Oil Air Separator System with Vertical Diffuser Screens
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Solution Overview
Problem
Existing oil and air separation systems in PCV systems allow oil vapors to escape through exhaust ports, contaminating the exhaust and degrading engine performance by lowering the octane of the combustion mixture and coating the air intake.
Innovation Solution
An oil and air separation system featuring a diffuser tube within a diffuser shield at the intake and vertically spaced diffuser screens at the exhaust, which prevents oil from flowing into the exhaust by using a modular design and filter materials to separate oil from blow-by gases, ensuring that oil collects in a reservoir and does not seep through the exhaust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single screen is used to hold filter material in the can, then the filter material is supported, but oil may flow along the screen to the exhaust port
Solution Approach 1:
The single screen is divided into two separate screens positioned at different vertical locations. The first screen is positioned higher to intercept oil flowing down the filter material, while the second screen is positioned lower to provide additional separation. This segmentation prevents oil from reaching the exhaust port by creating multiple barriers at different heights.
Solution Approach 2:
The solution adds a vertical dimension to the separation process by positioning screens at different heights rather than using a single horizontal screen. This creates a vertical gradient in the separation process, with oil being intercepted at higher positions before it can flow down to the exhaust port at lower positions.
2Reliability
If oil and air separator removes oil from blow-by gases, then engine performance is improved, but oil may still escape through the screen to exhaust
Solution Approach 1:
The separation system is segmented into multiple stages with two screens at different vertical positions. The first screen captures oil droplets as they form on the filter material, while the second screen provides a backup barrier. This multi-stage segmentation ensures oil is removed before it can escape to the exhaust, maintaining combustion mixture quality and octane level.
3Ease of manufacture
If traditional can design with single screen is used, then manufacturing is simple, but oil vapor contaminates exhaust
Solution Approach 1:
The can assembly is segmented to accommodate two screens at different heights, with each screen serving a specific function in the oil separation process. This segmentation maintains relative manufacturing simplicity while significantly improving exhaust quality by preventing oil vapor contamination through the dual-screen barrier system.
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
Effectively reduces the presence of oil in the exhaust, enhancing engine performance by maintaining the octane level and preventing airflow obstruction, while allowing clean air to enter the intake manifold.
Implementation Method 1
a diffuser tube positioned within a diffuser shield at a can intake for blow-by gases
Implementation Method 2
the oil is allowed to drop into the bottom of a can where the oil collects for later removal
Data Source
AI summary
An oil and air separation can includes: a diffuser tube positioned within a diffuser shield at a can intake for blow-by gases; and a first diffuser screen spaced vertically apart from a second diffuser screen proximate a can exhaust for blow-by gases, wherein the first diffuser screen and the second diffuser screen are spaced horizontally from the diffuser tube and extend about the diffuser shield.