NZ782628A - Crankcase Filter - Google Patents

Abstract

It can be difficult to determine from a quick visual inspection whether a crankcase filter is blocked and in need of replacement. Some filters vent gases to atmosphere when blocked but this does not meet global automotive emissions regulations. A further problem with crankcase filters is that they do not provide adjustability and flexible fitment in a vehicle. The invention provides a filter assembly 1 including a housing configured to contain a filter element for separating oil entrained in blow-by gases generated in an internal combustion engine. The housing having a first and second parts. The first part having at least one inlet 9 for providing blow-by gases generated in the engine to the filter element. The second part having at least one outlet 11 for providing substantially oil free gases from the filter element to an air intake of the engine. The first and second parts are advantageously mountable in a multitude of different positions relative to one another to thereby alter the position of the inlet relative to the outlet. The assembly further includes an internal by-pass valve 32 within said housing which is openable to direct the blow-by gases to bypass the filter element and exit the outlet 11, and a visual indicator 36 operable by the bypass valve 32. The visual indicator 36 advantageously providing a signal when the bypass valve 32 is open. o not provide adjustability and flexible fitment in a vehicle. The invention provides a filter assembly 1 including a housing configured to contain a filter element for separating oil entrained in blow-by gases generated in an internal combustion engine. The housing having a first and second parts. The first part having at least one inlet 9 for providing blow-by gases generated in the engine to the filter element. The second part having at least one outlet 11 for providing substantially oil free gases from the filter element to an air intake of the engine. The first and second parts are advantageously mountable in a multitude of different positions relative to one another to thereby alter the position of the inlet relative to the outlet. The assembly further includes an internal by-pass valve 32 within said housing which is openable to direct the blow-by gases to bypass the filter element and exit the outlet 11, and a visual indicator 36 operable by the bypass valve 32. The visual indicator 36 advantageously providing a signal when the bypass valve 32 is open.

Description

gases to bypass the filter element and exit the outlet 11, and a visual indicator 36 operable by the bypass valve 32. The visual indicator 36 ageously providing a signal when the bypass valve 32 is open.

CRANKCASE FILTER FIELD OF THE INVENTION The present invention relates to a crankcase filter for purifying crankcase gases generated in an internal combustion engine by removing entrained oil droplets therefrom.

BACKGROUND OF THE ION In an internal combustion engine, a n amount of gas generated within the tion chambers is forced past the piston rings into the crankcase. As the gases blow past the piston rings into the crankcase they are sometimes referred to as blow-by gases. The crankcase gases need to be vented to avoid excessive crankcase pressure. A ase filter is designed to remove inants such as oil droplets from the crankcase gases that vent from the crankcase before the cleaned gases are redirected back to the air intake system of the engine.

Over time crankcase filters can become d with oil stripped from the crankcases gases unless the filter element is routinely replaced. A problem with existing filters is that it can be difficult to determine from a quick visual inspection whether a filter is blocked and in need of replacement.

To avoid excess pressure in the event of a filter blockage, some existing ase filters incorporate a relief valve that vent gases to atmosphere once a predetermined internal pressure is achieved. However, a problem with such pressure relief valves that vent oil contaminated gases to atmosphere is that they do not meet global tive emissions regulations. 18248066_1 (GHMatters) P114188.NZ A further problem with known crankcase filters is that they do not provide adjustability and flexible fitment in a vehicle.

It would be desirable to provide a crankcase filter of the above described general type which has one or more improved es.

Any discussion of nts, devices, acts or knowledge in this specification is included to explain the context of the invention. It should not be taken as an admission that any of the material formed part of the prior art base or the common general knowledge in the relevant art on or before the priority date of the claims herein.

SUMMARY OF THE INVENTION In ance with a first aspect of the present invention there is provided a filter assembly for separating oil ned in blow-by gases generated in an internal tion engine. The filter assembly including a housing configured to n therein a filter element for separating oil entrained in blowby gases generated in the internal tions engine. The housing has at least a first part and a second part. The first part has at least one inlet for providing blow-by gases generated in an internal combustion engine to the filter t.

The second part has at least one outlet for providing substantially oil free gases from the filter element to an air intake of the internal combustion engine, wherein the first part and the second are mountable in a multitude of different positions relative to one another to thereby alter the position of the inlet relative to the outlet.

The first part and the second part are preferably mountable to one another in said multitude of different positions. An angular position of the inlet relative to the outlet being altered at each ng positon. More specifically, the inlet and the outlet can project in substantially the same direction when the 18248066_1 (GHMatters) P114188.NZ first part and the second part are in a first mounting position, and project in a substantially opposite directions when the first part and the second part are in a second ng position in which the second part is angularly displaced 180°degrees compared to the position of the second part in the first mounting position. In addition, the inlet and outlet may project at right angles to one r when the first part and the second part are in a third mounting position.

Preferably, the first part is a main body of the housing and the second part is an end portion that is insertable into an upper opening of the main body.

The end portion preferably includes an annular seal member engageable with an internal wall of the main body to seal the end cap to the main body.

The filter assembly may further include a replaceable filter element centrally located within a cylindrical portion of the main body. The filter element ably leaves an annular space between an external surface of the filter element and the internal wall of the main body.

The filter assembly may further include a by-pass valve within said housing. The by-pass valve being openable to direct the blow-by gases to bypass the filter t. In this , blow-by gases are preferably fed through the at least one inlet into the cylindrical portion of the main body. The blow-by gases passing into the annular space being then forced through walls of the filter element into a centre of the filter element when the by-pass valve is in a default closed on. The bypass valve preferably opens at a predetermined pressure, when pressure of accumulating blow-by gases within the annular space in the event of a blocked filter element reaches the predetermined pressure, to allow blow-by gases to bypass the filter t and exit the outlet.

The filter assembly may further include a visual indicator operable by the bypass valve. The visual indicator functioning to signal when the bypass valve is open. 66_1 (GHMatters) P114188.NZ In one form the visual indicator es an indicator stem which is visible in a window of the end portion when the bypass valve is opened. The indictor stem being pushed by the bypass valve as the bypass valve progressively opens.

The bypass valve is preferably internally housed in an upper region of the end portion. The bypass valve being in communication with an annular passage of the end n and the annular space around the filter element. The annular passage being defined between the inner wall of the end portion and an outer wall of the end portion with a free end of the annular passage projecting into the annular space around the filter element.

In a preferred form, the bypass valve is a diaphragm valve which biased to the default closed position.

Preferably, y gases passing through the walls of the filter element are substantially stripped of oil and pass into a chamber in the end portion defined by an inner wall of the end portion. The d blow-by gases substantially stripped of oil are then preferably fed from the chamber through the outlet to an air intake of the engine. Oil is preferably stripped from the blow by gases by at least one impervious to oil membrane of the filter element. The stripped oil passing to an oil collecting lower n of the main body.

In accordance with another aspect of the invention, there is provided a filter assembly for separating oil entrained in blow-by gases generated in an internal combustion engine. The filter ly including a housing configured to contain therein a filter element for separating oil entrained in blow-by gases generated in the internal combustions engine. The housing having at least one inlet for providing blow-by gases generated in an internal combustion engine to the filter element, and at least one outlet for providing ntially oil free gases from the filter element to an air intake of the internal combustion engine. The assembly r es an internal s valve within said housing. The by- 18248066_1 (GHMatters) P114188.NZ pass valve being openable to direct the blow-by gases to bypass the filter element and exit the outlet. The assembly further including a visual indicator operable by the bypass valve, the visual indicator functioning to signal when the bypass valve is open.

To assist in further understanding the invention, reference will now be made to the accompanying drawings which rate preferred embodiments. It is to be appreciated that these embodiments are given by way of ration only and that the invention is not to be limited by these illustrations.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a sectioned perspective view of a filter assembly in accordance with a preferred embodiment of the invention; Figure 1A is a cross-sectional view of the filter assembly illustrated in Figure 1; Figure 2 is a ned perspective view of an end cap of the filter assembly illustrated in Figure 1, and Figure 3 is a sectioned perspective view of the filter element of the filter assembly illustrated in Figure 1.

PTION OF RED MENTS With reference to the accompanying drawings, there is shown a filter assembly 1 for removing contaminants such as oil droplets from crankcase gases (otherwise known as blow-by gases) that vent from the crankcase of an internal combustion engine. The filter assembly 1 includes a g configured to contain therein a filter element 3 for separating oil entrained in blow-by gases 18248066_1 (GHMatters) P114188.NZ generated in the internal combustion engine. In this regard, the filter t 3 includes a filtering membrane 4 such that as the blow-by gases pass through the filter element 3, oil contaminants are collected and separated from the gases resulting in substantially oil-free gases.

The housing of the filter ly 1 includes a first part which is preferably in the form of a main body 5, and a second part which is preferably in the form of an end cap 7. The main body 5 is generally of cylindrical uction and has at least one inlet 9 providing a duct for blow-by gases generated in the internal combustion engine to the enter the filter ly 1 in the vicinity of the filter element 3. The end cap 7 es at least one outlet 11 providing a duct for substantially oil-free gases from the filter element 3 to exit the filter assembly 1 and be subsequently fed back to an air intake of the internal combustion engine.

The main body 5 and the end cap 7 are mountable in a multitude of different positions relative to one another to thereby alter the position of the inlet 9 relative to the outlet 11. This advantageously provides the filter ly 1 with flexibility and adjustability in the fitment of the filter assembly 1, for example within the engine bay of a motor vehicle where space constraints can make it difficult to find an riate mounting position for the filter assembly 1.

In a particularly preferred form, the end cap 7 can be mounted directly to the main body 5 and d in placed in a multiple number of different positions. The angular on of the inlet 9 relative to the outlet 11 can thereby be altered if the present position of the inlet 9 and outlet 11 is not suitable for a particular mounting location of the filter assembly 1. The main body 5 and end cap 7 are each preferably provided with a series of spaced apart mounting res 8 through which a series of fastening members 15 are provided to secure the end cap 7 to the main body 5. In a particularly preferred embodiment, four mounting apertures 8 are evenly spaced around a periphery of both the main body 5 and end cap 7. 18248066_1 (GHMatters) P114188.NZ In a first mounting position illustrated in Figure 1, the inlet 9 and outlet 11 project in substantially the same direction. If the position of the inlet 9 and outlet 11 is not suitable in this position for a particularly ng location of the filter assembly 1, the ing members 15 can be removed from the ng apertures 8 and the main body 5 rotated relative to the end cap 7 to a more suitable position before re-inserting the fastening members 15. In a second mounting on, the end cap 7 is rotated 180 s compared to the on of the end cap 7 in the first mounting position such that the inlet 9 and outlet 11 project in substantially opposite directions. In a third mounting position, the inlet 9 and outlet 11 project at ntially right angles to one another. In a fourth mounting positon, the inlet 9 and outlet 11 again project at substantially right angles to one another but the inlet 9 faces in the te direction compared to the position of the inlet 9 in the third mounting position. With four mounting apertures 8, the inlet 9 and outlet ports 9, 11 are able to be configured in four different positions without the operation of the filter assembly 1 being impacted.

As best illustrated in Figure 2, the end cap 7 includes an annular seal member 17 located in a channel provided in a downwardly ting exterior wall 19 of the end cap 7. When the end cap 7 is mounted to the main body 5 as illustrated in Figures 1 and 1A, the annular seal member 17 abuts with an internal wall 21 of the main body 5 to seal the end cap 7 to the main body 5.

The filter element 3 is centrally locatable within a cylindrical portion of the main body 5. A lower end of the filter element 3 includes an outwardly projecting annular flange 23 which houses a lower annular sealing ring 25. The lower annular g ring 25 of the filter element 3 abuts against the internal wall 21 of the main body 5 when inserted into the main body 5 as illustrated in Figure 1. An ng upper end of the filter element 3 includes an upper annular sealing ring 27 which seals against an inner wall 29 of the end cap 7 when the end cap 7 is positioned over the upper end of the filter element 3 once the filter element 3 has been inserted into the main body 5, as shown in Figures 1 and 1A.

When the filter element 3 is seated within the main body 5 an annular space 31 is 18248066_1 (GHMatters) P114188.NZ defined between an external surface 22 of the filter element 3 and the internal wall 21 of the main body 5.

The filter assembly 1 further includes a by-pass valve 32 d internally within an upper region of the end cap 7. The by-pass valve 32 functions to open at a ermined pressure in the event of a blocked filter element 3 to provide an ative pathway for blow-by gases, as will be ned below in r detail. The by-pass valve 32 is preferably in communication with an annular e 34 of the end cap 7. The annular passage 34 is d between the inner wall 29 of the end cap 7 and the exterior wall 19 of the end cap 7. The annular passage 34 has a lower end which projects downwardly into the annular space 31 around the filter element 3 when the end cap 7 is mounted to the main body 5. The annular passage 34 may also include one or more internal walls to divide the annular passage 34 into a series of passages or s.

When the filter element 3 is operating as intended and the by-pass filter 32 is therefore in a default closed position, the only pathway for blow-by gases, which fed through the inlet 9 into the annular space 31 within the main body 5, is through the filtering membrane 4 of the filter element 3. Blow-by gases which are forced through the filter membrane 4 are stripped of oil leaving oil-free gases to exit into a hollow central region of the filter element 3. The oil-free gases can flow upwardly into the end cap 7 and exit the filtering assembly 1 via the outlet 9 before being returned to the air intake of the engine. The stripped off oil may dropping down into a bottom region 42 of the main body 5 where the oil can be dispensed through an oil collecting outlet 44 located in a bottom wall of the main body 5.

Over time the filtering member 4 will become less effective as oil and other contaminants are collected g to the eventual blocking of the filtering membrane 4. When the filter element 3 becomes blocked, y gases will late in the annular space 31 and associated annular passage 34 leading to the by-pass valve 32. The by-pass valve 32 is configured to open at a 18248066_1 (GHMatters) P114188.NZ predetermined pressure to e a pathway for the release of the blow-by gases through the valve 32 such that they can then exit the outlet 11.

More specifically, when re of accumulating y gases reaches the predetermined pressure at which the by-pass valve 32 opens, blowby gases are able to pass through the by-pass valve 32 and subsequently exit the outlet 11 via a central release passage 31 which is normally blocked by the bypass valve 32.

The filter assembly 1 may further include a visual indicator which is operable by the by-pass valve 32. In this regard, the visual indicator ons to signal to a user when the by-pass valve 32 is open which indicates that the filter element 3 may be clogged with particles and require replacement. The visual indicator preferably includes an indicator stem 36 which is visible through a window 38 of the end cap 7 when the by-pass valve 32 is open. The indicator stem 36 is preferably in direct contact with the s valve 32 and is pushed upwardly s the window 38 as by-pass valve 32 progressively opens. The window 38 is preferably cylindrical with a hollow interior 47 and a closed upper end 30. The window 38 protrudes upwardly from a top wall 45 of the end cap 7 with the hollow interior 47 providing a space for the indicator stem 36 to project upwardly into when forced s by the by-pass valve 32 to indicate a blocked filter element 3.

In a particularly preferred embodiment, the by-pass valve 32 is a agm valve which is biased to the default closed position by a spring member 40 which surrounds the indicator stem 36. A lower end of the spring member 40 rests upon a substantially rigid plate-like compressor 46 of the diaphragm valve with an upper end of the spring member 40 being in engagement with the top wall 45 of the end cap 7. The diaphragm valve further includes a flexible diaphragm 51 positioned underneath the compressor 46. In the default closed position the diaphragm valve blocks crankcase gases from entering the upper end cap 7 via the annular bypass passages 34 but is free to 18248066_1 ters) P114188.NZ move up under spring re when a predetermined pressure is reached in the main body 5.

The annular passage 34 advantageously allows for the outlet 11 of the end cap 7 and the inlet 9 of the main body 5 to be configured in the abovementioned different positions relative to each other without impacting the functioning of the filter assembly 1.

The filter assembly 1 of the invention advantageously allows crankcase gases to bypass the filter element 3 by virtue of the internal bypass pressure relief valve 32 while still allowing the filter ly 1 to be configured for different inlet/outlet port positions and also signal to the user that the bypass mechanism 32 is operating and when the filter element 3 becomes obstructed and is due for replacement. 18248066_1 (GHMatters) P114188.NZ

Claims (14)

CLAIMS :

1. A filter assembly for separating oil entrained in blow-by gases generated in an al tion engine, the filter ly including a housing configured to contain therein a filter element for separating oil entrained in y gases generated in the internal combustions engine, the housing having at least a first part and a second part, the first part having at least one inlet for providing blow-by gases generated in an internal tion engine to the filter element, the second part having at least one outlet for providing ntially oil free gases from the filter element to an air intake of the internal combustion engine, wherein the first part and the second are mountable in a multitude of different positions relative to one another to thereby alter the position of the inlet relative to the outlet.

2. A filter assembly as claimed in claim 1 n the first part and the second part are mountable to one another in said multitude of different positions, an angular position of the inlet relative to the outlet being altered at each mounting positon.

3. A filter assembly as claimed in claim 2 wherein the inlet and the outlet project in substantially the same direction when the first part and the second part are in a first mounting position, and project in a substantially opposite directions when the first part and the second part are in a second mounting position in which the second part is angularly displaced 180°degrees compared to the position of the second part in the first mounting position.

4. A filter assembly as d in claim 3 wherein the inlet and outlet project at right angles to one another when the first part and the second part are in a third mounting position. 18248066_1 (GHMatters) P114188.NZ

5. A filter assembly as claimed in any one of the ing claims wherein the first part is a main body of the housing and the second part is an end portion, the end portion being insertable into an upper opening of the main body, the end portion including an annular seal member engageable with an internal wall of the main body to seal the end cap to the main body.

6. A filter assembly as claimed in claim 5 wherein the filter assembly further includes a replaceable filter element centrally located within a cylindrical portion of the main body, the filter element leaving an annular space between an external surface of the filter t and the al wall of the main body.

7. A filter assembly as claimed in claim 6 wherein the ly further includes a by-pass valve within said housing, the by-pass valve being le to direct the blow-by gases to bypass the filter element.

8. A filter assembly as claimed in claim 7 wherein blow-by gases are fed through the at least one inlet into the cylindrical portion of the main body; the blow-by gases passing into the annular space being forced through walls of the filter element into a centre of the filter element when the by-pass valve is in a default closed position.

9. A filter assembly as d in claim 8 wherein the bypass valve opens at a predetermined pressure, when re of accumulating blow-by gases within the annular space in the event of a blocked filter element reaches the predetermined pressure, to allow blow-by gases to bypass the filter element and exit the .

10. A filter assembly as claimed in claim 9 r including a visual indicator operable by the bypass valve, the visual indicator functioning to signal when the bypass valve is open. 18248066_1 (GHMatters) P114188.NZ

11. A filter assembly as claimed in claim 10 wherein the visual indicator includes an indicator stem which is visible in a window of the end portion when the bypass valve is opened, the indictor stem being pushed by the bypass valve when the bypass valve opens.

12. A filter assembly as claimed in any one of claims 7 to 11 n the bypass valve is internally housed in an upper region of the end portion, the bypass valve being in communication with an annular e of the end portion and the annular space around the filter element, the annular passage being defined between the inner wall of the end portion and an outer wall of the end portion, a free end of the annular passage projecting into the annular space around the filter element

13. A filter assembly as claimed in claim 12 wherein the bypass valve is a diaphragm valve which biased to said default closed position.

14. A filter assembly for separating oil entrained in blow-by gases generated in an internal combustion engine, the filter assembly including a g configured to contain therein a filter t for separating oil entrained in blow-by gases generated in the internal combustions engine, the housing having at least one inlet for providing blow-by gases generated in an internal combustion engine to the filter t, and at least one outlet for providing ntially oil free gases from the filter element to an air intake of the internal combustion engine, wherein the assembly further includes an internal by-pass valve within said housing, the by-pass valve being le to direct the blow-by gases to bypass the filter element and exit the outlet, and a visual indicator operable by the bypass valve, the visual indicator functioning to signal when the bypass valve is open. 18248066_1 (GHMatters) P114188.NZ