Patent Application
20150083655
The present invention relates to an oil deterioration prevention device. Specifically, the invention relates to an oil deterioration prevention device with an improved trapping effect on deterioration products of oil and with reduced oil flow resistance to prevent an increase in pressure loss.
A known conventional filter element is made from fibers, and fine particles (for example, hydrotalcite and the like) for removing carbon, acid, deterioration products and the like produced in the internal combustion engine (see, for example, Patent Literature 1). In an oil filter that uses this filter element, for example, as shown in
Another known filter uses a filter element obtained by molding an adhesive, processed fiber material and a filter element material containing sepiolite while applying heat (see, for example, Patent Literature 2). With the use of sepiolite, this filter can provide an excellent trapping effect on oil impurities, too. Therefore, it is suitable for lubricating car engines, in particular.
Patent Literature 1: JP A H03-296408
Patent Literature 2: JP A 2001-38119
However, the conventional oil filter described in Patent Literature 1 employs a form in which all oil sent from the oil pan passes through the filter element (so-called full flow style). There is thus the problem of high pressure loss due to the resistance of fine particles such as hydrotalcite and the like that form the filter element. The filter described in Patent Literature 2 has only been evaluated with respect to the trapping effect by using a test oil that contains a specific test dust including carbon black, ferric oxide, and the like. The document does not discuss anything regarding the trapping of other components produced by deterioration. Another problem is that sepiolite has little trapping effect on nitric ester, which is one kind of deterioration products of engine oil.
The invention was conceived in view of the above situation. An object of the present invention is to provide an oil deterioration prevention device with an improved trapping effect on deterioration products of oil and with reduced oil flow resistance to prevent an increase in pressure loss.
Initial deterioration products of oil polymerize to form a sludge. Therefore, initial deterioration products such as nitric ester and the like are adsorbed on the surface of pores of a mesoporous inorganic material held in a deterioration prevention unit installed inside the oil filter, before they form the sludge. Sludge formation is thus prevented, so that oil deterioration is suppressed. In the oil filter, also, the installation position of the deterioration prevention unit that holds a mesoporous inorganic material, which may be a resistance to oil flow, is suitably located relative to the oil flow inside the filter. Thereby, a structure that prevents an increase in pressure loss can be achieved.
The present invention was made based on such findings.
The invention as described in claim 1 in order to solve the above problem is characterized by including a filter unit having a filter element for filtering an oil, and a deterioration prevention unit having a powdery deterioration suppressing agent that prevents an oil from deteriorating, wherein the deterioration suppressing agent has a mesoporous inorganic material, and wherein part of oil sent from an oil storage unit is delivered to a lubrication target unit after being filtered in the filter unit, and an oil that is restrained in deterioration by the deterioration prevention unit is either returned to the oil storage unit or delivered to the lubrication target unit.
The invention as described in claim 2 is an invention according to claim 1 wherein an average pore diameter of the mesoporous inorganic material is in a range from 1 to 30 nm.
The invention as described in claim 3 is an invention according to claim 1 wherein a pore volume of the mesoporous inorganic material is in a range from 0.3 to 4.0 cm3/g.
The invention as described in claim 4 is an invention according to claim 1 wherein a specific surface area of the mesoporous inorganic material is in a range from 120 to 2,000 m2/g.
The invention as described in claim 5 is an invention according to any one of claims 1 to 4 wherein the mesoporous inorganic material is an oxide-based inorganic material including an element selected from the group consisting of Si, Al, Fe, Ca, and Mg.
The invention as described in claim 6 is an invention according to any one of claims 1 to 5 wherein the deterioration prevention unit has a porous layer that holds the deterioration suppressing agent and allows oil to pass through.
The invention as described in claim 7 is an invention according to claim 6 wherein the porous layer has a first porous layer and a second porous layer stacked upon one another in a direction in which oil flows, the first porous layer on an upstream side having a larger porosity than the second porous layer on a downstream side.
The invention as described in claim 8 is an invention according to claim 6 or 7 wherein the deterioration prevention unit has an intermediate layer that is disposed between a plurality of the porous layers, the intermediate layer not allowing the deterioration suppressing agent to pass through but allowing oil to pass through.
The invention as described in claim 9 is an invention according to any one of claims 1 to 8 wherein the oil deterioration prevention device has further a housing that accommodates the filter unit and the deterioration prevention unit, wherein the housing is formed with an oil inlet passage for allowing oil sent from the oil storage unit to flow into the housing, an oil outlet passage for allowing oil filtered in the filter unit to flow out to the lubrication target unit, and an oil return passage for returning the oil that is restrained in deterioration by the deterioration prevention unit to the oil storage unit.
According to the oil deterioration prevention device of the present invention, part of oil sent from an oil storage unit is delivered to lubrication target units after being filtered in the filter unit. On the other hand, oil that is restrained in deterioration by the deterioration prevention unit that holds a deterioration suppressing agent containing a mesoporous inorganic material is either returned to the oil storage unit or delivered to the lubrication target units. Therefore, part of oil sent from the oil storage unit flows through a bypass passage, so that oil flow resistance is reduced and an increase in pressure loss is prevented.
In the case where the mesoporous inorganic material has an average pore diameter of 1 to 30 nm, it can allow initial deterioration products to readily enter the pores to be fully adsorbed therein, so that sludge formation is prevented reliably and oil deterioration is suppressed.
In the case where the pore volume is in a range from 0.3 to 4.0 cm3/g, there will be sufficient pore space for adsorbing initial deterioration products, so that initial deterioration products are readily adsorbed, and sludge formation is prevented reliably and oil deterioration is suppressed.
In the case where the mesoporous inorganic material has a specific surface area of 120 to 2,000 m2/g, it has a sufficient surface area for adsorbing initial deterioration products, so that initial deterioration products are readily adsorbed, and sludge formation is prevented reliably and oil deterioration is suppressed.
In the case where the mesoporous inorganic material is an oxide-based inorganic material containing an element selected from the group consisting of Si, Al, Fe, Ca, and Mg, it can fully function as a deterioration suppressing agent, so that initial deterioration products will be adsorbed on the pore surface, and sludge formation is prevented reliably and oil deterioration is suppressed sufficiently.
In the case where the deterioration prevention unit includes a porous layer, the deterioration suppressing agent can be held in the porous layer in an appropriately scattered state. Therefore, the oil flow resistance can be reduced further, so that the deterioration prevention unit can have an even higher effect of oil deterioration prevention.
In the case where the porous layer has a first porous layer and a second porous layer, and the first porous layer on an upstream side has a larger porosity than that of the second porous layer on a downstream side, more deterioration suppressing agent can be held in the second porous layer than in the first porous layer. Therefore, oil will spread gradually as it flows from the first porous layer to the second porous layer. Therefore, the oil flow resistance can be reduced further, so that the deterioration prevention unit can have an even higher effect of oil deterioration prevention.
In the case where the deterioration prevention unit includes an intermediate layer, it will stop the deterioration suppressing agent from moving between a plurality of porous layers. Therefore, the deterioration suppressing agent is prevented from clumping together in the porous layer on the downstream side. Therefore, the oil flow resistance can be reduced further, so that the deterioration prevention unit can have an even higher effect of oil deterioration prevention.
In the case where there is provided a housing that accommodates the filter unit and the deterioration prevention unit, and the housing has an oil inlet passage, an oil outlet passage, and an oil return passage, oil sent from the oil storage unit will flow into the housing through the oil inlet passage, while the oil filtered in the filter unit will flow out from the oil outlet passage to lubrication target units. On the other hand, oil that is restrained in deterioration by the deterioration prevention unit will be returned via the oil return passage to the oil storage unit. Therefore, the oil deterioration prevention device, filter unit, and deterioration prevention unit can be readily replaced.
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice.
An oil deterioration prevention device (1, 101) according to Embodiment 1 includes a filter unit (3, 103) having a filter element (10) for filtering an oil, and a deterioration prevention unit (4, 104) having a powdery deterioration suppressing agent (17) that prevents the oil from deteriorating. The deterioration suppressing agent contains a mesoporous inorganic material, and part of oil sent from an oil storage unit is delivered to a lubrication target unit after being filtered in the filter unit. Meanwhile, an oil that is restrained in deterioration by the deterioration prevention unit is either returned to the oil storage unit or delivered to the lubrication target unit. The oil deterioration prevention device (1, 101) according to Embodiment 1 is characterized by this configuration (see, for example,
The “oil storage unit” may be, for example, an oil pan used in a wet sump engine, an oil tank used in a dry sump engine, an oil pan used in an automatic transmission, and the like. The “lubrication target units” may be, for example, various mechanisms in an engine (such as crankshaft, cylinder wall, valve operating mechanism and the like), various mechanisms in an automatic transmission, or the like. The “filter element” may be of any type and have any shape as long as it can filter oil. Examples of such a filter element may include fibrous bodies such as unwoven cloth, paper, woven or knitted fabric, foamed resin materials such as urethane, and porous resin films.
The “powdery deterioration suppressing agent” may be of any type and have any style of deterioration prevention as long as it contains a mesoporous inorganic material and can prevent oil from deteriorating. Mesoporous inorganic materials are porous inorganic materials. An average pore diameter of the mesopores is generally in a range from 1 to 50 nm, preferably from 1 to 30 nm, and more preferably from 2 to 25 nm. If the mesopores have an average pore diameter of less than 1 nm, the mesopore diameter will be smaller than the size of trapping target materials, and therefore the trapping performance tends to reduce. On the other hand, if the average pore diameter exceeds 30 nm, and in particular 50 nm, the specific surface area will be smaller and the trapping performance tends to reduce. Therefore, the mesoporous inorganic material to be used is preferably selected so that it has an average pore diameter suitable for the size of trapping target materials.
A pore volume of the mesoporous inorganic material is preferably in a range from 0.3 to 4.0 cm3/g, and particularly from 0.4 to 2.0 cm3/g. If the pore volume is less than 0.3 cm3/g, initial deterioration products will not be sufficiently adsorbed and sludge formation tends not to be fully prevented. On the other hand, fabrication of a mesoporous inorganic material having a pore volume of more than 4.0 cm3/g is physically difficult. Even if a mesoporous inorganic material having a pore volume of more than 4.0 cm3/g could be fabricated, the mesoporous structure itself may not be able to retain its strength and shape. If the pore volume is in the range of 0.4 to 2.0 cm3/g, initial deterioration products can be fully adsorbed. Such a mesoporous inorganic material can be fabricated easily and will have sufficient strength and be able to retain its shape.
Preferably, about 60% or more of the entire pore volume of the mesoporous inorganic material is taken up by pores in a range of about +40% of an average pore diameter of a pore diameter distribution curve. The fact that the mesoporous inorganic material satisfies this condition means that it has high uniformity in pore diameter. Here, “about 60% or more of the entire pore volume of the mesoporous inorganic material is taken up by pores in a range of about ±40% of an average pore diameter of a pore diameter distribution curve” means that, for example, if the average pore diameter is about 3 nm, a total sum of volumes of the mesopores having an average pore diameter of about ±40% of about 3 nm, i.e., in a range of about 1.8 to 4.2 nm, take up about 60% or more of the entire pore volume.
Furthermore, a specific surface area of the mesoporous inorganic material is preferably in a range from 120 to 2,000 m2/g, and more preferably from 400 to 1,200 m2/g. If the specific surface area is less than 120 m2/g, initial deterioration products will not be sufficiently adsorbed and sludge formation tends not to be fully prevented. On the other hand, fabrication of a mesoporous inorganic material having a specific surface area of more than 2,000 m2/g is physically difficult. Even if a mesoporous inorganic material having a specific surface area of more than 2,000 m2/g could be fabricated, the mesoporous structure itself may not be able to retain its strength and shape. If the mesoporous inorganic material has a specific surface area in the range of 400 to 1,200 m2/g, it can sufficiently adsorb initial deterioration products, have sufficient strength, and can retain its shape.
The mesoporous inorganic material is not limited to a particular type and may be any material as long as it has mesopores and can prevent oil from deteriorating, but preferably has the average pore diameter, pore volume, and specific surface area mentioned above. A mesoporous inorganic material having an average pore diameter from 1 to 30 nm and preferably from 2 to 25 nm and having a pore volume from 0.3 to 4.0 cm3/g and preferably from 0.4 to 2.0 cm3/g is more preferable. A mesoporous inorganic material having an average pore diameter from 1 to 30 nm and preferably from 2 to 25 nm and having a specific surface area from 120 to 2,000 m2/g and preferably from 400 to 1,200 m2/g is even more preferable. A mesoporous inorganic material having a pore volume from 0.3 to 4.0 cm3/g and preferably from 0.4 to 2.0 cm3/g and having a specific surface area from 120 to 2,000 m2/g and preferably from 400 to 1,200 m2/g is more preferable. A mesoporous inorganic material having an average pore diameter from 1 to 30 nm and preferably from 2 to 25 nm and having a pore volume from 0.3 to 4.0 cm3/g and preferably from 0.4 to 2.0 cm3/g and having a specific surface area from 120 to 2,000 m2/g and preferably from 400 to 1,200 m2/g is particularly preferable.
The average pore diameter, pore volume, and specific surface area of a mesoporous inorganic material can be measured in the following manner.
A nitrogen adsorption isotherm is determined at 77K by a constant volume process using an automatic gas adsorption measurement apparatus “BELSORP-mini II” (model name) manufactured by BELL JAPAN, INC. A heat treatment is carried out in vacuum at 150° C. for two hours as a pretreatment so as to remove the effects of adsorbed water. A pore volume (Vp) is determined from the amount of adsorption at P/P0 (relative pressure) of 0.95 of the absorption isotherm obtained. A pore diameter distribution is determined by a BJH method, and a peak value in this pore diameter distribution is defined as an average pore diameter. A specific surface area is calculated from the amount of adsorption at P/P0 (relative pressure) of 0.05 to 0.20 of the BET plot.
Oxide-based inorganic materials having various elements are a specific example of mesoporous inorganic materials. For example, oxide-based inorganic materials having an element selected from the group consisting of Si, Al, Fe, Ca, and Mg can be used. In addition to the above, oxide-based inorganic materials having an element such as Nb, Ta, Zr, Ti, Zn, and the like may also be used. For the mesoporous inorganic material, an oxide-based inorganic material having Si and/or Al is preferable. Examples of such oxide-based inorganic materials include an amorphous mesoporous silica-based inorganic material called FSM (Folded Sheet Mesoporous Material) that has a honeycomb structure, an activated white clay including Si, Al, and the like, silica gel, activated alumina, and the like. Note that sepiolite is excluded from the mesoporous inorganic materials as defined in the present invention since, even though it has mesopores, it has a small pore volume and exhibits a poor ability of adsorbing nitric ester, which is an initial deterioration product of oil.
The deterioration suppressing agent should at least contain a mesoporous inorganic material. The content of the mesoporous inorganic material is preferably 10% or more by mass based on 100% by mass of a total of the deterioration suppressing agent. Further the content thereof is more preferably 20% or more by mass, and the entire of the deterioration suppressing agent is a mesoporous inorganic material. If the deterioration suppressing agent contains other agents than mesoporous inorganic materials, the agents may be of any kind, including, for example, acidic white clay, diatom earth, zeolite, non-porous silica, hydrotalcite, various ion-exchange resin powders, and the like.
Furthermore, an average particle diameter of the mesoporous inorganic material is nor particularly limited. It is preferably in a range from 0.1 to 200 μm, for example, more preferably from 2.5 to 150 μm, and especially from 10 to 100 μm. This average particle diameter is a particle diameter when an accumulated weight is 50% in a particle size distribution measurement by a laser diffraction method (median diameter).
In one embodiment that can be given as one example of an oil deterioration prevention device according to Embodiment 1, the deterioration prevention unit (4, 104) holds a deterioration suppressing agent (17), and includes a porous layer (18, 118), which oil can pass through (see, for example,
In the embodiment described above, for example, the porous layer (18, 118) includes a first porous layer (18a, 118a) and a second porous layer (18b, 118b) stacked upon one another in a direction in which oil flows. The first porous layer which is on the upstream side may have a larger porosity than that of the second porous layer which is on the downstream side (see, for example,
In the embodiment described above, for example, the deterioration prevention unit (4, 104) may include an intermediate layer (19, 119) disposed between the plurality of porous layers (18, 118). While oil can pass through this intermediate layer (19, 119), the deterioration suppressing agent (17) cannot pass through (see, for example
One example of the oil deterioration prevention device according to Embodiment 1 is an embodiment [A] having a housing (2) that accommodates a filter unit (3) and a deterioration prevention unit (4) (see, for example,
In the embodiment [A] described above, for example, the oil outlet passage (6) may have a larger maximum cross-sectional area (S1) than a maximum cross-sectional area (S2) of the oil return passage (7) (see, for example,
In the embodiment [A] described above, for example, the filter unit (3) and the deterioration prevention unit (4) are arranged such as to divide the inner space of the housing (2) into an upstream space (R1) that connects to the oil inlet passage (5) and a downstream space (R2) that connects to the oil outlet passage (6). The deterioration prevention unit (4) further has a container case (20) for containing the deterioration suppressing agent (17). This container case may be formed with an inlet port (21) that opens to the upstream space, and an outlet port (22) that is separated from the upstream space and downstream space and connects to the oil return passage (7) (see, for example,
In the embodiment [B] described above, for example, the filter unit (103) and the deterioration prevention unit (104) are arranged such as to divide the inner space of the housing (102) into an upstream space (R1) that connects to the oil inlet passage (105) and a downstream space (R2) that connects to the oil outlet passage (106). The deterioration prevention unit (104) further has a container (120) for containing the deterioration suppressing agent (17). This container may be formed with an inlet port (121) that opens to the upstream space, and an outlet port (122) that opens to the downstream space (see, for example,
In the embodiment [A] described above, for example, the filter unit (3) and the deterioration prevention unit (4) that are tubular are disposed along the axial direction inside the housing (2). The container case (20) has tubular inner wall (20a) and outer wall (20b), and a plate-like bottom wall (20c) that connects these inner and outer walls at one end. The inlet port (21) is located to open opposite one axial end face of a tubular filter element (10) at one end in the axial direction of the container case, while the outlet port (22) is provided at the other axial end of the container case. The deterioration suppressing agent (17) may be contained in the space enclosed by these inner wall, outer wall, and bottom wall of the container case (see, for example,
Hereinafter, the present invention will be described in more detail by way of examples with reference to the drawings. In these examples, an oil deterioration prevention device that retards deterioration of engine oil (hereinafter also referred to simply as “oil”) will be shown. Tests were conducted to evaluate the deterioration prevention effects, using various mesoporous inorganic materials and others.
The oil deterioration prevention device 1 according to this Example includes a filter unit 3 and a deterioration prevention unit 4 accommodated inside a housing 2, as shown in
In the center of the axial member 2c is formed an oil outlet passage 6 for allowing oil filtered in the filter unit 3 to flow to lubrication target units of the engine (for example, crankshaft, cylinder wall, valve operating mechanism, and the like). This oil outlet passage 6 is connected to the lubrication target units of the engine via a passage or the like formed inside the engine. Further, an oil return passage 7 is formed on the radially outer side of the oil outlet passage 6 of the axial member 2c to return the oil that is restrained in deterioration by the deterioration prevention unit 4 to the oil pan 9. This oil return passage 7 is connected to the oil pan 9 via a pipe or the like. Here, as shown in
The filter unit 3 includes a filter element 10 for filtering oil as shown in
The protector 11 is pressed toward the bottom plate 2b by a spring 14 provided between itself and the case 2a. A known relief valve 15 is provided at one axial end of the protector 11. This relief valve 15 acts to communicate the upstream and downstream spaces R1 and R2 of the filter element 10 with each other when the pressure difference between these spaces R1 and R2 in the housing 2 exceeds a preset value.
The deterioration prevention unit 4 includes a powdery deterioration suppressing agent 17 made of a mesoporous inorganic material that prevents oil from deteriorating, as shown in
The porous layers 18 each include a first porous layer 18a and a second porous layer 18b stacked upon one another in the direction of oil flow, as shown in
The porous layers 18 and intermediate layers 19 are accommodated inside the container case 20, as shown in
At one end of the inner wall 20a of the container case 20 is inserted the small-diameter part 11b of the protector 11, while at the other end is inserted the distal end of the axial member 2c. A ring-like sealing member 23 made of rubber and provided on the outer circumference at the distal end of the axial member 2c makes pressure contact with the inner wall 20a of the container case 20. Further, the container case 20 is axially sandwiched between a rubber-made, ring-like sealing member 24 arranged on the outer circumference of the small-diameter part 11b of the protector 11 and the check valve 16. The inner space 25 surrounded by the inner wall 20a of the container case 20 connects to the inner space 26 of the protector 11 and the oil outlet passage 6. The outlet port 22 of the container case 20 connects to the oil return passage 7 via a space 27 enclosed by the check valve 16, sealing member 23, inner wall 20a, and axial member 2c such as to be separated from the inner space 25 of the inner wall 20a.
Next, how the above-mentioned oil deterioration prevention device 1 works will be described. A pump 29 (see
Foreign substances (for example, dust, worn metal particles, sludge, and the like) in the oil that has reached the filter unit 3 are trapped by the filter element 10, after which the oil flows through the through holes 12 of the protector 11 and is sent to the lubrication target units of the engine via the downstream space R2 and oil outlet passage 6. Meanwhile, oil that has reached the deterioration prevention unit 4 flows into the container case 20 from the inlet port 21 and passes through the porous layers 18 and intermediate layers 19. Foreign substances (for example, acidic substances and the like produced in the engine) in the oil are removed by adsorption by the deterioration suppressing agent 17, after which the oil flows out from the outlet port 22 and is returned to the oil pan 9 via the space 27 and oil return passage 7. Here, since the differential pressure P2 (several hundreds kPa) in the deterioration prevention unit 4 is normally higher than the differential pressure P1 (several kPa) in the filter unit 3 (see
As mentioned above, with the oil deterioration prevention device 1 of this Example, oil sent from the oil pan 9 flows separately into the filter unit 3 and deterioration prevention unit 4. Oil that is filtered in the filter unit 3 is delivered to the lubrication target units of the engine without passing through the deterioration prevention unit 4. On the other hand, oil that is restrained in deterioration by the deterioration prevention unit 4 is returned to the oil pan 9 without passing through the filter unit 3. Therefore, part of oil sent from the oil pan 9 flows through a bypass passage, so that oil flow resistance is reduced and an increase in pressure loss is prevented.
In this Example, the deterioration prevention unit 4 includes porous layers 18, so that the deterioration suppressing agent 17 (mesoporous inorganic material) can be held in the porous layers 18 in an appropriately dispersed state. Therefore, the oil flow resistance can be reduced further, so that the deterioration prevention unit 4 can have an even higher effect of oil deterioration prevention.
In this Example, the porous layers 18 each include a first porous layer 18a and a second porous layer 18b, and the first porous layer 18a that is on the upstream side has a larger porosity than the second porous layer 18b that is on the downstream side. Therefore, the second porous layer 18b can hold more deterioration suppressing agent 17 than the first porous layer 18a, so that oil spreads gradually as it flows from the first porous layer 18a to the second porous layer 18b (see
In this Example, the deterioration prevention unit 4 includes intermediate layers 19, so that the plurality of porous layers 18 are separated by the intermediate layers 19 to stop the deterioration suppressing agent 17 from moving between the porous layers 18, and therefore the deterioration suppressing agent 17 is prevented from clumping together in the downstream porous layer 18. Therefore, the oil flow resistance can be reduced further, so that the deterioration prevention unit 4 can have an even higher effect of oil deterioration prevention.
In this Example, a housing 2 that accommodates the filter unit 3 and the deterioration prevention unit 4 is provided, and the housing 2 is formed with oil inlet passages 5, an oil outlet passage 6, and an oil return passage 7. Therefore, oil sent from the oil pan 9 flows into the housing 2 through the oil inlet passages 5, while oil filtered in the filter unit 3 flows out from the oil outlet passage 6 to the lubrication target units of the engine, and oil that is restrained in deterioration by the deterioration prevention unit 4 is returned to the oil pan 9 through the oil return passage 7. Therefore, the oil deterioration prevention device 1, filter unit 3, and deterioration prevention unit 4 can be readily replaced.
In this Example, the oil outlet passage 6 has a cross-sectional area S1 that is larger than the cross-sectional area S2 of the oil return passage 7, so that a relatively large amount of oil can flow out from the oil outlet passage 6 to lubricate the lubrication target units of the engine favorably. On the other hand, a relatively small amount of oil flows through the oil return passage 7 so that the oil flow resistance can be reduced further.
In this Example, the filter unit 3 and the deterioration prevention unit 4 are arranged such as to divide the inner space of the housing 2 into an upstream space R1 that connects to the oil inlet passages 5 and a downstream space R2 that connects to the oil outlet passage 6. The deterioration prevention unit 4 includes a container case 20 that contains the deterioration suppressing agent 17, and this container case 20 is formed with an inlet port 21 that opens to the upstream space R1, and an outlet port 22 that connects to the oil return passage 7 such as to be separated from the upstream space R1 and downstream space R2. Therefore, oil sent from the oil pan 9 flows into the upstream space R1 inside the housing 2 through the oil inlet passages 5, while oil filtered in the filter unit 3 flows out through the downstream space R2 and oil outlet passage 6 to the lubrication target units of the engine. Meanwhile, oil that flows into the container case 20 from the inlet port 21 flows through the deterioration suppressing agent 17 to prevent deterioration before being returned to the oil pan 9 via the outlet port 22 and oil return passage 7.
In this Example, the filter unit 3 and the deterioration prevention unit 4 that are tubular are disposed along the axial direction inside the housing 2. The container case 20 has tubular inner wall 20a and outer wall 20b, and a plate-like bottom wall 20c that connects these inner wall 20a and outer wall 20b at one end. Further, the inlet port 21 is located to open opposite one axial end face of a tubular filter element 10 at one end in the axial direction of the container case 20, while the outlet port 22 is provided at the other axial end of the container case 20. The deterioration suppressing agent 17 is contained in the space enclosed by the inner wall 20a, outer wall 20b, and bottom wall 20c of this container case 20. Therefore, oil that flows into the container case 20 from the inlet port 21 flows through the entire deterioration suppressing agent 17 and out into the oil return passage 7 from the outlet port 22. Thus the oil deterioration prevention effect by the deterioration prevention unit 4 can be further enhanced. Moreover, the filter unit 3 and the deterioration prevention unit 4 can be readily arranged, and the device can be made smaller.
Next, a structure of an oil deterioration prevention device according to Example 2 will be described. The constituent elements of the oil deterioration prevention device according to Example 2 that are substantially the same as those of the oil deterioration prevention device 1 according to Example 1 are given the same reference numerals and will not be described in detail again.
The oil deterioration prevention device 101 according to this Example includes a filter unit 103 and a deterioration prevention unit 104 accommodated inside a housing 102, as shown in
In the center of the axial member 102c is formed an oil outlet passage 106 for allowing oil filtered in the filter unit 103 to flow to lubrication target units of the engine (for example, crankshaft, cylinder wall, valve operating mechanism, and the like). This oil outlet passage 106 is connected to the lubrication target units of the engine via a passage or the like formed inside the engine. Further, a communication passage that connects to the oil outlet passage 106 is formed on the radially outer side of the axial member 102c.
The filter unit 103 includes a filter element 10 for filtering oil. A tubular protector 111 is attached on the inner circumferential side of this filter element 10. This protector 111 includes a large-diameter part 111a that supports the filter element 10 and a small-diameter part 111b that protrudes axially from one end of the large-diameter part 111a. The wall forming this large-diameter part 111a has a large number of through holes 112. One end of the small-diameter part 111b is fixed to the outer circumferential surface of the axial member 102c. The filter element 10 is positioned such as to divide the inner space of the housing 102 into an upstream space R1 before filtration (i.e., space where unfiltered oil exists) that connects to the oil inlet passages 105, and a downstream space R2 after filtration (i.e., space where filtered oil exists) that connects to the oil outlet passage 106. The protector 111 is pressed toward the bottom plate 102b by a spring 14 provided between itself and the case. A known relief valve 15 is provided at one axial end of the protector 111.
The deterioration prevention unit 104 includes a powdery deterioration suppressing agent 17 made of a mesoporous inorganic material that prevents oil from deteriorating. This deterioration suppressing agent 17 is held in a plurality of (three in
The porous layers 118 each include a first porous layer 118a and a second porous layer 118b stacked upon one another in the direction of oil flow. Here, the first porous layer 118a which is on the upstream side has a porosity of about 0.98, and the second porous layer 118b which is on the downstream side has a porosity of about 0.92. Thus, since the first porous layer 118a has a lower density than the second porous layer 118b, the second porous layer 118b holds more deterioration suppressing agent 17 than the first porous layer 118a. Further, ring-like plates of nonwoven fabric that allow oil to pass through but not the deterioration suppressing agent 17 are arranged as intermediate layers 119 between the plurality of porous layers 118.
The porous layers 118 and intermediate layers 119 are accommodated inside the container 120. This container 120 includes the small-diameter part 111b of the protector 111, and upper and lower annular plates 120a arranged on the outer circumference of this small-diameter part 111b. An inlet port 121 that opens to the upstream space R1 is formed on the outer circumferential side of the container 120. An outlet port 122 that opens to the downstream space R2 is formed in the small-diameter part 111b.
Next, how the above-mentioned oil deterioration prevention device 101 works will be described. A pump 29 (see
Foreign substances (for example, dust, worn metal particles, sludge, and the like) in the oil that has reached the filter unit 103 are trapped by the filter element 10, after which the oil flows through the through holes 112 of the protector 111 and is sent to the lubrication target units of the engine via the downstream space R2 and oil outlet passage 106. On the other hand, oil that has reached the deterioration prevention unit 104 flows into the container 120 from the inlet port 121 and passes through the porous layers 118 and intermediate layers 119, so that foreign substances (such as, for example, acidic substances and the like produced in the engine) in the oil are removed by adsorption by the deterioration suppressing agent 17, after which the oil flows out from the outlet port 122 and is sent to the lubrication target units of the engine via the downstream space R2 and oil return passage 106.
As mentioned above, with the oil deterioration prevention device 101 of this Example, substantially the same advantageous effects as those of the oil deterioration prevention device 1 of Example 1 are achieved. In addition, oil sent from the oil pan 9 flows separately through each of the filter unit 103 and deterioration prevention unit 104, and oil filtered in the filter unit 103 is delivered to the lubrication target units of the engine without flowing through the deterioration prevention unit 104. On the other hand, the oil that is restrained in deterioration by the deterioration prevention unit 104 is delivered to the lubrication target units of the engine without flowing through the filter unit 103. Therefore, part of oil sent from the oil pan flows through a bypass passage, so that oil flow resistance is reduced and an increase in pressure loss is prevented.
In this Example, a housing 102 that accommodates the filter unit 103 and the deterioration prevention unit 104 is provided, and the housing 102 is formed with oil inlet passages 105 and an oil outlet passage 106. Therefore, oil sent from the oil pan 9 flows into the housing 102 through the oil inlet passages 105, while oil filtered in the filter unit 103 flows out from the oil outlet passage 106 to the lubrication target units, and the oil that is restrained in deterioration by the deterioration prevention unit 104 is sent out to the lubrication target units through the oil outlet passage 106.
In this Example, the filter unit 103 and the deterioration prevention unit 104 are arranged such as to divide the inner space of the housing 102 into an upstream space R1 that connects to the oil inlet passages 105 and a downstream space R2 that connects to the oil outlet passage 106. The deterioration prevention unit 104 includes a container 120 that contains the deterioration suppressing agent 17, and this container 120 is formed with an inlet port 121 that opens to the upstream space R1, and an outlet port 122 that opens to the downstream space R2. Oil sent from the oil pan 9 flows into the upstream space R1 inside the housing 102 through the oil inlet passages 105, while oil filtered in the filter unit 103 flows out through the downstream space R2 and oil outlet passage 106 to the lubrication target units. Meanwhile, oil that flows into the container 120 from the inlet port 121 flows through the deterioration suppressing agent 17 to prevent deterioration before flowing out to the lubrication target units via the outlet port 122, downstream space R2, and oil outlet passage 106.
The present invention is not limited to the Examples 1 and 2 described above and may be changed variously in accordance with the purposes and applications within the scope of the present invention. Namely, while the deterioration prevention units 4, 104 illustrated in the Examples 1 and 2 have a plurality of multi porous layers 18, 118 each having first and second porous layers 18a, 18b, 118a, and 118b, the invention is not limited to this, and as shown in
While one embodiment of porous layer 18, 118 illustrated in the Examples 1 and 2 described above has two, first and second, porous layers 18a, 18b, 118a, and 118b, the invention is not limited to this, and the porous layer may have, for example, three or more layers having different porosities. Also, while the deterioration prevention unit 4, 104 illustrated in the Examples 1 and 2 described above has intermediate layers 19, 119 arranged between the plurality of porous layers 18, 118, the invention is not limited to this, and, for example, the deterioration prevention unit may be configured with a plurality of adjacent porous layers 18, 118 directly stacked upon one another, without any intermediate layer 19 arranged therebetween. Further, while the deterioration prevention unit 4 illustrated in the Examples 1 and 2 described above has a container case 20 or container 120 accommodating the porous layers 18, 118 therein, the invention is not limited to this, and, for example, the porous layers 18, 118 may be arranged in the housing 2 without providing the container case 20 or container 120.
While the deterioration prevention unit 4, 104 illustrated in the Examples 1 and 2 described above has a plurality of porous layers 18, 118, the invention is not limited to this, and as shown in
While one embodiment of oil deterioration prevention device 1, 101 was illustrated in the Examples 1 and 2 above wherein the entire device including the housing 2, 102 is replaced (so-called spin-on design), the invention is not limited to this, and, for example, the oil deterioration prevention device may have a housing 2, 102 that is disassemblable, so that the filter unit 3, 103 and/or deterioration prevention unit 4, 104 can be directly replaced.
While one embodiment was illustrated in the Examples 1 and 2 above wherein the filter unit 3, 103 and deterioration prevention unit 4, 104 are accommodated in a single housing 2, 102, the invention is not limited to this, and, for example, the device may have a filter unit 3, 103 accommodated in a first housing, and a deterioration prevention unit 4, 104 accommodated in a second housing that is different from the first housing.
Further, while an oil deterioration prevention device 1, 101 illustrated in the Examples 1 and 2 above is used in a wet sump engine, the invention is not limited to this, and, for example, the oil deterioration prevention device may be used in a dry sump engine, or in an automatic transmission.
One technique of removing deterioration products in the oil deterioration prevention technology was investigated, wherein initial deterioration products are trapped before they polymerize and form a sludge, so as to prevent oil from deteriorating. A plurality of mesoporous inorganic materials having mesopores with a predetermined average pore diameter was used as the deterioration suppressing agent (filter medium). To compare the deterioration product trapping effect, sepiolite that does not have a peak value in the pore diameter distribution, acidic white clay that does not have a peak value in the pore diameter distribution, and diatom earth with too large an average pore diameter, zeolite with too small an average pore diameter, and non-porous silica were used in the tests.
Various filter medium listed in Tables 1 and 2 were used. The details of respective filter medium are as specified in Tables 1 and 2. Five filter medium (from (e) to (i) below) listed in Table 2 are for comparative test examples.
(a) Amorphous mesoporous silica (FSM) (trade name “TMPS-4” manufactured by Taiyo Kagaku Co., Ltd.);
(b) Activated white clay (trade name “Musashilite V” manufactured by Musashiyuka Kabushiki Kaisha,);
(c) Silica gel (trade name “C-500HG” manufactured by Wako Pure Chemical Industries, Ltd.);
(d) Activated alumina (trade name “VGL15” manufactured by Union Showa K.K.);
(e) Sepiolite (trade name “P-80V” manufactured by Ohmi Chemical Industry Co., Ltd.);
(f) Acidic white clay (trade name “Nikkanite S-200” manufactured by Nippon Kasseihakudo Kabushiki Kaisha);
(g) Diatom earth (trade name “Radiolite Special Flow” manufactured by Showa Chemical Industry Co., Ltd.);
(h) Zeolite (trade name “Zeolum A-3” manufactured by Tosoh Corporation); and
(i) Non-porous silica (trade name “SO-E2” manufactured by Admatechs Company Limited).
Filtering tests were conducted, with the mesoporous inorganic materials used as the filter medium and the filter medium of the comparative test examples, using NOx-deteriorated oil. More specifically, components of filtered oil were examined by Fourier transform infrared spectroscopic analysis (FT-IR) to determine the trapping effect on nitric ester, which is a component produced in the initial stage of deterioration.
NOx-deteriorated oil, which simulates an oil that was used in the gasoline engine for a long period of time, was prepared by bubbling NO2 gas in a genuine Toyota oil (trade name “Toyota Castle SM 5W-30”), which is a commercially available engine oil, and was used in the test. The bubbling conditions are as shown in Table 3.
In Table 3, of the total gas flow rate of 283 mL/min, 28 mL/min, which is a difference between the air flow rate of 205 mL/min and the nitrogen gas flow rate of 50 mL/min, was supplied as a nitrogen gas containing 1% by mass of NO2 from a gas cylinder.
NOx-deteriorated oil was filtered using a device shown in
(5-1) Analysis of Oil Components
NOx-deteriorated oil specimen and oil after filtration were both analyzed by FT-IR. The device used and analysis conditions are as follows:
Fourier transform infrared spectroscopic analysis device “Avatar 360” (model name) manufactured by Thermo Nicolet Japan Corporation,
Cell used: Cell for holding liquids manufactured by JASCO Corporation, KBr, t=0.1 mm
Number of accumulation: 32 times
(5-2) Initial Deterioration Product Trapping Rate
Focus was placed on nitric ester (wave number: 1,630 cm−1), which is one component of initial deterioration products and measured the peak height of nitric ester in the NOX-deteriorated oil before and after filtration, to determine the rate of trapping initial deterioration products from the diminution rate.
Using activated white clay that exhibited an excellent trapping effect with a trapping rate of more than 80% in the filtering test of Test Example 1, its deterioration prevention effect was evaluated by a real-time test with conditions closer to oil deterioration conditions in an actual engine.
A NOX-deterioration test device shown in
In Table 4, of the total gas flow rate of 283 mL/min, 28 mL/min, which is a difference between the air flow rate of 205 mL/min and the nitrogen gas flow rate of 50 mL/min, was supplied as a nitrogen gas containing 1% by mass of NO2 from a gas cylinder.
The test results were evaluated based on the changes in the acid number of oil after the test.
An oil deterioration prevention device having a bypass flow structure shown in
The test was conducted with an engine running under conditions shown in Table 5 for two cases: one with an oil deterioration prevention device having a deterioration prevention unit holding the FSM mentioned in (1) above for circulating the oil taken out from the engine oil pan with a pump, and the other without such a device. Evaluation was made based on the measurements of the amount of initial deterioration products produced during the operation of the engine and mixed into the oil, and the base number and acid number of the oil.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular structures, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
The present invention is not limited to the embodiments described in detail above, and can be modified or changed in various manners within the scope as set forth in the claims of the present invention.
The invention is widely applicable as a technique to prevent oil from deteriorating. The inventions is used favorably as a technique to prevent deterioration of engine oil of vehicles, in particular, such as cars, buses, and trucks, as well as railroad vehicles such as trains and railroad cars, construction vehicles, agricultural vehicles, industrial vehicles, and the like.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-106261 | May 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/062663 | 4/30/2013 | WO | 00 |
