Crankcase Evacuation Device Using Coalescing Material
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Solution Overview
Problem
Combustion engines generate undesired combustion by-products and pressures in the crankcase due to 'blow-by' gases, which existing ventilation systems do not effectively remove, leading to contamination and pressure issues.
Innovation Solution
A positive crankcase evacuation device (PCED) comprising an outer can, upper and lower lids, an internal frame with baffles, and coalescing material that condenses impurities within the crankcase gases, allowing for their drainage and return to the crankcase, effectively removing contaminants and managing pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a conventional crankcase ventilation system is used, then gases can escape from the crankcase, but combustion by-products and impurities are not effectively removed, leading to contamination
Solution Approach 1:
The patent introduces an intermediary device (the PCED canister with coalescing material) between the crankcase and the atmosphere. This intermediary captures and coalesces combustion by-products and impurities from the blow-by gases, separating them from the ventilation flow before discharge, thereby effectively removing contaminants while maintaining pressure balance
Solution Approach 2:
The patent employs coalescing material (a porous or fibrous medium) within the PCED canister. As blow-by gases pass through this material, impurities and combustion by-products are captured and coalesced into larger droplets that can be drained away, effectively filtering the gases while allowing ventilation to continue
2Stress or pressure
If positive crankcase ventilation is used to control internal pressure, then pressures are controlled, but impurities are not effectively separated and removed
Solution Approach 1:
The patent segments the crankcase ventilation system into two functional parts: the existing PCV valve that controls pressure by regulating gas flow, and the newly added PCED canister that handles impurity separation. This segmentation allows each component to specialize in its function - pressure control versus contaminant removal - thereby achieving both objectives simultaneously
Solution Approach 2:
The PCED canister acts as an intermediary component inserted into the ventilation pathway. It receives gases that have already been pressure-regulated by the PCV valve and further processes them by separating and removing impurities through the coalescing material, thus adding the impurity separation function without interfering with pressure control
3Stress or pressure
If blow-by gases are vented to control pressures, then internal pressures are managed, but contaminants accumulate in the crankcase
Solution Approach 1:
The patent implements a system where contaminants are discarded (separated and drained away from the crankcase) while the cleaned gases are recovered and returned to the crankcase or vented safely. The PCED canister continuously separates impurities from the blow-by gases, draining them away, thereby preventing contaminant accumulation while maintaining pressure management
Solution Approach 2:
The PCED canister serves as an intermediary that intercepts blow-by gases before they can deposit contaminants in the crankcase. It captures impurities through the coalescing material and drains them away, allowing only cleaned gases to be returned or vented, thus preventing contaminant buildup while maintaining pressure equilibrium
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 PCED efficiently removes impurities from the crankcase by condensing and draining them, reducing internal pressures and contaminants, thereby enhancing engine operation and performance.
Implementation Method 1
the gases can travel through the coalescing material, which can cause at least a portion of the impurities to convert to liquid form via condensation
Data Source
AI summary
A PCED can include an outer can, an upper lid having an upper lid intake and an upper lid exhaust, a lower lid having a lower lid exhaust, and an internal frame disposed within the can. With the internal frame disposed within the can, first, second, third, and fourth chambers can be formed, with the first chamber containing a coalescing material. Gases from a combustion engine crankcase can enter the PCED via the upper lid intake, move through the chambers, and exit the PCED via the upper lid exhaust and return to the crankcase. While moving through the chambers, impurities within the gas convert to liquid form via condensation, collect in the second chamber, and can be subsequently drained from the PCED via the lower lid exhaust.