flange 136 extends axially from an inner rim of the first endcap 126 away from the housing base 106. The second endcap 128 includes a second bearing mount flange 138 and a second endcap rotor flange 140. The second bearing mount flange 138 extends axially from an inner rim of the second endcap 128 towards the housing base 106. The second endcap rotor flange 140 extends axially from an outer rim of the second endcap 128 away from the housing base 106. The first bearing mount flange 136 and the second bearing mount flange 138 are configured to mount bearings and the second endcap rotor flange 140 is configured to couple to a rotor. In some embodiments, the filter element 124 includes an opening for the shaft 116 togo through the filter element 124 to be secured to a motor side housing. In this example, positive pressure created by pumping allows cleaned blowby gases to enter through clearances between the stationary shaft 116 and rotating elements to prevent any bypass. In some embodiments, the second bearing mount flange 138 extends axially away from an outer rim of the second endcap 128 away from the housing base 106 (e.g., as in FIG. 7, etc.).[O039| The filter element 124 further includes a first bearing 142 (e.g., ball bearing, roller bearing, etc.) and a second bearing 144 (e.g., ball bearing, roller bearing, etc.) supported by the shaft 116. The first bearing 142 is disposed along the longitudinal axis 122 and interfaces with a first portion of the shaft 116. The first bearing 142 is coupled within the first bearing mount flange 136. The first bearing 142 is positioned closer to the first shaft end 118 than the second shaft end 120. The second bearing 144 is disposed along the longitudinal axis 122 and interfaces with a second portion of the shaft 116. The second bearing 144 is positioned closer to the second shaft end 120 than the first shaft end 118. The second bearing 144 is coupled within the second bearing mount flange 138. At least one of the first bearing 142 and the second bearing 144 allow entry of blowby gas provided through the fluid inlet 112 so as to be lubricated by oil in the form of aerosol and oil in the blowby gas. Since the shaft 116 is stationary, an outer race of the first bearing 142 and the second bearing 144 spins instead of an inner race of the first bearing 142 and the second bearing 144. The first bearing 142 and the second bearing 144 are more easily aligned on the stationary shaft 116 than a rotating shaft. Complex housing positional tolerances are not needed for aligning the first bearing 142 and the second bearing 144 on the shaft 116. In some embodiments, the filter element 124 may include more than two bearings.|0040] The filter element 124 includes a hub 145 (e.g., core, etc.) and the hub 145 includes a first walled channel 146 (e.g., walled conduit, enclosed channel, etc.). The hub 145 binds the media 130 around the hub 145 and is decoupled from the shaft 116. The first walled channel 146 is surrounds a portion of the shaft 116 and the media 130 is disposed around and secured to the first walled channel 146. The first walled channel 146 defines a first aperture 148 (e.g., passage, etc.) between the shaft 116 and the first walled channel 146. The first aperture 148 is configured to alter a flow direction of the blowby gas. Oil in the form of aerosol and oil in theblowby gases are configured to travel from the fluid inlet 112 towards the first bearing 142, contact and flow through the first bearing 142, lubricate the first bearing 142, flow through the first walled channel 146 through the first aperture 148 towards the second bearing 144, contact the second bearing 144, and lubricate the second bearing 144. In some embodiments, the rotating crankcase ventilation system 100 may include additional features to enhance aerosol and / or oil to reach the second bearing 144 by diverting flow towards the second bearing 144, as described in further embodiments.|0041] The rotating crankcase ventilation system 100 includes a motor 150 (e.g., singlephase motor, three-phase motor, etc.) and the motor 150 includes a stator 152 and a rotor 154. The motor 150, the stator 152, and the rotor 154 are disposed along the longitudinal axis 122 and disposed within the housing main body 104. The second shaft end 120 is disposed within a first cavity 156 defined by the stator 152. The rotor 154 is disposed within a central second cavity 158 defined by the stator 152. The rotor 154 is configured to be coupled to the filter element 124 and the rotor 154 is configured to be coupled to the second endcap rotor flange 140. Therefore, the filter element 124 and associated elements of the filter element 124 (e.g., media 130, the first walled channel 146, etc.) are rotatable via rotation of the rotor 154.

[0042] In some embodiments, the second shaft end 120 is fixed below the second endcap 128 by at least one mounting point. For example, the second shaft end 120 may align with an additional shaft below the second endcap 128, and the additional shaft may extend within the first cavity 156. In some embodiments, the rotating crankcase ventilation system 100 may include a separator before and / or after the rotating elements to help enhance separation performances. In some embodiments, electric motor rotor magnets can be retained and assembled to the second endcap 128. In some embodiments, the filter element 124 is hydraulically, pneumatically, electrically, and / or mechanically driven. In some embodiments, the first bearing 142 and the second bearing 144 are tightly connected to both the stator 152 and the rotor 154 (e.g., the first bearing 142 and the second bearing 144 are tightly coupled to the first endcap 126 and the second endcap 128, and a rotation of the first endcap 126 and the second endcap 128 and therefore the first bearing 142 and the second bearing 144 are directly related to the rotation of the rotor 154).

[0043] Figure 4 depicts an embodiment of the rotating crankcase ventilation system 100. In this embodiment, the filter element 124 also includes a first turn 160 (e.g., curve, etc.), a second walled channel 162 (e.g., walled conduit, enclosed channel, etc.), a second aperture 164 (e.g., passage, etc.), and a second turn 168 (e.g., curve, etc.). The first turn 160 is located at a first end of the first aperture 148, between an end of the first walled channel 146 and the second endcap 128. The first walled channel 146 does not contact the media 130 and is cylindrical about the shaft 116. The media 130 is coupled to the second walled channel 162 instead of the first walled channel 146. The second aperture 164 is formed between the first walled channel 146 and the second walled channel 162. The second turn 168 is formed between the media 130 and an end of the second aperture 164 closest to the fluid inlet 112, opposite the second aperture 164 from the first turn 160. As recited previously, oil in the form of aerosol and oil in the blowby gas enters the fluid inlet 112, flows towards the first bearing 142, contacts the first bearing 142, lubricates the first bearing 142, flows through the first aperture 148 towards the second bearing 144, contacts the second bearing 144, lubricates the second bearing 144, and a portion of the blowby gas follows the sharp turn of the first turn 160. A portion of the blowby gas flows through the second bearing 144. The blowby gases flow around the first turn 160 and enter the second aperture 164. The blowby gases flow through the second aperture 164 towards the second turn 168, flow through the second turn 168, and enter the media 130 to be filtered. In some embodiments, the first turn 160 forms approximately a 180 degree turn between the first aperture 148 and the second aperture 164.|0044] In some embodiments, the second turn 168 is omitted and the blowby gases enter the media 130 at a location between the first bearing 142 and the second bearing 144. In a particular implementation, the media 130 is a depth filter. Still further, the blowby gases may enter the depth filter in a direction substantially perpendicular to the shaft 116, and the blowby gases may travel through the depth filter in a direction substantially perpendicular to the shaft 116.|0045] Figure 5 depicts an additional embodiment of the rotation crankcase ventilation system 100. In this embodiment, the hub 145 further includes a third walled channel 170 (e.g., walled conduit, enclosed channel, etc.), a third aperture 172 (e.g., passage, etc.), and pluralityof fins 174 (e.g., supports, stabilizers, etc.). The first walled channel 146 extends around the shaft 116 between the first bearing 142 and the second bearing 144, creating the first aperture 148 between the shaft 116 and the first walled channel 146. The second walled channel 162 extends around the first walled channel 146 and a portion of the second walled channel 162 angles slightly towards the shaft 116 as the second walled channel 162 extends towards the second endcap 128, creating the second aperture 164 between the first walled channel 146 and the second walled channel 162. The third walled channel 170 extends around the second walled channel 162 to create a third aperture 172 between the second walled channel 162 and the third walled channel 170.[00461 The plurality of fins 174 extend from the first walled channel 146 to the third walled channel 170 in a direction radially extending from the shaft 116. The plurality of fins 174 create additional structural stability between the first walled channel 146, the second walled channel 162, and the third walled channel 170. The first turn 160 is located at an end of the second aperture 164 between the second walled channel 162 and the second endcap 128. The second turn 168 is located at an end of the third aperture 172 opposite the first turn 160. Oil in the form of aerosol and oil in the blowby gas are configured to be provided by the fluid inlet 112, flow towards the second endcap 128, contact the first bearing 142, lubricate the first bearing 142, flow through the second aperture 164 towards the second bearing 144, contact the second bearing 144, and lubricate the second bearing 144. A portion of the blowby gas flows through the second bearing 144 and a portion of the blowby gas flows around the first turn 160, through the third aperture 172 towards the first endcap 126, around the second turn 168, and into the media 130 for filtering. This configuration modifies the first turn 160 to form greater than a 180-degree turn between the second aperture 164 and the third aperture 172, meaning the blowby gases flow around a tighter curve than in the embodiment of Figure 4. In some embodiments, the oil in the form of aerosol and oil in the blowby gas may also flow through the first aperture 148 toward the second bearing 144 to lubricate the second bearing 144.|<H)47] In some embodiments, the second turn 168 is omitted and the blowby gases enter the media 130 at a location between the first bearing 142 and the second bearing 144. In a particular implementation, the media 130 is a depth filter. Still further, the blowby gases mayenter the depth filter in a direction substantially perpendicular to the shaft 116, and the blowby gases may travel through the depth filter in a direction substantially perpendicular to the shaft 116.

[0048] Referring now to Figure 6, an additional embodiment of the rotation crankcase ventilation system 100 includes active lubrication of the first bearing 142 and the second bearing 144. In addition to the blowby flow gases method as described above, this embodiment includes methods to provide additional lubrication to the first bearing 142 and the second bearing 144 to supplement the blowy gases lubrication. This embodiment relates to utilizing a hollow shaft 116 to act as a manifold to carry pressurized oil to lubricate the bearings.

[0049] The rotation crankcase ventilation system 100 as depicted in Figure 6 includes a first lateral channel 176 (e.g., longitudinal conduit, etc.) an axial channel 178 (e.g., latitudinal conduit, etc.), a second lateral channel 180 (e.g., longitudinal conduit, etc.), and a third lateral channel 182 (e.g., longitudinal conduit, etc.) configured to receive lubricant. The first lateral channel 176 extends within the housing base 106 and is perpendicular to the longitudinal axis 122. The first lateral channel 176 is configured to allow entry of pressured lubricant oil to transfer pressurized lubricant oil proximate the second shaft end 120 from an exterior of the housing 102. The axial channel 178 extends along the longitudinal axis 122 of the shaft 116 between the first shaft end 118 and the second shaft end 120. The axial channel 178 is in fluid receiving communication with the first lateral channel 176. In some embodiments, the axial channel 178 extends along the entirety of the shaft 116, and the first shaft end 118 and the second shaft end 120 are open and may expel the lubricant. In some embodiments, the axial channel 178 extends along a portion of the shaft 116, and the first shaft end 118 and / or the second shaft end 120 is a closed manifold so the lubricant flows to the first bearing 142 and / or the second bearing 144.

[0050] In some embodiments, the lubricant is received through an aperture on the first shaft end 118. In some embodiments, the lubricant is received from the first shaft end 118 and the first lateral channel 176 is closed (e.g., the first shaft end 118 is open to allow entry of pressurized lubricant and the first lateral channel 176 is closed to prevent entry of pressurizedlubricant, etc.). In some embodiments, the lubricant is received from the first lateral channel 176, and the first shaft end 118 is closed (e.g., the first lateral channel 176 is open to allow entry of pressurized lubricant and the first shaft end 118 is closed to prevent entry of pressurized lubricant, etc.).[00511 The second lateral channel 180 and the third lateral channel 182 extend within the shaft 116 perpendicular to the longitudinal axis 122. The second lateral channel 180 is positioned adjacent the first bearing 142 and is configured to lubricate the first bearing 142. The second lateral channel 180 is located farther from the first shaft end 118 than the first bearing 142. The third lateral channel 182 is positioned adjacent the second bearing 144 and is configured to lubricate the second bearing 144. The third lateral channel 182 is located closer to the second shaft end 120 than the second bearing 144. In some embodiments, the second lateral channel 180 is omitted, and in some embodiments, the third lateral channel 182 is omitted. In this way, the user can customize the system to accommodate whichever bearing needs more lubrication. For example, if the oil in the form of aerosol and oil in the blowby gases are not sufficient lubrication for the second bearing 144, the first lateral channel 176, the axial channel 178, and the third lateral channel 182 may be created within the shaft 116 to accommodate further lubrication of the second bearing 144. The oil from the active lubrication drains on an upstream side of the filter element 124. The oil drains in the same location as the separated oil from the blowby flow. In some embodiments the oil drains in a different location than the separated oil from the blowby flow.

[0052] In some embodiments, the second turn 168 is omitted and the blowby gases enter the media 130 at a location between the first bearing 142 and the second bearing 144. In a particular implementation, the media 130 is a depth filter. Still further, the blowby gases may enter the depth filter in a direction substantially perpendicular to the shaft 116, and the blowby gases may travel through the depth filter in a direction substantially perpendicular to the shaft 116.

[0053] Referring now to Figures 7 and 8, additional embodiments of the rotation crankcase ventilation system 100 which utilizes aerosol lubrication to lubricate the second bearing 144and / or the first bearing 142. The shaft 116 may include a shaft aperture 184 located proximate the second bearing 144, the shaft aperture 184 closer to the second shaft end 120 than the second bearing 144. The axial channel 178 acts as a manifold for the aerosol to flow towards the second bearing 144, enter the shaft aperture 184, and lubricate the second bearing 144. In some embodiments, when there is not enough aerosol available to lubricate the second bearing 144, the axial channel 178 may also be configured to pump oil to shaft aperture 184, and therefore lubricate the second bearing 144. In some embodiments, the rotating crankcase ventilation system 100 may include additional features to enhance aerosol and / or oil to reach the second bearing 144 by diverting flow towards the second bearing 144, as described in further embodiments.

[0054] Referring now to Figures 9-10, the rotation crankcase ventilation systems 100 disclosed within the present application includes empirical data for separation efficiency and pressure restriction. According to test results of Figure 9, the overall separation efficiency for the rotation crankcase ventilation system 100 is 99.6%. According to the test results of Figure 10, the rotation crankcase ventilation system 100 has effective pumping, which allows the system to maintain a negative pressure. The effective pumping maintains a primary dynamic seal for the purposes of recirculation. The primary dynamic seal is located between the housing base 106 and the first endcap 126 near the fluid inlet 112.

[0055] Continuing with Figures 9-10, a secondary dynamic seal, which allows a lesser flow rate than the primary dynamic seal, is formed between the rotor 154 and the stator 152. Blowby flow passing between the rotor 154 or the stator 152 may pass through a tertiary dynamic seal between the rotor 154 and the shaft 116. The blowby flow through the secondary and tertiary dynamic seal locations is the same blowby flow. In some embodiments, the rotating crankcase ventilation system 100 includes only one of the secondary or tertiary dynamic seal.

[0056] Referring now to Figures 11-15, additional example embodiments of the shaft 116 are shown. Each of the first lateral channel 176, the axial channel 178, the second lateral channel 180, and / or the third lateral channel 182 may be configured to limit the oil flow from the active lubrication.

[0057] Referring now to Figure 11, in some embodiments the shaft 116 includes a set screw 186 disposed within one or more of the first lateral channel 176, the axial channel 178, the second lateral channel 180, and / or the third lateral channel 182. The set screw 186 may be adjusted to increase or decrease a gap between the set screw 186 and walls of the shaft 116, and therefore increase or decrease the amount of lubricant that passes through the first lateral channel 176, the axial channel 178, the second lateral channel 180, and / or the third lateral channel 182.|0058] Referring now to Figures 12-14, in some embodiments the shaft 116 includes a first insert 188 and a second insert 190. Each of the first insert 188 and the second insert 190 include a plurality of protrusions 189 configured to contact the oil and increase turbulence. The protrusions 189 of Figure 14 abruptly narrow the flow pathway multiple times to disrupt flow of the lubricant and increase turbulence. In other embodiments, such as shown in Figure 15, the first insert 188 is a metal insert including a plurality of fins 191 configured to increase turbulence. In still other embodiments, such as shown in Figure 16, the shaft 116 includes a media insert 192. The media insert 192 is received within at least one of the first lateral channel 176, the axial channel 178, the second lateral channel 180, and / or the third lateral channel 182 to restrict flow of the lubricant. In some embodiments, the media insert 192 is a metal mesh.|0059] Referring now to Figures 17—19, a bypass lubrication system 194 to lubricate the second bearing 144 and limit oil lubrication to the second bearing 144 is shown. The embodiment of Figures 17-19 may be used in addition to or instead of the active lubrication of Figures 6-8. The bypass lubrication system 194 includes a first tube 196 configured to receive pressurized lubricant. The bypass lubrication system 194 includes a restriction piece 198 configured to couple to the bypass lubrication system 194 and receive the pressurized oil.|0060] The restriction piece 198 includes a main branch 200 and a side branch 204 (e.g., lubrication portion etc.). The main branch 200 extends between a first end 206 and a second end 208. The main branch 200 includes a first portion 207 (e.g., a feed portion, etc.) and a second portion 209 (e.g., a main portion, etc ). The first portion 207 extends from the first end 206 to the second portion 209. The second portion 209 extends from the first portion 207 to thesecond end 208. The second portion 209 and the first portion 207 each are centered along an axis. The side branch 204 extends from the main branch 200 between the first end 206 and the second end 208 at an acute angle with respect to the second end 208. The side branch 204 extends from the first portion 207. The first end 206 of the main branch 200 is configured to couple to the first tube 196 and receive the pressurized lubricant (e.g., the first tube 196 couples to the first portion 207, etc.).(0061] In some embodiments, a diameter of a channel defined by the main branch 200 is greater than a diameter of a channel defined by the side branch 204. In some embodiments, a diameter of the channel defined by the second portion 209 is greater than a diameter of the channel defined by the side branch 204, and the diameter of the channel defined by the side branch 204 is greater than a diameter of the channel defined by the first portion 207.

[0062] In some embodiments, to reduce flow rate and eliminate the venturi effect, a diameter of the first portion 207 is greater than a diameter of the second portion 209, and a diameter of the second portion 209 is greater than a diameter of the side branch 204. The side branch 204 extends from the first portion 207 and is spaced away from the second portion 209. Each of the flows of the pressurized lubricant within the restriction piece 198 has an axial direction component of flow (e.g., the side branch 204 does not include reverse flow, etc.). In some embodiments, an axial flow direction is reversed, and the second end 208 of the main branch 200 is configured to couple to the first tube 196 to receive the pressurized lubricant (e.g., the first tube 196 couples to the second portion 209, etc.). The axial flow is less in embodiments when the pressurized lubricant flows from the first portion 207 to the second portion 209 than in embodiments when the pressurized lubricant flows from the second portion 209 to the first portion 207.|0063[ The bypass lubrication system 194 includes a second tube 210 and a third tube 212. The second tube 210 is configured to couple to the second end 208 of the main branch 200 (e.g., the second tube 210 is configured to couple to the second portion 209 etc.), receives at least a portion of the pressurized lubricant, and directs the portion of the pressurized lubricant to a sump (e.g., oil pan, etc.) of an engine. The third tube 212 is configured to couple to the sidebranch 204 and receives at least a portion of the pressurized lubricant. The third tube 212 directs the portion of the pressurized lubricant to lubricate the second bearing 144. For example, as shown in Figure 18, the first lateral channel 176 receives the pressurized lubricant, the pressurized lubricant flows along the axial channel 178, and the shaft aperture 184 receives the pressurized lubricant and lubricates the second bearing 144. In some embodiments, when an axial flow direction is reversed, the second tube 210 is configured to couple to the first end 206 of the main branch 200 (e.g., the second tube 210 couples to the first portion 207, etc.).|0064] In another example, the axial channel 178 receives the pressurized lubricant from the bypass lubrication system 194 and lubricates the second bearing 144 (e.g., the third tube 212 is received by the axial channel 178 of FIG. 7, etc.). In another example, the first lateral channel 176 receives the pressurized lubricant, the pressurized lubricant flows along the axial channel 178, the second lateral channel 180 lubricates the first bearing 142, and the third lateral channel 182 lubricates the second bearing 144 (e.g., the third tube 212 is coupled to the first lateral channel 176 of FIG. 6, etc.). A majority of the pressurized lubricant flows back to the sump, while at least a portion of the pressurized lubricant rises up in the shaft 116. The bypass lubrication system 194 eliminates small chokes (e.g., tight turns) when directly lubricating the second bearing 144. In some embodiments, the diameter of the second tube 210 is larger than the diameter of the third tube 212, limiting the flow of the pressurized lubricant traveling to the second bearing 144.{0065 { In some embodiments, the bypass lubrication system 194 includes a check valve. During high pressures, the bypass lubrication system 194 may act as a jet pump. That is, when the pressure within the bypass lubrication system 194 becomes high, high-speed flow creates a suction affect, potentially leading to uncontrolled flow dynamics. The check valve minimizes the jet pump effect, preventing backflow and assisting in controlling the pressure and flow rates. The check valve may also include a restriction (e.g., a narrowed passage, etc.) to further manage the pressure, reducing unwanted suction effects. In some embodiments, the bypass lubrication system 194 is a Y-tube (e.g., a Y-shaped tube). In some embodiments, the bypass lubrication system 194 also lubricates the first bearing 142. In some embodiments, the check valve is omitted, such as in embodiments when the side branch 204 extends from the firstportion 207, a diameter of a channel defined by the first portion 207 is greater than the a diameter of a channel defined by the second portion 209, and the diameter of the channel defined by the second portion 209 is greater than a diameter of a channel defined by the side branch 204.III. Configuration of Example Embodiments[0066| While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0067] As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the appended claims.10068] The term “coupled” and the like, as used herein, mean the joining of two components directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components beingintegrally formed as a single monolithically body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.

[0069] It is important to note that the construction and arrangement of the various systems shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and / or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. When the language “a portion” is used, the item can include a portion and / or the entire item unless specifically stated to the contrary.

[0070] Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

[0071] Additionally, the use of ranges of values (e.g., W1 to W2, etc.) herein are inclusive of their maximum values and minimum values (e.g., W1 to W2 includes W1 and includes W2, etc.), unless otherwise indicated. Furthermore, a range of values (e.g., W1 to W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e g., W1 to W2 can include only W1 and W2, etc.), unless otherwise indicated.

Claims

WHAT IS CLAIMED IS:

1. A rotating crankcase ventilation system comprising: a housing; a fluid inlet in fluid providing communication with an interior of the housing; a shaft disposed along a longitudinal axis and extending between a first shaft end positioned within the fluid inlet and a second shaft end positioned away from the first shaft end; and a filter element positioned within the interior of the housing and comprising: a first endcap; a second endcap; media extending between the first endcap and the second endcap; a first bearing disposed along the longitudinal axis and interfacing with a first portion of the shaft, the first bearing positioned closer to the first shaft end than the second shaft end; and a second bearing disposed along the longitudinal axis and interfacing with a second portion of the shaft, the second bearing positioned closer to the second shaft end than the first shaft end; wherein at least one of the first bearing and the second bearing allow entry of blowby gas provided through the fluid inlet so as to be lubricated by oil and aerosol in the blowby gas.

2. The rotating crankcase ventilation system of claim 1, further comprising: a walled channel surrounding a portion of the shaft, the walled channel and the second endcap defining an aperture therebetween, the aperture configured to alter a flow direction of the blowby gas; wherein the blowby gas is configured to move through the walled channel towards the second bearing, contact the second bearing, and the oil and the aerosol in the blowby gas is configured to lubricate the second bearing.

3. The rotating crankcase ventilation system of claim 2, wherein the walled channel is a first walled channel and the aperture is a first aperture, and further comprising a second walled channel surrounding the first walled channel, the media coupled to the second walled channel, the second walled channel and the first walled channel defining a second aperture therebetween.

4. The rotating crankcase ventilation system of claim 3, further comprising a third walled channel extending around the second walled channel, a third aperture defined between the first walled channel and the second walled channel, wherein the second walled channel is angled towards the shaft.

5. The rotating crankcase ventilation system of claim 1, wherein the shaft is coupled to the housing and the shaft is stationary.

6. The rotating crankcase ventilation system of claim 1, wherein the shaft further comprises: an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive a pressurized lubricant; and a lateral channel in fluid receiving communication with the axial channel and positioned adjacent the first bearing, the lateral channel configured to lubricate the first bearing and positioned farther from the first shaft end than the first bearing.

7. The rotating crankcase ventilation system of claim 1, wherein the shaft further comprises: an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive a lubricant; and a lateral channel in fluid receiving communication with the axial channel and positioned adjacent the second bearing, the lateral channel configured to lubricate the second bearing and positioned closer to the second shaft end than the second bearing.

8. The rotating crankcase ventilation system of claim 7, wherein the lateral channel is a first lateral channel, and the shaft further comprises a second lateral channel in fluid receiving communication with the axial channel and positioned adjacent the first bearing, the second lateral channel configured to lubricate the first bearing and positioned farther from the first shaft end than the first bearing.

9. The rotating crankcase ventilation system of claim 7, wherein the lubricant is one of a pressurized oil or an aerosol.

10. The rotating crankcase ventilation system of claim 1, further comprising a motor including a rotor; wherein the filter element is coupled to the rotor and is rotatable via rotation of the rotor.

11. The rotating crankcase ventilation system of claim 1, wherein the first bearing and the second bearing allow entry of the blowby gas provided through the fluid inlet so as to be lubricated by the oil and the aerosol in the blowby gas.

12. The rotating crankcase ventilation system of claim 1, wherein the media is an axial flow media and the blowby gas is configured to travel through the axial flow media.

13. The rotating crankcase ventilation system of claim 1, wherein the shaft further comprises: an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive a lubricant; and one or more inserts received within the axial channel and configured to increase turbulence of the lubricant.

14. The rotating crankcase ventilation system of claim 1, wherein: the shaft further comprises an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive a pressurized lubricant; andthe shaft defines an aperture in fluid receiving communication with the axial channel and positioned adjacent the second bearing, the aperture positioned closer to the second shaft end than the second bearing.

15. The rotating crankcase ventilation system of claim 14, further comprising: a restriction piece configured to receive the pressurized lubricant, the restriction piece including: a first channel defining a first diameter; and a second channel defining a second diameter greater than the first diameter; wherein the axial channel is configured to receive the pressurized lubricant from the first channel.

16. The rotating crankcase ventilation system of claim 1, further comprising a Y- shaped restriction piece, the Y-shaped restriction piece configured to receive pressurized lubricant, wherein the shaft further comprises an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive the pressurized lubricant from the Y-shaped restriction piece.

17. A rotating crankcase ventilation system comprising: a housing; a fluid inlet in fluid providing communication with an interior of the housing; a shaft disposed along a longitudinal axis and extending between a first shaft end positioned within the fluid inlet and a second shaft end positioned away from the first shaft end, wherein the shaft is coupled to the housing and the shaft is stationary, the shaft comprising: an axial channel extending within the shaft along the longitudinal axis, the axial channel configured to receive a lubricant; and a lateral channel in fluid receiving communication with the axial channel; anda filter element positioned within the interior of the housing and comprising: a first bearing disposed along the longitudinal axis and interfacing with a first portion of the shaft, the first bearing positioned closer to the first shaft end than the second shaft end; and a second bearing disposed along the longitudinal axis and interfacing with a second portion of the shaft, the second bearing positioned closer to the second shaft end than the first shaft end; wherein at least one of the first bearing and the second bearing allow entry of blowby gas as provided through the fluid inlet so as to be lubricated by oil and aerosol in the blowby gas and the lateral channel is positioned adjacent the second bearing and configured to lubricate the second bearing.

18. The rotating crankcase ventilation system of claim 17, further comprising: a walled channel surrounding a portion of the shaft; wherein the blowby gas is configured to move through the walled channel towards the second bearing, contact the second bearing, and the oil and the aerosol in the blowby gas is configured to lubricate the second bearing.

19. A rotating crankcase ventilation system comprising: a housing; a fluid inlet in fluid providing communication with an interior of the housing; a shaft disposed along a longitudinal axis and extending between a first shaft end positioned within the fluid inlet and a second shaft end positioned away from the first shaft end; a walled channel surrounding a portion of the shaft; and a filter element positioned within the interior of the housing and comprising: a first bearing disposed along the longitudinal axis and interfacing with a first portion of the shaft, the first bearing positioned closer to the first shaft end than the second shaft end; anda second bearing disposed along the longitudinal axis and interfacing with a second portion of the shaft, the second bearing positioned closer to the second shaft end than the first shaft end; wherein the first bearing and the second bearing allow entry of blowby gas provided through the fluid inlet so as to be lubricated by oil and aerosol in the blowby gas, and the blowby gas is configured to move through the walled channel towards the second bearing, contact the second bearing, and the oil and the aerosol in the blowby gas is configured to lubricate the second bearing.

20. The rotating crankcase ventilation system of claim 19, wherein the shaft is coupled to the housing and the shaft is stationary.

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