CN117242242A

CN117242242A - Crankcase ventilation filter with axial seal member

Info

Publication number: CN117242242A
Application number: CN202280030426.4A
Authority: CN
Inventors: 奇拉格·D·帕里克; M·V·霍尔兹曼; K·托夫斯兰; R·马丁; 顾雪瑞; 约瑟夫·阿佩尔汉斯; 加内什·拉姆·拉马努贾姆·卡斯基延
Original assignee: Cummins Filtration SARL
Current assignee: Cummins Filtration SARL
Priority date: 2021-08-09
Filing date: 2022-08-08
Publication date: 2023-12-15

Abstract

The rotary crankcase ventilation filter element includes a filter media comprising a plurality of filter media layers. The first end cap is positioned over the filter media first end of the filter media and the second end cap is positioned over the filter media second end of the filter media, the second end cap being coupled to the first end cap such that the first end cap and the second end cap define an interior volume within which the filter media is disposed. The second end cap includes an axial sealing member extending from a surface of the second end cap toward the filter media and forming an axial seal with the filter media. The axial sealing member projects substantially parallel to the axial fluid flow direction into the filter media.

Description

Crankcase ventilation filter with axial seal member

Cross-reference to related patent applications

The present PCT application claims priority from U.S. provisional application No. 63/230,936 filed on 8/9 of 2021, and incorporated herein by reference in its entirety.

Technical Field

The present disclosure relates generally to filters for use with internal combustion engine systems.

Background

During operation of an internal combustion engine, a portion of the combustion gases may flow from the combustion cylinder and into the crankcase of the engine. These gases are commonly referred to as "blowby" gases. Blowby gas includes a mixture of aerosol, oil, and air. Aerosols contained in blowby gases can potentially harm the environment if discharged directly into the environment. Thus, the blowby gas is typically directed out of the crankcase via a crankcase ventilation system (crankcase ventilation system). Crankcase ventilation systems may pass blowby gas through a coalescer (i.e., a coalescing filter element) to remove most or all of the aerosols and oil contained in the blowby gas. The filtered blowby gas ("clean" gas) is then vented to the environment (in the case of an open crankcase ventilation system) or directed back to the air intake (air inlet) of the internal combustion engine for further combustion (in the case of a closed crankcase ventilation system).

Some crankcase ventilation systems utilize rotating crankcase ventilation filter elements, such as rotating coalescer elements, that increase the filter efficiency of the crankcase ventilation system by rotating the coalescer elements during filtration. In rotating coalescer elements, contaminants (e.g. blowby gas suspended and entrained oil droplets) are separated at least in part by centrifugal separation techniques. In addition, rotation of the coalescer element may create a pumping effect, which reduces the pressure drop across the crankcase ventilation system.

Some rotary crankcase ventilation filter elements may include corrugated and/or wound axial filter media layers (corragated and/or or wound axial filter media layer), such as filter media layers wound into a roll. Blowby gas flows from the upstream side to the downstream side of the wound axial flow media and is substantially sealed via radial interference (radial interference) between the filter media and an end cap located on the upstream side of the filter element. However, such interference may result in uneven collapse of the axial flow channels. The filter media may be unevenly loaded with contaminants due to uneven collapse of the flow channels, which may lead to an imbalance of the filter element. Such imbalance can result in swirling (whisling) of the crankcase ventilation filter element during rotation, which can result in higher loads on the bearing supporting the filter element and ultimately failure of the bearing.

SUMMARY

Embodiments described herein relate generally to systems and methods for sealing filter media of a filter element to prevent passage of blowby gases, and in particular, to first and second end caps positioned on axial ends of the filter media, and an axial sealing member protruding from the second end cap toward the filter media to form an axial seal with the filter media.

In one set of embodiments, a rotary crankcase ventilation filter element includes a filter media. The first end cap is positioned over the filter media first end of the filter media and the second end cap is positioned over the filter media second end of the filter media, the second end cap being coupled to the first end cap such that the first end cap and the second end cap define an interior volume within which the filter media is disposed. The second end cap includes an axial sealing member extending from a surface of the second end cap toward the filter media and forming an axial seal with the filter media. The axial sealing member projects substantially parallel to the axial fluid flow direction into the filter media.

Another set of embodiments relates to a crankcase ventilation system. The crankcase ventilation system includes a housing having an inlet to receive a fluid, an outlet, and a rotary crankcase ventilation filter element. The rotary crankcase ventilation filter element includes a filter media, a first end cap, and a second end cap. The first end cap is positioned over the filter media first end of the filter media. The second end cap is positioned over the filter media second end of the filter media. The second end cap is coupled to the first end cap such that the first end cap and the second end cap define an interior volume, and the filter media is disposed within the interior volume. The second end cap includes an axial sealing member extending from a surface of the second end cap toward the filter media and forming an axial seal with the filter media. The axial sealing member projects substantially parallel to the axial fluid flow direction into the filter media.

Yet another set of embodiments relates to a rotary crankcase ventilation filter element. The rotary crankcase ventilation filter element includes a filter media and an end cap. An end cap is positioned over the filter media end of the filter media. The end cap includes an axial seal member and a sidewall. An axial sealing member extends from a surface of the end cap toward the filter media and forms an axial seal with the filter media. The axial sealing member projects substantially parallel to the axial fluid flow direction into the filter media. The sidewall extends from the outer periphery of the end cap toward the filter media. A radial gap is defined between the sidewall and the radially outer surface of the filter media.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in more detail below (where such concepts are provided as not mutually inconsistent) are contemplated as being part of the subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the subject matter disclosed herein.

Brief Description of Drawings

The above and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. It is to be understood that these drawings depict only several embodiments in accordance with the disclosure and are therefore not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

Fig. 1 is a cross-sectional view of a crankcase ventilation system according to an embodiment.

Fig. 2A is a side cross-sectional perspective view of a crankcase ventilation system according to another embodiment.

Fig. 2B is a side cross-sectional view of a filter element that may be included in the crankcase ventilation system of fig. 2A, according to an embodiment.

Fig. 2C is a side cross-sectional view of a portion of the filter element of fig. 2B indicated by arrow a in fig. 2B.

Fig. 2D is a top view of a portion of a filter media that may be included in the filter element of fig. 2B.

Fig. 3 is a side cross-sectional view of a filter element according to another embodiment.

Fig. 4 is a side cross-sectional view of a portion of the filter element of fig. 3 indicated by arrow B in fig. 3.

Fig. 5 is a perspective cross-sectional view of a portion of the filter element of fig. 3 indicated by arrow B in a first configuration.

Fig. 6 is a perspective cross-sectional view of a portion of the filter element of fig. 5 in another configuration.

Fig. 7 is a graph of the rate of imbalance growth based on an accelerated plugging test for a second end cap of a filter element forming a radial seal with filter media included in the filter element, a second end cap forming an axial seal via a triangular axial seal member according to the present disclosure, and another second end cap forming an axial seal with filter media included in the filter element via a flat axial seal member according to the present disclosure.

FIG. 8 is a graph of separation or filtration efficiency of a filter element forming an axial seal according to the depth of interference of an axial seal member of the filter element with the filter media of the filter element.

Fig. 9A is a side cross-sectional view of a crankcase ventilation system according to another embodiment.

Fig. 9B is a side cross-sectional view of the crankcase ventilation system of fig. 9A.

Fig. 9C is a side cross-sectional view of a portion of the filter element of fig. 9A and 9B.

Fig. 10A is a side cross-sectional view of a filter element that may be included in any of the crankcase ventilation systems described herein, according to an embodiment.

Fig. 10B is a side cross-sectional view of a portion of the filter element of fig. 10A indicated by arrow C.

Fig. 11A is a side cross-sectional view of a filter element that may be included in any of the crankcase ventilation systems described herein, according to an embodiment.

Fig. 11B is a side cross-sectional view of a portion of the filter element of fig. 11A indicated by arrow D.

Fig. 12 is a side cross-sectional view of a snap-fit feature that may be included in the filter element of fig. 10A or 10B, according to an embodiment.

Fig. 13A-13C are side cross-sectional views of the snap-fit feature of fig. 12, in accordance with various embodiments.

Fig. 14 is a side cross-sectional view of a filter element that may be included in any of the crankcase ventilation systems described herein, according to an embodiment.

Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, like numerals generally designate like parts unless the context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, may be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and form part of this disclosure.

Detailed Description

Embodiments described herein relate generally to systems and methods for sealing filter media of a filter element to prevent passage of blowby gases, and in particular, to sealing filter media to first and second end caps positioned on axial ends of the filter media, and an axial sealing member protruding from the second end cap toward the filter media to form an axial seal with the filter media.

Some rotary crankcase ventilation filter elements may include a corrugated and/or wound axial filter media layer, such as a filter media layer wound into a roll. Blowby gas flows from the upstream side to the downstream side of the wound axial flow media and is typically sealed via radial interference between the filter media and an end cap located on the upstream side of the filter element. However, such interference may result in uneven collapse of the axial flow channels. The filter media may be unevenly loaded with contaminants due to uneven collapse of the channels, which can lead to an imbalance of the filter element. For example, the filter media may comprise corrugated wound media, and radial interference of the end cap with the outer radial surface of the filter media may result in radial collapse of the corrugated channels.

These passages are affected by the engine blowby gas flow, which may contain contaminants observed in the engine blowby flow. Over time, these contaminants may enter these channels. The channel collapse may be non-uniform, which may result in uneven loading of contaminants at different locations of the filter medium over time. In a rotary crankcase ventilation system, these filter elements may be rotated at high speeds for separating aerosols from the blowby gas stream. Thus, over time, uneven loading of the channels can lead to out-of-balance creep. Such creep may result in higher loads on the support and reduce support life.

In contrast, embodiments of the rotary crankcase ventilation filter element described herein (which include end caps that form an axial seal with the filter media) may provide one or more benefits, including, for example: (1) Preventing uneven collapse of the channels of the filter media by forming an axial seal; (2) reducing the risk of unbalanced creep of the filter media; and (3) reducing support loading, thereby reducing maintenance intervals, reducing warranty issues, and reducing maintenance costs, and increasing the life of the filter element.

Referring to FIG. 1A, a cross-sectional view of a crankcase ventilation system 10 is shown, according to an example embodiment. The crankcase ventilation system 10 includes a rotating crankcase ventilation filter element 16 (e.g., a rotating coalescer element) driven by pressurized fluid or a motor. The crankcase ventilation system 10 generally processes blowby gas received from the crankcase of an internal combustion engine to remove aerosols, oil, and other particulates contained in the crankcase blowby gas. The crankcase ventilation system 10 generally includes a housing 12 having an inlet 14, a central compartment, and an outlet 18, the inlet 14 receiving crankcase blowby gas to be filtered (e.g., from a crankcase of an internal combustion engine), the central compartment having a rotating crankcase ventilation filter element 16 (e.g., a rotating coalescer element mounted in the central compartment), the outlet 18 providing filtered blowby gas to the internal combustion engine (in a closed crankcase ventilation system) or to the environment (in an open crankcase ventilation system).

During operation of the crankcase ventilation system 10, blowby gas enters the housing 12 through the inlet 14. Blowby gas is directed to the central compartment where it flows through the filter element 16 in an inside-out manner. In alternative arrangements, the crankcase ventilation system 10 may be configured with an outside-in flow arrangement. The filter element 16 may be coupled to a central shaft 50, which central shaft 50 transmits rotation to the filter element 16. The central shaft 50 may be rotationally driven by the turbine 22, which turbine 22 is rotated by an oil jet (a jet of oil) generated by the oil pump 24. The turbine 22 may be a pulse turbine. In other embodiments, the central shaft 50 may be driven by an electric motor. As the filter element 16 rotates, the filter element 16 (e.g., a rotating coalescer element) separates out oil, aerosols, and other contaminants contained in the blowby gas. The separated contaminants are exhausted from the housing 12 through a drain (drain) 26 and returned to the engine crankcase sump 28. The filter element 16 may include a first end cap 20, a second end cap 42, and a filter media 40 (e.g., a separation device). In various embodiments, filter media 40 may include corrugated and wound filter media configured for axial flow, such as filter element 100 or 200 described in further detail below. For example, the filter media 40 may include multiple layers of filter media formed by wrapping or winding a single layer of filter media into a cylindrical shape.

Referring to fig. 2A, a cross-sectional view of a crankcase ventilation system 10a according to another embodiment is shown. The crankcase ventilation system 10a includes a rotating crankcase ventilation filter element 100 (e.g., a rotating coalescer element) according to the present disclosure, the rotating crankcase ventilation filter element 100 (e.g., a rotating coalescer element) being further described with reference to fig. 2B-2D. The crankcase ventilation system 10a generally processes blowby gas received from the crankcase of an internal combustion engine to remove aerosols, oil, and other particulates contained in the crankcase blowby gas. The crankcase ventilation system 10a generally includes a housing 12a having an inlet 14a that receives crankcase blowby gas to be filtered (e.g., from a crankcase of an internal combustion engine), a central compartment having a rotating crankcase ventilation filter element 100 (e.g., a rotating coalescer element mounted in the central compartment), and an outlet 18a that provides filtered blowby gas to the internal combustion engine (in a closed crankcase ventilation system) or to the environment (in an open crankcase ventilation system).

During operation of the crankcase ventilation system 10a, blowby gas enters the housing 12a through the inlet 14 a. Unlike system 10, the blowby gas is directed to a central compartment where it flows axially through filter element 100 (as indicated by the flow arrows shown in fig. 2B). The filter element 100 may be coupled to a central shaft 50a, which central shaft 50a imparts rotation to the filter element 100. The central shaft 50a is rotationally driven by the motor 22a, the motor 22a being disposed in a portion of the cover 20a coupled to the housing 12a that extends into the interior volume defined by the housing 12a. As the filter element 100 rotates, the filter element 100 (e.g., a rotating coalescer element) separates out oil, aerosols, and other contaminants contained in the blowby gas. The separated contaminants are exhausted from the housing 12a (e.g., through a drain) and returned to an engine crankcase sump (e.g., crankcase sump 28).

Fig. 2B is a side cross-sectional view of a filter element 100 that may be used as a filter element in crankcase ventilation system 10 or 10a, according to an embodiment. The filter element 100 may be used to filter a fluid, such as air, fuel, an air-fuel mixture, blowby gas, or any other fluid used in an internal combustion engine. The filter element 100 includes a filter media 110, a hub 112, a first end cap 120 (e.g., a top end cap), and a second end cap 130 (e.g., a bottom end cap) coupled to the first end cap. In certain embodiments, the filter element 100 comprises a rotary crankcase ventilation filter element. In such embodiments, the filter element 100 may be configured to filter crankcase blowby gases received from the crankcase of an internal combustion engine, for example, to remove aerosols, oil, and other particulates contained in the crankcase blowby gases. In various embodiments, the filter element 100 may be mounted or coupled to the central shaft 50. The central shaft 50 may be operably coupled to a motor (e.g., a DC motor) or turbine and configured to rotate the filter element 100, for example, to facilitate centrifugal separation of aerosols, oil, water, etc. from the blowby gas.

The filter media 110 is along the longitudinal axis a of the filter element 100 _L And (5) positioning. In some embodiments, the filter media 110 may include corrugated and wound filter media configured for axial flow. For example, fig. 2D shows a top view of a portion of filter media 110. Filter medium110 include a plurality of filter media layers 111, which filter media layers 111 are formed by winding or coiling a single layer of filter media 110 into a cylindrical shape. In various embodiments, the filter media 110 may be configured for axial flow. For example, the corrugations of the plurality of filter media layers 111 may define axial flow channels therebetween to allow axial flow of gas through the axial flow channels. As previously described, the filter element 100 may include a rotary crankcase ventilation filter element mounted on a central shaft 50, the central shaft 50 configured to rotate the filter element 100. Rotation may cause oil, particulates, or other contaminants included in a fluid (e.g., blowby gas) flowing through channels formed between the multiple layers 111 of filter media 110 to coalesce. The coalesced droplets are then removed from the filter element 100.

The filter media 110 is wound around the outer circumference of the hub 112. Hub 112 defines a central channel 116, which central channel 116 may be configured to receive central shaft 50 or 50a for mounting hub 112 on central shaft 50/50a, thereby mounting filter element 100 on central shaft 50/50 a. Hub 112 also defines at least one hub through bore 114. The at least one hub through bore 114 is configured to axially align with corresponding through bores defined in the first coupling portion 128 of the first end cap 120 and the second coupling portion 138 of the second end cap 130 such that one or more portions of the hub 112 defining the at least one hub through bore 114 are interposed between the first coupling portion 128 and the second coupling portion 138. A coupling member 140 (e.g., screw, bolt, pin, rivet, etc.) may be inserted through the through-holes defined in the first coupling portion 128, the second coupling portion 138, and the hub through-hole 114 to couple the first end cap 120 to the second end cap 130 and secure the hub 112, and thus the filter media 110, between the first end cap 120 and the second end cap 130.

The first end cap 120 is positioned on a first end (e.g., top end) of the filter media 110 of the filter media. The first end cap 120 may include a first end cap body 122 and a first sidewall 124, the first sidewall 124 extending axially from an outer periphery of the first end cap body toward the second end cap 130 such that the first end cap 120 defines a portion of an interior volume within which at least a portion of the filter media 110 and the hub 112 are disposed. A plurality of radial flow channels 126 are defined in the first end cap 120 to allow dirty fluid to enter the filter media 110 through the plurality of radial flow channels 126 or alternatively to allow clean fluid to exit the filter element 100. The first end cap 120 may be formed from a strong and rigid material, such as plastic (e.g., polypropylene, high density polyethylene, polyvinyl chloride, etc.), metal (e.g., aluminum, stainless steel, etc.), polymer (e.g., reinforced rubber, silicone), or any other suitable material.

A second end cap 130 is positioned on a second end of the filter media 110 opposite the first end of the filter media. The second end cap 130 is coupled to the first end cap 120 such that the first end cap 120 and the second end cap 130 define an interior volume within which the filter media 110 is disposed. For example, the second sidewall 136 protrudes axially from the outer periphery of the second end cap 130 toward the first end cap 120 radially outward from the filter media 110. The second sidewall 136 is configured to engage the proximal end 129 of the first sidewall 124, e.g., snap-lock to the proximal end 129, friction fit with the proximal end 129, or generally contact the proximal end 129, so as to define an enclosed volume within which the filter media 110 is disposed. The second end cap 130 may be formed of a strong and rigid material, such as plastic (e.g., polypropylene, high density polyethylene, polyvinyl chloride, etc.), metal (e.g., aluminum, stainless steel, etc.), polymer (e.g., reinforced rubber, silicone), or any other suitable material.

In some filter elements, the second sidewall (e.g., second sidewall 136) is configured to form a radial seal with the filter media 110, which may cause uneven channel collapse of the filter media 110, thereby causing the filter media 110 to lose balance during rotation. In contrast, a radial gap 139 exists between the second sidewall 136 and the radially outer surface of the filter media 110. Alternatively, the second end cap 130 of the filter element includes an axial sealing member 134, the axial sealing member 134 extending from the surface 132 of the second end cap 130 toward the filter media 110 and forming an axial seal with the filter media 110. As shown in fig. 2A, the axial sealing member 134 protrudes or extends substantially parallel to the axial fluid flow direction into the filter media 110. As in figure 2B and fig. 2C, the axial sealing member 134 is located proximal of the second sidewall 136 and radially inward of the second sidewall 136. In various embodiments, the axial sealing member 134 may include a seal about the longitudinal axis a _L A circumferentially disposed seal bead.

The axial sealing member 134 contacts (i.e., taps) or slightly interferes with (i.e., protrudes axially inward into) the filter media 110 and may compress or crimp (crimp) a corresponding portion of the filter media 110. This creates a barrier to blowby gases and prevents the blowby gases from bypassing (bypass) filter media 110. In some embodiments, axial interference of axial sealing member 134 with filter media 110 may be in the range of 0.0 millimeters (mm) to 0.8mm, and may be controlled by adjusting the tightness of coupling member 140, i.e., a higher tightness of coupling member 140 may draw second end cap 130 closer to first end cap 120 and increase the depth of interference, i.e., the depth of axial sealing member 134 into filter media 110. In other embodiments, interference may be achieved by snap-fitting the second sidewall 136 to the proximal end 129 of the first sidewall 124. Fig. 8 is a graph of separation or filtration efficiency of filter element 100 forming an axial seal according to the depth of interference (axial seal interference) of axial seal member 134 of second end cap 130 with filter media 110. The separation efficiency increased from 98.4% at 0.2mm interference depth and reached a peak at 0.8mm interference depth where about 99.5% separation efficiency was observed. However, an increase in the interference depth beyond 0.8mm does not lead to a further improvement in the separation efficiency.

As shown in fig. 2B-2C, the axial sealing member 134 has a triangular shape and has a sharp tip (tip) that contacts the filter media 110. In other embodiments, the axial sealing member may have a blunt or flat tip. For example, fig. 3 is a side cross-sectional view of a filter element 200 according to another embodiment. Filter element 200 includes filter media 210, hub 212, first end cap 220, and second end cap 230. The filter media 210, hub 212, and first end cap 220 may be substantially similar to the filter media 110, hub 112, and first end cap 120, respectively, and will not be described in further detail herein.

Referring to fig. 4-5, the second end cap 230 of the filter element 200 of fig. 3 includes an axial sealing member 234, the axial sealing member 234 extending from a surface 232 of the second end cap 230 toward the filter media 210 and forming an axial seal with the filter media 210. The axial seal member 234 is located proximal of the second sidewall 236 and radially inward of the second sidewall 236. The axial sealing member 234 protrudes or extends substantially parallel to the axial fluid flow direction into the filter media 210 (as shown in fig. 2A). In various embodiments, the axial sealing member 234 may include a seal about the longitudinal axis a _L A circumferentially disposed sealing bead. Unlike the axial sealing member 134 of fig. 2C, the end of the axial sealing member 234 is blunt or flat. Due to the interference of the axial sealing member 234 with the filter media 210, the blunt or flat-shaped tip of the axial sealing member 234 may reduce damage to the filter media 210 and/or reduce telescoping of layers of the filter media 210 relative to the sharp-tipped axial sealing member 134. Fig. 5 shows a configuration of filter element 200 in which axial seal member 234 contacts filter medium 210 without any interference, i.e., without entering filter medium 210. Fig. 6 illustrates another configuration of filter element 200 in which axial seal member 234 interferes with filter medium 210 (e.g., up into filter medium 210 to an interference depth of 0.2mm to 0.8 mm).

The axial seal members 134, 234 do not cause uneven collapse of the channels of the filter media 110, which greatly reduces the risk of the filter media 110 being out of balance, as is the case with end caps forming a radial seal with the filter media 110. For example, fig. 7 is a graph of the rate of imbalance growth for a second end cap of a filter element forming a radial seal with filter media 110 included in filter element 100, a second end cap 130 forming an axial seal via a triangular axial sealing member 134, and a second end cap 230 forming an axial seal with filter media 110 included in filter element 100 via a flat axial sealing member 234. Based on the results of the accelerated test simulating the plugging of the media with contaminants over time, the average imbalance ratio for the second end cap forming the radial seal was about 0.09g-mm/h at a confidence interval of about + -0.025 g-mm/h. In contrast, the average imbalance ratio for the second end cap 130 forming an axial seal via the triangular seal member 134 is about 0.06g-mm/h at a confidence interval of + -0.04 g-mm/h, and the average imbalance ratio for the second end cap 230 forming an axial seal via the flat axial seal member 234 is about 0.05g-mm/h at a confidence interval of + -0.02 g-mm/h, both of which are significantly lower than the average radial seal imbalance ratio.

Referring to fig. 9A and 9B, a cross-sectional view of a crankcase ventilation system 10B according to another embodiment is shown. The crankcase ventilation system 10b is similar in many respects to the crankcase ventilation system 10/10a described herein with respect to fig. 1 and 2A. For example, the crankcase ventilation system 10b generally processes blowby gas received from the crankcase of an internal combustion engine to remove aerosols, oil, and other particulates contained in the crankcase blowby gas. The crankcase ventilation system 10b generally includes a housing 12b having an inlet (not shown) that receives crankcase blowby gas to be filtered (e.g., from a crankcase of an internal combustion engine), a central compartment having a rotating crankcase ventilation filter element 300 (e.g., a rotating coalescer element mounted in the central compartment), and an outlet 18b that provides filtered blowby gas to the internal combustion engine (in a closed crankcase ventilation system) or to the environment (in an open crankcase ventilation system).

During operation of the crankcase ventilation system 10a, blowby gas enters the housing 12b through the inlet. Unlike the system 10/10a, the crankcase ventilation system 10b includes a rotary crankcase ventilation filter element 300 (e.g., a rotary coalescer element) according to the present disclosure. The filter element 300 is substantially similar or identical to the filter element 100/200 described herein with respect to fig. 2A-4. Similar to system 10a, the blowby gas is directed to a central compartment where it flows axially through filter element 300.

The filter element 300 may be coupled to a central shaft 50b, which central shaft 50b transmits rotation to the filter element 300. The central shaft 50a is rotationally driven by a motor 22b, the motor 22b being disposed in a portion of the cover 20b coupled to the housing 12b that extends into the interior volume defined by the housing 12 b. As the filter element 300 rotates, the filter element 300 (e.g., a rotating coalescer element) separates out oil, aerosols, and other contaminants contained in the blowby gas. The separated contaminants are exhausted from the housing 12b (e.g., through a drain) and returned to the engine crankcase sump or crankcase sump.

Filter element 300 includes filter media 310, hub 312, first end cap 320, and second end cap 330. The filter media 310 and the hub 312 may be substantially similar to the filter media 110/210 and the hub 112/212, respectively, and will not be described in further detail herein. The first end cap 320 may be substantially similar to the first end cap 120/220. For example, the first end cap 320 includes a first end cap body 322, a first sidewall 324, and a radial flow channel 326, the first end cap body 322, the first sidewall 324, and the radial flow channel 326 being substantially similar to the first end cap body 122/222, the first sidewall 124/224, and the radial flow channel 126/226, respectively. Unlike the first end cap 120/220, the first end cap 320 includes a fan 350 disposed about the perimeter of the first end cap body 322. The fan 350 is described in more detail herein with reference to fig. 9C. The second end cap 330 may be substantially similar to the second end cap 130 or the second end cap 230. For example, the second end cap 330 may include an axial sealing member 334 that extends from a surface 332 of the second end cap 330 toward the filter media 310 and forms an axial seal with the filter media 310. The axial sealing member 334 may have a triangular shape (e.g., a sharp tip) that contacts the filter media 310 similar to the axial sealing member 134, or the axial sealing member 334 may have a blunt or flat tip similar to the axial sealing member 234.

Referring now to fig. 9C, a side cross-sectional view of a portion of the filter element 300 of fig. 9A and 9B is shown. The fan 350 includes a fan wall 352 extending radially away from the first end cap body 322. The fan wall 352 may include an upper portion continuous with the first end cap body 322 and a lower portion continuous with the first side wall 324. The fan wall 352 defines one or more radial passages 354, the radial passages 354 being in fluid receiving communication with one or more of the radial flow passages 326 and in fluid providing communication with the central compartment of the housing 12 b.

The fan 350 causes fluid received from the radial flow channel 326 to flow along a first flow path (e.g., a recirculation flow path) and a second flow path (e.g., an exhaust flow path). The first flow path is defined by the inner surface of the housing 12b, the outer surface of the first sidewall 324, and the second end cap 330. As the fluid flows along the first flow path, the fluid passes through the gap between the first sidewall 324 and the housing 12 b. The fluid then enters the filter element 300 via the inlet 338 defined by the second end cap 330. The second flow path is defined by outlet 18 b. As the fluid flows along the second flow path, the fluid exits the crankcase ventilation system 10b via the outlet 18 b.

Referring now to fig. 10A and 10B, a side cross-sectional view of a filter element 400 and a portion of the filter element of fig. 10A indicated by arrow C that may be included in any of the crankcase ventilation systems described herein is shown, according to an embodiment. Filter element 400 includes filter media 410, hub 412, first end cap 420, and second end cap 430. Filter media 410 and hub 412 may be substantially similar to filter media 110/210/310 and hub 112/212/312, respectively. For example, the hub 412 defines at least one hub through bore 414.

The first end cap 420 may be substantially similar to the first end cap 120/220/320. For example, the first end cap 420 includes a first end cap body 422, a first sidewall 424, and a plurality of radial flow channels 426. The first end cap body 422, the first sidewall 424, and the plurality of radial flow channels 426 are substantially similar to the first end cap body 122/222/322, the first sidewall 124/224/324, and the radial flow channels 126/226/326, respectively. Unlike the first end cap 120/220/330, the first end cap 420 includes a first coupling portion 428, which first coupling portion 428 is part of the snap-fit engagement structure 600. The engagement structure 600 is described in more detail herein with reference to fig. 12-13C.

Second end cap 430 may be substantially similar to second end cap 130/230/330. For example, the second end cap 430 may include an axial sealing member 434 that extends from a surface 432 of the second end cap 430 toward the filter media 410 and forms an axial seal with the filter media 410. The axial sealing member 434 may have a triangular shape (e.g., a sharp tip) that contacts the filter media 410 similar to the axial sealing member 134, or the axial sealing member 434 may have a blunt or flat tip similar to the axial sealing member 234. Unlike the second end cap 130/230/330, the second end cap 430 includes a second coupling portion 438 that is part of the snap-fit engagement structure 600.

The at least one hub through bore 414 is configured to axially align with the first coupling portion 428 of the first end cap 420 and the second coupling portion 438 of the second end cap 430. The first coupling portion 428 of the first end cap 420 and the second coupling portion 438 of the second end cap 430 extend at least partially through the at least one hub through hole 414 such that the first coupling portion 428 engages the second coupling portion 438.

Referring now to fig. 11A and 11B, a side cross-sectional view of a filter element 500 and a portion of the filter element of fig. 11A indicated by arrow D that may be included in any of the crankcase ventilation systems described herein is shown, according to an embodiment. Filter element 500 includes filter media 510, hub 512, first end cap 520, and second end cap 530. Filter media 510, hub 512, and second end cap 530 may be substantially similar to filter media 410, hub 412, and second end cap 430, respectively. For example, hub 512 defines at least one hub through bore 514.

The first end cap 520 may be substantially similar to the first end cap 420. For example, the first end cap 520 includes a first end cap body 522, a first sidewall 524, a plurality of radial flow channels 526, and a first coupling portion 528, the first end cap body 522, the first sidewall 524, the plurality of radial flow channels 526, and the first coupling portion 528 being substantially similar to the first end cap body 422, the first sidewall 424, the radial flow channels 426, and the first coupling portion 428, respectively. Unlike the first end cap 420, the first end cap 520 includes a fan 550, the fan 550 being substantially similar to the fan 350 described herein with reference to fig. 9A-9C.

Fig. 12 is a side cross-sectional view of a snap-fit engagement structure 600 that may be included in a filter element 400/500 according to an embodiment. The engagement structure 600 includes a first coupling portion 628 (e.g., first coupling portion 428/528) and a second coupling portion 638 (e.g., second coupling portion 438/538). The first coupling portion 628 may be part of a first end cap (e.g., first end cap 420/520). The second coupling portion 638 may be part of a second end cap (e.g., second end cap 430/530). The first coupling portion 628 engages the second coupling portion 638 in a snap-fit arrangement such that the first end cap 420/520 is coupled to the second end cap 430/530. The first coupling portion 628 and the second coupling portion 638 are axially aligned with the through bore of the hub (e.g., the through bore 414/514 of the hub 412/512) on the axis 690.

The first coupling portion 628 includes a first engagement body 630. The first engagement body 630 may extend axially away from the first end cap 420/520 and toward the second end cap 430/530. The first coupling portion 628 includes one or more fork members 640 extending axially away from the first engagement body 630.

One or more fork members 640 include an inner portion 642, an end portion 644, an angled member 646, a shoulder 648, and an outer portion 650. The inner portion 642 defines an inner surface of one or more fork members 640 and extends axially between the first engagement body 630 and the tip portion 644. The inner portion 642 is substantially parallel to the axis 690. The tip portion is disposed at a distal end of one or more fork members 640. Angled portion 646 extends axially and radially (e.g., inclined relative to axis 690 and radially away from axis 690) toward shoulder 648, away from end portion 644. Shoulder 648 extends axially and radially away from end portion 644 (e.g., is inclined relative to axis 690 and radially toward axis 690). The shoulder 648 defines a recess configured to receive a portion of the second coupling portion 638. The outer portion 650 defines an outer surface of one or more fork members 640 and extends axially between the first engagement body 630 and the shoulder 648. The outer portion 650 is substantially parallel to the axis 690.

One or more fork members 640 define a gap 652 between the fork members. The gap extends axially from the proximal end of the one or more fork members 640 toward the distal end of the one or more fork members 640. Proximal ends of one or more fork members 640 are defined at the first engagement body 630.

The second coupling portion 638 includes a second engagement body 632. The second engagement body 632 may be part of the second end cap 430/530. The second coupling portion 638 includes an outer wall 660 and an inner wall 680. A channel 670 is defined between the outer wall 660 and the inner wall 680. The channel 670 receives at least a portion of one or more fork members 640 therein.

The outer wall 660 extends axially away from the second engagement body 632 (e.g., toward the first end cap 420/520). The outer wall 660 may be cylindrically shaped or may be tapered such that the cross-sectional diameter of the outer wall 660 decreases along the axial length of the outer wall 660. The outer wall 660 includes an outer surface 662 and an inner surface 664. As shown in fig. 12, outer surface 662 is sloped with respect to axis 690.

The inner surface 664 defines a recess 668. Recess 668 is configured to receive shoulder 648. The inner surface 664 contacts the shoulder 648 of one or more fork members 640 at the recess 668. The inner surface 664 may contact the one or more fork members 640 and apply a force to the one or more fork members 640 radially inward and axially toward the second end cap 430/530. In some embodiments, the force at least partially deflects the one or more fork members 640 radially inward (e.g., toward the axis 690) such that the one or more fork members 640 are retained by the second coupling portion 638 in a snap-fit arrangement.

A first portion of the inner surface 664 (e.g., the portion above the recess 668) is substantially parallel to the axis 690. A second portion of the inner surface 664 (e.g., the portion below the recess 668) is inclined with respect to the axis 690. The second portion of the inner surface 664 is substantially parallel to the angled portion 646 of the one or more fork members 640.

The inner wall 680 includes a proximal portion 682 and a distal portion 684. Proximal portion 682. Proximal portion 682 is angled relative to axis 690. For example, a first angle may be defined between the proximal portion 682 and the axis 690. The first angle may be between 90 ° and 180 ° (including 90 ° and 180 °), or more specifically between 160 ° and 165 ° (including 160 ° and 165 °). When one or more fork members 640 are received in channel 670, proximal portion 682 may contact at least a portion of one or more fork members 640. The proximal portion 682 may contact the one or more fork members 640 and apply a force radially outward to the one or more fork members 640. In some embodiments, the force at least partially deflects the one or more fork members 640 radially outward (e.g., away from the axis 690) such that the one or more fork members 640 are retained by the second coupling portion 638 in a snap-fit arrangement.

In some embodiments, the inner wall 680 is hollow such that the inner wall 680 defines a central opening 686 that is axially aligned with the axis 690. In other embodiments, the inner wall 680 is not hollow.

Fig. 13A-13C are side cross-sectional views of the snap-fit feature of fig. 12, in accordance with various embodiments. In a first embodiment, the fork members 640a of the engagement structure 600a have a first axial length 602a (in a particular embodiment about 25.4 millimeters (mm)). The first axial length 602a is measured from a proximal end of the fork member 640a (e.g., at the opening of the gap 652 a) to a distal end of the fork member 640a (e.g., at the tip 644 a). In a particular implementation of the first embodiment, the engagement structure 600a may have a retention force of about 96 pounds (lb) force.

In a second embodiment, the fork members 640b of the engagement structure 600b have a second axial length 602b (in a particular embodiment about 19.05 mm). The second axial length 602b is measured from a proximal end of the fork member 640b (e.g., at the opening of the gap 652 b) to a distal end of the fork member 640b (e.g., at the tip 644 b). In a particular implementation of the second embodiment, the engagement structure 600b may have a retention force of about 117 lb.

In a third embodiment, the fork member 640c of the engagement structure 600c has a third axial length 602c (about 12.7mm in a particular embodiment). Third axial length 602c is measured from a proximal end of fork member 640c (e.g., at an opening of gap 652 c) to a distal end of fork member 640c (e.g., at tip 644 c). In a particular implementation of the third embodiment, the engagement structure 600c may have a retention force of about 147 lb.

Fig. 14 is a side cross-sectional view of a filter element 800 that may be included in any of the crankcase ventilation systems described herein, according to an embodiment. Filter element 800 includes filter media 810, hub 412, first end cap 420, and second end cap 430. Filter media 410 and hub 412 may be substantially similar to filter media 110/210/310/410/510 and hub 112/212/312/412/512, respectively. For example, the hub 812 defines at least one hub through bore 814.

The first end cap 820 may be substantially similar to the first end cap 120/220/320/420/520. For example, the first end cap 820 includes a first end cap body 822, a first sidewall 824, and a plurality of radial flow channels 826, the first end cap body 822, the first sidewall 824, and the plurality of radial flow channels 826 being substantially similar to the first end cap body 122/222/322/422/522, the first sidewall 124/224/324/424/524, and the radial flow channels 126/226/326/426/526, respectively. Unlike the first end cap 120/220/320/420/520, the first end cap 820 includes a first coupling portion 828. This first coupling portion 828 is described in more detail herein below.

The second end cap 830 may be substantially similar to the second end cap 120/220/320/420/520. Unlike the second end cap 120/220/320/420/520, the second end cap 830 includes a second coupling portion 838.

The at least one hub through bore 814 is configured to axially align with the first coupling portion 828 of the first end cap 820 and the second coupling portion 838 of the second end cap 830. The axial member 840 may extend through the through hole 814 and contact the first coupling portion 828 of the first end cap 820 and the second coupling portion 438 of the second end cap 430. The axial member 840 may be coupled to the hub 812, the first end cap 820, and/or the second end cap 830 such that the first end cap 820 is coupled to the second end cap 830. The axial member 840 may be coupled to the hub 812, the first end cap 820, and/or the second end cap 830 by a welding process.

In some embodiments, the filter element 100/200/300/400/500/800 can be configured to be removably coupled to the central shaft 50/50a/50b. In other embodiments, the filter element 100/200/300/400/500/800 can be secured to the central shaft 50/50a/50b.

It should be noted that the term "example" as used herein to describe embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to mean that such embodiments must be prominent or excellent examples).

As used herein, the term "substantially" and any similar terms are intended to have a broad meaning consistent with the use of such terms as is common and acceptable to those of ordinary skill in the art to which the presently disclosed subject matter pertains. Those skilled in the art who review this disclosure will appreciate that, unless otherwise indicated, these terms are intended to allow the description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be construed to indicate insubstantial or insignificant modifications or variations of the described and claimed subject matter are considered to be within the scope of the invention described in the appended claims.

The terms "coupled," "connected," and the like as used herein refer to two members being directly or indirectly joined to one another. Such joining may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved by the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or by the two members or the two members and any additional intermediate members being attached to one another.

It is important to note that the construction and arrangement of the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the embodiments described herein.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any embodiments or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

Claims

1. A rotary crankcase ventilation filter element comprising:

the filter medium is provided with a plurality of layers,

a first end cap positioned over a filter media first end of the filter media; and

a second end cap positioned on a second end of the filter media, the second end cap coupled to the first end cap such that the first end cap and the second end cap define an interior volume within which the filter media is disposed, the second end cap including an axial sealing member extending from a surface of the second end cap toward the filter media and forming an axial seal with the filter media, the axial sealing member protruding substantially parallel to an axial fluid flow direction into the filter media.

2. A rotary crankcase ventilation filter element according to claim 1 wherein:

the first end cap includes:

a first end cap body, and

a first sidewall extending axially from an outer periphery of the first end cap body toward the second end cap; and is also provided with

The second end cap includes a second sidewall extending from an outer periphery of the second end cap toward the first end cap and contacting a proximal end of the first sidewall.

3. The rotary crankcase ventilation filter element according to claim 2 wherein a radial gap exists between said second sidewall and a radially outer surface of said filter media.

4. The rotary crankcase ventilation filter element according to claim 2 wherein said axial seal member is located proximal to and radially inward of said second sidewall.

5. The rotary crankcase ventilation filter element according to claim 2 wherein said first end cap further comprises:

a plurality of radial flow channels; and

a fan disposed about a perimeter of the first end cap body, the fan comprising a fan wall extending radially away from the first end cap body, wherein the fan is in fluid receiving communication with one or more radial flow channels of the plurality of radial flow channels.

6. A rotary crankcase ventilation filter element according to claim 1 wherein:

the first end cap further includes a first coupling portion;

the second end cap includes a second coupling portion;

the first and second coupling portions at least partially define a through bore; and is also provided with

The rotary crankcase ventilation filter element includes a coupling member extending through the through bore and coupling the first end cap to the second end cap.

7. A rotary crankcase ventilation filter element according to claim 1 wherein:

the first end cap includes a first coupling portion; and is also provided with

The second end cap includes a second coupling portion configured to receive the first coupling portion in a snap-fit arrangement.

8. The rotary crankcase ventilation filter element according to claim 1 wherein said first end cap is welded to said second end cap.

9. The rotary crankcase ventilation filter element according to claim 1 wherein said axial seal member has a triangular shape defining a sharp tip that contacts said filter media.

10. The rotary crankcase ventilation filter element according to claim 8 wherein said axial seal member has an axial interference with said filter media of from 0.0 millimeters (mm) to 0.8mm.

11. The rotary crankcase ventilation filter element according to claim 1 wherein said axial seal member has a flat shape that contacts said filter media without interference.

12. A crankcase ventilation system comprising:

a housing having an outlet and an inlet for receiving a fluid;

a rotary crankcase ventilation filter element, said rotary crankcase ventilation filter element comprising:

the filter medium is provided with a plurality of layers,

13. The crankcase ventilation system according to claim 12 wherein:

the first end cap includes:

a first end cap body, and

14. The crankcase ventilation system according to claim 13 wherein a radial gap exists between said second sidewall and a radially outer surface of said filter media.

15. The crankcase ventilation system according to claim 13 wherein said axial sealing member is located proximal to and radially inward of said second sidewall.

16. The crankcase ventilation system according to claim 13 wherein said first end cap further comprises:

a plurality of radial flow channels; and

17. The crankcase ventilation system according to claim 16 wherein said second end cap defines a second end cap inlet, and wherein said fan is in fluid providing communication with said outlet and said second end cap inlet.

18. The crankcase ventilation system according to claim 12 wherein:

the first end cap further includes a first coupling portion;

the second end cap includes a second coupling portion;

19. The crankcase ventilation system according to claim 12 wherein:

the first end cap includes a first coupling portion; and is also provided with

20. The crankcase ventilation system according to claim 12 wherein said first end cap is welded to said second end cap.

21. The crankcase ventilation system according to claim 12 wherein said axial sealing member has a triangular shape defining a sharp distal tip contacting said filter media.

22. The crankcase ventilation system according to claim 12 wherein said axial seal member has an axial interference with said filter media of between 0.0 millimeters (mm) and 0.8 mm.

23. The crankcase ventilation system according to claim 12 wherein said axial seal member has a flat shape that contacts said filter media without interference.

24. A rotary crankcase ventilation filter element comprising:

a filter medium; and

an end cap positioned over a filter media end of the filter media, the end cap comprising:

an axial sealing member extending from a surface of the end cap toward the filter media and forming an axial seal with the filter media, the axial sealing member protruding substantially parallel to an axial fluid flow direction into the filter media; and

a sidewall extending from the outer periphery of the end cap toward the filter media, wherein a radial gap is defined between the sidewall and a radially outer surface of the filter media.