Crankcase Filtration System Vertical Flow Oil Separation

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Solution Overview

Problem

Existing crankcase ventilation systems require the engine to be shut down or idling to drain oil back into the engine, which is inefficient and limits continuous operation.

Innovation Solution

A filtration system with a valve lid and filter element configuration that allows oil vapor and crankcase fumes to flow in a specific direction, enabling oil vapor collection and separation from fumes without the need for pressurization or additional components like sumps and check valves, by utilizing breather and filter elements to separate oil vapor from crankcase fumes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sump and check valve system is used to return filtered oil to the engine, then oil can be retained and returned to the lubrication system, but the engine must be shut down or idling for oil drainage

Engineering Contradiction:

Improveoil retention and return capabilityVSAvoidcontinuous operation capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent extracts the oil drainage function from the sump and check valve system, allowing oil to be drained and returned to the engine continuously during operation rather than requiring shutdown. The filter element directly returns oil to the engine, eliminating the need for a sump and check valve system.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent enables continuous oil drainage and return during engine operation through the filter element design, eliminating the intermittent operation required by traditional sump and check valve systems. The oil is continuously separated and returned while the engine runs, maintaining both reliability and productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If a sump and check valve system is used for oil return, then oil can be collected and drained, but the system complexity increases with additional components

Engineering Contradiction:

Improveoil return functionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the sump and check valve components from the system, extracting only the essential oil separation and return function. The filter element directly returns oil to the engine, simplifying the system while maintaining the oil return function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the oil separation and return functions into the filter element itself, eliminating the need for separate sump and check valve components. This integration reduces system complexity while maintaining reliable oil return capability.

Inventive Principle:

Principle #5Merging (Combining)

3Object-generated harmful factors

If crankcase emissions are vented horizontally across filter elements, then oil can be filtered, but the system requires additional components like sumps and check valves

Engineering Contradiction:

Improveoil mist particle retentionVSAvoidcrankcase ventilation system structure

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts the oil filtration function from the horizontal venting system and integrates it into the vertical chamber design. The filter element is positioned to directly receive and filter vertically flowing emissions, eliminating the need for horizontal venting and associated complex components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the traditional horizontal venting approach to a vertical flow configuration. Emissions flow upward through the chamber and filter element, reversing the conventional direction and simplifying the system structure while maintaining effective oil mist particle retention.

Inventive Principle:

Principle #13The other way round (Inversion)

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

Enables continuous operation by separating oil vapor from crankcase fumes without the need for engine shutdown or idling, reducing component complexity and cost, and ensuring efficient return of oil vapor to the lubrication system.

Implementation Method 1

a filter element associated with a lower portion of the chamber... at least a portion of the oil vapor collects in the filter element, and at least a portion of the crankcase fumes flowing through the filter element

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS8156926B2Systems and methods for filtering crankcase fumes

Publication Date: 2012.04.17 CATERPILLAR INC

AI summary

A filtration system is disclosed. The filtration system includes a valve lid defining a chamber. The chamber is configured to extend substantially in a second direction. The filtration system also includes a filter element associated with a lower portion of the chamber. The filtration system further includes a passageway in flow communication with the lower portion of the chamber. The passageway is configured to provide flow communication for a mixture of oil vapor and crankcase fumes flowing into the chamber substantially in a first direction and substantially upward direction. The first direction is generally orthogonal to the second direction. The chamber is configured such that the flow of the mixture into the chamber results in at least a portion of the oil vapor collecting in the filter element, and at least a portion of the crankcase fumes flowing through the filter element.