AIR/OIL SEPARATOR ASSEMBLIES, COMPONENTS; AND, METHODS

FIELD OF DISCLOSURE

This disclosure relates to arrangements, systems, components, features and methods for separating hydrophobic fluids (such as oils), which are entrained as aerosols, from gas streams (for example air streams). Further, the arrangements also provide for filtration of other contaminants such as carbon material from the gas streams. The arrangements are typically used to filter crankcase ventilation gases from engine systems. Methods for conducting the separations are also provided.

BACKGROUND

Certain gas streams, such as engine blow-by gases (crankcase ventilation filter gases from engine crankcases) carry substantial amounts of entrained oil(s) (liquid) therein as aerosol. Often the oil (liquid) droplets within the aerosol are within the size of 0.1-5.0 microns.

In addition, such gas streams also carry substantial amounts of fine particulate contaminant such as carbon contaminant. Such contaminants often have an average particle size within the range of about 0.01-3.0 microns.

In some systems, it is desirable to vent such gases to the atmosphere. In general, it is preferred that before the gases are vented to the atmosphere, they be cleaned of a substantial portion of aerosol and/or organic particulate contaminant therein.

In other instances, it is desirable to direct the air or gas stream into equipment. When such is the case, it still can be desirable to separate aerosolized liquids and/or particulates from the stream during circulation, in order to provide such benefits as: reduced negative effects on the downstream equipment; improved efficiency; recapture of otherwise lost oil; and/or to address environmental concerns.

Improvements in crankcase ventilation filter systems, (i.e. blow-by or crankcase ventilation filter gas filtration systems) constructed for application with a variety of engine equipment systems are generally sought.

Herein improved features for such arrangements are provided, for convenience of installation, use, assembly and/or operation.

SUMMARY

According to the present disclosure, crankcase ventilation filter assemblies, features, components, and methods of assembly and use are provided to improve the prior art. Some of the features and methods described provide for convenient assembly; some for efficient space usage; and/or some for preferred operation.

There is no specific requirement that a crankcase ventilation filter assembly, component, feature, method of use or method of assembly include all of the features and techniques disclosed herein, in order to obtain some advantage. In general, selected use of the features and/or methods, without the use of others, can still lead to an advantageous system.

In an example system characterized herein, the cartridge is configured to provide for advantageous assembly, and for use with efficient utilization of the media pack positioned therein, relative to the vertical space available for installation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, cross-sectional view of a portion of a crankcase ventilation system, including cylinders and a filtration system;

FIG. 2 is a top view of the system of FIG. 1;

FIG. 3 is an enlarged, cross-sectional view of a portion of the system of FIG. 1, particularly showing the filtration system;

FIG. 4 is a cross-sectional view of the filter assembly used with the system in FIG. 1;

FIG. 5 is in an enlarged view of a portion of the filtration assembly of FIG. 4 shown in “detail D” of FIG. 4;

FIG. 6 is a perspective, cross-sectional view of the filter assembly of FIG. 4;

FIG. 7 is a top, perspective view of the housing used in the filtration assembly of FIG. 4;

FIG. 8 is an enlarged, cross-sectional view of a portion of the housing of FIG. 7;

FIG. 9 is a bottom, perspective view of the filter cartridge used in the filter assembly of FIGS. 4 and 6;

FIG. 10 is a top view of the filter cartridge of FIG. 9;

FIG. 11 is an enlarged, cross-sectional view of a portion of the filter cartridge of FIG. 10, the cross-section being taken along the line 11-11 of FIG. 10;

FIG. 12 is a cross-sectional view of the filter cartridge of FIG. 9, the cross-section being taken along the line 12-12 of FIG. 10;

FIG. 13 is a bottom, perspective view of the filter cartridge of FIG. 12;

FIG. 14 is an exploded, perspective of the filter cartridge of FIGS. 9, 10, 12 and 13;

FIG. 15 is an exploded, perspective view of first and second end pieces used in the filter cartridge of FIGS. 9, 10, 12, 13, and 14;

FIG. 16 is a perspective, cross-sectional view of the engine crankcase ventilation system of FIGS. 1 and 2;

FIG. 17 is an enlarged, perspective view of a portion of the system of FIG. 16, the portion being shown in “detail V” of FIG. 16;

FIG. 18 is a side view of the crankcase ventilation system, showing the cylinder head cover and filtration assembly, of FIGS. 1 and 2;

FIGS. 19 and 20 are side views of the crankcase ventilation system of FIG. 18, and showing steps of removing the filtration assembly from the cylinder head cover for servicing;

FIG. 21 is a cross-sectional, perspective view of the crankcase ventilation system of FIG. 1;

FIG. 22 is an enlarged, perspective, cross-sectional view of a portion of the system of FIG. 21, the portion being shown in “detail X” of FIG. 21;

FIG. 23 is an enlarged, cross-sectional view of a portion of the crankcase ventilation system shown at “Detail Z” in FIG. 1;

FIG. 24 is a cross-sectional view of the filtration assembly mounted on the cylinder head cover, the cross-section being taken along the line 24-24 of FIG. 2; and

FIG. 25 is an enlarged, cross-sectional view of a portion of the crankcase ventilation system of FIG. 1.

DETAILED DESCRIPTION
A. General Issues and Features

As indicated previously, the present disclosure relates, in general, to systems, arrangements, features, components and methods concerning crankcase ventilation filter assemblies. The Assignee of the present application is Donaldson Company, Inc. of Bloomington, Minn. As such, the application, in part, relates to other Donaldson Company, Inc. crankcase ventilation filter assemblies, including, for example, those described in WO 2007/053411; WO 2008/147585; WO 2008/115985; WO 2008/157251; and, WO 2009/018454; the complete disclosures of which each of being incorporated herein by reference.

The present disclosure relates to certain usable features for crankcase ventilation filter assemblies that can provide advantage relating to one or more of: assembly operation; assembly servicing; component operation and/or servicing; and/or, assembly or component generation, as described herein. There is no specific requirement that an assembly, component, feature, arrangement, system or method be applied with all of the detailed features as described herein, in order to obtain some benefit according to the present disclosure. This will be apparent from the descriptions herein, as well as a general understanding of the principles described.

As will be learned from detailed description herein below, many of the features depicted in the current assembly were developed, in part, for applications to enhance desirable crankcase ventilation filter assembly features and effects even when the installation location has limited vertical dimension for installation or when it is desirable to more efficiently use vertical space available. Indeed, herein example systems are described, and example dimensions are provided. However, there is no specific requirement that an assembly be constructed in accord with the specific dimensions provided in the example, nor is there a requirement that the principles only be applied in assemblies configured for installation in systems of similar limited vertical space. Nevertheless, many of the features depicted and described are particularly advantageous for applications involving limited vertical installation space and/or to take beneficial advantages of the vertical dimension of the space available.

B. Overview of Operation

In reference first to FIGS. 1-3, an engine crankcase ventilation system is shown generally at 40. While a variety of implementations are possible, in this example embodiment, the system 40 includes an engine having cylinders 42, a cylinder head cover 44 (also referred to herein as a rocker cover 44), oriented over the cylinders 42, and a gas/liquid filtration or separation assembly 46 (also referred to herein as a “filter assembly” or “filtration assembly.”) The cylinders 42 operate conventionally, and as part of the operation, produce blow-by gases. The blow-by gasses can carry oil, entrained as aerosol. The blow-by gases can also carry fine particulate contaminant, such as carbon contaminant. The gas/liquid filtration assembly 46 helps to coalesce the oil from the blow-by gases and return the oil to the engine crankcase. The air in the blow-by gases is filtered and cleaned, and then may be returned to the air intake of the engine turbo.

In general, in operation, blow-by gases from the cylinders 42 are directed into a regulator valve 48, then into the filtration assembly 46. The filtration assembly 46 coalesces oil from the blow-by gases, and the oil is collected in a drain arrangement 50 (FIG. 25), while the gas is cleaned and filtered. The cleaned gas is then directed out of the filter assembly 46, and may be directed into the air intake of a turbo of the engine; alternatively, it may be vented to the atmosphere. In the example embodiment shown, the drain arrangement 50 includes a valve arrangement 52 (FIG. 25) in communication with an opening 54 (FIG. 25) in the cylinder head cover 44. When pressure within the crankcase ventilation system 40 drops, such as when the engine is shut off, the valve arrangement 52 opens, and this allows the collected liquid, such as oil to flow from the valve arrangement 52 and into the engine. In some embodiments, the valves also work during engine running condition on pressure pulsations of the air stream.

In general, the gas/liquid separation assembly (filter assembly) 46 includes a filter cartridge 56 and a filter housing 58.

In one non-limiting example embodiment shown, the filter cartridge 56 is removable from and replaceable within the housing 58. The housing 58, including the filter cartridge 56, is removable from the cylinder head cover 44. In a preferred example, the cartridge 56 is removable without the use of tools from the head cover 44. One example of an implementation for the removability of the assembly 46 from the cylinder head cover 44 is shown in FIGS. 18-20. Removability of the filter assembly 46 from the cylinder head cover 44 allows for servicing of the system 40. More details of this are described below.

C. Example Filter Cartridge

In reference now to FIGS. 9-15, and independent of other features, an example embodiment of filter cartridge 56 is illustrated.

The filter cartridge 56 includes an extension of filter media 60. The filter media 60 can be arranged in various geometric forms.

In one non-limiting example, the filter media 60 can be tubular in shape with an inside tubular surface 62, and an outside tubular surface 64. By “tubular”, it is meant that the cross-section of the media 60 can be, for example, circular, oval, elliptical, square, square with rounded corners, rectangular, rectangular with rounded corners, racetrack-shaped, or any shape that forms a tube.

In the non-limiting embodiment illustrated, the cross-section of the filter media 60 is generally circular, so the inside tubular surface 62 is also an inside diameter, while the outside tubular surface 64 is also an outside diameter, as the media 60 is shown to be generally cylindrical in shape.

The media 60 has and defines a first axial end section 66 at one end, and a second axial end section 68 (FIG. 12) at the opposite end.

Independent of other features, the media 60 can be any type of media that is suitable for the intended function, and may be a multi-layer coil of media, such as glass or glass-free media. Also pre-formed media packs can be installed. One usable media includes Synteq XP media available from Donaldson Company, Bloomington, Minn.

Independently of above, the filter cartridge 56 can include a first end piece 70 (FIG. 14) and a second end piece 72 (FIG. 14). Preferably, the media 60 is positioned between the first end piece 70 and the second end piece 72.

In preferred embodiments, an axial length between the first axial end section 66 and second axial end section 68 is longer than a distance between the first end piece 70 and second end piece 72, such that there is an interference fit, including compression of the media 60 between the first and second end piece 70, 72.

The first end piece 72 can include a central flow aperture 74 therethrough and in gas flow communication with an open filter interior 65 of the filter media 60. The filter media 60 surrounds and defines the open filter interior 65.

Independent of the above, the first end piece 70 can include a perimeter rim 76. The perimeter rim 76 includes a portion 78 projecting radially from a position adjacent the inside tubular surface 62 and partially in extension along the first axial end section 66 toward the outside tubular surface 64.

Independently, as can be seen in FIGS. 9, 12, and 13, in the embodiment shown, the portion 78 does not extend the entire distance of the first axial end section 66 between the inside tubular surface 62 and outside tubular surface 64. Rather, the first axial end section 66 has an exposed media section 80 extending from the portion 78 of the rim 76 to the outside tubular surface 64. The exposed media section 80, as described below, forms a seal 82 with the housing 58, when the filter cartridge 56 is operably oriented in the housing 58.

In preferred embodiments, and independent of the above, the filter cartridge 56 is “seal member free,” which means that even though the exposed media section 80 forms a seal, the filter cartridge 56 has no additional part whose purpose is to form a seal. That is, the filter cartridge 56 is free of additional gaskets, O-rings, elastomeric seal members, plastic deformable ribs, or additional compressed media patches that serve to seal.

Independent of the above, the second end piece 72 is a closed end piece 84. In one example, the closed end piece 84 includes a closed external receiver 86 (FIG. 12) projecting into the open filter interior 65 and toward the first end piece 70. The external receiver 86 projects toward the first end piece 70 a distance from the second axial end section 68. The distance can vary depending on the particular application.

In one useful embodiment shown, the distance that the external receiver 56 projects from the second end piece 72 toward the first end piece 70 and first axial end section 66 is at least one-tenth of the overall diameter of the media 60; further, it is at least 20%, and typically 25-40% of the overall length of the media 60 between first axial end section 66, and second axial end section 68. In one embodiment, the actual dimension is about 15-20 millimeters.

Independently, the second end piece 72 further includes a media cover 104 surrounding the closed external receiver 86. The media cover 104 extends over the second axial end section 68.

In the embodiment shown, the filter cartridge 56 can include a liner 88 supporting the media 60 along the inside tubular surface 62. In the embodiment shown, the liner 88 extends between the first end piece 70 and the second end piece 72.

While a variety of embodiments are possible, and independent of the above, in one particularly preferred arrangement, the liner 88 is integral with the first end piece 70. The first end piece 70, including the perimeter rim 76, portion 78, and liner 88 can be part of a pre-form 90 that is made from a molded, plastic in advance. The liner 88 is porous to allow for the passage of gas flow from the media 60, through the liner 88, and into the open filter interior 65.

As can be seen in FIGS. 12, 13, 14, and 15, independent of the above, the perimeter rim 76 of the first end piece 70 includes drainage apertures 106. In operation, when the blow-by gases flow through the media 60, entrained oil and any other liquid present is coalesced by the media 60, and it flows by gravity in a direction toward the perimeter rim 76 of the first end piece 70, in which the drainage apertures 106 provide drainage holes allowing an escape path for the coalesced liquid or oil. In the embodiment shown, the drainage apertures 106 are evenly and circumferentially spaced in the rim 76 and immediately adjacent to the inner liner 88 and the inside tubular surface 62.

Independent of the above, the perimeter rim 76 has a free edge 77. When assembled as part of the filter cartridge 56, the free edge 77 is adjacent to the exposed media section 80. In some example embodiments, the free edge 77 can include a plurality of spaced projections 79. When arranged with a filter housing, the projections 79 can be part of a key arrangement 81 (FIGS. 7 and 9), which is explained further below.

Independent of the above, in preferred arrangements, the liner 88 and the second end piece 72 are attached. Many different ways are possible and in one example embodiment shown, the liner 88 and the second end piece 72 are attached by a snap-fit connection.

In FIG. 15, and independent of the above, it can be seen how on the second end piece 72, there is latch structure 92 projecting or extending from media facing surface 94 of the second end piece 72. The latch structure 92 can include a plurality of latches 96. The latches 96 can be arranged circumferentially, such that they can hook into the liner 88. In FIG. 11, there is an enlarged view showing one of the latches 96 hooked into or engaged with the liner 88. Of course, the structure could be reversed, and the liner 88 could have the hooks, while the second end piece 72 could have a circular open grid structure that receives the latches 96.

Independently, the liner 88 may include an indexing mechanism 98 to help orient the second end piece 72 properly on the liner 88. Many ways of indexing can be used. In the embodiment shown, the indexing mechanism 98 includes a plurality of circumferentially spaced ribs 100. In the example illustrated, the ribs 100 project into the open filter interior 65. In the embodiment shown, there are four ribs 100, which are received between spaced rib pairs 102 extending from the surface 94 of the second piece 72.

In FIG. 12, and independent of the above, it can be seen how the inner liner 88 extends axially a distance greater than the axial length of the media 60. The liner 88 can also project or extends past the perimeter rim 76. Between the perimeter rim 76 and the liner 88, a step 108 (FIG. 12) can be formed.

Independent of the above, in accordance with principles of this disclosure, there can be handle 110 (FIG. 12) for use in grasping and manipulating the filter cartridge 56. The handle 110 can project from the filter cartridge 56. The handle 110 can include a structure that allows for grasping and manipulation by a human hand, such that the filter cartridge 56 can be manipulated. The handle 110 is particularly convenient during servicing of the filter assembly 46, for example when the cartridge 56 is removed and replaced in the housing 58.

In the embodiment shown, independent of the above, the handle 110 is projecting from the second end piece 72. A variety of locations and geometric configurations can be used. In one non-limiting example, the handle 110 is projecting from the closed external receiver 86 of the second end piece 72.

Independently, the handle 110 can be a tab 112 extending or projecting from the cartridge 56. For example, the tab 112 can extend or project from the external receiver 86. Independent of the above, the tab 112 can project from the external receiver 86 by a distance that is not axially any greater than the media cover 104 of the second end piece 72.

D. Example Filter Assembly

In reference now to FIGS. 4-8, the filter assembly 46 is now discussed in greater detail. As mentioned previously, the filter cartridge 56 is operably assembled, preferably for selective replacement within filter housing 58.

Independent of the above features, the filter housing 58 includes a housing body 114 defining an open end 116 (FIG. 7). The housing 58 includes a service cover 118. The service cover 118 is preferably removable to selectively cover and uncover the open end 116. When the cover 118 is removed from the housing body 114, the filter cartridge 56 may be accessed. The filter cartridge 56 can be inserted and removed from the housing body 114 through the open end 116, when the service cover 118 is removed.

In reference to FIGS. 4 and 5, as mentioned previously, the filter cartridge 56 is operably positioned in the housing body 114. Independent of the above, the cartridge 56 can be operably positioned in the housing body 114, such that the exposed media section 80 of the first axial end section 66 of the media 60 is compressed against a portion, such as wall 120 of the housing 58 to form seal 82 therebetween. In this example, the wall 120 is a portion of a bottom wall 122 of the housing body 114.

Independent of the above, the cover 118 can include a projection arrangement 124 (FIG. 6). The projection arrangement 124 can be oriented to extend into the closed external receiver 86 of the second end piece 72.

Many embodiments of the projection arrangement 124 are possible. In one non-limiting example shown, the projection arrangement 124 is dish-shaped. The projection arrangement 124 can have a same outer general shape as that of the external receiver 86.

Independently, the projection arrangement 124 can include a protrusion 126. In non-limiting examples, the protrusion can extend in a direction from a base 128 of the dish 130 of the projection arrangement 124 and in a direction adjacent to the outside section 132 of the service cover 118. The outside section 132 is the section that surrounds the dish 130 forming the projection arrangement 124.

Independently, the projection arrangement 124 can be centered within the outside section 132. The protrusion 126 can extend from the base 128 of the dish 130 a length that does not extend beyond the outside section 132.

Independent of the above, the protrusion 126 can define and have a receiving pocket 134 therewithin. As can be seen in FIG. 6, the handle 110 can extend into the receiving pocket 134. The protrusion 126 can have an exterior shape that permits it to be manipulated with a tool, such as a wrench. By placing a wrench over the protrusion 126, the service cover 118 can be selectively tightened or loosened relative to the housing body 114.

Independently and as can be seen in FIG. 6, a seal member 214 between the cover 118 and the housing body 114 helps to form a seal 216 between the cover 118 and the housing body 114.

Independent of the above, the filter assembly 46 can include an outlet assembly 136. The outlet assembly 136 forms an air tube 138 between the open filter interior 65 and an area outside of the housing 58.

In some non-limiting implementations, the outlet assembly 136 is in air flow communication with the air intake for the turbo for the engine. In other non-limiting implementations, the outlet assembly 136 vents to the atmosphere.

Independent of the above, the outlet assembly 136 can include an air tube 138. The tube 138 can be a portion of the housing body 114.

The air tube 138 may include an open inlet end 140 (FIGS. 6 and 7), which is oriented within the open filter interior 65. The open inlet end 140 is adjacent to and spaced from the second end piece 72.

The outlet assembly 136 may include an open outlet end 142. The outlet end 142 can extend radially from a remaining portion of the housing 58. When the filter cartridge 56 is installed within the housing 58, the inlet end 140 of the outlet assembly 136 is within the open filter interior 65 while the outlet end 142 of the outlet assembly 136 is outside of the tubular section of media 60.

Independently, in FIG. 7, it can be seen how in the non-limiting example shown, the portion of the outlet assembly 136 that is located within the open filter interior 65 is non-circular in shape which may include an elongate snorkel 144.

In an non-limiting example of operation independent of the above, the location of the inlet end 140 of the snorkel 144 allows any further liquid in the filtered gas within the open filter interior 65 to coalesce and drop by gravity to the bottom wall 122, before the air that exits can reach the inlet end 140 located at an upper section of the open filter interior 65 and adjacent to the second end piece 72. Also, in a worst operation condition, if the filter cartridge 56 were to fill up with oil, oil will not run into outlet assembly 136 and then into the air intake, because of the high pick-up location of the inlet end 140 of the snorkel 144. The filtered air that reaches the inlet end 140 flows through the volume 146 (FIGS. 4 and 6) within the snorkel 144, and then turns a corner at a right angle to pass under the filter cartridge 56, within the volume 148, and then out past the end 142 of the outlet tube 138.

As can be seen in FIGS. 4, 6, and 7, and independent of the above, the bottom wall 122 of the housing body 114, which is at an end opposite of the open end 116, includes a plurality of stops or stand offs 150. The stand offs 150 extend from the bottom wall 122 and are oriented to hold the cartridge 56. In the example shown, there are a plurality of circumferentially spaced stand offs 150 extending or projecting from the bottom wall 122. The standoffs 150 can include holders or cradles 152 for engaging the first end piece 170.

In a non-limiting example, the stand offs 150 engage the inner liner 88 to hold the cartridge 56. This keeps the cartridge 56 off of the bottom wall 122, which allows for the draining and collection of oil, without having the filter media 60 be soaked in a pool of collected oil.

Independently, another function of the standoffs 150 is that they prevent the filter cartridge 56 from turning when the protrusion 126 on the cover 118 is turned to tighten the cover 126 on the housing body 114. By preventing the filter cartridge 56 from turning, the exposed media section 80 forming the seal 82 does not become damaged.

Independent of the above, the wall 120 may further include a plurality of discontinuous or intermittent spaced beads 91 (FIG. 7). The beads 91 extend or project from the wall 120. The beads 91 can help to hold the cartridge 56 off of the wall 120. When oil is drained and collected, the filter media 60 will not need to be resting within it and be soaked in a pool of collected oil.

As mentioned previously, the filter assembly 46 can include key arrangement 81, independent of the features above. The key arrangement 81 can be used to help align a filter cartridge 56 and the housing body 114. Independently, another feature of the key arrangement 81 can be preventing the filter cartridge 56 from turning, if the arrangement includes protrusion 126 on the cover 118 that is turned to tighten the cover 126 on the housing body 114. In that arrangement, the key arrangement 181 can prevent the filter cartridge 56 from turning so the exposed media section 80 forming the seal 82 does not become damaged.

Independently, one example of the key arrangement 81 includes the plurality of spaced projections 79, forming key projections 83 on the free edge 77 of the perimeter rim 76. The key arrangement 81 also includes a plurality of spaced key receivers 85. The key receivers 85 can be shaped to receive the key projections 83. As shown in FIG. 7, the key receivers 85 can be in the housing body 114. In one example, the key receivers 85 can be along the bottom wall 122 of the housing body 114. For example, the key receivers 85 can be in the housing body 114 in a location that is adjacent to the wall 120 (FIG. 6) of the housing body 114 where the seal 82 is formed with the filter cartridge 56.

A variety of embodiments are possible. In the example shown, and independent of the above, the key projections 83 are curved forming a portion of a circle. The key receivers 85 have the same or about the same shape in the form of recesses in the wall 120. Many embodiments are possible, and in the example shown in FIG. 13, spaced between the key projections 83 are straight segments 87.

Independent of the above, the bottom wall 122 may include as part of the drain arrangement 50 at least one drainage hole 154. In some example embodiments, there can be more than one drainage hole 154, and in the non-limiting example shown in FIG. 7, there are two drainage holes 154. Oil that is coalesced by the media 60 drains by gravity from along the inside tubular surface 62 and through the drainage apertures 106 in the perimeter rim 76. The oil flows by gravity to the surface 156 (FIG. 6) of the bottom wall 122 and is directed in a direction to the drainage holes 154.

Independently, the surface 156 may be shaped in a manner to encourage the flow of the liquid to the drainage holes 154. For example, the bottom wall 122 can include a bump or housing bottom wall projection 158 projecting in a direction toward the open end 116, such that any liquid that forms on the projection 158 will drain by gravity toward the surface 156 and eventually to the drainage holes 154. The drainage holes 154 and valve assembly 52 (described further below) are positioned on the lowest point of the filter assembly 46, even considering engine tilt angles during shut down (parking on a hill, etc.). The housing bottom wall projection 158 extends into the open filter interior of the cartridge 56 and also helps to orient the cartridge 56 within the housing 58.

As can be seen in FIGS. 3, 16, and 21, independently, the cylinder head cover 44 can include a matching bump or cylinder head cover projection 159 to nest within the housing bottom wall projection 158. This nesting of cover projection 159 of the cylinder head cover 44 within the housing bottom wall projection 158 of the housing 58 can help to locate and hold the housing 58 relative to the cylinder head cover 44.

In some non-limiting arrangements, the cylinder head cover projection 159 is provided to avoid interference with the injectors. In some arrangements, if no cylinder head cover projection 159 is needed, then the housing bottom wall projection 158 will not be needed, and the housing bottom wall 122 can be flat.

As mentioned previously, while there may be a single hole 154 or a plurality of holes 154, in the non-limiting example shown, there are two drainage holes 154. The drainage holes 154 can each include a drain tube 160, 161 (FIG. 4) in axial extension from the bottom wall 122.

Independent of the above, a valve assembly 52 can be provided. In a non-limiting example, each of the drain tubes 160, 161 can have a valve assembly 52 (FIG. 25) controlling the opening and closing of the drainage holes 154. The valve assembly 52 can be either built into each of the drain tubes 160, 161, or it can be part of the cylinder head cover 44. In one non-limiting example in FIG. 25, the drain tubes 160, 161 are removably sealed within a pair of openings 54 in the cylinder head cover 44. A seal member 162 is provided for sealing the drain tubes 160, 161. Many ways of sealing can be used, and in the example shown, the seal member 162 is held by and circumscribes each of the drain tubes 160, 161 to form a seal between the drain tubes 160, 161 and each opening 54 in the cylinder head cover 44. The valve arrangement 52 is shown as part of the cylinder head cover 44, but in other embodiments are possible, including the valve arrangement 52 being part of the housing body 114.

A variety of different types of valves can be used. In the non-limiting example shown in FIG. 25, the valve arrangement 52 is an umbrella valve 164. In this embodiment, the umbrella valve 164 for each drain hole 154 is held by and built into the cylinder head cover 44. In operation, liquid, such as oil, drains to the surface 156 of the bottom wall 122 and through the drain holes 154 to the interior of the drain tubes 160, 161. The oil stays collected therein, and blocked from flowing further due to the umbrella valve 164. When the air pressure conditions within the crankcase ventilation system 40 changes, such as when the engine shuts off, the umbrella valve 164 opens, which allows the collected liquid to flow between an opening of the valve head 166 and the cylinder head cover 44, which allows the liquid to flow back into the engine. Changes in the crankcase ventilation system 40 that could cause the valve 164 to open includes, for example, a pressure drop in the system 40, or a pressure pulsation in the system 40. The valve 164 will open when the pressure conditions within the system 40 change beneficially for oil drainage.

Independent of the above, the filter housing 58 further includes an inlet tube 168. Many different embodiments are possible. In one non-limiting example, the inlet tube 168 can extend from a side wall 170 of the housing body 114. The inlet tube 168 can be in gas flow communication with an outlet of the regulator valve 48 (FIG. 3). A seal member 172 forms a seal between the inlet tube 168 and the portion of the cylinder head cover 44 holding the regulator valve 48.

As can be seen in FIGS. 4, 6, and 7, and independent of the above, there can be a baffle or barrier 174 built into the housing body 114 adjacent to where the filter cartridge 56 is situated and at the end of the inlet tube 168, to protect the media 60 from being directly impacted or bombarded with the gas flow directly from the inlet tube 168. Therefore, the gas flow through the inlet tube 168 hits the barrier 174, instead of the media 60 at that location, and the air flow must then be directed upwardly and radially around the media in a direction toward the open end 116 and to other portions of the media 60.

In reference now to FIG. 24, independent of the above, the filter assembly 46 can further include a bypass valve assembly 176. Many embodiments are possible, and a non-limiting example is shown in FIG. 24. In FIG. 24, the bypass valve assembly 176 extends from the side wall 170 of the housing body 114. If the media 60 becomes clogged or occluded, pressure on the valve head 178 will act against the spring 180 and allow an open passage between the housing body 114 and the valve head 178, which will then allow for the air to exit the filter assembly 46 through relief opening 182. In some example embodiments, the bypass valve assembly 176 can have an outside tube 177 that is shaped to be connectable to a hose to evacuate the gases escaping in bypass mode away from the engine or engine bay. The bypass valve assembly 176 can be circumferentially spaced from the inlet tube 168.

Independent of the above, the filter assembly 46 can further include a connection arrangement 190 constructed and arranged to permit the housing 58 to be selectively attached and removed from the cylinder head cover 44 of an engine. Many different types of connection arrangements 190 can be used including a variety of fasteners (e.g., screws, bolts).

In the embodiment shown in FIGS. 4 and 6, and independent of the above, the connection arrangement 190 allows for attachment and removal without the use of tools.

In the non-limiting example shown in the drawings, the connection arrangement 190 can include a latch member 192. The latch member 192 can be cantilevered from a remaining portion of the housing 58. In the non-limiting arrangement shown, the latch arrangement 192 extends from a remaining portion of the housing 58 in an axial direction away from the open end 116 of the housing 58.

For example, independent of the above, in the illustrated embodiment, the latch member 192 can extend from the bottom wall 122 in an axial direction away from the open end 116 of the housing 58. The latch member 192 can include a hook 194 that engages a latch keeper 196, such as a catch 198 in the cylinder head cover 44. See FIG. 17. The latch member 192 may include a projection 200. The projection 200 may include operating instructions, such as “push” to inform a person how to disengage the latch arrangement 190. By pushing on the projection 200, the hook 194 is moved away from the catch 198, which then allows the filter housing 58 to be moved away and off of the cylinder head cover 144, without the use of tools.

In one non-limiting example embodiment, the latch member 192 can extends a distance from the bottom wall 122 that is about 40-60% of the overall height of the housing 58 between the cover 118 and an end of the drain tubes 160, 161. The distance can vary.

Independent of the above, FIGS. 18-20 illustrate steps in servicing the filter assembly 46 by removing it from the cylinder head cover 44. The latch member 192 can be pushed to release the latch member 192 from the cylinder head cover 44. In FIG. 19, it can be seen how the housing 58 can be tilted vertically, upwardly and away from the cylinder head cover 44 at an angle relative to the cylinder head cover 44 of not greater than 30 degrees and generally a vertical distance of not greater than 20 millimeters. These angles and distances may be particularly advantageous in arrangements where there is limited vertical space for servicing. After the housing 58 is tilted, the housing 58 can be moved laterally from the cylinder head cover 44. During the step of removing the housing 58 from the cylinder head cover 44, the housing 58 can be unsealed from between the housing inlet tube 168 and the cylinder head cover 44, and unsealed from between the housing drainage tubes 160, 161 and the cylinder head cover 44.

E. Other Features of the System

Independent of the above, the cylinder head cover 44 may include a blow-by outlet 202 (FIG. 23). The regulator valve 48 can be positioned to cover the blow-by outlet 202. The regulator valve 48 may be in fluid communication with the inlet tube 168 of the filter assembly 46 (See FIG. 3). The regulator valve 48 can includes a valve member 204 in the form of a diaphragm that is biased by spring 206. A removable cover 208 can allows for access to the regulator valve 48. The regulator valve 48 helps to regulate the flow of blow-by and control the pressure level in the crankcase from the engine to the filter assembly 46. As can be seen in FIGS. 1, 3, and 23, the valve member 204 of the regulator valve 48 can be mounted on a portion of the cylinder head cover 44 constructed to hold the valve member 204.

The blow-by outlet 202 may include a pre-separator 209 to help with separating liquid from gas before flowing into the filter assembly 46. In the non-limiting example shown, the pre-separator 209 is illustrated as a vaned splash guard 210. The splash guard 210 can include vanes 212 to help prevent liquid, such as oil from splashing or flowing directly through the blow-by outlet 202. The vanes 212 may help to coalesce liquid in the blow-by aerosol before it flows into the regulator valve 48. A variety of embodiments are possible, and the example shown is non-limiting.

F. Methods

Periodically, the gas/liquid separation filter assembly 46 will need servicing. In a method of servicing and independent of the above, the filter housing 58 is removed from the cylinder head cover 44 by releasably detaching the housing 58 from the cylinder head cover 44.

In one non-limiting example, the step of releasably detaching includes releasing the latch member 192 connecting the housing 58 and the cylinder head cover 44.

The filter cartridge 56 is replaced within the housing 58 with a new filter cartridge.

The housing 58 is secured to the cylinder head cover 44 by releasably attaching the housing 58 to the cylinder head cover 44. In a non-limiting example, the step of releasably attaching can include engaging the latch member 192 to connect the housing 58 and the cylinder head cover 44.

The step of removing the housing 58 can include pushing the latch member 192 that is integral with the housing 58 to release the latch member 192 from the latch keeper 196 on the cylinder head cover 44.

The step of removing the housing 58 from the cylinder head cover 44 can include unsealing the housing 58 from between the housing inlet tube 168 and the cylinder head cover 44, and also unsealing the housing 58 from between a housing drainage tube arrangement 160, 161 and the cylinder head cover 44.

The step of replacing the filter cartridge 56 can include removing the cover 118 of the housing 58, grasping the handle 110 projecting from the cartridge 56, and then pulling the cartridge 56 from the housing 58.

A new filter cartridge can be installed in the housing 58, and the new filter cartridge also can have a projecting handle 110.

The cover 118 can be replaced by orienting projection arrangement 124 of the cover 118 into the external receiver 86 of the new filter cartridge 56 and allowing the projecting handle 110 of the new filter cartridge 56 to extend into receiver pocket 134 of the protrusion 126 of the cover 118.

The cover 118 can be pressed against the filter cartridge 56 to form seal 82 between and against the exposed media section 80 at the first axial end section 66 and the bottom wall 122 of the housing 58. As can be seen in FIG. 6, seal member 214 helps to form seal 216 between the cover 118 and the housing body 114.

The step of securing the housing 58 to the cylinder head cover 44 may include forming sealing connections between the housing inlet tube 168 and the cylinder head cover 44; and a housing drainage tube arrangement, which includes drain tubes 160, 161, and the cylinder head cover 44.

The step of securing may include tilting the housing 58 away from the cylinder head cover 44 at an angle not greater than 30 degrees between the bottom wall 122 of the housing 58 and the cylinder head cover 44.

The step of replacing a filter cartridge can include removing the cartridge 56 from the housing 58 and then inserting a new filter cartridge in the housing 58. Independent of the above, the new filter cartridge can include a plurality of spaced key projections 83. There can be a step of orienting the spaced key projections 83 into a plurality of spaced key receivers 85 in the housing 58.

A method of filtering a crankcase ventilation system can use the structure as described above. The method can include directing blow-by gases into the blow-by outlet 202 of the cylinder head cover 44, and then through the regulator valve assembly 48.

The blow-by gases can be directed from the regulator valve assembly 48 and into the inlet tube 168 of the housing 58 of the filtration assembly 46.

The blow-by gases can be directed from the inlet tube 168 and through the media 60 in the filter cartridge 56. The media 60 can coalesce liquid from the blow-by gases.

The coalesced liquid may drain from the media 60 by gravity to the bottom wall 122 of the housing 58 and into the drain arrangement, which can include drainage holes 154.

The drain arrangement 50 may include valve arrangement 52 in communication with opening 54 in the cylinder head cover 44.

There can be a step of directing gas that passes through the media 60 and into outlet tube 138 and then outside of the housing 58.

There can be the step of collecting the coalesced liquid in the drain arrangement 50, specifically, in the drain tubes 160, 161 until pressure within the crankcase ventilation system changes, which allows the valve arrangement 52 to open, permitting the liquid to flow back into the engine.

G. Example Dimensions

Example dimensions of usable embodiments are described. These are example only, and variations in the dimensions are possible.

The housing 58 can have an overall diameter of about 180 mm; a length from the service cover 118 to an end of the drain tubes 160, 161 of about 87 mm; and a length from the service cover 118 to a free end of the latch member 192 of about 131 mm.

The filter cartridge 56 can have an overall diameter of about 150 mm and an overall length (height) of about 58 mm. The media 60 can have a length (height) of about 50 mm. The aspect ratio of the filter cartridge (diameter: length (height)) is about 2-3.25, and in many instances 2.5-3.0.

H. Example Principles

A filter cartridge for use in gas/liquid separation; the filter cartridge comprises an extension of filter media surrounding an open filter interior; the filter media can have an inside surface, an outside surface, a first axial end section, and second axial end section.

There can be a first end piece.

There can be a second end piece.

The media can be positioned between the first and second end pieces.

The first end piece can have a central flow aperture therethrough in gas flow communication with the open filter interior.

The first end piece can include a perimeter rim.

The perimeter rim can have a portion projecting radially from a position adjacent the filter media inside surface and partially in extension along the first axial end section toward the filter media outside surface. The first axial end section can have an exposed media section extending from the perimeter rim to the filter media outside surface; the exposed media section forming a seal with a housing, when the filter cartridge is operably oriented in a housing.

The second end piece can be on the second axial end section of the filter media.

The second end piece can be a closed end piece.

The second end piece can have a closed external receiver therein projecting into the open filter.

The second end piece receiver may project toward the first end piece a distance from the second axial end section.

A liner can support the media along the filter media inside surface.

The liner may extend between the first end piece and second end piece.

The liner can be integral with the first end piece.

The liner and the second end piece are snap-fit together.

A handle can project from the filter cartridge.

The handle can project from the second end piece.

The handle may project from the closed external receiver of the second end piece.

The second end piece can include a media cover surrounding the closed external receiver; the media cover extending over the second axial end section of the media.

The handle may extend from the filter cartridge an axial distance no greater than the media cover of the second end piece.

The perimeter rim of the first end piece can include drainage apertures.

The perimeter rim may have a free edge adjacent to the exposed media section.

The free edge can include a plurality of spaced projections.

The media may have a multi-layer coil of media or pre-formed media.

A gas/liquid separation assembly comprises a filter cartridge and a housing including a housing body that can have an open end and a removable cover over the open end.

The filter cartridge can be operably positioned in the housing body with the exposed media section of the first axial end section of the media compressed against a wall of the housing to form a seal therebetween.

The second end piece may have a closed external receiver therein projecting into the open filter and toward the first end piece a distance from the second axial end section.

The cover can include a projection arrangement extending into the closed external receiver of the second end piece.

The cartridge can include a handle projecting from the closed external receiver of the second end piece.

The projection arrangement of the cover can include a protrusion with a receiving pocket; the handle extending into the receiving pocket.

An outlet assembly can be in airflow communication between the open filter interior and an area outside of the housing.

The outlet assembly can include an air tube in the housing body; the air tube can have an open inlet end adjacent and spaced from the second end piece and can be oriented within the open filter interior, and an open outlet end extending from the housing.

The housing can include a bottom wall at an end opposite of the open end.

The bottom wall may include standoffs extending from the bottom wall.

The standoffs can be holding the cartridge.

The standoffs can engage a liner supporting the media along the filter media inside surface.

The bottom wall of the housing can include at least one drainage hole.

The bottom wall of the housing can include a plurality of drainage holes.

Each drainage hole may be defined by a respective drain tube in axial extension from the bottom wall.

The bottom wall can include a housing bottom wall projection extending into the open filter interior.

The housing can include an inlet tube.

The inlet tube can extend from a sidewall wall of the housing.

A bypass valve assembly may extend from the housing.

The bypass valve assembly can extend from a sidewall of the housing and can be circumferentially spaced from the inlet tube.

A connection arrangement may be constructed and arranged to permit the housing to be selectively attached and removed from a cylinder head cover of an engine.

The connection arrangement can include a latch member cantilevered from a remaining portion of the housing.

The latch member can extend from the remaining portion of the housing in an axial direction away from the open end of the housing.

The housing can include a bottom wall at an end opposite of the open end.

The latch member may extend from the bottom wall in an axial direction away from the open end of the housing.

A key arrangement can be provided to align the filter cartridge and the housing body.

The key arrangement may include a plurality of spaced key projections on a free edge of the perimeter rim.

The key arrangement may include a plurality of spaced key receivers in the housing body shaped to receive the key projections.

The spaced key receivers in the housing body are adjacent to the wall of the housing body forming the seal with the filter cartridge.

A system for gas/liquid separation for an engine crankcase may comprise an engine with cylinders producing blow-by gases; and a cylinder head cover oriented over the cylinders; and a gas/liquid separation assembly operably assembled on the cylinder head cover in fluid communication with the blow-by gases of the engine.

The cylinder cover can include a blow-by outlet.

A regulator valve assembly can cover the blow-by outlet.

The regulator valve assembly can be in fluid communication with an inlet tube of the housing of the gas/liquid separation assembly.

The blow-by outlet can include a pre-separator.

The cylinder head cover can include a receiving hole arrangement.

The receiving hole arrangement can be in fluid communication with the at least one drainage hole in the bottom wall of the housing.

A valve arrangement can be positioned in the receiving hole arrangement in the cylinder head cover; the valve arrangement controlling flow of liquid from the at least one drainage hole in the bottom wall of the housing.

The cylinder head cover can include a latch keeper constructed and arranged to receive and engage a latch member on the housing.

A method of servicing a gas/liquid separation assembly of an engine crankcase can include a step of removing a gas/liquid filter housing from a cylinder head cover by releasably detaching the housing from the cylinder head cover.

The method of servicing can include replacing a filter cartridge within the housing with a new filter cartridge.

The method of servicing can include securing the housing to the cylinder head cover by releasably attaching the housing and the cylinder head cover.

The step of releasably detaching the housing from the cylinder head cover can include releasing a latch connecting the housing and the cylinder head cover.

The step of securing the housing to the cylinder head cover by releasably attaching the housing and the cylinder head cover can include engaging the latch to connect the housing and the cylinder head cover.

The step of releasably detaching the housing can include pushing a latch member that can be integral with the filter housing to release the latch member from a latch keeper on the cylinder head cover.

The step of removing the gas/liquid filter housing from the cylinder head cover may include unsealing the housing from between a housing inlet tube and the cylinder head cover; and unsealing the housing from between a housing drainage tube arrangement and the cylinder head cover.

The step of removing the gas/liquid filter housing can include tilting the housing vertically upwardly away from the cylinder head cover not more than 20 mm.

The step of removing the gas/liquid filter housing can include tilting the housing at an angle between the housing and cylinder head cover of not greater than 30°, and then moving the housing laterally from the cylinder head cover.

The step of replacing a filter cartridge can include removing a cover of the housing; grasping a handle projecting from the cartridge; pulling the cartridge from the housing.

The step of replacing a filter cartridge can include inserting a new filter cartridge in the housing can have a projecting handle.

There can be a step of replacing the cover by orienting a projection arrangement into an external receiver of the new filter cartridge and allowing the projecting handle of the new filter cartridge to extending into a receiver pocket of a protrusion of the cover.

There may be the step of pressing the cover against the filter cartridge to form a seal between and against exposed media at an axial end and a bottom wall of the housing.

The step of securing the housing to the cylinder head cover can include forming sealing connections between (i) a housing inlet tube and the cylinder head cover; and (ii) a housing drainage tube arrangement and the cylinder head cover.

The step of securing can include tilting the housing away from the cylinder head cover at an angle not greater than 30°.

The step of replacing a filter cartridge can include removing the cartridge from the housing.

The step of replacing a filter cartridge can include inserting a new filter cartridge in the housing.

The new filter cartridge can include a plurality of spaced key projections.

The step of replacing a filter cartridge can include orienting the spaced key projections into a plurality of spaced key receivers in the housing.

A method of filtering a crankcase ventilation system can comprise directing blow-by gases into a blow-by outlet of a cylinder head cover and through a regulator valve assembly; directing the blow by gases from the regulator valve assembly into an inlet tube of a housing of gas/liquid separation assembly; the gas/liquid separation assembly including a filter cartridge operably sealed therein; directing the blow-by gases from the inlet tube through media in the filter cartridge and coalescing liquid from the blow by gases; allowing the coalesced liquid to drain from the media to a bottom wall of the housing and into a drain arrangement; the drain arrangement including a valve arrangement in communication with an opening in the cylinder head cover; directing gas that passes through the media into an outlet tube and outside of the housing; and collecting the coalesced liquid in the drain arrangement until pressure conditions within the crankcase ventilation system changes, allowing the valve arrangement in the drain arrangement to open, allowing the liquid to flow into the engine.

The step of allowing the coalesced liquid to drain from the media to a bottom wall of the housing and into a drain arrangement can include draining the liquid into a valve arrangement which can have a valve secured to the cylinder head cover.

The method can include putting a filter cartridge into a housing through an open end of the housing.

The filter cartridge can have an extension of filter media surrounding an open filter interior; the filter media can have an inside surface, an outside surface, a first axial end section, and second axial end section.

The filter cartridge can have a first end piece including a perimeter rim.

The first axial end section can have an exposed media section extending from the rim to the filter media outside surface.

The method can include axially compressing the filter cartridge against a wall of the housing to form a seal between and against the exposed media section of the filter cartridge and the wall of the housing.

The step of axially compressing can include placing a cover over the open end of the housing; securing the cover to the housing; and while securing the cover, axially compressing the filter cartridge against the wall of the housing with the cover.

A gas/liquid separation assembly can comprise a housing including an inlet, an gas outlet, a liquid drain arrangement, and a connection arrangement.

The connection arrangement can be constructed and arranged to permit the housing to be selectively attached and removed from a cylinder head cover of an engine without the use of tools.

A filter cartridge can be removably sealed within the housing.

The housing can include a removable cover selectively exposing an open end of the housing to allow access to the filter cartridge.

The liquid drain arrangement can include at least one drainage hole in the bottom wall of the housing.

The connection arrangement can include a latch member cantilevered from a remaining portion of the housing.

The housing can include a bottom wall at an end opposite of the open end.

The connection arrangement can include a latch member extending from the bottom wall in an axial direction away from the open end of the housing.

A system for gas/liquid separation for an engine crankcase can comprises an engine with cylinders and producing blow-by gases; a cylinder head cover oriented over the cylinders; and a gas/liquid separation assembly supported by and releasably attached to the cylinder head cover by the connection arrangement, such that the assembly can be in fluid communication with the blow-by gases of the engine.

The above specification includes examples of embodiments and principles of this disclosure. Many embodiments can be made applying these principles.

	Number	Date	Country
	61549471	Oct 2011	US
	61576080	Dec 2011	US

AIR/OIL SEPARATOR ASSEMBLIES, COMPONENTS; AND, METHODS

Information

Publication Number

Date Filed

Date Published

Inventors

CPC

US Classifications

International Classifications

Abstract

Description

Claims

Parent Case Info

PCT Information

Provisional Applications (2)