PCV Separator Fastening for Sealing and Tamper-Resistant Removal
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Solution Overview
Problem
The existing blow-by gas treatment devices for internal combustion engines face challenges in maintaining sealing performance while making it difficult to remove the PCV separator, as the fastening mechanism with bolts complicates both the installation and removal processes.
Innovation Solution
The proposed solution involves a blow-by gas treatment device with a PCV separator fastened using a combination of break head bolts and unbreakable flange bolts, where the break head bolt is designed to separate upon reaching a certain torque, making it difficult to remove the PCV separator, while the unbreakable flange bolts ensure strong fastening and sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the PCV separator is fastened to the engine component with multiple break head bolts, then it becomes difficult to remove the PCV separator, but the sealing performance may decrease due to the complex fastening mechanism
Solution Approach 1:
The fastening system is segmented into two types of bolts: break head bolts (first bolts) that break after tightening to prevent removal, and unbreakable head bolts (second bolts) that maintain continuous fastening force. This segmentation allows different bolts to serve different functions - one for security against removal and another for maintaining sealing performance.
Solution Approach 2:
Different regions of the fastening system are assigned different bolt types based on local requirements. The break head bolts are positioned at specific locations where removal prevention is critical, while unbreakable head bolts are positioned at locations where continuous fastening force is needed to maintain sealing performance around the sealant.
2Ease of operation
If only break head bolts are used to fasten the PCV separator, then it becomes difficult to remove, but the cost and complexity of the fastening system increases
Solution Approach 1:
The fastening system is divided into two groups of bolts with different characteristics. The break head bolts provide the removal prevention function, while the unbreakable head bolts provide the continuous fastening function. This segmentation allows each type of bolt to be optimized for its specific function rather than requiring all bolts to have all functions.
Solution Approach 2:
The break head bolts are designed as disposable components that break after serving their purpose of preventing removal. Once broken, they cannot be reused, but this is acceptable since the PCV separator itself would need to be removed and reinstalled. This approach is more economical than using expensive unbreakable bolts for all positions.
3Reliability
If the sealant is provided around each gas hole in the PCV separator, then sealing performance is ensured, but the manufacturing complexity increases
Solution Approach 1:
The sealant application is localized to specific regions around the gas holes where sealing is most critical. Rather than applying sealant uniformly across the entire flange surface, the sealant is concentrated at the gas hole perimeters where blow-by gas leakage is most likely to occur, optimizing sealing effectiveness while reducing material usage and application complexity.
Data Source
AI summary
A blow-by gas treatment device for an internal combustion engine includes: a positive crankcase ventilation (PCV) separator configured to be fastened to the internal combustion engine with a plurality of bolts; and one of a single sealant or a plurality of sealants configured to seal gas leakage of blow-by gas from a gap between the internal combustion engine and the PCV separator; wherein the plurality of bolts includes at least one break head bolt and three or more unbreakable head bolts, the unbreakable head bolt being a bolt in which a bolt head is not separated even when a fastening torque corresponding to a tightening torque applied to the break head bolt is applied to the bolt head.