Hot Filter Assembly for Closed Crankcase Vent Contaminant Burn-Off

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Solution Overview

Problem

Current systems for managing blow-by gases typically involve routing the gases from the crankcase to an oil separator. The oil separator separates the oil from the crankcase. The remaining gases are routed to the air intake of the engine system. The small droplets can deposit on various engine components, including the turbocharger, charge air cooler, intake manifold, injectors, and intake valves. These deposits can reduce engine performance, decrease fuel economy, and increase ownership costs.

Innovation Solution

A hot filter assembly is coupled to and/or integrated with the exhaust manifold or turbine housing of the engine system. The hot filter assembly can be configured to passively heat blow-by gases passing therethrough, thereby burning remaining contaminants in the gases from the crankcase due to its positioning against the exhaust manifold or turbine housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If blow-by gases are routed directly from the oil separator to the air intake, then the system complexity is reduced, but contaminants deposit on engine components reducing performance and increasing ownership costs

Engineering Contradiction:

Improvesystem complexityVSAvoidengine performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

A hot filter assembly is introduced as an intermediary component between the oil separator and air intake. This assembly uses the hot exhaust manifold as a heat source to passively heat and filter the blow-by gases, removing contaminants before they reach the air intake without requiring complex active heating systems or additional energy input

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-generated harmful factors

If a hot filter assembly is added to burn contaminants, then emissions are reduced and engine performance is improved, but the device complexity increases

Engineering Contradiction:

ImproveemissionsVSAvoiddevice complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The hot filter assembly is merged with the exhaust manifold by positioning it against the hot surfaces of the manifold. This integration allows the filter assembly to utilize the waste heat from exhaust gases to burn contaminants passively, eliminating the need for separate heating systems, pumps, or control mechanisms while reducing emissions

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hot filter assembly is designed to self-heat using the thermal energy already present in the exhaust manifold. The system serves itself by using waste heat to perform the filtration function without requiring external energy input or complex control systems, thereby reducing device complexity while improving emissions

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If the hot filter assembly is positioned against the exhaust manifold, then passive heating and contaminant burning is achieved, but the positioning requirements increase installation complexity

Engineering Contradiction:

Improveenergy efficiencyVSAvoidinstallation ease

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The hot filter assembly is designed as a separate, modular component that can be independently manufactured and then installed against the exhaust manifold. This segmentation allows for standardized production of the filter assembly and flexible installation positioning, reducing manufacturing and installation complexity while maintaining the passive heating function

Inventive Principle:

Principle #1Segmentation

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 hot filter assembly effectively burns and filters out contaminants, resulting in reduced CO2, NOx, and particulate matter emissions, thereby improving engine performance and compliance with regulatory standards.

Implementation Method 1

the hot filter assembly can be configured to passively heat blow-by gases passing therethrough, thereby burning remaining contaminants in the gases from the crankcase due to its positioning against the exhaust manifold or turbine housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

burning remaining contaminants in the gases from the crankcase

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentEP4707554A1Apparatuses and methods for a closed crankcase ventilation system of an internal combustion engine

Publication Date: 2026.03.11 DAIMLER TRUCK NORTH AMERICA LLC

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AI summary

Described herein are engine systems, closed crankcase ventilation systems, and hot filter assemblies that are configured to filter out contaminants from the closed crankcase ventilation system prior to being returned to an air intake of the engine system. In some examples, a closed crankcase ventilation system can include an engine comprising a crankcase, an oil separator coupled to the crankcase, and a hot filter assembly coupled to the oil separator and mounted to an exhaust manifold of the engine or a turbine housing of a turbocharger. The hot filter assembly comprises a housing defining a cavity, a gas inlet fluidly coupled between the oil separator and the cavity, a gas outlet fluidly coupled between the cavity and an air intake of the engine, and at least one baffle extending across the cavity and defining a first and second gas pathways on opposite sides of the baffle.