Compressed gas assisted inertial impactor with elastomeric nozzles

Abstract

A gas-liquid separator includes a housing base, a cover, a sub-separator assembly, and an impaction surface. The cover is coupled to the housing base and together with the housing base defines an internal volume. The sub-separator assembly is disposed within the internal volume. The sub-separator assembly defines at least three mixing chambers along a flow direction through the sub-separator assembly. The sub-separator assembly includes an elastomeric nozzle defining one of the at least three mixing chambers. The impaction surface is disposed downstream of the sub-separator assembly.

Description

COMPRESSED GAS ASSISTED INERTIAL IMPACTOR WITH ELASTOMERIC NOZZLESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to PCT Application No. PCT / CN2024 / 094756, filed May 22, 2024, the entire contents of which are hereby incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to inertial impactors for use in crankcase ventilation 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 referred to as “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 potentially 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) or another filter element to remove most or all 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] One type of separator uses inertial impaction air-oil separation for removing oil particles from the crankcase blowby gas (or aerosol). In such arrangements, the separator accelerates the blowby gas stream to high velocities through nozzles or orifices that direct the same against an impactor, causing a sharp directional change effecting the oil separation.Another type of separator uses coalescence in a coalescing filter to collect and remove oil droplets.SUMMARY

[0005] One embodiment of the present disclosure relates to gas-liquid separator. The gasliquid separator includes a housing base, a cover, a sub-separator assembly, and an impaction surface. The cover is coupled to the housing base and together with the housing base defines an internal volume. The sub-separator assembly is disposed within the internal volume. The subseparator assembly defines at least three mixing chambers along a flow direction through the sub-separator assembly. The sub-separator assembly includes an elastomeric nozzle defining one of the at least three mixing chambers. The impaction surface is disposed downstream of the sub-separator assembly.

[0006] In some embodiments, the at least three mixing chambers include a first mixing chamber defining a first volume, a second mixing chamber disposed downstream from the first mixing chamber and defining a second volume, and a third mixing chamber disposed downstream from the second mixing chamber and defining a third volume. In some embodiments, the third volume is greater than the second volume, and the second volume is greater than the first volume.

[0007] In some embodiments, a cross-sectional diameter of each of the at least three mixing chambers increases in a stepwise manner between adjacent ones of the at least three mixing chambers along the flow direction.

[0008] In some embodiments, the sub-separator assembly is structured so that blowby gas enters a first mixing chamber of the at least three mixing chambers along a substantially radial direction, and so that a flow direction of the blowby gas is reoriented along a substantially axial direction through remaining ones of the at least three mixing chambers.

[0009] In some embodiments, the sub-separator assembly includes a baffle defining an opening, and an outlet tube extending through the opening and defining at least one of the atleast three mixing chambers. In some embodiments, the elastomeric nozzle engages both the baffle and the outlet tube.

[0010] In some embodiments, a first mixing chamber of the at least three mixing chambers is defined by a first cylindrical bore having a central axis that extends along a first direction, and a second mixing chamber of the at least three mixing chambers is defined by a second cylindrical bore having a central axis that extends along a second direction that is substantially perpendicular to the first direction.

[0011] In some embodiments, the sub-separator assembly further includes a support panel that is sealingly engaged between the cover and the housing base.

[0012] In some embodiments, the sub-separator assembly further includes a filter media engaged with the impaction surface.

[0013] In some embodiments, the housing base includes a first inlet structured to receive a blowby gas stream, and a second inlet structured to a receive compressed air from a compressed air source. In such embodiments, the cover may include a first outlet configured to receive a filtered blowby gas stream from the sub-separator assembly. One of the housing base and the cover may include a second outlet configured to drain liquid from the sub-separator assembly.

[0014] Another embodiment of the present disclosure relates to a sub-separator assembly. The sub-separator assembly includes a nozzle plate, an outlet tube, and an elastomeric nozzle. The nozzle plate defines a nozzle. The outlet tube extends axially away from the nozzle plate. The outlet tube at least partially defines a first mixing chamber and a second mixing chamber. The first mixing chamber extends in a substantially radial direction relative to a central axis of the outlet tube. The second mixing chamber extends in a substantially axial direction away from the first mixing chamber. The elastomeric member is coupled to the outlet tube and defines a third mixing chamber downstream from the second mixing chamber.

[0015] In some embodiments, the sub-separator assembly further includes a baffle defining an opening. In some embodiments, the outlet tube extends through the opening, and the elastomeric member extends at least partially through the opening and engages both the baffleand the outlet tube. In such embodiments, the outlet tube may define a slot extending in the substantially axial direction along an outer surface of the outlet tube where the elastomeric member engages the outlet tube.

[0016] In some embodiments, the first mixing chamber defines a first volume, the second mixing chamber defines a second volume, and the third mixing chamber defines a third volume, and wherein the third volume is greater than the second volume, and the second volume is greater than the first volume.

[0017] In some embodiments, a cross-sectional diameter of the third mixing chamber along a flow direction therethrough is greater than a cross-sectional diameter of the second mixing chamber, and a cross-sectional diameter of the second mixing chamber is greater than a cross- sectional diameter of the first mixing chamber.

[0018] In some embodiments, the sub-separator assembly further includes a support panel extending radially away from the nozzle plate on either side of the nozzle plate, and a sealing member coupled to the support panel and extending along a perimeter edge thereof.

[0019] Another embodiment relates to method of manufacturing a sub-separator assembly and / or a gas-liquid separator. The method includes forming a nozzle plate defining a nozzle and forming an outlet tube that includes at least two mixing chambers onto the nozzle plate, where the at least two mixing chambers includes a first mixing chamber that extends in a substantially radial direction relative to a central axis of the outlet tube; and a second mixing chamber that extends in a substantially axial direction away from the first mixing chamber.

[0020] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the subject matter disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

[0022] FIG. l is a front side cross-sectional view of a gas-liquid separator, according to an embodiment.

[0023] FIG. 2 is a right side cross-sectional view of the gas-liquid separator of FIG. 1.

[0024] FIG. 3 is front side cross-sectional view of a sub-separator assembly of the gasliquid separator of FIG. 1.

[0025] FIG. 4 is another front side cross-sectional view of the sub-separator assembly in FIG. 3.

[0026] FIG. 5 is a front side cross-sectional view of a gas-liquid separator, according to another embodiment.

[0027] FIG. 6 is a side cross-sectional view of a jet pump driven drain assembly for a separator assembly, according to an embodiment.

[0028] FIG. 7 is a flow diagram of a method of manufacturing a gas-liquid separator, according to an embodiment.

[0029] Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of thesubject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.DETAILED DESCRIPTION

[0030] Referring to the figures generally, embodiments described herein relate to gas-liquid separators that use jet driven inertial separation to facilitate removal of oil from a blowby gas stream. The gas-liquid separators disclosed herein include a sub-separator assembly defining multiple expansion and / or mixing chambers downstream of a compressed gas source. During operation, compressed air is injected into the sub-separator assembly, which accelerates the blowby gas stream through the mixing chambers.

[0031] In some embodiments, the sub-separator assembly is structured to receive the blowby gas stream along a radial direction and to redirect the blowby gas stream along an axial direction through subsequent mixing chambers. The change in flow direction between the mixing chambers facilitates mixing of the air with the blowby gas stream and cooling associated therewith. Mixing between the blowby gas stream and the air from the compressed gas source continues as the flow expands within each adjacent chamber prior to inertial separation. In some embodiments, the size (e.g., the cross-sectional diameter, the volume, etc.) of each the mixing chambers increases (e.g., in a stepwise manner, etc.) between adjacent chambers along the flow direction, which can further improve cooling of the aerosol mixture upstream of the impaction surface and promote oil separation performance. The combination of a radial inlet geometry for the blowby flow, an axially directed inlet for the motive flow (e.g., compressed gas), and at least three mixing chambers, can improve vacuum performance over a wider range of flow rates and operating conditions for the gas-liquid separator.

[0032] In at least one embodiment, the sub-separator assembly includes an elastomeric nozzle defining a final mixing chamber upstream of the impactor. The elastomeric nozzle can function as the final mixing chamber and can provide a dynamic response that accommodates awider range of flow conditions through the separator, without significantly affecting oil separation performance.

[0033] Referring to FIGS. 1-2, side cross-sectional views of a gas-liquid separator 100 are shown, according to an embodiment. The gas-liquid separator 100 may be included in an open crankcase ventilation system in which the filtered blowby gas is vented to the environment surrounding an engine system, or a closed crankcase ventilation system in which the filtered blowby gas is returned to the engine (e.g., through the intake manifold, etc.). The gas-liquid separator 100 includes a housing base 102, a sub-separator assembly 104, and a cover 106. In other embodiments, at least a portion of the sub-separator assembly 104 may be integrated into the housing base 102 and / or the cover 106.

[0034] The housing base 102 and the cover 106 together form a housing assembly for the gas-liquid separator 100. The housing base 102 and the cover together define an internal volume 108. In the embodiment of FIGS. 1-2, the cover 106 is coupled to the housing base 102 (e.g., via securing members and / or fastening members such as screws, nuts, bolts, rivets, etc.). A seal member 112 is disposed between the housing base 102 and the cover 106 and forms an axial seal therebetween. In the embodiment of FIGS. 1-2, the seal member 112 is coupled to the sub-separator assembly 104 and faces axially away from a support panel 114 of the sub-separator assembly 104 (e.g., the seal member 112 is an axially directed seal member). In other embodiments, the seal member 112 is a radially directed seal member that forms a radial seal between the housing base 102, the sub-separator assembly 104, and / or the cover 106.

[0035] The gas-liquid separator 100 includes a first inlet 116, a second inlet 118, a first outlet 128, and a second outlet 130. In the embodiment of FIGS. 1-2, the housing base 102 defines the first inlet 116 and the second inlet 118.

[0036] The first inlet 116 is structured to receive an unfiltered blowby gas 10 (e.g., blowby, blowby gas stream, etc.) and communicate the blowby gas 10 at a first flow velocity into the internal volume 108. In some embodiments, the gas-liquid separator 100 further includes a crankcase depression regulator (CDR) valve 117 or another form of pressure regulating valve between the first inlet 116 and the sub-separator assembly 104. In other embodiments, the gas-liquid separator 100 includes a CDR valve or another form of pressure regulating valve between the sub-separator assembly 104 and the outlet. Such arrangements can provide more uniform flow conditions through the gas-liquid separator 100 and within the engine crankcase. In other embodiments, the gas-liquid separator 100 does not includes a CDR valve.

[0037] The second inlet 118 is structured to receive compressed gas 12 (e.g., air, etc.) from a compressed gas source 14 and communicate the compressed gas 12 into the internal volume 108. The second inlet 118 may also include an inlet entry portion 120 extending into the internal volume 108 that is structured to deliver the compressed gas 12 to the sub-separator assembly 104. In the embodiment of FIGS. 1-2, the inlet entry portion 120 is a hollow cylindrical protrusion that extends into the internal volume 108.

[0038] The cover 106 includes at least one outlet, shown as first outlet 128, and an impaction plate 122. In the embodiment of FIGS. 1-2, the impaction plate 122 is disposed downstream of the sub-separator assembly 104 and upstream of the first outlet 128.Accordingly, the blowby gas 10 (which has been combined with the compressed gas 12) exiting from the sub-separator assembly 104 impacts the impaction plate 122, which separates the blowby gas 10 into cleaned blowby gas 16 (e.g., a filtered blowby gas, etc.) and separated liquid, oil, gas, and / or aerosol (referred to herein as fluid) that was previously contained in the blowby gas 10.

[0039] In some embodiments, the impaction plate 122 (which may also be referred to as an impaction surface or a separation surface) is integrally formed with the cover 106 (e.g., as a unitary body from a single piece of material). For example, the impaction plate 122 may be formed by a planar (e.g., flat, etc.) surface of the cover 106 that is disposed downstream of and extends over at least a portion of the sub-separator assembly 104 (e.g., in a direct flow path of the blowby gas 10 and compressed gas 12 flow streams flowing from the sub-separator assembly 104). The planar surface forming the impaction plate 122 (that the blowby gas 10 impacts) extends substantially perpendicular to a flow direction 22 of the blowby gas 10 and the compressed gas 12 (e.g., at an angle of approximately 90 degrees, etc.) flowing out of the subseparator assembly 104.

[0040] An impaction plate flange 124 extends from the outer peripheral edges of the impaction plate 122 (as a part of the cover 106) towards the housing base 102. The impaction plate flange 124 extends circumferentially around the impaction plate 122 and extends axially away from the impaction plate 122 in a direction opposite the fluid flow direction of the blowby gas 10 received from the sub-separator assembly 104. In some embodiments, the impaction plate flange 124 defines a hollow cylindrical extension that circumscribes the impaction plate 122. The impaction plate flange 124 extends into the internal volume 108.

[0041] In some embodiments, the gas-liquid separator 100 further includes a filter media 126 (e.g., a patch of filter media such as a disc of filter media) disposed on the impaction plate 122 between the outlet of the sub-separator assembly 104 and the impaction plate 122 along the flow direction 22. The combined blowby gas 10 and compressed gas 12 stream impacts the filter media 126 such that the filter media 126 filters the blowby gas 10 prior to impacting the impaction plate 122.

[0042] Referring still to FIGS. 1-2, during operation, the blowby gases 10 accelerated by the compressed gas 12 impact the impaction plate 122, causing separation of fluid 18 from the blowby gas 10 and creating cleaned blowby gas 16. The fluid collects in one of the housing base 102 or the cover 106 (within the internal volume 108) and drains from the housing base 102 or the cover 106 via the second outlet 130 (e.g., a drain, etc.). The cleaned blowby gas 16 flows through the internal volume 108, around the impaction plate flange 124, and out through the first outlet 128 (e.g., a gas outlet). The first outlet 128 is configured to receive the clean blowby gas 16 from the sub-separator assembly 104 and to deliver the clean blowby gas 16 to an environment surrounding the engine / vehicle and / or back to the engine (e.g., via a turbocharger inlet, an inlet manifold, etc.).

[0043] The sub-separator assembly 104 is configured to separate liquid oil from the blowby gas 10. The sub-separator assembly 104 is disposed within the internal volume 108. In the embodiment of FIGS. 1-2, the sub-separator assembly 104 is formed independently from the housing base 102 and the cover 106, as a separate piece of material that is removable from the housing base 102 and the cover 106. In other embodiments, at least portions of the sub-separator assembly 104 may be integrally formed with the housing base 102 and / or the cover 106.

[0044] The sub-separator assembly 104 includes a nozzle plate 132, an outlet tube 134, an elastomeric member 136, a baffle 137, the support panel 114, and the seal member 112. In other embodiments, the sub-separator assembly 104 may include additional, fewer, and / or different components.

[0045] Referring to FIG. 3, the sub-separator assembly 104 defines at least three mixing chambers 138 (e.g., expansion chambers, etc.) along the flow direction 22 of the blowby gas 10 and the compressed gas 12 through the sub-separator assembly 104. The at least three mixing chambers 138, shown as a first mixing chamber 140, a second mixing chamber 142, and a third mixing chamber 144, are defined by different components of the sub-separator assembly 104, as will be further described.

[0046] The nozzle plate 132 is structured to receive compressed gas 12 from the second inlet 118 (see FIG. 1), via the inlet entry portion 120, to accelerate the compressed gas 12, and to direct the compressed gas 12 toward the outlet tube 134. The nozzle plate 132 defines at least one nozzle. In the embodiment of FIG. 3, the nozzle plate 132 defines plurality of nozzles 133 (e.g., a plurality of channels, etc.) that are spaced apart from one another in a uniform pattern across the inlet entry portion 120, and that are oriented substantially parallel to the flow direction 22 of compressed gas 12 through the inlet entry portion 120. A diameter or a flow area of each one of the plurality of nozzles 133 is smaller than (and downstream of) a diameter or a flow area of the inlet entry portion 120, where the flow area refers to the cross-sectional area taken along a plane approximately perpendicular to the flow direction 22 therethrough. The plurality of nozzles 133 thereby function as a motive jet and accelerate the compressed gas 12 into the sub-separator assembly 104 (and subsequently into a portion of the internal volume 108 defined by the cover 106), which draws in and accelerates the blowby gas 10.

[0047] In some embodiments, the nozzle plate 132 also includes a skirt 139 extending along a perimeter thereof and axially from the perforated panel. In some embodiments, the skirt 139 is a cylindrical protrusion that extends into the inlet entry portion 120. In some embodiments,the skirt 139 is formed in a shape that corresponds with the shape of the nozzle plate 132. In other embodiments, the shape of the skirt 139 may be different. The skirt 139 is sealingly engaged (e.g., via a second sealing member 146) with the inlet entry portion 120 so as to prevent leakage of compressed gas 12 across the perforated panel.

[0048] The outlet tube 134 is engaged with the nozzle plate 132 and extends axially away from the nozzle plate 132. In the embodiment of FIG. 3, the outlet tube 134 is one of a plurality of outlet tubes that extend from the nozzle plate 132. In some embodiments, the outlet tubes are integrally formed with the nozzle plate 132 as a monolithic body from a single piece of material, together forming a sub-separator insert that is configured to be received at least partially within an opening through the baffle 137. In other embodiments, the outlet tube(s) are formed separately from the nozzle plate 132 and / or are supported above the nozzle plate 132. The outlet tube 134 is a hollow cylindrical protrusion that extends substantially parallel to the flow direction of compressed gas 12 through the inlet entry portion 120 of the second inlet 118 and the plurality of nozzles 133.

[0049] In the embodiment of FIG. 3, the outlet tube 134 at least partially defines the first mixing chamber 140 and the second mixing chamber 142. The outlet tube 134 at least partially defines a plurality of bores, including a first bore 152 and a second bore 154 extending therethrough. In the embodiment of FIG. 3, the first bore 152 and the second bore 154 are cylindrical bores having a cylindrically shaped cross-section along a flow direction therethrough.

[0050] The first bore 152 is disposed at a proximal end of the outlet tube 134, adjacent to the nozzle plate 132. The first bore 152 extends along a first direction 156 that is substantially perpendicular to the flow direction 22 through the plurality of nozzles 133. The first bore 152 defines the first mixing chamber 140. In the embodiment of FIG. 3, the first bore 152 (e.g., the first mixing chamber 140) extends along a substantially radial direction 148 relative to a central axis of the outlet tube 134. In some embodiments, the first bore 152 extends through the central axis of the outlet tube 134. In some embodiments, the first bore 152 extends across the entire diameter of the outlet tube 134 between opposing sides of the outlet tube 134 so as to enable receiving the blowby gas 10 from multiple sides of the outlet tube 134.

[0051] The second bore 154 defines the second mixing chamber 142. The second bore 154 (e.g., the second mixing chamber 142) is fluidly coupled to the first bore 152 and extends in a second direction 157 that is substantially perpendicular to the first direction 156. In the embodiment of FIG. 3, the second bore 154 extends in substantially axial direction 158 away from the first bore 152 (e.g., the first mixing chamber 140). The second bore 154 is disposed at an intermediate (e.g., central, etc.) position along the first bore 152 and is substantially coaxial with a respective one of the plurality of nozzles 133.

[0052] During operation, blowby gas 10 entering the first bore 152 (e.g., the first mixing chamber 140) at a first flow velocity is drawn into the second bore 154 by the compressed gas 12 that is injected into the first bore 152 at a second flow velocity that is higher than the first flow velocity. Since the compressed gas 12 is flowing at a higher velocity than the blowby gas 10, the compressed gas 12 causes the blowby gas 10 to flow at a third flow velocity that is greater than the first flow velocity but less than the second flow velocity (i.e., the compressed gas 12 increases the flow velocity of the blowby gas 10). The compressed gas 12 also generates a pumping effect that reduces pressure drop across the sub-separator assembly 104.

[0053] The baffle 137 (e.g., a baffle panel, a baffle plate, etc.) is structured to capture and retain the fluid (e.g., the liquid, the separated oil, etc.) and to guide the fluid to the second outlet 130. The baffle 137 is also structured to support the elastomeric member 136. In the embodiment of FIG. 3, the baffle 137 includes a disc-shaped panel defining a plurality of openings 160 that are each aligned with a respective one of the plurality of outlet tubes. The disc-shaped panel is radially aligned with the nozzle plate 132 so that the outlet tubes extend at least partially through the openings 160. In some embodiments, the baffle 137 also includes a baffle flange (shown as baffle flange 262 in FIG. 5) that extends axially away from a perimeter edge of the disc-shaped panel and toward the impaction plate flange 124. In the embodiment of FIG. 3, the baffle flange 162 circumscribes the disc-shaped panel and is concentric with the impaction plate flange 124.

[0054] The elastomeric member 136 is arranged in a series flow arrangement with, and downstream of, the outlet tube 134. The elastomeric member 136 is coupled to a distal end (or outlet end) of the outlet tube 134. The elastomeric member 136 defines a one of the at leastthree mixing chambers. In the embodiment of FIG. 3, the elastomeric member 136 defines the third mixing chamber 144. The third mixing chamber 144 is structured to further combine the blowby gas 10 and the compressed gas 12 and to communicate the combination of the blowby gas 10 and the compressed gas 12 into the internal volume 108 and toward the impaction plate 122. In the embodiment of FIG. 3, the elastomeric member 136 is one of a plurality of elastomeric members that are each coupled to respective ones of the plurality of outlet tubes. In other embodiments, a single elastomeric member 136 may be disposed around / above multiple ones of the plurality of outlet tubes 134. In some embodiments, as shown in FIG. 3, the elastomeric member 136 has a duck billed shape or a conical shape.

[0055] In the embodiment of FIG. 3, the elastomeric member 136 is an elastomeric nozzle made from a flexible material that is structured to deform responsive to changes in gas pressure upstream and downstream of the elastomeric nozzle. The flexible structure of the elastomeric nozzle provides a dynamic and variable response based on operating conditions through the elastomeric nozzle. For example, the flexible structure enables the elastomeric nozzle to open or close by varying degrees to accommodate different flow conditions therethrough (e.g., by opening wider at higher combined flow through the elastomeric member 136, which can result in a similar exit velocity as occurs at lower flows when the elastomeric member 136 defines a narrower opening).

[0056] The elastomeric member 136 is positioned along the fluid flow path (e.g., of both the blowby gas 10 and the compressed gas 12) through the sub-separator assembly 104. The elastomeric member 136 may be mounted on or fluidly coupled to the outlet tube 134. In the embodiment of FIG. 3, each elastomeric member 136 is engaged with, and sandwiched between, the baffle 137 and a respective one of the outlet tubes. In such an arrangement, the elastomeric member 136 circumscribes a respective one of the outlet tubes. Such an arrangement provides greater support to the elastomeric member 136 and resists deformation of a proximal end of the elastomeric member 136 during operation.

[0057] In some embodiments, the outlet tube 134 further includes at least one slot 143 extending in the substantially axial direction 158 along an outer surface 141 of the outlet tube134 where the elastomeric member 136 engages the outlet tube 134. In some embodiments, theat least one slot 143 is an elongated groove or channel that enables fluid flow past the elastomeric member 136, which can prevent accumulation of oil within the elastomeric member 136, while still providing enhanced structural stability for the elastomeric member 136.

[0058] The distal end (e.g., the downstream end, etc.) of the outlet tube 134 is positioned within the elastomeric member 136 such that the blowby gas 10 and the compressed gas 12 is output from the outlet tube 134 into the third mixing chamber 144.

[0059] Referring to FIG. 4, the sub-separator assembly 104 is uniquely designed to improve mixing of the blowby gas 10 with the compressed gas 12, and to reduce the pressure drop between the housing base 102 and the cover 106. A size of each adjacent mixing chamber increases along the flow direction 22 through the sub-separator assembly 104. The first mixing chamber 140 defines a first volume 164 (e.g., a volume based on a diameter or flow area of the flow passage and a length of the flow passage between an inlet and an outlet of the flow passage along a flow direction therethrough, a volume of approximately half of the first bore 152), the second mixing chamber 142 defines a second volume 166 that is greater than the first volume 164, and the third mixing chamber 144 defines a third volume 168 that is greater than both the second volume 166 and the first volume 164.

[0060] In some embodiments, the third volume 136 is defined by the unobstructed portion of the interior cavity of the elastomeric member 136 (e.g., downstream from the outlet tube 134). In such embodiments, the third volume 168 may be smaller than the second volume 166 under certain flow conditions (e.g., when the elastomeric member 136 is closed off to flow therethrough, and / or a low flow rates when the end opening defined by the elastomeric member 136 is small). In flow conditions at which the end opening of the elastomeric member 136 is substantially fully open, the unobstructed volume of the cavity defined by the elastomeric member 136 may be greater than the second volume 166 and the first volume 164. In some embodiments, and as shown, the total volume of the inner cavity of the elastomeric member 136, including the portion occupied by the outlet tube 134, is larger than the second volume 166.

[0061]

[0062] In the embodiment of FIG. 4, a cross-sectional diameter of each of the at least three mixing chambers, shown as a first cross-sectional diameter 170 of the first mixing chamber 140, a second cross-sectional diameter 172 of the second mixing chamber 142, and a third cross-sectional diameter 174 of the third mixing chamber 144, increases between adjacent ones of the at least three mixing chambers along the flow direction 22 through the sub-separator assembly 104, so that the second cross-sectional diameter 172 is greater than the first cross- sectional diameter 170, and so that the third cross-sectional diameter 174 is greater than both the second cross-sectional diameter 172 and the first cross-sectional diameter 170. In some embodiments, the first cross-sectional diameter 170, the second cross-sectional diameter 172, and the third cross-sectional diameter 174 increase in a stepwise manner between adjacent ones of the at least three mixing chambers so that the flow area increases as the blowby gas 10 and the compressed gas 12 enter each adjacent chamber.

[0063] The sub-separator assembly 104 (e g., the nozzle plate 132, the outlet tube(s) 134, and / or the elastomeric member 136) is dimensioned to improve separation efficiency while maintaining similar pressure drop over a range of flow conditions. In the embodiment of FIG. 4, a second cross-sectional diameter 172 of the second mixing chamber 142 along the flow direction 22 therethrough is approximately 4 times a nozzle diameter 177 of the nozzle 133. Additionally, the second cross-sectional diameter 172 is approximately 1.25 times the first cross-sectional diameter 170 through the first mixing chamber 140. A second length 179 of the second mixing chamber 142 along the flow direction 22 therethrough is approximately 3.5 times greater than a first length 178 of the first mixing chamber 140. A third length 180 of the third mixing chamber is approximately equal to the second length 179, while the third cross- sectional diameter 174 of the third mixing chamber 144 along the flow direction 22 therethrough is approximately 1.25 times the second cross-sectional diameter 172.

[0064] It should be understood that the dimensions and arrangement of the sub-separator assembly 104 may be different in various embodiments. For example, referring to FIG. 5, a separator assembly 200 is shown in which a second length 278 of a second mixing chamber 242 (and its respective outlet tube 234) is approximately twice the second length 179 of the second mixing chamber 142 of FIG. 4. The separator assembly 200 also does not include the pluralityof elastomeric members and instead directs flow from the outlet tubes directly into an internal volume of the separator assembly 200. Such an arrangement can simplify manufacturing and reduce the number of components needed for the separator assembly 200 in certain applications.

[0065] Referring back to FIG. 4, the increase in volume and flow area along the flow direction 22 through the sub-separator assembly 104 (i.e., between each of the first mixing chamber 140, the second mixing chamber 142, and the third mixing chamber 144) provides multiple stages of expansion and facilitates cooling of the blowby gas 10 and the compressed gas 12 mixture, which can increase separation efficiency of liquid oil from the blowby gas 10. The use of at least three mixing / expansion stages can also increase transport time for mixing of the combined blowby gas and compressed air mixture, as well as the overall space available for mixing between the blowby gas 10 and the compressed gas 12, which can further cool the blowby gas 10 prior to impaction.

[0066] Referring back to FIG. 3, the support panel 114 is structured to sealingly engage the sub-separator assembly 104 with the housing base 102 and the cover 106 so as to prevent leakage of blowby gas 10 between the housing base 102 and the cover 106. The support panel 114 circumscribes the nozzle plate 132 and extends radially away from the nozzle plate 132 on all sides of the nozzle plate 132. In some embodiments, the support panel 114 is integrally formed (e.g., via an injection molding operation, etc.) with the nozzle plate 132 and the baffle 137 as a monolithic body from a single piece of material. In other embodiments, the support panel 114 may be formed separately from the nozzle plate 132 and / or the baffle 137.

[0067] The seal member 112 is coupled to the support panel 114 and extends along a perimeter edge 176 thereof. In the embodiment of FIG. 3, the sub-separator assembly 104 includes a pair of seal members to sealingly engage opposing sides of the support panel 114 along a perimeter edge of the housing base 102 and the cover 106.

[0068] During operation, the compressed gas 12 flows into the gas-liquid separator 100 through the inlet entry portion 120. The inlet entry portion 120 receives the compressed gas 12 and directs the compressed gas 12 into the at least one nozzle 133. The sub-separator assembly104 is structured so that the blowby gas 10 enters the first mixing chamber 140 along a substantially radial direction 148, and is reoriented along a substantially axial direction 158 through the second mixing chamber 142 and the third mixing chamber 144. The compressed gas 12 expands and mixes with incoming blowby gas 10 in each of the first mixing chamber 140, the second mixing chamber 142, and the third mixing chamber 144. The mixture of the compressed gas 12 and the blowby gas 10 then flows out from the elastomeric member 136 into the internal volume 108, and toward the impaction plate 122.

[0069] Referring to FIG. 6, in some embodiments, the separator assembly (e.g., the gasliquid separator 100 of FIGS. 1-4, etc.) also includes a jet pump driven drain assembly, shown as drain assembly 200. In some embodiments, the drain assembly 200 is disposed within a housing base of the separator assembly. The drain assembly 200 is configured to use compressed gas 12 from a compressed gas source to facilitate the removal of separated fluid 18 (e.g., oil) from the housing (e.g., the housing base, the housing cover, etc.) downstream of the sub-separator assembly. Such an arrangement can prevent pooling of liquid oil within the separator assembly or re-entrainment of oil into the cleaned blowby gas downstream of the subseparator assembly. In some embodiments, the compressed gas source is the same source that is used to provide compressed gas 12 to the nozzle plate of the sub-separator assembly, so that the compressed gas source is shared between the sub-separator assembly and the drain assembly 200.

[0070] In the embodiment of FIG. 6, the drain assembly 200 includes a jet pump 202 (e.g., a venturi pump, etc.), which accelerates the compressed gas 12 through a nozzle 204 of the jet pump 202, creating an region of low pressure that draws the separated fluid 18 from an internal drain 206 of the separator assembly, through the jet pump 202, and toward a check valve 208 that is disposed at a second outlet of the separator assembly (e.g., the second outlet 130 as shown in FIG. 2).

[0071] In some embodiments, the internal drain 206 is configured to direct the separated fluid 18 toward the jet pump 202. The internal drain 206 may include a funnel and / or drain line that is disposed within the housing base downstream of the sub-separator assembly. In the embodiment of FIG. 6, the internal drain 206 is disposed over the jet pump 202 so that theseparator fluid 18 leaving the internal drain 206 falls onto or pools adjacent to the jet pump 202 (e.g., a fluid inlet of the jet pump 202).

[0072] In the embodiment of FIG. 6, the jet pump 202 is fluidly coupled to an inlet entry portion of the separator assembly (e.g., the inlet entry portion 120 of FIG. 1) and is configured to receive the compressed gas 12 from the inlet entry portion. The check valve 208 is configured to prevent backflow into the drain assembly 200 through the second outlet. The check valve 208 is coupled to the separator assembly at the second outlet. In some embodiments, the check valve 208 includes a diaphragm or a spring-based valve to enable unidirectional flow through the second outlet.

[0073] Referring to FIG. 7, a method 300 of manufacturing a sub-separator assembly is shown, according to an embodiment. The method 300 may be used to manufacture any of the sub-separator assembly designs and / or sub-separator insert designs disclosed herein.

[0074] The method 300 includes providing (e.g., forming) at least a portion of a subseparator insert and / or a nozzle plate, at 302. In some embodiments, operation 302 includes forming a nozzle plate defining a nozzle or a plurality of nozzles across the nozzle plate (e.g., spaced at approximately equal intervals across the nozzle plate). In some embodiments, operation 302 includes forming a skirt onto the nozzle plate that extends from an outer perimeter of the nozzle plate and substantially normal to the nozzle plate.

[0075] The method 300 also includes forming at least two mixing chambers extending away from the nozzle plate, at 304. In some embodiments, operation 304 includes forming an outlet tube onto the nozzle plate that extends axially away from the nozzle plate. In some embodiments, operation 304 includes forming a first bore through the outlet tube so that the first bore extends in a radial direction through the outlet tube (e.g., a radial direction relative to a central axis of the outlet tube). Operation 304 may also include forming a second bore through the outlet tube that has a greater cross-sectional size and / or volume than a volume of the first mixing chamber. In some embodiments, operation 304 includes forming the second bore by forming a bore that extends away from the first bore in a substantially perpendicular orientation relative to the first bore (e.g., parallel to the central axis of the first bore).

[0076] In some embodiments, the method 300 also includes forming a third mixing chamber downstream of the at least two mixing chambers, at 306. In some embodiments, operation 306 includes coupling an elastomeric nozzle onto the outlet tube that defines an internal cavity having a greater cross-sectional size and / or volume relative to the second bore and the first bore.

[0077] In some embodiments, the method 300 also includes installing the sub-separator assembly into a housing, at 306. In some embodiments, operation 306 includes coupling the sub-separator assembly, including the nozzle plate, the outlet tube, and the elastomeric nozzle, to a baffle panel and / or a support panel. In some embodiments, operation 306 also includes inserting the baffle panel and / or the support panel into an interior cavity of a housing.Operation 306 may also include sealingly engaging the baffle panel and / or the support panel with the housing so that flow entering the housing is directed through the sub-separator assembly.

[0078] As used herein, the terms “about” and “approximately” generally mean plus or minus 10% of the stated value. For example, about 0.5 would include 0.45 and 0.55, about 10 would include 9 to 11, about 1000 would include 900 to 1100.

[0079] It should be noted that the term “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and / or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0080] As utilized herein, the term “substantially” and any 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 unless otherwise noted. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications oralterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0081] The term “coupled” and the like as used herein mean the joining of two members 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 members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0082] It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the embodiments described herein.

[0083] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any embodiment or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular embodiments. 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 above 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.

Claims

WHAT IS CLAIMED IS:

1. A gas-liquid separator comprising: a housing base; a cover coupled to the housing base, the housing base and the cover together defining an internal volume; a sub-separator assembly disposed within the internal volume, the sub-separator assembly defining at least three mixing chambers along a flow direction through the subseparator assembly, the sub-separator assembly including an elastomeric nozzle defining one of the at least three mixing chambers; an impaction surface disposed downstream of the sub-separator assembly.

2. The gas-liquid separator of claim 1, wherein the at least three mixing chambers include a first mixing chamber defining a first volume, a second mixing chamber disposed downstream from the first mixing chamber and defining a second volume, and a third mixing chamber disposed downstream from the second mixing chamber and defining a third volume, wherein the third volume is greater than the second volume, and the second volume is greater than the first volume.

3. The gas-liquid separator of claim 1, wherein a cross-sectional diameter of each of the at least three mixing chambers increases in a stepwise manner between adjacent ones of the at least three mixing chambers along the flow direction.

4. The gas-liquid separator of claim 1, wherein the sub-separator assembly is structured so that blowby gas enters a first mixing chamber of the at least three mixing chambers along a substantially radial direction and is reoriented along a substantially axial direction through remaining ones of the at least three mixing chambers.

5. The gas-liquid separator of claim 1, wherein the sub-separator assembly includes a baffle defining an opening, and an outlet tube extending through the opening and defining at least one of the at least three mixing chambers, and wherein the elastomeric nozzle engages both the baffle and the outlet tube.

6. The gas-liquid separator of claim 1, wherein a first mixing chamber of the at least three mixing chambers is defined by a first cylindrical bore having a central axis that extends along a first direction, and wherein a second mixing chamber of the at least three mixing chambers is defined by a second cylindrical bore having a central axis that extends along a second direction that is substantially perpendicular to the first direction.

7. The gas-liquid separator of claim 1, wherein the sub-separator assembly further includes a filter media engaged with the impaction surface.

8. The gas-liquid separator of claim 1, wherein the housing base includes: a first inlet structured to receive a blowby gas stream; and a second inlet structured to a receive compressed air from a compressed air source, wherein the cover includes a first outlet configured to receive a filtered blowby gas from the sub-separator assembly, and wherein one of the housing base and the cover includes a second outlet configured to drain liquid from the sub-separator assembly.

9. The gas-liquid separator of claim 1, further comprising a drain assembly coupled to one of the housing base or the cover, the drain assembly comprising: a jet pump; and a check valve downstream from the jet pump.

10. A sub-separator assembly for a gas-liquid separator, comprising: a nozzle plate defining a nozzle; an outlet tube extending axially away from the nozzle plate, the outlet tube at least partially defining: first mixing chamber extending in a substantially radial direction relative to a central axis of the outlet tube; anda second mixing chamber extending in a substantially axial direction away from the first mixing chamber; and an elastomeric member coupled to the outlet tube and defining a third mixing chamber downstream from the second mixing chamber.

11. The sub-separator assembly of claim 10, further comprising a baffle defining an opening, wherein the outlet tube extends through the opening, and wherein the elastomeric member extends at least partially through the opening and engages both the baffle and the outlet tube.

12. The sub-separator assembly of claim 11, wherein the outlet tube defines a slot extending in the substantially axial direction along an outer surface of the outlet tube where the elastomeric member engages the outlet tube.

13. The sub-separator assembly of claim 10, wherein the first mixing chamber defines a first volume, the second mixing chamber defines a second volume, and the third mixing chamber defines a third volume, and wherein the third volume is greater than the second volume, and the second volume is greater than the first volume.

14. The sub-separator assembly of claim 10, wherein a cross-sectional diameter of the third mixing chamber along a flow direction therethrough is greater than a cross-sectional diameter of the second mixing chamber, and a cross-sectional diameter of the second mixing chamber is greater than a cross-sectional diameter of the first mixing chamber.

15. The sub-separator assembly of claim 10, wherein a cross-sectional diameter of each of the first mixing chamber, the second mixing chamber, and the third mixing chamber increases in a stepwise manner between adjacent ones of the first mixing chamber, the second mixing chamber, and the third mixing chamber along a flow direction through the first mixing chamber, the second mixing chamber, and the third mixing chamber.

16. The sub-separator assembly of claim 10, wherein the first mixing chamber is defined by a first cylindrical bore that extends through the outlet tube, and the second mixingchamber is defined by a second cylindrical bore that extends at least partially through the outlet tube and into the first cylindrical bore.

17. The sub-separator assembly of claim 10, wherein the nozzle is one of a plurality of nozzles defined by the nozzle plate, and wherein the outlet tube is one of a plurality of outlet tubes that extend from the nozzle plate at respective ones of the plurality of nozzles.

18. The sub-separator assembly of claim 10, further comprising: a support panel extending radially away from the nozzle plate on either side of the nozzle plate; and a sealing member coupled to the support panel and extending along a perimeter edge thereof.

19. A method of manufacturing a sub-separator assembly, the method comprising: forming a nozzle plate defining a nozzle; and forming an outlet tube that includes at least two mixing chambers onto the nozzle plate, the at least two mixing chambers comprising: a first mixing chamber that extends in a substantially radial direction relative to a central axis of the outlet tube; and a second mixing chamber that extends in a substantially axial direction away from the first mixing chamber.

20. The method of claim 19, wherein further comprising coupling an elastomeric nozzle defining a third mixing chamber to the outlet tube.

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