VALVE, OIL SEPARATOR, AND VENTILATION SYSTEM

Abstract

A valve, an oil separator, and a ventilation system are described. These are used particularly in internal combustion engines, for example for separating oil mist or oil droplets from blow-by gases (crankcase gases). In particular a valve which can be used for example as a bypass valve in a ventilation system is described.

Claims

1-21. (canceled)

22. A valve comprising a valve disc having a valve closure member, a retaining element for the valve closure member, said retaining element at least partially surrounding the valve closure member, and at least one retaining arm, which connects the retaining element and the valve closure member to one another in a flexible manner, and a valve seat having a valve opening and a valve bearing member, which surrounds the valve opening and which is designed for the bearing of the valve closure member such that, in the closed position of the valve, the valve closure member bears against the valve bearing member and closes the valve, wherein the retaining element, the at least one retaining arm and the valve closure member are designed such that at least one through-opening is formed between at least two of the parts of the valve disc including the retaining element, the at least one retaining arm and the valve closure member, and the valve has at least one separating element, which is arranged such that it extends through the at least one through-opening at least in the open position of the valve.

23. The valve according to claim 22, wherein at least one, several or all of the separating elements extends through the at least one through-opening in each position of the valve.

24. The valve according to claim 22, wherein the valve disc has at least two retaining arms and at least two through-openings, and in each case at least one separating element is arranged in at least two of the through-openings.

25. The valve according to claim 22, wherein one, several or all separating elements are designed as a baffle element, including a baffle plate, and/or are formed of an open porous material or with an open or closed porous and/or lattice-like surface.

26. The valve according to claim 22, wherein one, several or all separating elements are formed in one piece with the valve seat or are connected to the valve seat by means of a form fit, friction fit and/or adhesive join, including after manufacture of the separating elements.

27. The valve according to claim 22, wherein one, several or all separating elements are mounted on the side of the valve closure member that faces away from the valve seat or are mounted laterally in relation to the valve closure member.

28. The valve according to claim 22, wherein one, several or all separating elements are connected to one another, including in the shape of a circle, by web-like elements.

29. The valve according to claim 22, wherein one, several or all separating elements are designed as baffle plates which extend along a respective associated through-opening, and the end thereof that is at the smallest distance from the valve closure member, and including also the end thereof that is at the greatest distance from the valve closure member, is angled relative to the movement direction of the valve closure member during opening of the valve.

30. The valve according to claim 29, wherein the angled end of a baffle plate is angled in such a way that the distance between the end of the baffle plate and the adjacent end of the associated through-opening remains substantially constant during opening and/or closing of the valve or changes between the open position and the closed position of the valve.

31. The valve according to claim 22, wherein two, several or all separating elements overlap one another as viewed in the radial direction from the valve closure member.

32. The valve according to claim 22, wherein the entirety of the separating elements extend around the entire circumference of the valve closure member as viewed in the radial direction from the valve disc.

33. The valve according to claim 22, wherein one, several or all separating elements are flat and the surface thereof extends substantially or completely perpendicular to the bearing plane of the valve closure member and/or substantially or completely in the circumferential direction around the valve closure member.

34. The valve according to claim 22, wherein the retaining arms run in a curved manner, including in a spiral shape, between the retaining element and the valve closure member, including with a concave curvature as viewed outwards in the radial direction from the valve closure member, and/or with through-openings therebetween which run in a correspondingly curved manner, including in a spiral shape, around the valve closure member.

35. The valve according to claim 22, wherein the circumferential edge of the valve closure member has substantially a rounded shape.

36. The valve according to claim 22, wherein the valve bearing member is designed as a web or collar which runs along the edge of the valve opening.

37. The valve according to claim 22, wherein at the points where a separating element extends through the through-openings, the clear width of the through-openings in each valve state is greater than the thickness of the separating elements, in that the separating elements are at a predefined distance from the edges of the through-openings.

38. The valve according to claim 22, wherein the valve closure member is comprised of spring steel, including spring steel of material number 1.4310, and/or plastic, including fibre-reinforced, including glass-fibre-reinforced PA (polyamide), PPS (polyphenylene sulphide), PPA (polyphthalamide), PI (polyimide), PEI (polyetherimide), PAI (polyamide-imide), PEEK (polyether ether ketone), PSU (polysulphone) and/or LCP (Liquid Crystal Polymer).

39. The valve according to claim 22, wherein the valve seat comprised of plastic, including fibre-reinforced, including glass-fibre-reinforced PA (polyamide), PPS (polyphenylene sulphide), PPA (polyphthalamide), PI (polyimide), PEI (polyetherimide), PAI (polyamide-imide), PEEK (polyether ether ketone), PSU (polysulphone) and/or LCP (Liquid Crystal Polymer).

40. The valve according to claim 22, wherein the valve is a bypass valve for an oil separating element, the oil separator separates oil droplets or oil mist from gas that is to be cleaned, including from blow-by gases, where the oil separator comprises at least one oil separating element through which the gas that is to be cleaned can flow.

Description

DESCRIPTION OF THE DRAWINGS

[0033] In the drawings:

[0034] FIG. 1 shows one embodiment of an internal combustion engine having a ventilation system;

[0035] FIG. 2A shows a valve from above in different views;

[0036] FIG. 2B shows a valve of FIG. 2A in a perspective view;

[0037] FIG. 2C shows a sectional view of the valve of FIGS. 2A and 2B;

[0038] FIG. 2D shows a side view of the valve of FIGS. 2A to 2C;

[0039] FIG. 2E shows a vertical plan view of the valve of FIGS. 2A to 2D;

[0040] FIG. 3A shows a further valve disc of a valve;

[0041] FIG. 3B shows a further valve disc of a valve;

[0042] FIG. 3C shows a further valve disc of a valve;

[0043] FIG. 3D shows a further valve disc of a valve;

[0044] FIG. 4 shows another valve;

[0045] FIG. 5A an embodiment of a separating element in a valve;

[0046] FIG. 5B an embodiment of a separating element in a valve;

[0047] FIG. 5C an embodiment of a separating element in a valve;

[0048] FIG. 6 shows an illustration of the improvement achieved by the valve.

DETAILED DESCRIPTION

[0049] FIG. 1 shows an internal combustion engine 1 having a ventilation system.

[0050] The internal combustion engine 1 comprises a crankcase 3, a cylinder head 2, and a valve cover 4. The intake tract 10 of the internal combustion engine has a fresh-air filter 11, a compressor 12 and a throttle 13, which are connected to one another via an intake line 14 having the sections 14a and 14b and are connected to an intake manifold 5 via the section 14c. The blow-by gases arising in the crankcase 3 are directed towards an oil separator 20 via ventilation lines which are not shown in full here. The oil separator 20 is arranged here on the valve cover 4 and can be regarded as a section of a ventilation line. The oil separator 20 has a housing 21 which is divided by a dividing wall 23 into a pressure-side chamber 26 and a suction-side chamber 27. Arranged in the dividing wall 23 is an oil separator 22, via which the blow-by gases can normally be directed from the crankcase 3 to the intake tract 10. To this end, the suction-side chamber 27 is connected by two lines 24a and 24b to the intake line 14, in particular to the sections 14a and 14c. The section 24a ends in the section 14a of the intake line upstream of the compressor 12, while the section 24b ends in the section 14c of the intake line downstream of the compressor and here also downstream of the throttle 13. Non-return valves 25a and 25b are arranged in both line sections 24a and 24b.

[0051] During full-load operation, the compressor 12 in the section 14a generates a strong negative pressure, so that the blow-by gases are directed from the suction-side chamber 27 into the section 14a. During no-load operation, the throttle 13 is closed, so that a strong negative pressure prevails in the section 14c. In this case, the blow-by gases are directed from the suction-side chamber 27 into the intake line 14 via the line 24b.

[0052] Arranged in the dividing wall 23 is an oil separator 22 which is configured such that a sufficient separation of oil mist and oil droplets from the blow-by gases is ensured during normal operation. Also arranged in the dividing wall 23 is a valve 30, which is in the closed state during normal operation.

[0053] The valve 30 is configured such that, when the oil separator 22 is non-functional (for example is clogged or sooted) or in the event of extremely high volumetric flow rates of blow-by gas which the oil separator alone cannot allow to pass, said valve opens and enables the blow-by gases to pass from the pressure-side chamber 26 to the suction-side chamber 27. At the same time, the valve ensures a basic separation of oil mist and oil droplets from the blow-by gases in its open state. This prevents entirely uncleaned blow-by gases from being directed into the intake line 14.

[0054] FIGS. 2A to 2E show a valve in different views. FIG. 2A shows a view of the valve 30 from above, without the valve closure member. The valve 30 has a valve seat 32, which is provided with a base plate 40 and a valve bearing member 33 which protrudes in a ring-shaped manner from the base plate 40 towards the viewer from the base plate 40. Said valve bearing member is a circumferentially closed web. Adjacent to the web, a number of separating elements 39a to 39c protrude from the base plate 40, the height of the separating elements 39a to 39c above the base plate 40 being greater than the height of the web or valve seat 32.

[0055] The valve bearing member surrounds a valve opening 31. Said valve bearing member is in turn surrounded, together with the separating elements 39a to 39c, by a retaining region 41 which likewise protrudes in a web-like manner from the base plate 40 towards the viewer.

[0056] FIG. 2B shows a side view of the valve from FIG. 2A. The separating elements 39a to 39c completely surround the valve bearing member 33 in the radial direction in an overlapping manner. If a valve closure member is arranged on the valve bearing member 33 in a manner not shown here and forms between the valve closure member and the valve bearing member 33 an annular gap for the passage of gases, said gases are deflected in the radial direction and are directed towards the separating elements 39a to 39c. The latter form baffle separating plates. A lateral deflection also takes place at the separating elements 39a to 39c, so that the gases can flow through both upwards in the viewing direction and also laterally between the separating elements. When flowing off laterally, the gases will additionally be subjected to a circular movement, so that a centrifugal separating function is also realized.

[0057] FIG. 2C shows a sectional view of the valve as shown in the two FIGS. 2A and 2B. The separating elements 39a and 39c are produced and connected in one piece with the valve seat 32 and the base plate 40. Since all the webs 32, 39a to 39c and 41 protrude in parallel perpendicular to the plane of the base plate 40, this element shown in FIG. 2C has no undercuts and therefore can be produced inexpensively, for example using the injection moulding method. Here, the one-piece component is made of glass-fibre-reinforced PA 6.6. The diameter d.sub.31 of the valve opening is 15 mm, while the distance d.sub.39 between the baffle separating plates 39a and 39c is 20 mm. The baffle separating plates 39a and 39c are each rectangular and both have a constant protruding height h.sub.39 of 11 mm above the base plate. The protruding height h.sub.32 of the circumferential web 32 is 5.8 mm, and the protruding height h.sub.41 of the webs of the retaining region 41 is 2.8 mm.

[0058] FIG. 2D shows the same valve in side view, the valve disc 34 now also being shown. Said valve disc has a retaining element 36 which extends along the retaining region 41 and is connected to the latter. Extending inwardly from said retaining element 36 are spiral-shaped retaining arms 37a to 37c, which merge into the valve closure member 34.

[0059] FIG. 2E shows a vertical plan view of the valve disc 34, which is produced here entirely as a punched component from a spring-steel sheet having a thickness of 0.15 mm. The circumferential retaining element 36 is located on the outer circumferential edge of the valve disc 34. The valve closure member 35 is arranged in the centre. The valve closure member 35 and the retaining element 36 are connected to one another via flexible retaining arms 37a to 37c. The retaining arms are arranged in a spiral shape, so that the valve closure member 35 can lift out of the plane of the drawing under suitable pressure conditions. Due to the spiral shape of the retaining arms 37a and 37c, however, said valve closure member will also rotate about its central axis, which is perpendicular to the plane of the drawing.

[0060] To form the retaining arms 37a to 37c, through-openings 38a to 38c are formed between the retaining arms. These through-openings 38a to 38c then receive the separating elements 39a to 39c shown in the preceding sub-figures. The separating elements and the through-openings are dimensioned such that they do not make contact with one another and consequently the valve closure member 35 can lift out of the plane of the drawing in FIG. 2E in a friction-free manner.

[0061] FIG. 3A shows another valve disc 34 of a valve. This has a retaining element 36 with a through-opening 36 for fastening elements, for example pins, rivets or screws. Extending inwardly from this retaining element 36 is a single retaining arm 37 which runs in a spiral shape and tapers towards the valve closure member 35. Formed between the valve closure member 35 and the retaining arm 37 is a likewise spiral-shaped through-opening 38, in which a correspondingly designed separating element can be arranged. This separating element can extend from the inner end of the through-opening 38 along the entire circumference of the valve closure member 35 and consequently can completely and in one piece surround the valve closure member 35. It may extend beyond the through-opening 38.

[0062] With a valve designed in this way, the gas can flow radially from the slot-shaped opening that exists between the valve bearing member and the valve closure member 35 in the open state of the valve towards the separating element arranged in the through-opening 38 and is deflected from there in a circular movement parallel to the bearing plane of the valve closure member 35. The use of such a valve disc 35 and of a separating element designed in a manner corresponding to the through-opening 38 thus leads to the formation of an additional oil separator.

[0063] FIG. 3B shows a further valve disc 34 of a valve 30, which is similar to the valve disc shown in FIG. 2E. However, in the valve disc of FIG. 3B, the outer edge of the valve disc 34 comprises locking teeth 44, which are able to engage with an annular snap-in geometry outside of the retaining region 41 of valve 30. The teeth 44 thus are guided upon lift-of or closure of the valve disc in lift-of direction and closing direction by said snap-in geometry. The locking thereby prevents an (excessive) spin of the valve discs when opening the bypass valve. The number and width of the locking teeth 44 is thereby variable or can be optimized for design of the valve.

[0064] In FIG. 3C, a valve disc 34 is shown, which is similar to that of FIG. 3B. In place of the teeth at the outer edge, the valve disc 34 now comprises through holes 36, with which guide elements, e. g. pins, rivets or screws, can engage. This guidance of the through holes 36 in FIG. 3C also prevents twisting of the valve disc 34 upon opening or closing of the valve.

[0065] In FIG. 3D, a further valve disc 34 is shown, which is similar to the valve disc 34 shown in FIG. 3C. In contrast to the valve disc 34 shown in FIG. 3C, the through holes 36 are now arranged in half round flaps 50, which protrude from the peripheral edge of the valve disc 34.

[0066] FIG. 4 shows another embodiment of a valve in cross-section. In general, this valve is designed in the same way as in FIG. 2. However, the separating elements 39a to 39c are not formed in one piece with the base plate 40 and the valve seat 32. Instead, they are now fastened to an element 43, which is located downstream of the gas flow. The separating elements 39a to 39c protrude from this element 43 towards the base plate 40 and, in the same way as in FIG. 2, extend through openings between the valve closure member 35, the retaining arms 37 and the retaining element 36/retaining region 41.

[0067] FIGS. 5A to 5C show side views of different embodiments of separating elements 39.

[0068] FIG. 5A shows a rectangular separating element 39, as also used for example in FIG. 2B. The diagram in FIG. 5 is a plan view and does not take account of the curvature of the retaining element 39 around the central axis of the valve 30. This curvature depends on the curvature of the retaining arms and of the through-openings between the valve closure member, the retaining arms and the retaining element, and can be adapted accordingly.

[0069] FIG. 5B shows a trapezoidal separating element 39. Due to the trapezoidal shape, the rotational movement of the valve closure member 35 during the opening and closing of the valve is taken into account so that the ends of the through-openings 37 can always maintain the same distance from the separating element 39.

[0070] FIG. 5C shows another embodiment of the trapezoidal separating element shown in FIG. 5B. The opposite side faces which protrude vertically from the base plate 40 are now curved in order to copy more accurately the rotational movement of the valve closure member.

[0071] FIG. 6 shows at one side a measurement of the pressure loss through the valve as a function of the volumetric flow rate through the valve (dashed lines, left-hand scale). It can be seen that an additional pressure loss due to the additional use of separating elements occurs only at relatively large volumetric flow rates, here of at least 75 l/min, and is less than 15%. At low volumetric flow rates, the pressure loss is even reduced, and this can be attributed to additional vibration effects.

[0072] At the other side, FIG. 6 shows a measurement of the 50 value, that is to say the particle size of the smallest particles that are 50% separated out (continuous and dash-dotted line, right-hand scale). It can be seen here that, by using the baffle walls, the 50 value can be reduced at least to half as large particles at least for volumetric flow rates below 82 l/min, in particular even considerably further between 40 and 701/min. A clear reduction in the 50 value is also achieved above 82 l/min, namely by at least .

[0073] The oil separation is thus considerably improved by a valve, without this leading to considerable increases in pressure loss.