Springless Umbrella Valve Assembly for Crankcase Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crankcase pressure regulator systems in internal combustion engines rely on diaphragms and springs, which wear out over time and require frequent replacement, and are prone to pressure fluctuations due to atmospheric pressure changes.
Innovation Solution
A springless pressure regulator assembly with a moveable partition and valve assembly that adjusts the valve orifice orientation in response to pressure differentials between the crankcase and atmospheric chamber, maintaining a constant vacuum without the need for springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diaphragm and spring system is used to maintain constant vacuum, then the pressure regulator can control crankcase pressure, but the system requires many small moving parts that wear over time and need frequent replacement
Solution Approach 1:
The patent removes the spring component from the pressure regulation system entirely. The valve member is directly connected to the diaphragm, eliminating the need for springs and their associated moving parts. This extraction of the spring element reduces wear and maintenance requirements while maintaining pressure control functionality.
Solution Approach 2:
The valve member and diaphragm are directly connected and function as an integrated unit. The valve member is biased by the diaphragm's movement, combining what were previously separate components (valve mechanism and pressure sensing element) into a unified system with fewer moving parts.
2Reliability
If a diaphragm and spring system is used to maintain constant vacuum, then the pressure regulator can control crankcase pressure, but the springs wear over time and need to be replaced before failure
Solution Approach 1:
The spring component is completely removed from the system. The valve member is directly actuated by diaphragm movement, eliminating the spring's finite service life and replacement requirements. This extends the operational duration of the pressure regulation system.
3Adaptability or versatility
If atmospheric pressure changes occur, then the valve member moves to adjust pressure, but this causes pressure fluctuations in the crankcase
Solution Approach 1:
The diaphragm continuously senses pressure changes in the crankcase and provides feedback to the valve member. When atmospheric pressure changes cause pressure differentials, the diaphragm moves the valve member to adjust the orifice opening, creating a feedback control system that maintains stable crankcase pressure despite external variations.
Solution Approach 2:
The system automatically adjusts to pressure changes without external intervention. The diaphragm and valve member work together in a self-regulating mechanism where pressure differentials directly move the valve to compensate for changes, maintaining stable crankcase vacuum without requiring external control.
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 assembly effectively maintains a consistent crankcase pressure by adjusting the valve orifice orientation based on pressure changes, ensuring efficient operation and reducing the need for frequent maintenance.
Implementation Method 1
The partition is moveable in a first axial direction and a second axial direction opposite the first axial direction responsive to a change in a pressure differential between the pressure in the regulator chamber and the pressure in the atmospheric chamber
Data Source
AI summary
An integrated assembly includes a primary housing which carries the filter element. A partition resides in a secondary housing which seals off an atmospheric chamber from a pressure regulator chamber. The partition is moveable in a first axial direction and a second axial direction opposite the first axial direction response to a change in a pressure drop across the filter element. A valve assembly changes from a closed configuration to partially open configurations, and to a fully open configuration responsive to movement of the partition. The movement of the valve keeps a pressure in a crankcase downstream of said filter.