Integrated Oil Scraper and Air/Oil Separator for Crankcase

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Solution Overview

Problem

Existing internal combustion engine designs face challenges in efficiently separating air from oil, leading to high casting complexity and increased power requirements for oil circulation, as they often require extensive channels and separate components for air/oil separation.

Innovation Solution

The integration of oil scrapers with air/oil separators, where the oil outlet openings are positioned above the oil level in the pan, eliminating the need for additional channels and pumps, and utilizing centrifugal force for automatic oil separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate air/oil separating elements and long channels are used, then air and oil separation is achieved, but casting complexity and space requirements increase

Engineering Contradiction:

Improveair-oil separation qualityVSAvoidcasting complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the air/oil separator and oil scraper into a single integrated component. The air/oil separator is formed as one piece with the oil scraper, eliminating the need for separate components and reducing casting complexity while maintaining effective air-oil separation functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component performs multiple functions simultaneously: it scrapes oil from the crankshaft, separates air from oil, and directs oil flow back to the oil pan. This multi-functionality reduces the number of separate components needed, simplifying the overall system while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate air/oil separating elements are used, then air and oil separation is achieved, but space requirements increase

Engineering Contradiction:

Improveair-oil separation qualityVSAvoidspace requirement

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

By merging the air/oil separator and oil scraper into a single integrated component, the patent significantly reduces the space required in the crankcase. The negligible spacing between the air/oil separator and oil scraper eliminates the need for additional channels, creating a compact configuration that fits within existing engine spaces.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If additional channels are integrated into the crankcase, then oil circulation is improved, but casting complexity increases

Engineering Contradiction:

Improveoil circulation efficiencyVSAvoidcasting complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent integrates the oil circulation function directly into the air/oil separator structure, which is formed as one piece with the oil scraper. This eliminates the need for separate additional channels in the crankcase, maintaining oil circulation efficiency while avoiding increased casting complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The high kinetic energies prevailing in the air/oil separator enable oil to be scraped off and returned automatically without requiring additional pumping channels. The system uses its own operational energy to drive oil circulation, eliminating the need for complex channel networks.

Inventive Principle:

Principle #25Self-service

4Speed

If oil is returned to oil pan with high kinetic energy, then oil return speed increases, but air content in oil increases

Engineering Contradiction:

Improveoil return speedVSAvoidair content in oil

Core Design Contradiction:

SpeedVSQuantity of substance

Solution Approach 1:

The integrated air/oil separator combines the separation function with the oil return function. As oil is scraped off the crankshaft and enters the air/oil separator, air and oil are separated immediately, then the oil is directed back to the oil pan through the integrated structure. This ensures oil returns quickly while maintaining low air content.

Inventive Principle:

Principle #5Merging (Combining)

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 results in a compact design that reduces space and casting complexity, ensures efficient oil return without resistance, and eliminates the need for additional components, enhancing the engine's reliability and operational efficiency.

Implementation Method 1

the air/oil separator is installed in a reclining manner. Yet this feature does not have a negative impact on its function, because the oil does not flow into said air/oil separator due to gravity, but rather due to high centrifugal force

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

the negligible spacing between the air/oil separator and the oil scrapers eliminates the need for a pump, since the oil is scraped off due to the high kinetic energies prevailing in the air/oil separator

Methodology Applied

Scientific EffectKinetic energy:

Implementation Method 3

to the density difference between air and oil allows the oil to be separated automatically, such an automatic oil separation being the goal

Methodology Applied

Scientific EffectDensity difference: Density Gradient

Data Source

PatentUS7472675B2Internal combustion engine

Publication Date: 2009.01.06 DR ING H C F PORSCHE AG

AI summary

An internal combustion engine includes a crankcase in which a crankshaft is rotatably mounted. Mechanisms are provided for scraping off the oil from the rotating crankshaft. An oil pan is arranged below the crankcase for holding the oil scraped off by the scrapers.