Filter element, oil separator, and method for controlling prevailing pressure in crankcase ventilation system
10865672 ยท 2020-12-15
Assignee
Inventors
Cpc classification
B01D46/4272
PERFORMING OPERATIONS; TRANSPORTING
F01M2013/0044
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01M13/0011
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/2414
PERFORMING OPERATIONS; TRANSPORTING
F01M2013/0055
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/0031
PERFORMING OPERATIONS; TRANSPORTING
F01M13/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01M2013/0438
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
B01D46/00
PERFORMING OPERATIONS; TRANSPORTING
F01M13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/24
PERFORMING OPERATIONS; TRANSPORTING
B01D46/42
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention describes a filter element for an oil separator of a crankcase ventilation system in which a filter element is configured to separate oil from fluid and that has a covering surface extending parallel to a direction of flow, together with at least one cover element covering surface in at least some regions. An oil separator is taught having the filter element with at least one pressure control valve controlling crankcase pressure and has a valve closing body that operates in conjunction with a valve seat.
Claims
1. A filter element for an oil separator of a crankcase ventilation system, the filter element comprising: at least one filter medium surrounding a central axis, the at least one filter medium configured to separate oil from aerosol, the at least one filter medium having an axial end surface forming a covering surface extending in a radial direction relative to the central axis; and a cover element formed as an annular end plate, fixed onto and fully covering the covering surface of the at least one filter medium; wherein the cover element forms a tubular projection on an axially outer surface of the cover element, the tubular projection projecting axially outwardly away from the at least one filter medium, the tubular projection having an open interior which opens through the cover element into an interior of the at least one filter medium, wherein the tubular projection is a clean fluid discharge element configured to remove cleaned fluid from an interior of the filter element; wherein an axially outer end of the tubular projection of the filter element has an annular sealing surface forming a valve seat; wherein the tubular projection is configured as a clean fluid discharge element that extends away from the filter element and is configured to remove cleaned fluid from an interior of the filter element to the valve seat of the cover element; wherein the valve seat of the cover element is configured as a sealing surface for a pressure control valve body of the crankcase ventilation system to sealably close against.
2. The filter element according to claim 1, wherein the filter element is oval-cylindrical; and wherein the filter element has a cavity in the interior of the at least one filter medium; wherein the fluid to be filtered flows from the outer surface of the filter medium to the cavity; and wherein the cavity is connected directly to the clean fluid discharge element in order to remove the cleaned fluid.
3. The filter element according to claim 1, wherein the clean fluid discharge element and/or the annular sealing surface is formed of at least one mechanically fixed and/or rigid material; wherein the at least one mechanically fixed and/or rigid material is a moldable material selected from the set consisting of: polyurethane, polyamide, or polyamide formed from polyamide 66 with 35% glass fiber (PA 66 GF 35).
4. The filter element according to claim 1, wherein the annular sealing surface, the clean fluid discharge element, and the cover element are integrally formed as a unitary one-piece component.
5. The filter element according to claim 1, wherein the at least one filter medium is a multi-layered non-woven wrap.
6. The filter element according to claim 1, wherein the cover element and clean fluid discharge element are continuously closed.
7. An oil separator for a crankcase ventilation system, comprising: an oil separator housing including: a first housing part; and a second housing part secured to the first housing part and enclosing a chamber therein; a filter element according to claim 1 arranged in the chamber of the oil separator housing; wherein the first housing part includes at least one oil separator clean fluid outlet configured to remove the cleaned fluid the pressure control valve is configured to limit the negative pressure applied in the crankcase ventilation system, the pressure control valve formed in combination by: the valve seat of the filter element; and a valve closing body accommodated in the first housing part that operates in conjunction with and sealably closes against the valve seat; wherein the sealing surface of the tubular projection of the cover element of the filter element forms the valve seat against which the valve closing body sealably closes when the pressure control valve is in a closed state.
8. The oil separator according to claim 7, wherein the valve closing body comprises at least one elastic valve closing body sealing element, at least on a region thereof arranged to contact with the valve seat of the filter element; and wherein the at least on a region of the at least one valve closing body is surrounded by an elastic valve closing body sealing element on the region thereof that is arranged to contact with the valve seat of the filter element.
9. The oil separator according to claim 8, wherein the valve closing body sealing element is formed out of at least one elastomer; wherein the at least one elastomer are selected from the set: ethylene acrylate rubber (EAR) and/or from acrylate rubber and/or from hydrogenated nitrile rubber (H)NBR.
10. The oil separator according to claim 7, wherein the valve closing body sealing element is connected fixedly, non-releaseably to the valve closing body; wherein the valve closing body sealing element is applied onto the valve closing body by a spray process.
11. The oil separator according to claim 7, wherein the valve closing body is flat or level on the region thereof that faces the valve seat and contacts with the valve seat of the filter element.
12. The filter element according to claim 1, wherein the annular sealing surface of the tubular projection is circular, substantially flat and free of burrs.
13. The filter element according to claim 1, wherein a circumferential edge of the annular sealing surface of the tubular projection is rounded.
14. A method for limiting the crankcase vacuum of a crankcase ventilation system to a predetermined value, comprising: providing an oil separator housing enclosing a chamber therein; providing a filter element configured to separate oil from fluid, including: at least one filter medium surrounding a central axis, the at least one filter medium configured to separate oil from aerosol, the at least one filter medium having an axial end surface forming a covering surface extending in a radial direction relative to the central axis; and a cover element formed as an annular end plate, fixed onto and fully covering the covering surface of the at least one filter medium; wherein the cover element forms a tubular projection on an axially outer surface of the cover element, the tubular projection projecting axially outwardly away from the at least one filter medium, the tubular projection having an open interior which opens through the cover element into an interior of the at least one filter medium, wherein the tubular projection is a clean fluid discharge element configured to remove cleaned fluid from an interior of the filter element; wherein an axially outer end of the tubular projection of the filter element has an annular sealing surface forming a valve seat; wherein the tubular projection is configured as a clean fluid discharge element that extends away from the filter element and is configured to remove cleaned fluid from an interior of the filter element to the valve seat of the cover element; wherein the valve seat of the cover element is configured as a sealing surface for a pressure control valve closing body of the crankcase ventilation system to sealably close against; and providing the pressure control valve configured to limit the negative pressure applied in the crankcase ventilation system, the pressure control valve formed in combination by: a valve closing body that operates in conjunction with valve seat of the cover element; wherein the sealing surface of the filter element forms the valve seat against which the valve body closes; arranging the filter element replaceably in the chamber of the oil separator housing; arranging the valve closing body of the pressure control valve in the oil separator housing such that the valve closing body is closeable against the valve seat of the filter element; operating the pressure control valve responsive to prevailing pressure in the crankcase ventilation system to limit the crankcase vacuum such that the valve closing body is moved relative to the filter element and the valve seat of the filter element to control crankcase vacuum.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) As already discussed above, there are several approaches to advantageously embodying and developing the teaching of the present invention.
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(15) Identical or similar designs, elements, or features are provided with identical reference signs in
DETAILED DESCRIPTION
(16)
(17) The oil separator 200 comprises a substantially oval-cylindricalin particular, circular-cylindricalfilter housing composed of a first filter housing part 210namely, a housing coverand a second filter housing part 220namely, a housing body. The second filter housing part 220 has an inlet 222 for the oil-containing air 500. Arranged in the filter housing is a filter element 100 comprising at least one filter medium 10 made of a filter material that has been arranged in an annular shape, e.g., a circular ring shape or an oval ring shape (see
(18) The oil separator 200 has a pressure control valve, in order to limit the crankcase vacuum to a defined value. The pressure control valvedepicted by way of example in
(19) On the end facing away from the valve closing body 310, the membrane 320 is connected to the first filter housing part 210, for example, by being clipped into the first filter housing part 210. Alternatively, the membrane 320 may also be mounted between the filter housing part 210 and the cover element 214. Preferably, the membrane is clamped between the first filter housing part 210 and an insert 350 forming even more preferably the lower stop of the spring 330, as in the presently-described embodiment. The insert 350 has openings, so that the ambient pressure can act on the membrane 320 and on the valve closing body 310.
(20) In order to be closed, the pressure control valve has a valve seat 52 arranged on the filter element 100. In contrast to the prior art illustrated in
(21) The membrane 320 is configured to seal the clean air outlet 212 and the interior 12 of the filter medium 10 off from the ambient air pressure, and to keep the valve closing body axially movable.
(22) The valve closing body 310 can be moved relative to the valve seat 52, as illustrated in
(23) The pressure control valve is configured such that the membrane 320 is subjected to the pressure 600 prevailing in the clean air outlet 212 on the side thereof facing the filter element 100 or the housing interior, in the region of the circular ring area A.sub.M defined by the diameters .sub.M and .sub.M, and the valve closing body 310 is subjected to the pressure 610 prevailing in the interior 12 of the filter medium 10 on the side thereof facing the filter element 100 or the housing interior, in the region of the circular area A.sub.D defined by the inner diameter .sub.0 of the sealing surface 52. On the side facing away from the filter element 100 or the housing interior, the membrane 320 and the valve closing body 310 are also subjected to the ambient pressure. Preferably also provided is a return spring 330 that subjects the membrane 320 and/or the valve closing body 310 to a force that acts in a direction of opening, i.e., is directed away from the filter element 100. At least one opening in a pressure control valve cover element 214 and/or an insert 350 causes ambient pressure to be applied to the back side of the membrane; this ventilation makes it possible for the pressure control valve to work undamped.
(24) Preferably, a return spring 330as already describedis arranged on the side of the valve closing body 310 that faces away from the filter element 100. The return spring 330 subjects the valve closing body 310 and/or the membrane 320 arranged thereon to a force 620 (see
(25) On the way from the interior 12 of the filter medium 10 to the clean air outlet 212, the clean fluid flows through a flow channel 340 (see
(26) With decreasing pressure in the clean air outlet 212 or on the exit side of the pressure control valve, the membrane 320 makes a stroke movement in the direction of the valve dome or valve seat 52, thereby reducing the cross-sectional area of the flow channel 340. This increases the flow resistance of the pressure control valve over the valve seat 52.
(27) The control behavior of the pressure control valve can be adjusted via the diameter cross-section ratios .sub.M, .sub.D of the membrane 320 and the inner diameter of the sealing surface 52 or the end surface of the clean fluid discharge element 50 that faces away from the filter element 100.
(28) The valve closing body 310 is in the rest position (closed position) when a) the force F of the return spring 330 b) minus the differential pressure p from the atmospheric pressure and the crankcase pressure 610, multiplied by the cross-sectional area A.sub.D (defined by the inner diameter .sub.D of the valve seat 52) c) minus the differential pressure p from the atmospheric pressure and the suction pressure 600, multiplied by the cross-sectional area A.sub.M (defined by the ring between the cross-section diameter .sub.M of the membrane 320 and the inner diameter .sub.D of the valve seat 52) equals zero.
In summary, this gives:
0=F.sub.return spring 330F(.sub.(crankcase pressure 610)F(.sub.suction pressure 600)=F.sub.return spring 330p(.sub.atmospheric pressurecrankcase pressure)*A.sub.Dp(.sub.atmospheric pressuresuction pressure)*A.sub.M
(29) The return spring 330 prevents the membrane 320 from being permanently closed at small suction vacuum pressures 600 from the turbocharger or intake duct of the engine. In addition, the location of the pressure control characteristics can be varied by means of the return spring 330. This means that with a harder return spring 330, the suction vacuum pressure 600 can act more intensely on the crankcase, and the curve shifts downward.
(30)
(31) As depicted in
(32) The ratio of the cross-section diameters .sub.M and .sub.D of the membrane 320 and the sealing surface 52 influences the slope 700, 702 of the pressure control curve. If a negative pressure prevails in the crankcase relative to the atmosphere, and the pretension of the return spring 330 is overcome, then the membrane 320 moves onto the sealing surface 52, and the flow resistance increases.
(33) First, if the suction vacuum pressure 600 is large enough and the return spring 330 is compressed, this results in a curved curve, and finally in a minimum of the crankcase pressure.
(34) At even higher suction vacuum pressures, a slight increase in the pressure 610 is to be observed in the interior 12 of the filter medium, in particular, the crankcase pressure. In these operational ranges, the membrane 320 closes the suction side of the valve intermittently, and thus throttles or interrupts the volume flow. This intermediate pressure is higher than the minimum pressure, because when the valve seat 52 is closed and there is a strong suction vacuum pressure 600, the pressure 610 in the crankcase must be correspondingly higher, in order to for the membrane 320 to again be lifted off from the valve seat 52 against the suction vacuum pressure acting on the outside thereof.
(35) The oil separator 200 may have an overpressure valve 800 (
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(37) The sealing surface 52 on the clean fluid discharge element 50 is spaced apart from the axial outer surface of the cover element 40. The axial installation space required for the clean fluid outlet 212 is thereby bridged. The length of the clean fluid discharge element 50, as measured from the axial, outer surface of the cover element 40, corresponds to the diameter of the clean fluid outlet 212 of the upper housing part 210. This makes it possible to achieve a streamlined overall design with which the positioning of the sealing surface 52 on the cover element 40 or on the filter element 100 is not accompanied by disadvantages.
(38) The cover element 40 is configured as an end plate of the filter element 100, as is preferred, in the embodiment illustrated in detail in
(39) The clean fluid discharge element 50 is integrally, sealingly connectedas is preferredto the cover element 40 in the embodiment illustrated in detail in
(40) The clean fluid discharge element 50 is preferably a circular-cylindrical, straight tube, as also illustrated in the drawings. This tube comprises a closed cylindrical wall and two open ends, wherein the sealing surface 52 is configured on one end that faces away from the cover element, and the other end is connected to the cover element 40, so that a fluid connection to the interior 12 of the filter medium 10 or filter body is formed. The ends are preferably oriented so as to be perpendicular to the central axis.
(41) In the embodiment illustrated in detail in
(42) The crankcase ventilation system has two spaces that must be separated from one anothernamely, the pre-filtration space or pre-filtration side 250, on which the not-yet-cleaned blow-by gas is located, and the post-filtration space or post-filtration side 240, on which the cleaned gas is located. In addition, the pre-filtration space 250 and post-filtration space 240 must also be separated from the atmosphere. To solve this problem only with a seal, the filter element 100illustrated, for example, in
(43) The filter element seal 60 (see
(44) A special advantage of the filter element seal 60 illustrated in
(45) The filter element seal 60 illustrated in
(46) A defined radial seal can be provided in the oil separator 200 illustrated in
(47) The radially sealing region 64 may be configured in the manner of an O-ring (see
(48) In the interior 12 of the filter medium 10, a central tube 70 configured as a support element for the filter medium 10 may be arranged. The central tube supports the filter medium 10 and protects same against collapse.
(49) In order to ensure that the fluid flows through the filter medium 10 into the interior 12 of the filter medium 10, the filter element 100 has another cover element 42in particular, another end plate 42on the end thereof that faces the oil outlet 230.
(50) In order to seal off the post-filtration side of the filter element from the pre-filtration side of the filter element, another filter element seal 62configured, for example, as an O-ringmay be associated with the additional cover element 42, in order to seal off the additional cover element 42 from the housing part 220. This additional filter element seal 62 is preferably arranged radially outward on the additional cover element 42. The cover element 42 is also preferably configured as an end plate, in particular, as an open end plate having a central opening for the oil drain.
(51)
(52) The valve closing body 310 and the membrane 320 perform a vertical stroke movement in the pressure control (see
(53) The components of pressure control illustrated in
(54) The return spring 330 is arranged on the side of the valve closing body 310 that faces away from the valve seat 52, and is supported down in the insert 350, which preferably also has an opening. The return spring 330 is thus located on the atmosphere side. The valve closing body 310 preferably has at least one and particularly preferableas is presently shownthree or four continuations 311 that protrude through at least one opening of the insert 350. The return spring may thus preferably be axially mounted between the insert 350 and the continuation or continuations 311, in particular, the hooks at the end of the continuations. In this manner, the return spring 330 can exert an opening forcein particular, a force oriented away from the sealing surface 52on the valve closing body.
(55)
(56) According to an advantageous embodiment, it is provided that the return spring 330 is located on the atmosphere side in the embodiment of the present invention illustrated in
(57) In contrast to the filter medium 100 illustrated in
(58) Instead of a combination seal, the crankcase ventilation system illustrated in
LIST OF REFERENCE SIGNS
(59) 10 Filter medium, in particular, non-woven wrap 12 interior or cavity enclosed by the filter medium 10 20 direction of flow of the fluid to be filtered; in particular, direction of flow of the pre-filtration fluid 500 flowing through the filter medium 10, in the present invention (see