Separating Module, Line Module, and Ventilation Device

Abstract

A separating module for a ventilation device has a housing that surrounds a separating element designed to separate liquid particles from a gas flow. A line module and a ventilation device with such a separating module and such a line module are provided. The housing of the separating module is designed to be connected to the line module that has at least three geometrically parallel channels and the housing of the separating module has corresponding housing openings to be connected to the at least three channels. Several separating modules and several line modules can be combined to adapt the ventilation system as needed.

Claims

1. A separating module for a ventilation device, wherein the ventilation device is configured to discharge a gas flow laden with liquid particles from a component of an internal combustion engine, the separating module comprising: a separating element configured to separate liquid particles from the gas flow laden with liquid particles; a housing surrounding the separating element; the housing configured to be connected to a line module comprising at least three channels that are geometrically parallel to each other, the housing comprising housing openings that correspond to the at least three channels.

2. The separating module according to claim 1, wherein the separating element comprises at least one annular filter medium configured to separate the liquid particles from the gas flow laden with liquid particles and wherein the housing is essentially cylindrical and comprises an annular wall surface, a first cover surface, and a second cover surface, wherein the first and second cover surfaces cover at least areas of end faces of the annular wall surface, wherein the housing openings are arranged on the first cover surface.

3. The separating module according to claim 2, wherein the first cover surface provided with the housing openings forms a flange plane and the housing openings are arranged in the flange plane.

4. The separating module according to claim 2, further comprising an integrally embodied seal disposed on the first cover surface and configured to provide axial sealing contact relative to the line module to seal the housing openings relative to each other and relative to the environment.

5. The separating module according to claim 2, wherein the housing openings include a first housing opening, a second housing opening, and a third housing opening, wherein the at least three channels include a first channel, a second channel, and a third channel, wherein: the first housing opening is an unfiltered gas opening and is associated with the first channel, wherein the unfiltered gas opening is configured to be supplied by the first channel with the gas flow laden with liquid particles; the second housing opening is a clean gas opening and is associated with the second channel, wherein the clean gas opening is configured to supply the second channel with a cleaned gas flow that is generated from the gas flow laden with liquid particles by passing the gas flow laden with liquid particles through the separating module; and the third housing opening is a return opening and is associated with the third channel, wherein the return opening is configured to supply the third channel with a liquid that has been separated in the separating module from the gas flow laden with liquid particles.

6. The separating module according to claim 5, wherein the at least one filter medium comprises a hollow interior, wherein, after passing through the unfiltered gas opening, the gas flow laden with liquid particles flows into the hollow interior, passes through the at least one filter medium from the hollow interior to the exterior of the at least one filter medium and the cleaned gas flow that is free of liquid particles or essentially free of liquid particles exits from an outer surface of the at least one filter medium.

7. The separating module according to claim 5, further comprising at least one deflection element arranged in the area of the unfiltered gas opening and configured to deflect the gas flow laden with liquid particles.

8. The separating module according to claim 7, wherein the at least one deflection element comprises at least one baffle plate acting as a pre-filter and arranged in the area of the unfiltered gas opening so as to be oriented at an angle to or vertical to the gas flow laden with liquid particles.

9. The separating module according to claim 1, further comprising a pressure control valve disposed in the housing and configured to control a pressure existing in the ventilation device, wherein the pressure control valve comprises a valve seat and a valve closing body interacting with the valve seat, wherein the pressure control valve further comprises a restoring spring acting on the valve closing body in a direction facing away from the valve seat.

10. The separating module according to claim 9, wherein the pressure control valve limits a negative pressure existing in the ventilation device.

11. The separating module according to claim 9, wherein the housing openings include a clean gas opening and the at least three channels include a clean gas channel associated with the clean gas opening, wherein a cleaned gas flow, generated from the gas flow laden with liquid particles by passing the gas flow laden with liquid particles through the separating element, flows through the pressure control valve, subsequently passes through the clean gas opening to exit from the separating module, and flows into the clean gas channel.

12. The separating module according to claim 9, wherein one of the at least three channels is a clean gas channel and wherein the housing openings include a first housing opening and a second housing opening, wherein the pressure control valve is configured such that ambient pressure acts on a first side of the valve closing body, a suction pressure existing in the clean gas channel acts on a second side of the pressure control body inside the valve seat, and a crankcase pressure acts on the second side of the pressure control body outside of the valve seat, wherein additionally an opening force of the restoring spring acts on the valve closing body, wherein the separating module is configured such that a pressure existing in the component of the internal combustion engine is applied at least to the first housing opening and the suction pressure existing in the clean gas channel is applied at least to the second housing opening.

13. The separating module according to claim 12, wherein the restoring spring is arranged in the area where the suction pressure is acting.

14. The separating module according to claim 1, further comprising separating module channels conducting fluids, wherein all of the separating module channels are associated with one of the housing openings, respectively.

15. A line module comprising at least three channels that are geometrically parallel to each other and configured to be connected to housing openings of a housing of a separating module according to claim 1.

16. The line module according to claim 15, comprising a connector flange configured to connect the line module to the separating module, wherein the first connector flange is planar and arranged parallel to the at least three channels.

17. The line module according to claim 16, wherein the connector flange comprises connecting openings, wherein each one of the at least three channels has associated therewith one of the connecting openings to connect the at least three channels to the housing openings of the separating module.

18. The line module according to claim 16, further comprising two connecting flanges configured to connect the line module to a further line module, wherein the two connecting flanges are parallel to each other and/or are perpendicular to the at least three channels and/or are perpendicular to the connector flange.

19. The line module according to claim 18, wherein the at least three channels each have opposed ends that are open at the two connecting flanges so that, by connecting the line module to a further line module, the at least three channels of the line module and at least three channels of the further line module together form continuous, straight channels with a continuous constant cross-section.

20. The line module according to claim 15, configured to create a detachable connection between the housing openings of the separating module and at least three component channels of a component of an engine.

21. The line module according to claim 15, integrated in a part of an internal combustion engine, the part selected from the group consisting of a crankcase, an engine block, an oil pan, a cylinder head, and a cylinder head cover.

22. The line module according to claim 21, wherein at least one of the at least three channels is at least partly formed in the part of the internal combustion engine.

23. A line module assembly comprising a plurailty of the line module according to claim 15, wherein the plurality of the line module are connected to one another such that the at least three channels of a first line module are directly attached to the at least three channels of a second line module that is directly adjacent to the first line module.

24. A ventilation device discharging from an internal combustion engine a gas flow laden with liquid particles, separating liquid particles from the gas flow; and returning the separated liquid particles to the internal combustion engine; the ventilation device comprising: at least one separating module, each including: a separating element configured to separate liquid particles from the gas flow laden with liquid particles; a housing surrounding the separating element into which that separating element is arranged; the housing configured to be connected to a line module comprising at least three channels that are geometrically parallel to each other, the housing comprising housing openings that correspond to the at least three channels. at least two line modules, each including: at least three channels that are geometrically parallel to each other and configured to be connected to housing openings of the housing of the at least one separating modules; wherein each one of the at least one separating modules has associated therewith one of the at least two line modules.

25. The ventilation device according to claim 24, wherein the at least three channels include a first channel, a second channel, and a third channel, wherein: the first channel is an unfiltered gas channel configured to supply a gas flow laden with liquid particles to the separating module; the second channel is a clean gas channel configured to discharge a clean gas that is generated from the gas flow laden with liquid particles by passing the gas flow laden with liquid particles through the separating module; and the third channel is a return channel configured to discharge liquid particles separated by the separating module from the gas flow laden with liquid particles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] As already discussed above, there are several approaches to advantageously embodying and developing the teaching of the present invention. In this regard, reference is made to the dependent claims; other embodiments, features, and advantages of the present invention are explained in greater detail in the following, inter alia using the exemplary embodiment illustrated in FIGS. 1 through 6.

[0048] FIG. 1 is an isometric illustration of a view obliquely from above onto an exemplary embodiment of a ventilation device in accordance with the present invention.

[0049] FIG. 2 is an isometric illustration of a front elevation of the ventilation device of FIG. 1.

[0050] FIG. 3 depicts a longitudinal section of a separating module, connected to a line module, of the ventilation device of FIG. 1.

[0051] FIG. 4 is a detail view of the line module and the separating module of FIG. 3.

[0052] FIG. 5 is a side view, partly shown in longitudinal section, of the ventilation device of FIG. 1.

[0053] FIG. 6 is an exploded illustration of a separating module, connected to a line module, of the ventilation device of FIG. 1.

[0054] Identical or similar configurations, elements, and features are provided with identical reference symbols in FIGS. 1 through 6.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0055] In the exemplary embodiment of the present invention illustrated in FIGS. 1 and 2, a ventilation device 300, specifically a modular crankcase ventilation system, is illustrated that is embodied for: [0056] discharging a gas flow laden with liquid particles, specifically an aerosol made of oil and air, from a crankcase of an internal combustion engine (not shown); [0057] separating the liquid particles from the gas flow, especially separating the oil from the aerosol; and, [0058] returning the separated liquid particles, especially the separated oil, to the crankcase.

[0059] The crankcase ventilation system 300 comprises a plurality of separating modules 100, each of which is associated with a line module 200. FIGS. 3 through 6 each depict a combination of a separating module 100 and a line module 200 of the crankcase ventilation system 300 illustrated in FIGS. 1 and 2.

[0060] The modular structure of the line module 200 and of the separating module 100 has the advantage that any number of separating modules may be arranged in parallel and thus the crankcase ventilation system may be optimally adapted to the operating conditions. However, the line module may also be embodied with continuous channels, i.e., channels extending along a plurality of separating modules, for instance also by embodying at least some of the channels in a part of an internal combustion engine, for instance in a crankcase, engine block, oil pan, cylinder head, or cylinder head cover. The number of separating modules that may be arranged along one conduit may equal the number of cylinders in an internal combustion engine, or, in a V-arrangement, half the number of cylinders. Thus, variants with 2, 3, 4, 5, 6, 8, 10, and 12 are realistic, but even other numbers are possible, especially between 2 and 10 or 2 and 20.

[0061] The separating modules 100 and the line modules 200 are each independent elements or elements embodied separately from one another. In contrast, in the separating module illustrated in FIG. 2 of DE 44 29 822 A1, the lower area of the housing of this separating module is formed by the line module associated with it.

[0062] Each separating module 100 comprises a cylindrical or annular housing 10 that surrounds a separating element 20 embodied for separating the liquid particles from the gas flow.

[0063] The housing 10 comprises an annular wall surface 8 and two cover surfaces 4, 6 embodied for covering at least areas of the end faces of the annular wall surface 8. In contrast thereto, in the prior art illustrated in FIG. 1 of DE 44 29 822 A1, the separating module comprises an open end face.

[0064] The separating module 100 is detachably connectable to the line module 200. Since the separating module 100 is embodied as an independent element and both of its end faces are at least partially covered by a cover surface 4, 6, the separating module 100 may be transported separated from the line module, wherein the housing 10 of the separating module 100 protectively surrounds the separating element 20 received therein.

[0065] To be able to open the housing 10, one of the cover surfaces 4, 6 is embodied as a cover 4. For exchanging the separating element 20 embodied as a replacement element, the cover 4 may be detached from the wall surface 8 of the housing 10 and then the separating element 20 may be removed from the housing 1, as illustrated in FIG. 6.

[0066] The cover surface 6 opposing the cover 4 is embodied as the housing bottom and comprises corresponding housing openings, 12, 14, 16 for three geometrically parallel channels 210, 220, 230 of the line module 200.

[0067] The separating element 20 comprises at least one annular filter medium 22 embodied for separating the liquid particles from the gas flow, especially a coalescence filter element and/or a bellows and/or at least one wound filter element made of woven or non-woven fabric, for instance made of glass fiber, metal fiber, plastic fiber, especially polyester fiber, and mixtures thereof or a combination of successive layers of said materials.

[0068] For supporting the annular filter medium 22, the separating element 20 furthermore comprises a support tube 24 that is, for instance, metallic or made of plastic. The filter medium 22 is arranged about the support tube 24, for instance it is wound onto the support tube 24.

[0069] For at least covering areas of the cover surfaces of the annular filter medium 22, the annular filter medium 22 comprises two filter element cover elements 26, 28, for instance two end discs.

[0070] In the exemplary embodiment illustrated in FIGS. 1 through 6, the filter medium cover element 28 is positioned sealingly against the housing 10 and is embodied to reliably prevent unfiltered air from traveling past the cover surfaces of the annular filter medium 22 and into an interior of the annular filter medium 22. The filter medium cover element 26 is embodied closed so that it preferably closes off the interior of the annular filter medium 22 from the clean side of the separating element 20. Thus, the filter element cover elements 26, 28 separate the unfiltered side of the separating element 20 from the clean side of the separating element 20.

[0071] In the illustrated embodiment, the filter medium cover element 26 arranged in the area of the housing cover 4 is positioned against the housing cover 4 (see FIGS. 3 and 5) and is supported thereon. Alternatively, it would also be possible for support to be provided by a surface 8 of the housing. To establish a gas-tight connection between the housing cover 4 and the housing 10, a sealing element 27 is preferably arranged between the housing cover 4 and the housing 10.

[0072] The additional cover element 28 arranged in the area of the housing bottom 6 is positioned directly against the housing bottom 6.

[0073] In the illustrated exemplary embodiment, the three geometrically parallel channels 210, 220, 230 are embodied as fluid channels and are integrated into the line module 200. The line module 200 is embodied as a flange, specifically as a base module embodied for supporting the separating module 100.

[0074] A first one of the housing openings 12, 14, 16 of the housing 10 is an unfiltered gas opening 12, wherein this unfiltered gas opening 12 is embodied to be supplied by the channel 210 of the line module 200 associated therewith with the gas flow that is discharged from the internal combustion engine and laden with liquid particles, the so-called unfiltered gas. The unfiltered gas opening 12 is thus embodied to be connected to an unfiltered gas channel 210 of the line module 200 that is embodied for supplying unfiltered gas to the separating module.

[0075] A second one of the housing openings 12, 14, 16 of the housing is a clean gas opening 14, wherein this clean gas opening 14 is embodied to supply the channel 220 of the line module 200 associated therewith with a gas flow that has been cleaned in the separating module 100, especially with clean gas. The clean gas opening 14 is thus embodied to be connected to a clean gas channel 220 of the line module 200 that is embodied for discharging clean gas separated by the separating module 100.

[0076] A third one of the housing openings 12, 14, 16 of the housing 10 is a return opening 16, wherein this return opening 16 is embodied to supply the channel 230 of the line module 200 associated therewith with liquid that has been separated in the separating module 100, especially with separated oil. The return opening 16 is thus embodied to be connected to an oil return channel 230 of the line module 200 that is embodied for discharging oil separated by the separating module 100.

[0077] The line module 200 depicted in FIGS. 1 through 6 comprises three fluid channels, specifically an unfiltered gas channel 210, a clean gas channel 220, and a return channel 230. The unfiltered gas channel 210 of the line module 200 represents a direct connection between a raw side channel of the separating module 100 and an unfiltered gas conducting channel of the internal combustion engine. The clean gas channel 220 of the line module 200 represents a direct connection between a clean side channel of the separating module 100 and a clean gas conducting channel of the internal combustion engine. The return channel 230 of the line module 200 represents a direct connection between a separated liquid guiding channel of the separating module 100, especially a separated oil guiding channel of the separating module, and a liquid conducting channel, especially an oil conducting channel, of the internal combustion engine.

[0078] The line module preferably comprises two connecting flanges 240 for connecting to a connecting flange 240 of a further line module 200. The two connecting flanges 240 are preferably arranged parallel to one another and/or perpendicular to the channels 210, 220, 230 and/or perpendicular to the connector flange 202. Both ends of the channels 210, 220, 230 are open at the connecting flanges 240 so that, by connecting two line modules 200 at the connecting flanges 240, the channels 210, 220, 230 of the line modules 200 may be connected such that continuous, straight channels 210, 220, 230 with a continuous constant cross-section are formed. By stringing together a plurality of line modules 200, with a separating module 100 mounted on each one of them, different filtration performance may be realized modularly in a simple manner in a very compact space.

[0079] In contrast to this, the line module illustrated in FIGS. 2 and 3 of DE 44 29 822 A1 has five fluid channels, specifically two channels associated with the inlet openings 23, 30 (reference numbers relate to DE 44 29 822 A1) and embodied for conducting unfiltered gas or clean gas, two channels associated with the outflow openings 31, 32 and embodied for conducting unfiltered gas or clean gas, and one annular channel 48 embodied for conducting separated oil. The line module 200 if the invention as depicted in FIGS. 1 through 6 is therefore constructed much more compactly compared to the prior art disclosed in DE 44 29 822 A1.

[0080] The housing openings 12, 14, 16 are surrounded by and separated from one another by walls formed by the housing bottom 6.

[0081] In order to connect the corresponding housing openings 12, 14, 16 gas-tightly to the geometrically parallel channels 210, 220, 230 of the line module 200, a sealing element 50 is arranged between the housing 10 of the separating module 100 and the line module 200, especially at an area of the walls that surrounds the housing openings 12, 14, 16 and faces the line module 200.

[0082] The line module 200 preferably comprises a connector flange 202 that is embodied flat and arranged parallel to the three channels 210, 220, 230 for attaching the separating module 100 to the line module. The sealing element is preferably positioned sealingly against this connector flange and is braced between the separating module 100 and the line module.

[0083] For fluidic connection, each line module 200 preferably comprises on the connector flange 202 a respective connecting opening 212, 214, 216 for connecting the channels 210, 220, 230 to the housing openings 12, 14, 16 of a separating module 100.

[0084] The housing opening 12 is connected to the channel 210 via the connecting opening 212, the housing opening 14 is connected to the channel 220 via the connecting opening 214, and the housing opening 16 is connected to the channel 230 via the connecting opening 216.

[0085] As illustrated in FIGS. 3 through 5, for sealing the connection between the corresponding housing openings 12, 14, 16 of the housing 10 of the separating module 100 and the geometrically parallel channels 210, 220, 230 of the line module 200, the walls of the housing openings 12, 14, 16 may have on their area facing the line module 200 a profile seal 50 received in a groove. This profile seal 50 may be embodied as a lifetime component.

[0086] The flow direction of the gas flow is marked in FIG. 4 by means of arrows.

[0087] A deflection element 13 embodied for deflecting the gas flow is arranged in the area of the unfiltered gas opening 12. The deflection element 13 illustrated in FIG. 4 is a baffle plate arranged at an angle or perpendicular to the gas flow. This baffle plate 13 conducts the supplied unfiltered gas as if through a labyrinth. The baffle plate 13, arranged in the area of the inlet 12 for unfiltered gas, acts as a pre-separating element.

[0088] After flowing through the unfiltered gas opening 12, the unfiltered gas supplied to the unfiltered gas opening 12 flows into a hollow interior 23 of the filter medium 22 and then flows through the filter medium 22 from the inside to the outside.

[0089] The separating module 100 comprises a pressure control valve 60, comprising a valve closing body 62 that cooperates with a valve seat 66. The pressure control valve 60 is received in the housing 10 and is especially arranged in the area of the wall surface of the separating module 100; it is embodied for controlling the pressure in the ventilation device 300, especially for limiting the negative pressure present in the crankcase ventilation system. Moreover, the pressure control valve 60 comprises a restoring spring 64 that acts on the valve closing body 62 in the direction facing away from the valve seat 66. The valve seat 66 of the pressure control valve 60 is formed by a side wall of the housing 10 of the separating module 100.

[0090] After flowing through the filter medium 22, the separated clean gas flows through the pressure control valve 60 and then the clean gas exits the separating module through the clean gas opening 14 and directly enters the clean gas channel 220 of the associated line module 200.

[0091] The pressure control valve 60 is embodied such that the ambient pressure acts on one side of the valve closing body 62 and preferably on one side of the membrane that carries it. On the other side, the suction pressure existing in the clean gas channel 220 acts inside the valve seat 66 and the crankcase pressure acts outside the valve seat 66. In addition, the force of the spring 64 acts on the valve closing body 62.

[0092] The separating module 100 is embodied such that the pressure existing in the crankcase is applied to the unfiltered gas opening 12 of the housing and the suction pressure is applied to the clean gas opening 14 of the housing 10.

[0093] The restoring spring 64 of the pressure control valve 60 acting on the valve closing body 62 with a spring force is arranged in the area of the suction pressure, especially in the area of the gas outlet of the pressure control valve. This has the advantage that installation space is saved compared to the prior art disclosed, for instance, in WO 2005 088 417 A1, in which the restoring spring is arranged in the area of the crankcase pressure.

[0094] Thus, FIGS. 1 through 6 illustrate a compactly embodied modular crankcase ventilation system 300 that comprises a plurality of units, each formed by a separating module 100 and a line module 200. The number of units of the crankcase ventilation system 300 formed from separating module 100 and line module 200 is variable as desired.

[0095] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.

LIST OF REFERENCE CHARACTERS

[0096] 4 First cover surface, especially cover, of the housing 10 [0097] 6 Second cover surface, especially bottom, of the housing 10 [0098] 8 Wall surface of the housing 10 [0099] 10 Housing of the oil separator 100 [0100] 12 First housing opening, especially unfiltered gas opening, of the housing 10 for the oil separator 100 [0101] 13 Deflection element, especially baffle plate [0102] 14 Second housing opening, especially clean gas opening, of the housing 10 for the oil separator 100 [0103] 16 Third housing opening, especially oil return opening, of the housing 10 for the oil separator 100 [0104] 20 Separating element, especially oil separating element or air-oil separator element [0105] 22 Annular filter medium, especially coalescence filter element, bellows, or wound filter element, for instance made of glass fiber or nonwoven fabric [0106] 23 Hollow interior of the filter medium 22 [0107] 24 Support tube, especially center tube, for supporting the annular filter medium 22 [0108] 26 Cover element, especially end disc, for covering an axial end area, especially an end-face area or a cover surface, of the filter medium 22 [0109] 27 Sealing element compressed between filter medium cover element 26 and surface 8 of the housing 10 [0110] 28 Second or other cover element, especially second or other end disc, for covering another axial end area, especially another end-face area or another cover surface, of the filter medium 22 [0111] 50 Sealing element, especially profile seal, arranged on the area of the separating module 100 facing the line module 200 and embodied for sealing the connection between the separating module 100 and the line module 200 [0112] 60 Pressure control valve [0113] 62 Valve closing body, especially control pin, of the pressure control valve 60 [0114] 64 Restoring spring for pressure control valve 60 [0115] 66 Valve seat for pressure control valve [0116] 100 Separating module, especially oil separator [0117] 200 Line module, especially for directly or indirectly attaching the separating module 100 to a connector element or connecting head embodied on a component of an engine, for instance a receiving flange or base module embodied for receiving the separating module 100, especially as an integral component of a part of an internal combustion engine, for instance the channels are embodied in a crankcase, engine block, oil pan, cylinder head, or cylinder head cover [0118] 202 Connector flange, especially connector flange plane, for attaching the separating module 100 [0119] 210 First channel of the line module 200, especially unfiltered gas channel, especially unfiltered air supply line [0120] 212 First connecting opening of the line module 200, for connecting the first channel 210 to the first housing opening 12 [0121] 214 Second connecting opening of the line module 200, for connecting the second channel 220 to the second housing opening 14 [0122] 216 Third connecting opening of the line module 200, for connecting the third channel 230 to the third housing opening 16 [0123] 220 Second channel of the line module 200, especially clean gas channel, for instance clean air supply line or clean air discharge line [0124] 230 Third channel of the line module 200, especially return channel, for instance oil return channel [0125] 240 Connecting flange, especially connecting flange plane, for connecting to a connecting flange of a further line module 200, especially perpendicular to connector flange 202 and channels 210, 220, 230 [0126] 300 Ventilation device, especially device for separating oil from an oil-air mixture or from an aerosol, for instance crankcase ventilation system