Oil pick-up assembly

Abstract

An oil pick-up assembly includes an upper housing having an upper shell extending from a first end of the assembly to a second end of the assembly. The upper shell defines a mounting plane of the assembly. The upper housing further includes an upper peripheral flange surrounding the upper shell. The oil pick-up assembly also a lower housing having a lower shell extending from the first end of the assembly to the second end of the assembly. The lower shell includes a first portion adjacent to the first end and substantially parallel to the mounting plane and a second portion adjacent to the second end and formed at a first oblique angle relative to the mounting plane. The lower shell also includes a lower peripheral flange surrounding the lower shell, the lower peripheral flange of attached to the upper peripheral flange of the upper housing to form a chamber.

Claims

1. An oil pick-up assembly for a motor vehicle, the oil pick-up assembly comprising: an upper housing comprising: an upper shell extending from a first end of the assembly to a second end of the assembly, the upper shell defining a mounting plane of the assembly; an outlet tube extending from the second end, the outlet tube having a central axis that is parallel to the mounting plane; and an upper peripheral flange surrounding the upper shell; and a lower housing comprising: a lower shell extending from the first end of the assembly to the second end of the assembly, the lower shell including a first portion adjacent to the first end and substantially parallel to the mounting plane and a second portion adjacent to the second end and formed at a first oblique angle relative to the mounting plane; and a lower peripheral flange surrounding the lower shell, the lower peripheral flange attached to the upper peripheral flange of the upper housing to form a chamber.

2. The oil pick-up assembly of claim 1, wherein the lower housing comprises a pick-up tube extending from the second portion at a second oblique angle relative to the mounting plane.

3. The oil pick-up assembly of claim 2, wherein the pick-up tube extends continuously along a longitudinal axis extending from a proximal end connected to the second portion of the lower shell to a distal end.

4. The oil pick-up assembly of claim 3, wherein the pick-up tube tapers from the first end to the second end.

5. The oil pick-up assembly of claim 1, wherein the first portion of the lower shell is connected to the second portion of the lower shell by an arcuate intermediate portion.

6. The oil pick-up assembly of claim 1, wherein a portion of the upper peripheral flange that surrounds the upper shell extends along the second end of the assembly at a third oblique angle relative to the mounting plane.

7. The oil pick-up assembly of claim 6, wherein a value of the third oblique angle is the same as a value of the first oblique angle.

8. The oil pick-up assembly of claim 1, wherein the upper peripheral flange is welded to the lower peripheral flange.

9. The oil pick-up assembly of claim 1, wherein the upper housing comprises at least one mounting tab extending from the upper shell, the at least one mounting tab including a mounting surface defining the mounting plane of the upper housing.

10. A method of manufacturing an oil pick-up assembly for a motor vehicle, the method comprising the steps of: forming an upper housing including an upper shell extending from a first end of the assembly to a second end of the assembly and an upper peripheral flange surrounding the upper shell, the upper shell defining a mounting plane of the assembly and an outlet tube extending from the second end, the outlet tube having a central axis that is parallel to the mounting plane; forming a lower housing including a lower shell extending from the first end to the second end and a lower peripheral flange surrounding the lower shell, wherein: the lower peripheral flange of the lower housing is attached to the upper peripheral flange of the upper housing to form a chamber; and the lower shell comprises a first portion adjacent to the first end and substantially parallel to the mounting plane, and a second portion adjacent to the second end and formed at a first oblique angle relative to the mounting plane; and attaching the upper peripheral flange of the upper housing to the lower peripheral flange of the lower housing.

11. The method of claim 10, wherein forming the lower housing comprises forming a pick-up tube extending from the second portion at a second oblique angle relative to the mounting plane.

12. The method of claim 11, wherein forming the pick-up tube comprises extending the pick-up tube continuously along a longitudinal axis from a proximal end connected to the second portion of the lower shell to a terminal distal end.

13. The method of claim 12, wherein forming the pick-up tube comprises tapering the pick-up tube.

14. The method of claim 10, wherein forming the lower shell comprises forming an arcuate intermediate portion connecting the first portion of the lower shell to the second portion of the lower shell.

15. The method of claim 10, wherein forming the upper housing comprises forming a portion of the upper peripheral flange that surrounds the upper shell to extend along the second end of the assembly at a third oblique angle relative to the mounting plane.

16. The method of claim 15, wherein a value of the third oblique angle is the same as a value of the first oblique angle.

17. The method of claim 10, wherein attaching the upper peripheral flange of the upper housing to the lower peripheral flange of the lower housing comprises welding the upper peripheral flange to the lower peripheral flange.

18. The method of claim 10, wherein forming the upper housing comprises: forming at least one mounting tab extending from the upper shell; and forming the at least one mounting tab with a mounting surface defining the mounting plane of the upper housing.

Description

DESCRIPTION OF DRAWINGS

(1) FIG. 1 is bottom-rear perspective view of an example of oil pick-up assembly.

(2) FIG. 2 is a top-front perspective view of the oil pick-up assembly of FIG. 1.

(3) FIG. 3 is a bottom-front exploded perspective view of the oil pick-up assembly of FIG. 1.

(4) FIG. 4 is a top-rear exploded perspective view of the oil pick-up assembly of FIG. 1.

(5) FIG. 5 is a rear elevation view of the oil pick-up assembly of FIG. 1.

(6) FIG. 6 is a front elevation view of the oil pick-up assembly of FIG. 1.

(7) FIG. 7 is a right side elevation view of the oil pick-up assembly of FIG. 1.

(8) FIG. 8 is a left side elevation view of the oil pick-up assembly of FIG. 1.

(9) FIG. 9 is a top plan view of the oil pick-up assembly of FIG. 1.

(10) FIG. 10 is a bottom plan view of the oil pick-up assembly of FIG. 1.

(11) FIG. 11 is a cross-sectional view of the oil pick-up assembly of FIG. 1, taken along Line 11-11 of FIG. 9.

(12) FIG. 12 is a cross-sectional view of the oil pick-up assembly of FIG. 1, taken along Line 12-12 of FIG. 9.

(13) Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

(14) Referring to FIGS. 1-12, an oil pick-up assembly 10 for an internal combustion engine (not shown) is provided. As described throughout this application, the assembly 10, and features thereof, may be described as extending from a first end 12a to a second end 12b disposed at an opposite end of the assembly 10 than the first end 12a. The assembly 10 also includes a pair of sides 14a, 14b each extending from the first end 12a to the second end 12b. Additionally, the assembly 10 may be described as including a top side 16 and a bottom side 18 disposed on an opposite side of the assembly 10 than the top side 16.

(15) The assembly 10 includes an upper housing 100 and a lower housing 200 that cooperate to define an internal chamber or reservoir 20 of the assembly 10, which receives and contains a volume of oil while the engine is in operation. Generally, the assembly 10 is configured to draw oil from within an oil pan (not shown) of the engine and to supply the oil the engine block for lubrication and cooling of components (e.g., crankshaft, pistons, connecting rods) of a powertrain of the engine. The assembly 10 of the present disclosure is configured to optimize a flow of the oil from the oil pan to the engine block.

(16) The upper housing 100 includes an upper shell 110 forming a portion of the reservoir 20. An upper peripheral flange 120 extends along a lower portion of the upper shell 110 and defines an interface for attaching the upper housing 100 to the lower housing 200. One or more mounting tabs 130a, 130b extend from the upper shell 110 at the first end 12a, and are configured for attaching the assembly 10 to the engine. As shown in FIGS. 7 and 8, the mounting tabs 130a, 130b include a top surface 132a, 132b (FIG. 8) that define a reference mounting plane P.sub.10 of the assembly 10. The upper housing 100 further includes an outlet tube 140 in communication with the reservoir 20 and extending from the upper shell 110 at the first end 12a. The outlet tube 140 includes a central axis A.sub.140 that is substantially parallel to the mounting plane P.sub.10 of the assembly 10.

(17) Referring to FIGS. 2-4, the upper shell 110 is defined by a top wall 112 and an upper peripheral wall 114. The top wall 112 may be flat or contoured and the upper peripheral wall 114 extends from the top wall 112 to a distal end at an opposite end of the peripheral wall 114 than the top wall 112. As shown, the peripheral wall 114 extends continuously around the outer periphery of the top wall 112. Thus, the peripheral wall 114 extends along each of the first end 12a, the second end 12b, the first side 14a, and the second side 14b of the assembly 10. The top wall 112 and the upper peripheral wall 114 cooperate to define an upper portion of the reservoir 20 of the pick-up assembly 10 when the upper housing 100 is assembled to the lower housing 200.

(18) The upper housing 100 further includes an upper peripheral flange 120 projecting outwardly from the distal end of the upper peripheral wall 114 of the upper housing 100. The upper peripheral flange 120 includes an upper central rib 122 configured to function as a weld bead and a pair of continuous channels 124a, 124b extending along opposite sides of the upper central rib 122. The channels 124a, 124b act as flow regions for the material of the upper central rib 122 when upper central rib is softened during a welding process, as described in greater detail below. The upper central rib 122 may have a trapezoidal cross-sectional shape, whereby a width (i.e., the distance between channels 124a, 124b) of the upper central rib 122 tapers towards a distal end, allowing the central rib 122 to be more easily formed using a conventional molding process.

(19) As best shown in FIG. 3, the lower peripheral flange 120 extends continuously around the upper housing 100. Specifically, the lower peripheral flange 120 includes a first end portion 120a extending along the first end 12a, a second end portion 120b extending along the second end 12b, a first side portion 120c extending along the first side 14a, and a second side portion 120d extending along the second side 14b.

(20) As best shown in FIGS. 3, 7, and 8, each of the first side portion 120c and the second side portion 120d of the upper peripheral flange 120 include a first segment 126a, 126b disposed adjacent to the first end 12a and a second segment 128a, 128b disposed adjacent to the second end 12b. Generally, the first segments 126a, 126b of the side portions 120c, 120d extend substantially parallel to the mounting plane P.sub.10 of the assembly 10, and the second segments 128a, 128b of the side portions 120c, 120d extend at an oblique angle θ.sub.128 relative to the mounting plane P.sub.10 of the assembly 10. Accordingly, a of the peripheral wall 114 of the upper shell 110 increases along a direction of the second segments 128a, 128b towards the second end 12b. As shown, the first segments 126a, 126b may be connected to the respective second segments 128a, 128b by an arcuate intermediate segment 127a, 127b such that each side portion 120c, 120d of the upper peripheral flange 120 transitions from the first segments 126a, 126b to the second segment 128a, 128b along the arcuate intermediate segment 127a, 127b.

(21) Referring to FIGS. 1, 4, and 12, the second end portion 120b of the upper peripheral flange 120, which extends along the second end 12b of the upper housing 100, extends from the upper shell 110 at an oblique angle θ.sub.120b relative to the mounting plane P.sub.10 of the assembly. Specifically, the second end portion 120b of the upper peripheral flange 120 extends at a downward angle θ.sub.120b relative to the mounting plane P.sub.10. In the illustrated example, the angle θ.sub.120b of the second end portion 120b is substantially the same as the angle θ.sub.128 of the second segments 128a, 128b of the side portions 120c, 120d of the upper peripheral flange 120. More specifically, the second end portion 120b is coplanar with the angled second segments 128a, 128b.

(22) As introduced previously, the upper housing 100 includes a pair of the mounting tabs 130a, 130b each extending from the peripheral wall 114 at the first end 12a. Each mounting tab 130a, 130b includes a top surface 132a, 132b that cooperate to define the mounting plane P.sub.10 of the assembly 10. Each tab 130a, 130b also includes a respective bottom surface 134a, 134b formed on an opposite side from the top surface 132a, 132b, where a distance from the top surface 132a, 132b to the bottom surface 134a, 134b defines a thickness of each mounting tab 130a, 130b.

(23) Each of the mounting tabs 130a, 130b includes an aperture 136 extending through the thickness of the mounting tab 130a, 130b. Each aperture 136 is configured to receive a compression-limiting bushing 30 and a fastener 40 for attaching the assembly 10 to a corresponding mounting interface of the engine. As shown in FIG. 11, each of the mounting tabs 130a, 130b may include a pair of protuberances 137 projecting radially inwardly into the aperture 136 adjacent to each of the top surface 132a, 132b and the bottom surface 134a, 134b. Thus, each aperture 136 includes a pair of the protuberances 137 at a first end and a pair of the protuberances 137 at a second end. The protuberances 137 interface with corresponding notches 32 formed in ends of the compression-limiting bushing 30 to prevent axial and rotational movement of the bushing 30 within the aperture 136. Details of the compression-limiting bushing 30 can be found in co-pending application Ser. No. 17/000,670 titled “Compression Limiter”, filed on Aug. 24, 2020, the contents of which are hereby incorporated by reference in their entirety.

(24) Each mounting tab 130a, 130b may also include a fastener retainer 138 integrally molded at one end of the aperture 136. As best shown in FIG. 3, the retainer 138 is formed as ring connecting opposing ends of the protuberances 137 adjacent to the bottom surface 134a, 134b. The retainer ring 138 has an inside diameter that is less than a major diameter of a threaded portion of the fastener 40 such that the fastener 40 can be threaded through the retainer ring 138. Thus, the retainer ring 138 is configured to hold the fastener 40 captive within the aperture 136 during handling and storage of the assembly 10, prior to installation on the engine. The retainer ring 138 is formed of a relatively soft material, such that when the assembly 10 is attached to the engine and the fasteners 40 are torqued, threads of the fastener 40 will strip the interior diameter of the retainer ring 138 to allow the fastener 40 to rotate freely relative to the retainer ring 138 and the mounting tabs 130a, 130b.

(25) The compression limiter 30 is disposed within the aperture 136 of each mounting tab 130a, 130b. As best shown in FIG. 3, the compression limiter 30 is a tubular body having an outside diameter corresponding to an inside diameter of the aperture 136 and an inside diameter configured as a clearance hole for the fastener 40. Each end of the compression limiter 30 includes a pair of notches 32, which—as discuss previously—cooperate with the protuberances 137 of each mounting tab 130a, 130b to secure the axial and rotational position of the compression limiter 30 within the respective mounting tab 130a, 130b. In some examples, the compression limiter 30 may be co-molded with the upper housing 100 in a molding process (e.g., injection molding), whereby the protuberances 137 are formed as the molding material flows into the notches 32 of the compression limiter 30.

(26) The outlet tube 140 of the upper housing 100 extends from the second end 12b along the central axis A.sub.140. As discussed previously, the central axis A.sub.140 of the outlet tube 140 is parallel to the mounting plane P.sub.10 of the housing. The outlet tube 140 may include one or more grooves for receiving an o-ring 50. As shown in FIGS. 1, 7, and 8 the outlet tube 140 may include a support ring 142 connecting the outlet tube 140 to the upper peripheral flange 120. The support ring 142 includes an annular portion 144 surrounding the outlet tube 140 and a lower leg 146 attached to the second end portion 120b of the upper peripheral flange 120.

(27) The lower housing 200 includes a lower shell 210 forming a lower portion of the reservoir 20. A lower peripheral flange 220 extends along an upper portion of the lower shell 210 and defines an interface for attaching the lower housing 200 to the upper housing 100. The lower housing 200 further includes a pick-up or inlet tube 230 extending along a longitudinal axis A.sub.230 from the lower shell 210 at an oblique angle θ.sub.230 relative to the mounting plane P.sub.10 of the assembly 10.

(28) Referring to FIGS. 1, 3, and 4, the lower shell 210 is defined by a bottom wall 212 and a lower peripheral wall 214. The bottom wall 212 may be flat or contoured and the lower peripheral wall 214 extends from the bottom wall 212 to a distal end at an opposite end of the lower peripheral wall 214 than the bottom wall 212. As shown, the lower peripheral wall 214 extends continuously around the outer periphery of the bottom wall 212. Thus, the lower peripheral wall 214 extends along each of the first end 12a, the second end 12b, the first side 14a, and the second side 14b of the assembly 10. The bottom wall 212 and the lower peripheral wall 214 cooperate to define a lower portion of the reservoir 20 of the pick-up assembly 10 when the lower housing 200 is assembled to the upper housing 100.

(29) The lower housing 200 further includes a lower peripheral flange 220 projecting outwardly from the distal end of the lower peripheral wall 214 of the lower housing 200. The lower peripheral flange 220 includes a lower central rib 222 configured to function as a weld bead and a pair of continuous channels 224a, 224b extending along opposite sides of the lower central rib 222. The channels 224a, 224b act as flow regions for the material of the lower central rib 222 when lower central rib 222 is softened during a welding process, as described in greater detail below. The lower central rib 222 may have a trapezoidal cross-sectional shape, whereby a width of the lower central rib 222 (i.e., a distance between the channels 224a, 224b) tapers towards a distal end, allowing the central rib 222 to be more easily formed using a conventional molding process.

(30) As best shown in FIG. 4, the lower peripheral flange 220 extends continuously around the lower housing 200. Specifically, the lower peripheral flange 220 includes a first end portion 220a extending along the first end 12a, a second end portion 220b extending along the second end 12b, a first side portion 220c extending along the first side 14a, and a second side portion 220d extending along the second side 14b. As best shown in FIGS. 7 and 8, each of the first side portion 220c and the second side portion 220d of the lower peripheral flange 220 include a first segment 226a, 226b disposed adjacent to the first end 12a and a second segment 228a, 228b disposed adjacent to the second end 12b. Generally, the first segments 226a, 226b of the side portions 220c, 220d extend substantially parallel to the mounting plane P.sub.10 of the assembly 10, and the second segments 228a, 228b of the side portions 220c, 220d extend at the oblique angle θ.sub.128 relative to the mounting plane P.sub.10 of the assembly 10. As shown, the first segments 226a, 226b may be connected to the respective second segments 228a, 228b by an arcuate intermediate segment 227a, 227b such that each side portion 220c, 220d of the lower peripheral flange 220 transitions from the first segments 226a, 226b to the second segment 228a, 228b along the arcuate intermediate segment 227a, 227b. Accordingly, the segments 226a, 226b, 227a, 227b, 228a, 228b of the lower peripheral flange 220 are configured to interface with the segments 126a, 126b, 127a, 127b, 128a, 128b of the upper peripheral flange 120 to attach the lower housing 200 to the upper housing 100.

(31) Referring to FIGS. 7, 8, and 12, the second end portion 220b of the lower peripheral flange 220, which extends along the second end 12b of the lower housing 200, extends from the lower shell 210 at the oblique angle θ.sub.120b relative to the mounting plane P.sub.10 of the assembly. Specifically, the second end portion 220b of the lower peripheral flange 220 extends at a downward angle θ.sub.120b relative to the mounting plane P.sub.10. In the illustrated example, the angle θ.sub.220b of the second end portion 220b is substantially the same as the angle θ.sub.128 of the second segments 228a, 228b of the side portions 220c, 220d of the lower peripheral flange 220. More specifically, the second end portion 220b is coplanar with the second segments 228c, 228d.

(32) During assembly of the upper and lower housings 100, 200, the upper central rib 122 of the upper peripheral flange 120 is aligned with the lower central rib 222 of the lower peripheral flange 220. The central ribs 122, 222 are then subjected to a polymer welding process, such as an infrared or ultrasonic welding process, to join the upper central rib 122 to the lower central rib 222 along the entire periphery of the reservoir 20. During the welding process, the materials of the upper and lower central ribs 122, 222 flow into the adjacent channels 124a, 124b, 224a, 224b as the upper and lower peripheral flanges 120, 220 are pressed together.

(33) Unlike the upper housing 100, which has an increasing height corresponding to the bend and angle of the side portions 120c, 120d, the lower housing 200 has a substantially constant height. Accordingly, the bottom wall 212 of the lower housing 200 has a profile corresponding to the path of the side portions 220c, 220d of the lower peripheral flange 220. For example, the bottom wall 212 includes a first segment 216 disposed adjacent to the first end 12a that is substantially parallel to the mounting plane P.sub.10. Additionally, the bottom wall 212 includes a second segment 218 disposed at the second end 12b and extending at the same angle θ.sub.128 as the second segments 128, 228 of the peripheral flanges 120, 220. The first and second segments are connected by an arcuate intermediate segment 217, which may include an intermediate stepped portion 219. This bent or curved profile of the bottom wall 212 provides the lower housing 200 with an initial transition into the deeper well portion of an oil pan within which the pick-up assembly may be installed.

(34) The lower housing 200 further includes an inlet tube 230 extending continuously from a proximal end 231 attached to the second segment 218 of the bottom wall 212 to a terminal distal end 232. The inlet tube 230 includes a pair of end walls 234a, 234b and a pair of sidewalls 236a, 236b. A first one of the end walls 234a extends from the second segment 218 of the bottom wall 212 adjacent to the intermediate segment 217 and a second one of the end walls 234b extends from the second segment 218 of the bottom wall 212 adjacent to the second end portion 220b of the lower peripheral flange 220. As shown, each of the end walls 234a, 234b is flat, such that the inlet tube 230 extends along a straight longitudinal axis A.sub.230 from the bottom wall 212 to the distal end 232. The longitudinal axis A.sub.230 is oriented at an oblique angle θ.sub.230 that is greater than the angle θ.sub.128 of the second segment 218 of the bottom wall 212. Accordingly, the second segment 218 of the bottom wall 212 and the inlet tube 230 cooperate to provide a compound bend around a transition point of an oil pan (i.e., the transition between the shallow portion and the sump of the pan)

(35) A distance from the first end wall 234a to the second end wall 234b defines a thickness T.sub.130 of the inlet tube 230. In the illustrated example, each of the end walls 234a, 234b is straight along the entire length of the inlet tube 230 from the bottom wall 212 to the distal end 232 of the inlet tube 230. However, the thickness T.sub.130 of the inlet tube 230 tapers constantly and continuously as the end walls 234a, 234b converge with each other along the direction from the bottom wall 212 to the distal end 232.

(36) As best shown in FIGS. 5 and 6, the sidewalls 236a, 236b of the inlet tube 230 include a first sidewall 236a connecting the end walls 234a, 234b on a first side 14a of the inlet tube 230 and a second sidewall 236b connecting the end walls on an opposite second side 14b of the inlet tube 230. A distance from the first sidewall 236a to the second sidewall 236b defines a width W.sub.230 of the inlet tube 230. As shown, the sidewalls 236a, 236b may each include an upper portion 237a, 237b extending from the bottom wall 212 and a lower portion 238a, 238b extending from the upper portion 237a, 237b to the distal end 232. The upper portions 237a, 237b converge with each other at a first rate and the lower portions 238a, 238b converge with each other at a second rate along the length of the inlet tube 230. Accordingly, the width W.sub.230 of the inlet tube 230 tapers at the first rate along the upper portions 237a, 237b and the width W.sub.230 of the inlet tube 230 tapers at a more gradual second rate along the lower portions 238a, 238b of the inlet tube 230. The upper portions 237a, 237b and the lower portions 238a, 238b are connected to each other by an arcuate intermediate portion 239a, 239b.

(37) By forming the inlet tube with the straight end walls 234a, 234b and the converging sidewalls 236a, 236b in combination with the bent bottom wall 212, the lower housing 200 can be formed in an injection molding process using conventional, stationary tooling. In other words, the geometries of the bottom wall 212 and the inlet tube 230 are configured such that the lower housing 200 can be removed from a mold without requiring portions of the mold to move relative to each other. This advantageously minimizes mold complexity and costs associated with designing and manufacturing the mold. While minimizing mold complexity, the design of the present disclosure also provides improved functional benefits. For example, the bent bottom wall 212 and the angled inlet tube 230 cooperate to bend around a transition of an oil pan, such that the mounting tabs 130a, 130b and the first end 12a of the assembly 10 fit within a shallow portion of the oil pan while the second end 12b and the inlet tube 230 extend into the deeper sump portion of the oil pan to maintain constant a submersion within the oil supply contained in the oil pan.

(38) A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.