Separator Transfer Tube Drainage for Crankcase Ventilation

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Solution Overview

Problem

Existing separator systems for internal combustion engines require an additional drainage port for crankcase ventilation filters, which complicates manufacturing and increases space requirements, and often have inefficiencies in separating air and oil mixtures using dual liquid drain outlets.

Innovation Solution

A separator system with a housing containing a separator chamber and a coalescer chamber, where a separator in the separator chamber separates air and oil by inertial impaction and a coalescer filter element in the coalescer chamber separates air and oil by coalescence, utilizing a transfer tube and pressure differential to eliminate the need for a second liquid drain outlet, thereby simplifying the design and reducing space and manufacturing complexities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a dual stage separation system with separator chamber and coalescer chamber is used, then air and oil separation performance is improved, but the number of drainage ports increases and device complexity increases

Engineering Contradiction:

Improveair and oil separation performanceVSAvoidnumber of drainage ports

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the drainage functions of both the separator chamber and coalescer chamber into a single common drainage port. The transfer tube enables liquid from the separator chamber to be moved to the coalescer chamber, where both liquids are drained through the same port, thereby reducing the number of drainage ports from two to one while maintaining effective separation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transfer tube acts as an intermediary mechanism that transports pre-separated liquid from the separator chamber to the coalescer chamber. This intermediary device enables the consolidation of drainage functions, allowing liquids from both chambers to be managed through a single drainage port while preserving the dual-stage separation effectiveness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a second liquid drain outlet is added to the separator chamber, then liquid drainage capability is improved, but manufacturing complexity and space requirements increase

Engineering Contradiction:

Improveliquid drainage capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent merges the drainage operations of both chambers into a single drain outlet located in the coalescer chamber. By using the transfer tube to move liquid from the separator chamber to the coalescer chamber, the system maintains full drainage capability for both chambers while requiring only one drain outlet, thereby simplifying manufacturing and reducing space requirements.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If dual drainage ports are provided for separator and coalescer chambers, then drainage efficiency is improved, but housing space requirements and manufacturing costs increase

Engineering Contradiction:

Improvedrainage efficiencyVSAvoidhousing space requirements

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The transfer tube serves as an intermediary that enables efficient liquid transfer from the separator chamber to the coalescer chamber. This allows the system to maintain effective drainage for both chambers while using a single drain outlet, thereby reducing housing space requirements and manufacturing costs without sacrificing drainage efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively separates air and oil without the need for a second drainage port, enhancing manufacturing efficiency and space utilization while maintaining effective separation performance.

Implementation Method 1

a separator in a separator chamber separating gas and liquid by inertial impaction

Methodology Applied

Scientific EffectInertial impaction: Inertia

Implementation Method 2

a coalescer filter element in a coalescer chamber separating gas and liquid by coalescence

Methodology Applied

Scientific EffectCoalescence: Coagulation

Implementation Method 3

supplying the pre-separated liquid from the separator chamber through a transfer tube to the downstream subchamber

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS7776139B2Separator with transfer tube drainage

Publication Date: 2010.08.17 ATMUS FILTRATION IP INC

AI summary

A dual stage coalescer includes a separator in a separator chamber separating gas and liquid by inertial impaction, and a coalescer filter element in a coalescer chamber separating gas and liquid by coalescence. A transfer tube extends between the separator chamber and a downstream subchamber in the coalescer chamber at the downstream face of the coalescer filter element, and supplies pre-separated liquid from the separator chamber through the transfer tube to the noted downstream subchamber as driven by pressure differential between the separator chamber and the downstream subchamber, to eliminate a dedicated housing drain outlet from the separator chamber. The coalescer may provide a crankcase ventilation filter for an internal combustion engine having blowby gas containing an air-oil mixture.