Dual-Screen Oil Separator Prevents Vapor Migration in PCV Systems

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Solution Overview

Problem

Existing oil and air separation systems in PCV systems allow oil vapors to escape through the exhaust, contaminating the engine's intake manifold and degrading performance, as the screen in the can facilitates oil migration from the intake to the exhaust filter.

Innovation Solution

The system includes a first screen to hold the oil filter assembly proximate the intake and a second screen proximate the exhaust, vertically spaced to prevent oil migration from the intake to the exhaust, ensuring that oil collects at the bottom and is not recycled into the exhaust.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single screen is used to hold the oil filter assembly in the can, then the structure is simple, but oil vapors can migrate from the intake to the exhaust through the screen

Engineering Contradiction:

Improvescreen structureVSAvoidoil vapor migration

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The single screen is divided into two separate screens: a first screen proximate the intake and a second screen proximate the exhaust. This segmentation prevents oil vapors from migrating through the screen by creating separate filtering zones, thereby eliminating the harmful effect while maintaining structural simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first screen acts as an intermediary barrier that intercepts oil vapors before they can reach the second screen or escape through the exhaust. This intermediary structure prevents the harmful migration of oil vapors while allowing the system to remain relatively simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If oil is recycled with blow-by gases into the intake manifold, then the PCV system recycles gases effectively, but engine performance degrades due to oil contamination

Engineering Contradiction:

Improvegas recycling efficiencyVSAvoidengine performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The oil filter assembly with dual screens extracts and removes oil vapors from the blow-by gases before they enter the intake manifold. This extraction prevents oil contamination while maintaining effective gas recycling, thereby preserving engine performance.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The oil vapors that would otherwise harm engine performance are converted into a beneficial filtering function by the dual screen system. The screens capture and retain oil vapors, transforming them from a harmful contaminant into a removed substance that protects the engine.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If oil collects at the bottom of the can, then oil separation is effective, but oil may still escape through the exhaust via the screen

Engineering Contradiction:

Improveoil collectionVSAvoidoil escape through exhaust

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The dual screen configuration segments the oil collection zone from the exhaust zone. The first screen collects oil vapors near the intake, and the second screen prevents any remaining oil vapors from escaping through the exhaust, ensuring complete oil separation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second screen acts as an intermediary barrier between the oil collection zone and the exhaust outlet. It prevents oil vapors from escaping through the exhaust while allowing clean gases to pass through, maintaining effective oil separation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This configuration significantly reduces or eliminates oil vapors in the exhaust, improving engine performance by preventing oil from degrading the combustion mixture and maintaining airflow.

Implementation Method 1

a first screen that holds an oil filter assembly proximate a can intake for blow-by gases

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

a second screen that holds an oil filter assembly proximate a can exhaust for blow-by gases

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 3

the first screen and the second screen are spaced vertically apart from one another

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS8968446B1Oil and air separation system and method

Publication Date: 2015.03.03 UPR PROD

AI summary

An oil and air separation can includes: (i) a first screen that holds an oil filter assembly proximate a can intake for blow-by gases, and (ii) a second screen that holds a second oil filter assembly proximate a can exhaust for blow-by gases, wherein the first screen and the second screen are spaced vertically apart from one another.