Vortex and Spring-Tongue Oil Separator for Engine Blow-by Gas

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Solution Overview

Problem

Existing oil separator arrangements for internal combustion engines are costly due to the need for complex control elements and experience significant pressure losses at varying volume flows, particularly at high volumes.

Innovation Solution

The proposed solution involves a vortex chamber separator with an open gas inlet and outlet, and a spring-tongue oil separator with a downstream baffle wall, which automatically adjusts to volume flows without additional control elements, ensuring a non-exponential pressure loss characteristic over a large volume-flow range by leveraging the blow-by-gas pressure to open or close the spring tongue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If control elements (valves, switch elements) are added to oil separators to control volume flow, then oil separation effectiveness is improved, but device complexity and production costs increase

Engineering Contradiction:

Improveoil separation effectivenessVSAvoidcontrol elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The vortex chamber separator and spring-tongue separator automatically adjust their flow resistance and opening degree based on the blow-by-gas pressure and volume flow themselves, without requiring external control elements. The system self-regulates by leveraging the physical properties of the gas flow to control the separation process

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention removes all control elements (valves, switch elements, sensors) from the oil separator arrangement, extracting the problematic components that caused complexity and cost increases while maintaining separation effectiveness through passive physical design

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If helically rotating gas vortices are generated in cyclone separators, then oil separation is enhanced, but pressure loss increases exponentially at high volume flows

Engineering Contradiction:

Improveoil separation efficiencyVSAvoidpressure loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention divides the oil separation function into two distinct segments: the vortex chamber separator handles low-volume-flow separation with minimal pressure loss, while the spring-tongue separator handles high-volume-flow separation with linear pressure loss characteristic, together covering the full operating range without the exponential pressure loss of traditional cyclones

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using helically rotating vortices that cause exponential pressure loss increase, the invention inverts the approach by using a spring-tongue mechanism that opens with increasing volume flow to maintain a non-exponential (linear) pressure loss characteristic while still achieving effective separation

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If multiple oil separators are connected in parallel with individual control elements, then separation capacity over large volume-flow range is improved, but production costs increase

Engineering Contradiction:

Improveseparation capacity rangeVSAvoidproduction costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention merges two different separator types (vortex chamber separator and spring-tongue separator) into a single parallel arrangement that collectively provides separation capacity over the entire volume-flow range, eliminating the need for multiple controlled separators and reducing production costs

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration achieves effective oil separation with minimal pressure losses at low volume flows and maintains high separation efficiency at higher flows, eliminating the need for additional control elements and reducing production costs.

Implementation Method 1

a vortex chamber separator with an open gas inlet and outlet, which automatically adjusts to volume flows without additional control elements

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

each oil separator comprising a cantilever leaf spring with one end fixed, said leaf spring automatically opening a gas inlet opening as a function of the pressure of the blow-by-gas present

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

Oil particles are separated by inertia on account of the deflection of the gas at the wall surrounding the tip of the spring tongue

Methodology Applied

Scientific EffectInertia: Inertia

Data Source

PatentUS7842115B2Oil separator arrangement and cylinder head cover for an internal combustion engine

Publication Date: 2010.11.30 DICHTUNGSTECHN G BRUSS

AI summary

An oil separator arrangement for an internal combustion engine incorporates a vortex chamber oil separator with a vortex chamber extending in a longitudinal direction, where the vortex chamber includes a wall extending in a longitudinal direction, a gas inlet, and a gas outlet opening. The gas inlet is disposed tangential to the wall for tangentially blowing-in of blow-by-gas into the vortex chamber, so that at least one gas vortex flow rotating helically along the wall in the longitudinal direction is generated, where at least one further oil separator is connected in parallel to the vortex chamber oil separator. The further oil separator incorporates a separation chamber with an inlet-side spring tongue automatically controlled by the applied blow-by-gas, and a baffle wall disposed downstream the spring tongue.