Axial Impeller Oil Separator for Combustion Engine Aerosol

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Solution Overview

Problem

Existing oil separators for internal combustion engines are not efficient enough in separating oil from aerosol, leading to carbonization of intake valves, pistons, and combustion chambers due to incomplete separation before recirculation.

Innovation Solution

An oil separator with a housing featuring a drivable axial impeller that generates a straight-line aerosol flow, impacting an internal wall for high-speed separation, combined with a radial dividing wall and strategically positioned air and oil outlet openings to enhance separation efficiency and design simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional oil separators are used, then the device can separate oil from aerosol, but the separation efficiency is insufficient leading to carbonization of intake valves, pistons, and combustion chambers

Engineering Contradiction:

Improveseparation efficiencyVSAvoidcarbonization of intake valves, pistons, and combustion chambers

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The oil separator is divided into functionally distinct segments: an impeller section for generating centrifugal force, an impact wall section for high-speed collision and separation, and outlet openings positioned at specific locations for differentiated discharge. This segmentation allows each component to optimize its specific function, achieving complete oil separation while preventing carbonization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The impeller performs preliminary action by generating strong centrifugal force that pre-accelerates the aerosol flow before it reaches the impact wall. This preliminary acceleration ensures that when the aerosol strikes the impact wall, the oil droplets are already in a state ready for immediate separation, enhancing the overall separation efficiency and preventing carbonization.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If an axial impeller is used to generate straight-line aerosol flow, then the design becomes simpler and separation efficiency improves, but the device must be positioned precisely to utilize gravity effectively

Engineering Contradiction:

Improvedesign complexityVSAvoidinstallation positioning precision

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

Instead of using a radial impeller that creates circular flow patterns, this invention inverts the approach by using an axial impeller that generates straight-line flow. This inversion simplifies the overall device design and manufacturing while the straight-line flow path makes the gravity-dependent oil drainage more direct and reliable, reducing the need for complex positioning adjustments.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system utilizes the engine's own gravitational field to aid oil separation and drainage. The axial impeller creates a flow path where separated oil naturally drains downward into the crankcase without requiring additional active drainage mechanisms. This self-service approach using gravity reduces device complexity while maintaining effective oil removal.

Inventive Principle:

Principle #25Self-service

3Productivity

If the air outlet opening is positioned as high as possible against gravity, then blow-by gases can escape effectively, but the oil separation process becomes more dependent on gravitational force

Engineering Contradiction:

Improveblow-by gas recirculation efficiencyVSAvoidoil separation reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The high-positioned air outlet opening acts against the gravitational force by positioning the gas discharge point at the highest possible location in the housing. This creates a vertical flow path where buoyant gases naturally rise to the outlet while oil droplets, being heavier, are forced downward by gravity into the crankcase. This anti-weight positioning maximizes both gas escape efficiency and oil separation reliability.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution achieves effective separation of oil from aerosol, allowing oil to flow back into the crankcase and blow-by gases to be recirculated, reducing carbonization risks and simplifying the design compared to traditional separators.

Implementation Method 1

a drivable impeller rotating about a rotational axis, which impeller is adapted to generate an aerosol flow along an axial direction

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

Due to the gravity at the impact wall, the separated oil can flow downwards and be transported back into the crankcase

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS11015499B2Oil separator for separating oil from aerosol in a combustion engine

Publication Date: 2021.05.25 BAYERISCHE MOTOREN WERKE AG

AI summary

An oil separator separates oil from aerosol in a combustion engine. The oil separator includes a housing having an inlet opening for the aerosol, an impeller which can be rotatably driven about a rotational axis, and which is adapted for generating an aerosol flow along an axial direction of the impeller and arranged in the housing, and an impact wall which is designed in such a way that a projection of the impeller oriented axially and downstream in the air flow impinges on the impact wall. At least one part of a projection of the impeller oriented axially and downstream in the air flow impinges on the inlet opening.