US20140208703A1

US20140208703A1 - Gas/liquid separator and components; liquid drain flow assemblies; systems of use ; and, features; and, components

Info

Publication number: US20140208703A1
Application number: US14/129,700
Authority: US
Inventors: Gert Willems; Miloslav Krystufek
Original assignee: Donaldson Co Inc
Current assignee: Donaldson Co Inc
Priority date: 2011-07-29
Filing date: 2012-07-27
Publication date: 2014-07-31
Also published as: DE112012003172T5; CN103717286A; WO2013019643A2; WO2013019643A3

Abstract

According to the present disclosure gas/liquid separator assemblies, such as crankcase ventilation filter assemblies, and components are described. Also described are liquid flow control arrangements for facilitating liquid flow from a region of first effective pressure to a region of second higher effective pressure are described. In examples, the flow control arrangements are configured so they can be used in association with a gas/liquid separator, managing separation of liquids from crankcase ventilation gases, for example for internal combustion engines. Example arrangements are described, used with crankcase ventilation gas filter assemblies. Combinations of equipment, and various components usable in those combinations, are described.

Description

This application is being filed on 27 Jul., 2012, as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Gert Willem, a citizen of Belgium, and Krystufek Miloslav, a citizen of the Czech Republic, applicants for the designation of the US only.

CROSS-REFERENCE TO RELATED APPLICATIONS

The application includes the content of, with edits, U.S. Ser. No. 61/513,207, filed Jul. 29, 2011. The complete disclosure of U.S. Ser. No. 61/513,207 is incorporated herein by reference. A claim of priority is made to U.S. Ser. No. 61/513,207 to extent appropriate.

FIELD OF THE DISCLOSURE

The present disclosure relates to methods and equipment for directing flow of liquid between regions of different internal pressure. The systems, methods, assemblies, features and components described, are particularly well configured to provide convenient flow (of collected coalesced liquid, such as oil) from crankcase ventilation gas/liquid separation assemblies to a crankcase of an associated engine, although alternate applications are possible. The disclosure includes components for use with such system.

BACKGROUND

A. Liquid Drain Flow Between Regions of Different Pressure

In a variety of systems, it is desirable and/or necessary to cause a liquid drainage flow to occur between regions of different internal pressure. This can pose issue, when liquid begins in a region of relatively low pressure and must flow to a region of relatively higher pressure. Herein, methods, techniques and equipment are provided to facilitate such flow.
A typical example application is in connection with a gas/liquid separator such as a gas/oil separator for managing crankcase ventilation gases, from a crankcase of an engine such as a diesel engine. In general, crankcase ventilation gases comprise a gaseous component having suspended therein, liquid oil. After removal from the crankcase, the oil particles are coalesced and drained.
A variety of systems for managing crankcase ventilation gases and separating them between the gaseous and liquid components are known. Examples include, for example, coalescer and inertia separators; electrostatic separators; cyclones; rotating coalesers; axial vortex tube separators; cone-stack centrifuges and, spiral vane centrifuges.
In general, in many systems for managing crankcase ventilation gases, once the liquid is separated from the gases, it needs to be drained back into the crankcase or engine sump. This, in many instances, involves liquid flow from a region of separation which may be a lower pressure, into an engine crankcase that may be a higher pressure. Techniques described herein were developed specifically to address such circumstances.
It is noted that the system for separating crankcase ventilation gases into a gas component and a liquid component can be of a variety of types as indicated. Herein, example systems are described which involve crankcase ventilation filter assemblies, i.e. assemblies in which the separation occurs as the gases are passed through a coalescing/filter media. The techniques described can be applied, however, in connection with alternate systems for managing crankcase ventilation gases.

B. Crankcase Ventilation Filter Assemblies Generally

Certain gas streams, such as engine blowby gases i.e. crankcase ventilation gases from the crankcase of diesel engines, carry substantial amounts of entrained oils (liquid) therein, as aerosol. In some instances, many of the oil (liquid) droplets within the aerosol are within the size of 0.1-5.0 microns. In addition, such gas streams can also carry substantial amounts of fine particulate contaminants, such as carbon contaminants. Such contaminants often have an average particle size within the range of 0.5-3.0 microns.
In some instances, it is desired to vent such gases to the atmosphere. In general, it is preferred that before the gases are vented to the atmosphere, they be cleaned of a substantial portion of aerosol and/or organic particulate contaminant therein.
In other instances it is desirable to direct the filtered gas stream into equipment. When such is the case, it may be desirable to remove (or reduce levels of) aerosolized liquid and/or particulate from the gas stream during circulation, in order to provide such benefits as: reduced negative effect on downstream equipment; improved efficiency; recapture of otherwise lost oil; and/or to address environmental concerns.
Crankcase ventilation filter systems usable in a variety of equipment systems to accomplish this are well known. Examples are described in PCT WO 2007/053411 A2; WO 2008/147585 A2; WO 2008/115985 A2; WO 2008/157251 A2; WO 2009/018454 A2; U.S. Ser. No. 61/425,869; U.S. Ser. No. 61/503,008; and, in U.S. Ser. No. 61/503,063, each of which is incorporated herein by reference.

C. Example Engine Systems Including a Crankcase Ventilation Gas/Liquid Separator Assembly

In FIG. 1, an example system 1 using a crankcase ventilation gas/liquid separator assembly is depicted. Referring to FIG. 1, at 3 an engine system is depicted, comprising for example, an internal combustion engine such as a diesel engine for a vehicle such as a truck, or for construction or farm equipment, etc. At 4 is a depicted a vent outlet from the engine 3, for crankcase ventilation gases. At 5 a crankcase ventilation gas/liquid separation system is depicted. The crankcase ventilation gases are directed into the system 5 via the line indicated at 4 x. At 6, a coalesced or collected liquid drain take-off for liquid from the crankcase ventilation gases is shown. In line 6, the liquid drain would be of oil(s) coalesced within the system 5, and removed from the gas. At 7 a gas take-off from the gas/liquid separator system is shown. The particular system 1 depicted is a closed system. Thus, the gases at outlet 7 are shown directed, via line 8 into an air induction system 9 for the equipment of use. In some systems, the gases from outlet 7 may be vented to the atmosphere, as shown at optional line 8 x.
At 10, an air cleaner for induction air from line 11 is depicted. At 12, a filtered air outlet from the air cleaner 10 is shown, directing filtered air into turbo 13 and to engine 3 via line 14.
The system 5 used for separating crankcase ventilation gases from line 4 into a gas component and a collected or coalesced liquid component, can comprise a variety of arrangements as indicated above. In certain specific examples provided herein, the system or assembly 5 is a crankcase ventilation filter system. An example such system is described in the next section.

D. An Example Crankcase Ventilation Filter Assembly, FIG. 2

In FIG. 2, a side elevational view of a crankcase ventilation filter assembly is depicted. The particular assembly depicted in FIG. 2, is one described in U.S. Ser. No. 61/503,008, incorporated herein by reference.
In general, the crankcase ventilation filter assembly 30 comprises a housing 31 defining an interior volume and having removably positioned therein a filter arrangement (not depicted), in the form of a serviceable filter cartridge.
The housing 31 generally includes a gas flow inlet arrangement 34, a gas flow outlet arrangement 35 and a liquid drain outlet arrangement 36. Typically the housing 31 includes a housing body or base 37 and a removable access or service cover 38.
In operation, crankcase gases are directed from the engine to the assembly 30, via gas flow inlet arrangement 34. Within the housing 31, the gases are passed through filter media of the filter arrangement. Within the media, particulates within the gas flow stream are collected. This generally includes coalescing of liquid oil particles. The gases, after passing through the media, are then directed to the gas flow outlet arrangement 35. This gas flow may be directed to the air induction system for the engine system of concern, or be vented to the atmosphere, as discussed above with respect to FIG. 1. Again, when the gases are directed to the air induction system, for example into the air cleaner system, the overall crankcase ventilation filter system may be referred to as “closed” or “CCV.” When the gas flow is vented to the atmosphere, the overall crankcase ventilation filtration system may be referred to as “open” or “OCV.”
As described, liquid (oil) that coalesces within the media and will generally drain to the liquid drain outlet 36. This liquid is then directed outwardly from the assembly 30 and preferably back into the crankcase.
Again, the assembly 30 is intended to represent a variety of example prior art assemblies and may vary in specific detail. The features and descriptions generally described, are typical, alternate assemblies which includes features for the same general type of operation are described in PCT WO 2007/053411 A2; WO 2008/147585 A2; WO 2008/115985 A2; WO 2008/157251 A2; WO 2009/018454 A2; U.S. Ser. No. 61/425,869; U.S. Ser. No. 61/503,008; and, in U.S. Ser. No. 61/503,063; each incorporated herein by reference.
With assemblies that include cylindrical media packs and cartridges, the assembly may be configured for either in-to-out flow during filtering or out-to-in flow during filtering. These terms are meant to refer to the direction of gas flow through the media as the filtration process occurs, i.e. does it pass through the cylindrical media from a location within the interior of the cylinder through the media to the exterior, or does it pass from exterior of the media through the media to interior, as the filtration occurs. The identified PCT WO 2007/053411 A2; WO 2008/147585 A2; WO 2008/115985 A2; WO 2008/157251 A2; WO 2009/018454 A2 and in U.S. Ser. No. 61/425,869 and U.S. Ser. No. 61/503,008; include examples of both types of arrangements. A typical characteristic of each is that the housing includes a gas flow inlet arrangement, a gas flow outlet arrangement; and, a liquid drain arrangement. It is also noted that in one of the references previously identified, namely WO 2008/147585, an assembly in which the media pack is configured as a panel rather than a cylindrical configuration is provided. Principles described herein can be used in connection with any of these arrangements and variations thereof.

E. An Issue with Respect to Liquid Drain and Direction Back into the Crankcase

It is noted that with crankcase ventilation gas/liquid separator assemblies of the type generally characterized herein above, liquid that is collected drains therefrom into a region or lower pressure, for example downstream of filter media. That is, such a collection/drain region is typically of lower pressure than a region upstream of the media or in the crankcase. Thus, for crankcase ventilation filter assemblies, the filter cartridge (media) and seals associated therewith generally separate the housing into: an upstream, relatively higher pressure, region; and, a downstream, relatively lower pressure, region. The upstream, relatively higher pressure, region is generally a region that receives gas flow from the crankcase, and thus reflects the crankcase internal pressure. The downstream, relatively lower pressure, region is, in closed systems, a region in communication with downstream air induction equipment, and is subject to the intake air draw of the engine air induction system.
Issues relate to accomplishing effective liquid drain from liquid collected in a relatively lower pressure region being drained to a crankcase having a condition of generally higher pressure. Principles according to the present disclosure are provided to affect this.

SUMMARY

According to an aspect of the present disclosure, equipment and techniques are described for managing liquid flow from a region of relatively low pressure to a region of relatively higher pressure. Typical applications involve management of liquid flow from a crankcase ventilation system gas/liquid separator. The liquid separated is directed back into the crankcase of an engine, typically from a region of lower pressure than the crankcase. The equipment and techniques described herein facilitate this drainage, i.e. this flow control.
A flow control arrangement in accord with the techniques described herein can be managed in accord with a variety of specific equipment configurations. In general, a flow transition chamber is provided, between a region of relatively lower pressure and the region of relatively higher pressure. Various valve arrangements are used to cycle the transition region between filling with liquid from a lower pressure side and draining liquid to the higher pressure side.
In addition to liquid flow control arrangement components and features thereof, the present disclosure also includes an aspect relating to selected identified combinations of gas/liquid separator assemblies and liquid flow control arrangements. The gas/liquid separator assembly may be of a variety of types, specific examples described comprising crankcase ventilation filter assemblies. Also, some example techniques, configurations and components for such arrangements, or for the gas/liquid separator assembly component of such arrangements, are described.
There is no specific requirement that a system, component, assembly method or technique include all of the detailed features describe herein, in order to provide some advantage in accord with the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an engine system using a crankcase ventilation gas/liquid separator assembly.

FIG. 2 is a schematic depiction of a crankcase ventilation filter assembly useable in a system in accord with the present disclosure, as a gas/liquid separator assembly.

FIG. 3 is a schematic depiction of a engine system using a crankcase ventilation gas/liquid separator assembly and liquid drain flow management arrangement in accord with the present disclosure.

FIG. 3A is a fragmentary schematic depiction of an engine system using a gas/liquid separator assembly and liquid drain flow management system in accord with the present disclosure; the view of FIG. 3A including more detail for a selected portions than the depiction of FIG. 3.

FIG. 4 is a schematic cross-sectional view of a liquid drain flow control module usable in a liquid drain flow management system in accord with the present disclosure; the cross-sectional view of FIG. 4 being taken generally along line 4-4, FIG. 5.

FIG. 5 is a schematic top plan view of the liquid drain flow control module of FIG. 4.

FIG. 6 is a schematic cross-sectional view generally analogous to FIG. 4, depicted with liquid drainage thereto, from a gas/liquid separator assembly.

FIG. 7 is a schematic view analogous to FIG. 6, depicted with a greater amount of liquid flow into the module depicted, relative to FIG. 6.

FIG. 8 is a schematic view analogous to FIGS. 6-7, shown in a further stage of liquid flow in which a drainage flow from the liquid flow control module to the crankcase has started to occur.

FIG. 9 is a schematic cross-sectional view of a portion of a housing component of a liquid flow control module depicted in FIGS. 4-8; the view of FIG. 9 being taken generally along line 9-9, FIG. 10.

FIG. 10 is a top plan view of a housing component of FIG. 9.

FIG. 11 is a schematic cross-sectional view of a top cover component of the liquid flow control module depicted in FIGS. 4-8.

FIG. 12 is a schematic side elevational view of a transition chamber float valve component of the module directed in FIGS. 4-8.

FIG. 13 is a schematic cross-sectional view of an umbrella valve component depicted in the module of FIGS. 4-8.

FIG. 13A is a schematic depiction of an umbrella valve component mounted in a portion of an assembly for use.

FIG. 14 is a schematic side elevational view of a restriction port filter component of the assembly depicted in FIGS. 4-8.

FIG. 15 is a schematic cross-sectional view of a second embodiment of a liquid flow control module in accord with the present disclosure; the view of FIG. 15 being taken generally along line 15-15, FIG. 16.

FIG. 16 is a schematic top plan view of the liquid flow control module of FIG. 15.

FIG. 17 is a schematic cross-sectional view of a third embodiment of a liquid flow control module according to the present disclosure; the view of FIG. 17 being taken along line 17-17, FIG. 18.

FIG. 18 is a schematic top plan view of the liquid flow control module of FIG. 17.

FIG. 19 is a schematic cross-sectional view of a combination of a gas/liquid separator assembly and a liquid flow control module according to the present disclosure.

FIG. 20 is a schematic depiction of the assembly of FIG. 19 in association with an engine system.

FIG. 21 is a schematic cross-sectional view of a second embodiment of a combination of gas/liquid separator assembly and a liquid flow control module according to the present disclosure.

FIG. 22 is a schematic cross-sectional view of a third embodiment of a combination of gas/liquid separator assembly and a liquid flow control module according to the present disclosure.

FIG. 23 is a schematic depiction of a fourth example of a combination of a gas/liquid separator assembly and a flow control module according to the present disclosure.

FIG. 24 is a schematic depiction of an engine system including a combination of a gas/liquid separator assembly and a liquid flow control module in accord with the present disclosure.

FIG. 25 is a schematic depiction of another system including an engine, a gas/liquid separator arrangement and liquid flow control arrangement according to the present disclosure.

FIG. 26 is a schematic depiction of another system including an engine, a gas/liquid separator arrangement and a liquid flow control arrangement according to the present disclosure.

FIG. 27 is a schematic depiction of another system including an engine a gas/liquid separator arrangement and liquid flow control arrangement according to the present disclosure.

DETAILED DESCRIPTION

I. An Improved Engine System Including a Liquid Drain Flow Arrangement According the Present Disclosure

A. The Engine System and the Liquid Drain System Generally, FIGS. 3 and 3A
The reference numeral 50, FIG. 3, generally indicates an engine system including a crankcase ventilation gas/liquid separator arrangement and a liquid drain flow control arrangement in accord with the present disclosure. Referring to FIG. 3, at 51 an engine is depicted schematically. The engine 51 includes a lower oil sump 52, depicted having oil 53 therein.
Still referring to FIG. 3, at 55 an air induction system for the engine 51 is depicted. The air induction system 55 includes air cleaner 56. In general, air cleaner 56 is configured to filter air being drawn into engine 51 as combustion air.
At 57 a turbocharger is depicted positioned within the air induction system or arrangement 55 at a typical location relative to the air cleaner 56, i.e. downstream therefrom.
At 58 a crankcase breather exit or crankcase ventilation gas flow exit from the engine 51 is depicted. Gases are transferred from the breather exit 58 through line 59 to a crankcase ventilation gas/liquid separator assembly 60, which can, for example, be a crankcase ventilation filter assembly 60 f. If a crankcase ventilation filter assembly 60 f is used as separator 60, it can be generally in accord with arrangements described in PCT WO 2007/053411 A2; WO 2008/147585 A2; WO 2008/115985 A2; WO 2008/157251 A2; WO 2009/018454 A2; U.S. Ser. No. 61/425,869; U.S. Ser. No. 61/503,008; and, in U.S. Ser. No. 61/503,063; or, variations therefrom, although alternatives are possible. In general, as described above for the example assembly of FIG. 2, the gas/liquid separator assembly 60 includes a gas flow inlet arrangement 61, gas flow outlet arrangement 62 and a liquid drain outlet arrangement 63.
The particular system 50 depicted is a closed system with respect to the crankcase ventilation filter gases. Thus, gas flow from outlet arrangement 62 is being depicted directed into line 65 and back into the air induction system 55 at 66; in the example depicted the location 66 being downstream of the air cleaner 56 and upstream of the turbocharger 57, although alternatives are possible.
In general, liquid drainage from liquid drain outlet 63 is directed via line 70 eventually back into the sump 52, as shown at 71.
In general, the pressure at line 59 reflects the crankcase pressure of the engine 51, whereas the pressure at line 65 reflects a lower pressure (for example a downstream side pressure of the filter assembly 60 f, affected by the gas (air) draw of the air induction system 55). Typically, an effective pressure at line 59 will be higher than an effective pressure at line 65; line 65 being subject to gas intake draw from the engine 51.
Within the gas/liquid separator assembly 60 in the example crankcase ventilation filter assembly 60 f, two regions of different pressure are created. For a crankcase ventilation filter assembly 60 f, these are upstream and downstream of an associated filter cartridge 72. Typically, the liquid at drain 63 receives liquid from a location downstream of an upstream most portion of filter cartridge 72 and the assembly 60 and thus generally reflects a region of pressure analogous to the outlet arrangement 62, i.e. lower than inlet 61.
However, the sump 52 within the engine 51 generally reflects the engine crankcase pressure, which is higher and more indicative of the pressure at line 59 and at the gas flow inlet arrangement 61. An issue then is getting good flow of liquid from the liquid drain outlet arrangement 63 into a relatively higher pressure sump 52 within the engine 51.
To provide for this, a liquid drain flow management (or control) system 75 is provided. Such a liquid drain flow management system 75 is depicted schematically in FIG. 3A.
Referring to FIG. 3A, the liquid drain flow management system 75 can be understood to comprise: a first (one-way) flood valve arrangement 77 for managing liquid flow into the liquid drain flow management system 75 from the liquid drain outlet 63 of the crankcase ventilation gas/liquid separator assembly 60 and inhibiting a backpressure or back flow from being transferred thereto; a second one-way flood valve arrangement 78 configured to facilitate liquid drainage from the liquid drain flow management system to the sump 52 and inhibiting backflow from the sump 52 into the liquid drain flow management system 75; and, a third valve arrangement 80 configured to move between two positions: (1) a first in which liquid drain flow entering flow module 81 from the crankcase ventilation gas/liquid separator assembly 60 is facilitated (while the equipment inhibits that liquid from draining to the sump 52); and, (2) a second position in which liquid flow from the gas/liquid separator assembly 60 is inhibited (but the equipment facilitates liquid drainage from the module 81 to the sump 52).
In general, as the third valve arrangement 80 is converted between the two extreme positions identified, internal pressure conditions within selected portions of the flow module 81 are modified between two extremes, a lower pressure extreme when the third valve arrangement 80 is in the first position; and, a higher pressure extreme when the third valve arrangement 80 is in the second position. This will be understood from further description below.
For the example liquid drain flow management arrangement 75 depicted, a float valve arrangement is used as the third valve 80. This is a convenient, inexpensive, type of assembly. It is noted that alternate arrangements can be used in accord with principles according to the present disclosure.
B. An Example Drain Flow Management System—FIGS. 4-7
An example usable liquid drain flow management arrangement in accord with the principles for arrangement 75 can be understood by review of the liquid drain flow control module 81 depicted in FIGS. 4 and 5.
More specifically, in FIG. 4 a schematic cross-sectional view is provided of a liquid drain flow module 81 usable as a liquid drain flow management arrangement 75, FIGS. 3 and 3A. The view is taken along line 4-4, FIG. 5 (a top schematic view).
Referring to FIG. 4, flow module 81 depicted comprises a housing 82 having a liquid drain flow inlet 83, a liquid drain flow outlet 84, a first gas pressure tap or port 85; and, a gas (crankcase) pressure tap or port 86. The housing 82 is configured to define a first internal volume or transition chamber 87. In the example depicted the housing 82 also defines a second internal drain chamber 88, in this example comprising a portion of a housing bottom 88 b, although alternatives are possible. The module 81 includes a valve member arrangement 95 moveably positioned in the internal chamber 87, as the third valve arrangement 80.
In the particular assembly 75 depicted, at 96 a flood valve arrangement that corresponds to the first valve arrangement 77, FIG. 3A is depicted; and, at 97 a valve arrangement corresponding to the second drain valve arrangement 78, FIG. 39 is depicted. That is, for the particular assembly 75 depicted, the first valve arrangement 77 and the second valve 78 referenced above, with respect to general operation in connection with FIG. 3A, are incorporated into the module 81 as valve arrangements 96 and 97. Alternatives are possible.
Operation of the flow module 81 will be understood by reference to FIGS. 4-8.
Still referring to FIG. 4, when module 81 is installed for typical operation liquid flow inlet 83 is configured to receive liquid from the crankcase ventilation gas/liquid separator assembly liquid flow outlet 63, FIG. 3A. Tap 85 is provided in gas flow communication with a lower pressure gas region, for example a downstream side of filter media of crankcase ventilation filter assembly 60 f, FIG. 3A. (For example it can be in communication with line 65). Tap 86 is provided in gas flow communication with crankcase ventilation gas region of higher pressure, for example upstream of a crankcase ventilation gas/liquid separator assembly 60. Such a communication can be provided by communication with line 59, FIG. 3.
Referring again to FIG. 4, the assembly 81 is depicted as it would appear before liquid has begun to drain into the housing 82. In an example application with a filter assembly 60 f as the gas/liquid arrangement assembly 60, the pressure at inlet 85 can correspond to the downstream pressure of the crankcase ventilation filter assembly 60 affected by the engine induction system draw. In the same, example, application, the pressure at region 86 can correspond to the crankcase pressure. Flow module 81 is depicted configured so that generally the liquid flow inlet 83 is isolated from the higher pressure region 86. Valve 96 is an openable one way valve, for example an umbrella valve. There is no current liquid flow shown in FIG. 4 and valve 97 is depicted closed generally due to the higher pressure in region 88 than in transition chamber 87.
Still referring to FIG. 4, it is noted that should the inlet gases from the crankcase at tap 86 include any liquid therein; the liquid can drain to the bottom of chamber 88 and into outlet 84, without needing to pass into the transition chamber 87 or through the valve arrangement 97.
Referring to FIG. 4, a second gas flow tap or aperture arrangement 100 is depicted providing some gas flow communication into transition chamber 87; i.e. from inlet 89 to tap 85. In the example depicted, each of tap 85, and aperture arrangement 100 are positioned at a location above valve 95 when the valve is in the first orientation depicted in FIG. 4, although alternatives are possible. Aperture 100 is shown covered by optional filter member 101. Preferred aperture 100 and filter 101 arrangements are discussed below.
In FIG. 6, the flow module 81 is depicted with liquid drain beginning to occur from the crankcase ventilation gas/liquid separator assembly. The liquid (dark cross-hatch) is shown filling inlet 83 and draining through a flow aperture arrangement 103 managed by one way (flood) valve arrangement 96 into an interior 87 i of transition chamber 87. The liquid is generally isolated in transition chamber 87 (from bottom 88 b) as the float valve 95 begins to rise, with valve arrangement 97 closed.
As the liquid begins to fill (flood) transition chamber 87, it will eventually reach a point where the float valve 95 significantly rises. The float valve 95 will eventually float up to a top position closing off tap 85 at valve seat 110. Whether the closing is complete or partial is a matter of choice. Both can be configured to operate. Herein, when the float valve 95 is positioned to engage tap 85, and valve seat 110, the valve member 95 will be characterized as being in a position in which the valve seat of the first gas flow conduit is inhibited from gas flow therethrough. Whether this inhibition is in complete closing or partial closing, again, is a matter of choice.
In FIG. 7, sufficient liquid volume rise leading to this closing effect is depicted. Referring to FIG. 7, float valve 95 is shown having risen sufficiently, due liquid entry into the interior chamber 87 from inlet 83, such that valve head 111 on valve member 95 inhibits (closes) gas entry through valve seat 110 to tap 85. Pressure within region 86 (due to gas inlet from bleed aperture 100) can now increase, since tap 85 is closed and inlet tap 86 and aperture arrangement 100 are not.
Still referring to FIG. 7, it is noted that in the example, internal chamber 87 is configured so that aperture arrangement 100 is positioned above a highest level of liquid within chamber 87 when valve member 95 is raised to its uppermost position. This will be typical.
The pressure increase in transition chamber 87 that results from arrangement of valve member 95 with seat 110 will allow one way valve arrangement 97 to open. This is depicted in FIG. 8. It is noted that the pressure increase in chamber 87 will also tend to close flood valve arrangement 96.
Referring to FIG. 8, one way valve 97 is depicted open sufficiently to allow liquid to drain into region 88 and to outlet 84. When this occurs, valve member 95 will drop, opening seat 110 and returning the arrangement to the orientation generally shown in FIGS. 4 and 6. The operation will, of course, cycle.
Thus, the assembly depicted in FIGS. 4-8 when used in accord with the general characterizations given, facilitates drainage of liquid from a relatively low pressure region of a crankcase ventilation gas/liquid separator assembly to a relatively higher pressure region of an engine or sump. A valve is used within a housing transition chamber configured to cycle between orientations to facilitate such drainage to advantage.
The principles can be practiced in a variety of specific arrangements, as can be seen from the following descriptions. In general, a module is preferred, in which the first, second and third valves are all contained within the same assembly, although in some applications, one or more of the one way valve arrangements 96 and 97 can be alternately positioned.
C. A More General Characterization of Features and Principles Relating to FIGS. 4-8
Now that the basic operation of principles depicted in FIGS. 4-8 is understood, general characterizations of those features and principles will be understood. In general, a liquid flow control arrangement is provided for use in facilitating liquid flow from a region of first effective pressure to region of a second, higher, effective, pressure. The liquid filter arrangement can be configured as a flow control module, with all valve componentry included therein, however alternatives are possible. With a system including a flow control module such as module 81, FIGS. 4-8, the system can be seen as comprising a housing 82 including a transition chamber 87 comprising a sidewall 87 s and a transition chamber bottom 87 b. In more general terms, the transition chamber 87 can be characterized as having a wall or wall arrangement that defines the transition chamber interior 87 i.
The arrangement includes, defined by the transition chamber 87, a liquid drain outlet aperture arrangement 98 configured for drainage of liquid from an interior 87 i of a transition chamber 87.
There is included within the system 81 (i.e. within the module when a module is used) a transition chamber one-way drainage valve arrangement 97 positioned to control liquid drain through the liquid drain outlet aperture arrangement from the transition chamber 87.
A first gas flow conduit 85 is configured in gas flow communication with an interior 87 i of the transition chamber 87. The gas flow conduit 85 defines a valve seat 110 in the transition chamber 87. The valve seat 110 is typically positioned at a location above a maximum or highest operating liquid height within the transition chamber 87 during normal use. The term “high operating liquid height” and variants thereof as used herein, is meant to refer to location above a normal height to which liquid (flood) will reach within the chamber 87 i, during a typical expected operation. It is preferred that the gas flow conduit 85 and valve seat 110 not be submerged, as will be apparent from the above description of operation.
A second gas flow conduit 100 is provided in flow communication with interior 87 i of the transition chamber 87. The second gas flow conduit 100 is also typically positioned at a location above the maximum (or highest expected) normal operating liquid height within the transition chamber during normal use.
A liquid flow inlet or flood arrangement 103 is provided, allowing for liquid flow inlet into the interior 87 i of the transition chamber 87. A transition chamber one-way flood valve arrangement 96 is positioned to control liquid flow though the liquid flow inlet arrangement 103 to the interior 87 i of the internal chamber 87.
The assembly of module 81 includes a transition chamber valve arrangement 95 including a valve member, positioned in the transition chamber interior 87, movable upon entrance of liquid flow through the liquid flow inlet arrangement 103 to the transition chamber 87 and liquid drain flow from the transition chamber 87 between:
(1) a first position in which both the first gas flow conduit 85 and the second gas flow conduit 100 are open; and,
(2) a second position in which the valve seat 110 in the first gas flow conduit 85 is engaged, inhibiting gas flow therethrough; and in which the second gas flow conduit 100 remains open.
Generally, the transition chamber one-way flood valve arrangement and the transition chamber drainage one-way valve arrangement is configured such that:
(1) when the transition chamber valve arrangement is in first position, the one-way flood valve arrangement is configured to facilitate liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to inhibit liquid drainage flow from the transition chamber; and,
(2) when the transition chamber valve arrangement is in the second position, the one-way flood valve arrangement is configured to inhibit liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to facilitate liquid drainage flow from the transition chamber.
In general, such an operation is facilitated by providing the first gas flow conduit 85 in communication with a region or lower pressure or vacuum draw; and, the second gas flow conduit 100 in communication with a higher pressure volume. An example system depicted, the first gas flow conduit can be provided in gas flow communication with the downstream side of a crankcase ventilation filter assembly; and, the second gas flow conduit can provided in gas flow communication with an engine crankcase, although alternatives are possible.
It is noted that in typical and preferred application of the principles described herein, gas flow through aperture arrangement 100 (the second gas flow conduit) is restricted. This will generally facilitate operation of the valve arrangement 95 within the transition chamber 87, as discussed in the next section.
The system or module 81 can include a higher pressure chamber 88 separated from the transition chamber 87 and including: (1) an interior upper volume portion 88 u in gas flow communication with a second gas flow conduit 100; and, (2) an interior lower volume bottom portion 88 b in both gas and liquid flow communication with the liquid flow outlet 84. This construction provides that a gas pressure within bottom 88 generally reflects the inlet gas pressure at inlet 86.
D. Providing of Restriction to Gas Flow Through the Second Gas Flow Conduit 100 from the Interior Volume Portion of the Higher Pressure Chamber 88, to the Interior 87 i of the Transition Chamber 87
In general, as indicated above, it is preferable provide for some restriction of gas flow into the transition chamber 87, from the higher pressure region defined by the interior volume portion 88 u of the higher pressure chamber 88 through the second gas flow conduit 100. The reason for this is that a restriction of gas flow through the second gas flow conduit 100 can help ensure that the draw through the first gas flow conduit 85 is substantial, which facilitates liquid entering interior 87 i through the one-way flood valve arrangement 96.
Herein, the second gas flow conduit 100 will be referred to as “restrictive flow port arrangement” when it is provided in some manner with restriction to gas flow therethrough, from upstream regions.
A variety of techniques can be used to provide restriction with respect to gas flow through the second gas flow conduit 100. These techniques can be used separately or together. An example technique is to provide a filter arrangement 101 over the aperture 100. Filter media of the filter arrangement 101 will provide for restriction to gas flow through aperture 100. Referring to FIG. 6, a filter arrangement 101 is shown positioned under internal flange 115 and over aperture 100. The flange 115 covers the media 101 and ensures that liquid entering through aperture 86 does not directly fall upon the media 101.
Another manner of restricting flow through aperture 100 is by restricting the size of aperture arrangement 100 for gas flow therethrough. The size of aperture arrangement 100 in this context is meant to refer to the cross-sectional size. Typically, the aperture 100 will be circular in cross-sectional dimension, but alternatives are possible. When more than one aperture is used as the aperture arrangement 100, the general reference is to the total cross-sectional size.
Typically, the total cross-sectional size of aperture arrangement 100 is not greater than 13 sq. mm, usually not greater than 7 sq. mm, and often not greater than 4 sq. mm. Typical example arrangements for aperture arrangement 100 will comprise a single aperture having a diameter on the order of about 1-2 mm.
Another way of characterizing the amount of restriction, is to refer to the flow aperture 100 as a pilot flow, relative to the flow in line 59, FIG. 3A. Typically, the flow in the tap 86, FIG. 4, and through aperture 100, should be no more than about 0.1% of the gas flow exiting the crankcase via the crankcase ventilation arrangement, typical no more than 0.05% of that flow, and preferably no more than 0.04% of this flow.
E. Assembly of Drain Flow Management System 75—FIGS. 9-14
In FIGS. 9-14, componentry 82 usable to form module 81 is depicted. In FIG. 9, depicted are: housing section 116 with housing bottom 117 secured thereto. The housing section 116 and housing bottom 117 can be separately made, and then be secured to one another. The securement can be a permanent attachment such as through sonic welding, or it can be a disconnectable attachment.
The housing section 116 for the example assembly depicted includes three region. The first is (internal) transition chamber 87 referenced above. The second is high pressure region 88 comprising, together, tap 86, associated down corner 86 x and bottom region 88 with outlet 84 in communication therewith. The third is liquid flow inlet 83 with downcomer 83 x associated therewith.
Downcomer 83 x communicates with interior 87 through flow aperture arrangement 103. A one-way valve arrangement 96 discussed above will be associated with aperture arrangement 103 to control flow from downcomer 83 x into interior 87 as discussed above.
Aperture 100 discussed above, provides communication between downcomer 86 x and interior chamber 87. The frame 115 depicted includes a top 115 x and sidewall 115 y positioned to receiver filter arrangement 101 discussed above therein, over aperture 100 and to protect filter arrangement 101 from material dripping thereon, from inlet 86.
Transition chamber 87 is generally defined by sidewall 87 s and bottom 87 b. The bottom 87 b includes an aperture arrangement 98 therethrough which allows drainage from region 87 into lower region 88. Aperture 87 t provides for mounting one way valve assembly as discussed previously and as referenced in more detail below.
The sidewall 87 s can have a variety of shapes. The particular example depicted is a generally cylindrical shape with a plurality of spaced vertical valve centering ribs 87 r therein. The region 87 would typically include at least four ribs 87 r, typically 4-8 such ribs 87 r. The ribs 87 r generally help center float valve 95 within the assembly when used as discussed below. It is note that the ribs 87 r depicted terminate at upper ends below aperture 100. This is preferred, but alternatives are possible.
In FIG. 10, a top plan view of the housing portion viewable in FIG. 9 is shown. Features already described generally include: aperture 87 t, drain arrangement 98; transition chamber 87; inlet 86; downcomer 86 x; liquid inlet 83; downcomer 83 x and ribs 87 r.
In FIG. 11, a top or cover 120 for housing 82 is depicted. The cover 120 would be secured to upper edge or ledge 121, FIG. 9, when flow module 81 is assembled. Cover 120 includes an outer flange or lip 125 which can be secured to edge 121, for example permanently with an adhesive or sonic welding operation. Top 120 includes port 85 therethrough, and a valve seat 110 positioned along an interior 120 x of the cover 120. The valve seat 110 is sized and positioned so that in use it will be positioned in chamber 87 at a location to engaged by a float valve and be at least partially closed when the float valve is used in accord with the description above for FIGS. 4-8.
In FIG. 12, a usable float valve or valve member, for member 95 is depicted. The float valve member 95 includes an upper end 130 having valve closure member or projection 131 thereon. The closure 131 is sized and shaped so that as the valve member 95 rises within the housing 82, member 131 will eventually engage and close valve seat 110, FIG. 11. For the particular example depicted, the valve projection 131 has a rounded end for engagement with the seat 110, although alternatives are possible.
The valve member 95 depicted, includes an (optional) outwardly directed radial flange 133 adjacent end 130. The flange 133 is sized and positioned to be located above ribs 87 r, FIG. 9, when installed, see FIG. 4. The valve 95 includes a sidewall 135 and bottom 136.
Typically the valve member 95 is sized and shaped to fit within region 87 appropriately, centered by the ribs 87 r, and to rise and fall as liquid enters and leaves internal chamber 87, in accord with the described intended operation.
In FIG. 13, a valve member 140 usable as one-way valve 96 and one way valve 97 is schematically depicted. The valve member 140 is an umbrella valve, which mounts within an aperture by post 141. An umbrella portion 142 is sized and shaped to fit over flow aperture(s) within the assembly, generally over a downstream end thereof, to substantially close those aperture(s) or open them selectively, as it flexes in use.
In FIG. 13A a schematic depiction of an umbrella valve member 148 inserted in an aperture 143 is depicted, controlling flow through aperture 144.
Umbrella valve arrangements can be made from a variety of materials including, for example, EPDM; silicone rubber; fluorosilicone materials; and, FKM (fluoroelastomers, sometimes referenced as FPM).
In FIG. 14, a filter member is depicted, usable as member 101, FIG. 4, by insertion into a receiver region 150, FIG. 9, surrounded by flange 115 y and underneath shelf 115 x. The shelf 115 x and flange 115 y help prevent liquid carried through tap 86 from directly impinging the filter 101. The filter 101 adds to restriction by being positioned over aperture 100 and also helps prevent material carried within gases entering tap 86 from flowing through port 100 and entering chamber 87.

II. Example Additional Embodiments, FIGS. 15-18

The techniques described herein can be applied in a variety of forms. For example, alternate configurations of the stand alone module for liquid drain management are possible. Also, the principles can be applied in a housing in which the flow control module is secured to a crankcase ventilation gas/liquid separator assembly. Some examples of alternate module configurations are shown in FIGS. 15-18.
A. An Example Alternate Module Configuration with a Side-by-Side Arrangement of One Way Valves, FIGS. 15-16
Attention is directed to FIGS. 15 and 16 in which an alternate geometric configuration of a liquid drain management (or flow control arrangement) operable in accord with the principles described herein above is depicted. FIG. 15 is a cross-sectional view taken generally along line 15-15, FIG. 16.
Referring to FIG. 15, a liquid drain flow management system or arrangement 200 is depicted. Similarly, to unit 81, FIG. 4, unit 200 comprises a module 201 comprising a housing 202. The housing includes a liquid drain inlet 203, an inlet downcomer 203 x; a first gas pressure tap 205 with a valve seat 205 x associated therewith; and, a high pressure side gas inlet 207, in communication with second gas flow inlet or tap 226.
The housing 202 defines an internal transition chamber 210 in which is positioned float valve 211. The transition chamber 210 includes by a wall defining an internal sidewall 212 and bottom 213. The housing 202 is separated into regions exterior to internal chamber 210 and within the two channels 203 x, 207 x. The channels are separated by inner wall or divider 215. Region 207 x, which is direct flow communication with tap 207, is also in direct flow with liquid drain outlet 216.
At 218 a liquid flow (flood) aperture arrangement to the transition chamber 210 is depicted, providing for flow communication between downcomer 203 x and an interior of chamber 210. Flow through aperture arrangement 218 is managed by one-way flood valve arrangement 219.
At 220 a liquid flow transition chamber drain aperture arrangement is depicted providing for liquid flow communication between an transition chamber 210 and a lower portion of downcomer 207 x, allowing for liquid drainage from transition chamber 210, i.e. to liquid drain 216. Flow through aperture arrangement 220 is managed by one-way transition chamber drain valve arrangement 221.
Float valve 211 is configured with a hat or valve closure portion 225 configured and positioned so that as float valve 211 rises in chamber 210, valve 225 will eventually engage valve seat 205 x, inhibiting gas flow through tap 205.
Sidewall 212 includes pilot aperture or gas tap arrangement 226 therethrough, allowing for gas flow between region 207 x and the interior the transition chamber 210. Aperture 226 is covered by filter arrangement 227 secured within frame 228.
Operation of arrangement 201 is analogous to operation of assembly 81. The principal difference relates to the location of the flood (inlet) aperture arrangement 218 so that liquid flow into chamber 210 is at a location generally underneath the float valve 211, and such that the valve members 209 and 221 operate side-by-side. The differences from arrangement 81, FIG. 4, generally relate to extending downcomer 203 x to a location underneath chamber 210 and providing the divider wall 215 appropriately.
In operation then, liquid will enter module 201, i.e. housing 202, through inlet 203. As liquid enters, it will flow through inlet aperture arrangement 218, managed by one-way flood valve 219, which will open under the influence of liquid flow and allow that flow into chamber 210. Liquid rise in chamber 210 will drive float 211 upwardly until head 225 seals aperture 205 a. This will inhibit gas flow through pressure tap 205, which is generally a low pressure side pressure tap analogous to pressure tap 85, FIG. 4. When this occurs, bleed through aperture 226 will eventually raise the pressure in chamber 210 sufficiently so that the drain valve 221 can open and liquid can drain through aperture arrangement 220 into a lower portion of downcomer 207 x and outwardly from the assembly 201 through drain 216. As this occurs, the float valve 211 will lower, reopening valve seat 205 x. Also, as pressure in chamber 210 increases, flood valve 219 will have closed.
It can be seen from a review of FIGS. 15 and 16 that although analogous operation of the arrangement of FIGS. 4-8 is shown, the assembly 200 can be provided with different specific configurations and features. This is a general observation, and many alternatives are possible.
B. A Second Alternate Embodiment, FIGS. 17 and 18
In FIGS. 17 and 18, a third (second alternate) embodiment is depicted, using many principles generally analogous to those of the embodiments of FIGS. 15 and 16. In FIG. 17, a cross-sectional view is taken generally along line 17-17, FIG. 18.
Referring to FIG. 17, the liquid flow control management system 250 is also shown in a form of a module 251 comprising a housing 252 having a liquid inlet 253, a first low pressure side gas flow outlet or tap 254 and a high pressure side gas flow inlet or tap 255. The housing 252 includes a lower liquid drain outlet 256.
The housing 252 defines an inlet chamber or downcomer 253 x for liquid entering module 251 (housing 252); and, a chamber or downcomer 255 x from high pressure side inlet 255 in direct communication with liquid drain outlet 250. The drain outlet, then, is in housing bottom region or chamber 258.
The housing defines an internal transition chamber 260 in communication with tap 254 through an aperture surrounded by valve seat 254 x. The chamber 260 is defined by sidewall 261 and a bottom 262. Liquid flood or inlet aperture arrangement 264 is in direct flow communication with downcomer 253 x and provides for liquid flow from downcomer 253 x to enter chamber 260. Flow through inlet aperture arrangement 264 is managed by one-way flood valve arrangement 265 which, in the example depicted, comprises a ring 265 r and is positioned coaxially with a second valve member as discussed below. Divider wall 267 prevents liquid entering inlet 253 from directly reaching liquid drain outlet 250 without passage into transition chamber 260.
At 270 a liquid drain outlet arrangement from transition chamber 260, into a lower portion of downcomer 255 x and drain 250 is shown, with liquid flow through transition chamber drain outlet or aperture arrangement 270 managed by one-way drainage valve arrangement 271.
At 273, a second port or gas flow (tap) aperture in communication with to an interior of transition chamber 260 is shown. The aperture 273 is in gas flow communication with inlet 253, with filter 273 (secured by frame 275) positioned thereover.
Operation will be generally analogous to the units described with respect to FIGS. 4-8; and 15-16. Liquid will enter through inlet 253 and flow through downcomer 253 x until aperture arrangement 274 is reached. The liquid will flow through aperture arrangement 264, opening one-way flood valve arrangement 265 (by lifting an outer perimeter thereof) and begin to fill chamber 260. As this occurs, float 280 will begin to rise and eventually valve head 281 will rise and engage seat 254 x, inhibiting gas flow through tap 254. (Tap 254 being a first gas flow conduit in communication with a vacuum draw or low pressure side of equipment).
When the valve member 280 is floated such that head 281 closes aperture 254 x, high pressure side inlet 255 via port 273 will allow pressure within chamber 260 to begin to increase. This is what helps liquid flow through aperture arrangement 270, controlled by valve member 271 to occur. As the liquid voids chamber 280, valve member 280 will drop, reopening tap 254. Also, increased pressure in transition chamber 80 will tend to close valve 265.
Reviewing FIGS. 17 and 18, in comparison with previously discussed FIGS. 15 and 16, it will be understood that operation is generally analogous, the differences relating to specific geometric configuration, and to the seat that in the example of FIG. 17, the valve members 265, 271 are coaxially positioned. Also, valve member 265 is a half-donut type ring instead of an umbrella valve.

III. Mounting of the Flow Control Module to the Crankcase Ventilation Gas/Liquid Separator Arrangement

In the embodiments described above, generally the liquid flow management system was a flow control module that could be positioned on, or separately from, a crankcase ventilation gas/liquid separator assembly, with equipment for use. There is no specific requirement that the flow control module not be mounted to, or not be, integral with, the crankcase ventilation gas/liquid separator assembly. Indeed, advantages can be obtained, when the flow control module is mounted on a gas/liquid separator assembly. Examples are depicted and described in this section.

A. An Example Embodiment, FIG. 19

Referring to FIG. 19, at 300, an assembly is depicted which includes a crankcase ventilation gas/liquid separator assembly 301 and a liquid flow control arrangement 302 in accord with the present disclosure. These components are “integral” in the example depicted. By “integral” in this context, it is meant that the assembly 300 comprises major housing components of the gas/liquid separator arrangement 301 and liquid flow control arrangement 302 mounted to one another. Thus, for example, the assembly 300 can be shipped and installed as a unit.
Still referring to FIG. 19, the assembly 300 is depicted as having a gas/liquid separator assembly 301 that comprises a crankcase ventilation filter assembly 303. It is noted that the principles can be practiced with alternate types of gas/liquid separator assemblies.
Attention is first directed to the filter assembly 303. The filter assembly 303 generally comprises a housing 305 comprising a housing bottom 306 defining an interior 307; and a removable access or service cover 308.
Positioned within an interior 307 is a serviceable filter cartridge 310, in the example depicted comprising media 311 surrounding an open filter interior 312. The example cartridge 310 depicted comprises media 311 positioned between end pieces 313, 314 and around central support 315. The cartridge 310 is removably sealed within housing 300, by seal 316.
By “serviceable”, it is meant that the cartridge 310 can be removed from housing 300 and be replaced, without damage to either the housing or cartridge, i.e. it is a removable and replaceable service component. For the example depicted, end piece 313 will typically be an upper end piece and end piece 314 will typically be a lower end piece, in installation.
The housing 305 defines a gas flow inlet arrangement 320 and a gas flow outlet arrangement 321.
In operation, gas to be filtered enters housing interior 307 through gas flow inlet 320. It passes through the media 311. Within the media 311 the gases are filtered, and liquid carried within the gas is coalesced. The coalesced liquid drains to a bottom 323 of housing 305 and through lower liquid drain outlet 324. As the gas reaches interior 312 it can pass upwardly through end piece 313 past regulator valve arrangement 326 and to gas flow outlet 321.
Typically, gas flow inlet 320 would receive gases from a crankcase and be subject to crankcase pressures. Typically, outlet 321 would be connected to an air induction system (if CCV), and thus there would be a vacuum drawn at outlet 321.
Still referring to FIG. 19, at 328, a tap from inlet 320 is shown, directed to liquid drain management arrangement 302. The tap 328, then, is in direct gas flow communication with the engine crankcase and is subject to the pressures thereof. The tap 328 can be viewed as being in communication with an interior of housing 305 at a location of high pressure (or high pressure region), i.e. upstream of cartridge 310.
Referring to liquid drain management arrangement 302, housing section 330 is depicted. The housing section 330 is secured to housing base 305 underneath bottom 323. The housing section 330 defines an interior transition chamber 331 in which float valve 332 is positioned.
In general, the features of liquid drain management arrangement 302 depicted are generally analogous to those of the arrangement of FIG. 4-8 except the housing 330 is depicted mounted on a crankcase ventilation gas/liquid separator assembly 301. Liquid flow conduit 324 communicates with an interior of housing 302 via the downcomer 324 x. Interior chamber 331 can receive liquid flow from downcomer 324 x via flow aperture arrangement 334 managed by a first one-way (flood) valve arrangement 335. Liquid drain from transition chamber 331 to liquid drain outlet 336 is by flow through transition chamber drain aperture arrangement 337 managed by one-way transition chamber drainage valve arrangement 338.
The assembly 302 includes a low pressure side tap 340 defined in part by valve seat 340 x. Tap 340 is in gas flow communication with the housing 304 at a lower pressure region downstream of the media 311 and thus is subject to downstream pressure conditions with respect to the media 311 and the draw at outlet 321. The float valve 332 includes a head 341 sized such that as the float valve 332 rises, the valve head 341 will eventually engage seat 340 x, inhibiting gas flow therethrough.
Housing 330 includes high pressure side tap 345 configured to receive gas flow and pressure conditions directly from inlet 320 and the crankcase itself, via line 326.
The internal chamber 331 defined by sidewall 350 includes second gas flow part or pressure tap 351 therethrough over which is positioned filter 352 secured by frame 353.
It is noted that low pressure tap 340 extends to a location above a highest expected normal liquid collection height within a bottom 323 of housing 305, so that liquid does not drain through tap 340, but rather through outlet 324, from housing 305. Typically, tap 340 will comprise a projection 340 p having a conduit therethrough (i.e. a conduit projection 340 p) that extends upwardly within housing 306 to a location surrounded by media 311 of the cartridge 310. In some instances, this will involve extension through a central aperture (see aperture 314 a, in the lower end piece 314). However as will be apparent from other embodiments described herein below, in some instances the end piece 314 will not have a central aperture 314 a therethrough, but rather will have a closed section extending across open filer interior 312. In a typical arrangement, the projection 340 p defining tap 340 with a conduit therethrough, will extend at least 5 mm, typically at least 8 mm and often at least 10 mm upwardly into an interior of the housing 305. The projection 340 p may extend considerably further if desired, for example, 20 mm or more.
Operation is as generally previously described. Liquid draining from the crankcase ventilation filter assembly 303 through drain aperture 324 well enter downcomer 324 x and flow through aperture arrangement 334 (managed by one-way flood valve arrangement 335) into transition chamber 331. As this occurs, float 332 will begin to rise and eventually valve 341 will engage valve seat 340 x, inhibiting gas flow through tap 340; the tap 340 being in gas flow communication with a downstream side of the filter cartridge 311, and being subject to the draw at outlet 321. With the valve seat 340 x closed, bleed through aperture 351 will allow for a higher pressure condition within chamber 331 and liquid drain through aperture arrangement 337 managed by valve member 338. This liquid drain will lead the assembly 301 via drain outlet 336. Higher pressure in transition chamber 331 will tend to close flood valve arrangement 335. As the liquid level lowers, valve member 332 will begin to lower, opening valve seat 340 x closing valve 338 and again allowing drainage to occur from drain 324 via downcomer 324 x into chamber 331, with the cycle repeating as the system is operated.
In FIG. 20, a schematic depiction of the assembly 300 is provided, in an engine system indicated generally at 370. Referring to FIG. 20, in assembly 370, the engine is indicated at 371. At 372, a vent for crankcase gases is shown, directing those gases via line 373 to inlet 320 of a gas/liquid separator assembly generally in accord with arrangement 301, FIG. 19. At 321, filtered gas outlet from assembly 301 is shown, directed via line 375 back into an air induction system 376 at 378. This would be a flow for a closed crankcase ventilation system or CCV. At 379, an alternate outlet path, for example, to the atmosphere, is indicated as an option for an open crankcase ventilation filter (OCV) system.
At 380, the flow control module is shown schematically, generally in accord with previous figures, see for example FIG. 3A.
It is noted that the filter assembly 303 is configured so that the cartridge 310 can be removed and be replaced or serviced during the lifetime of the equipment. This will be typical when the crankcase ventilation gas/liquid separator assembly is a filter assembly 303.

B. A Second Example, FIG. 21

In FIG. 21, another example system depicting a gas/liquid separator assembly having a liquid flow control management system mounted thereon, is depicted at 400. As with the example depicted in FIGS. 19 and 20, the gas/liquid separator assembly depicted in FIG. 21, is a crankcase ventilation filter assembly, although alternatives are possible.
Referring to FIG. 21, the assembly 400 depicted, comprises gas/liquid separator assembly 401 having mounted thereon a liquid flow management arrangement or flow control module 402. The gas/liquid separator assembly 401 for the system 400 depicted, comprises a crankcase ventilation filter assembly 403.
The crankcase ventilation filter assembly 403 comprises a housing 404 including a removable service cover 405. The housing 404 defines an interior 404 i having, removably positioned therein, serviceable filter cartridge 407. The cartridge 407 is removably sealed to the housing 404 by seal arrangement 407 s.
The housing 404 defines a gas flow inlet 410, a gas flow outlet 411 and a liquid drain outlet 433.
The cartridge 407 comprises media 412 positioned around (and defining) an open filter interior 413. In the example depicted, the cartridge 407 is configured with the media 412 oriented surrounding a central support 414 in extension between a first and second end pieces 415, 416. In the example depicted, the seal arrangement 407 s is positioned on an end piece 415. The end piece 415 has a central gas flow aperture 415 a therethrough, in communication with the open filter interior 413.
End piece 416 is closed in extension across open filter interior 413. That is, end piece 416 includes a central section 416 c that is a closed end that extends across open filter interior 413.
In general, end cap 415 may be sometimes referred to as a “top” or “upper” end cap since it is the end cap directed upwardly in typical use. Analogously, end cap 416 will generally be referenced as a “lower” or “bottom” end cap, since it is the end cap generally directed downwardly.
Still referring to FIG. 21, it is noted that central section 416 c of end cap 416 includes a central projection portion 416 p which projects into open filter interior 413. This creates a recess 416 r for projection therein of a projection discussed below.
In operation, gases enter inlet 410 from the engine crankcase ventilation vent. The gases are directed through aperture 415 a and into interior 413 and the gases is directed “in-to-out” through the media 412. Liquid coalesced would eventually drain to bottom 420 of housing 404. The gases can pass outwardly from the housing via outlet 411, to be directed to an air induction system, as discussed above, or elsewhere.
The flow control module 402 is shown secured to a bottom 420 of housing 404. The module 402 comprises a housing 430 defining a transition chamber 431 with a float valve 432 therein. A flood valve arrangement 434 is shown providing for liquid drainage into interior chamber 431 from housing bottom 420 through aperture arrangement 433. The flood valve arrangement 434 can be an umbrella valve as shown, although alternatives are possible.
The housing 430 has a bottom 435 with a liquid drain arrangement 436 therein. Drainage to outlet 437 is provided by a transition chamber drain liquid arrangement 436 managed by transition chamber drain control valve arrangement 438. In the example depicted, the valve arrangement 438 is another umbrella valve in this instance over aperture arrangement 438 a, although alternatives are possible.
At 440 a low pressure side tap or outlet from housing 430 is depicted, along with valve seat 440 x.
The low pressure side tap or outlet 440 generally comprises a projection having a conduit therethrough, projecting upwardly into an interior of housing 404. Preferably it projects to a location at least 5 mm usually at least 8 mm and often at least 10 mm above a bottom 420 of housing 403. Also, preferably, the projection defining tap 440 extends upwardly to a location surrounded by the media 412. In the example depicted, the projection 440 p projects into recess 416 r.
Valve member 432 includes a valve head 432 x thereon. The valve head 432 x is configured so that as the valve member 432 rises within chamber 431, the valve head 432 x will eventually engage seat 440 x, inhibiting gas flow outwardly through outlet 440. It is also noted that tap or outlet 440 is configured in gas flow communication with a region of housing 404 at a downstream side of the cartridge 407 and at a location above a likely level of collected liquid within housing bottom 420.
At 445, a second gas flow conduit or tap is provided as a higher pressure side gas low inlet to housing 430. Tap 445 can be in direct communication with a gas flow inlet 410 if desired. For the particular example depicted, however, tap 445 receives gas flow downwardly from a bottom end of the media 412 as the gases flow across the media 412 from an inner perimeter 412 i to an outer perimeter 412 p during filtering. Since the outlet for gas flow from the media 411 depicted at 446 is not all the way to the outer perimeter 412 p, gas pressure at tap 446 will be higher than at outlet region 411. This will provide the restricted pilot flow and pressure differential for a desirable operation of the assembly 402. Although alternatives are possible, typically, the tap 446 will be positioned for gas flow therethrough underneath the media 412 at a location less than 50% of a distance across the media 412 from inner perimeter 412 i to outer perimeter 412 p; i.e. from an upstream side to a downstream side in normal gas flow.
In operation, as the gases flow through the media 412 from in-to-out, coalescing occurs. The collected liquid drains to region 420 and through inlet aperture 433 or drain aperture, controlled by umbrella valve 434, into transition chamber 431 of housing 430. This will cause the valve member 432 to float. When the valve member 432 floats sufficiently to close seat 440 x, gas entry at aperture 445 will allow the pressure within interior 431 to rise sufficiently, to obtain liquid flow through aperture arrangement 438 a managed by valve arrangement 438. Should any coalesced liquid drain through aperture 445, it will simply enter chamber 431.

C. Another Variation, FIG. 22

In FIG. 22, another variation of the application and principles according to the present disclosure is provided, by assembly 450. In general terms, assembly 450 comprises a gas/liquid separator arrangement 451 having a flow control module 452 in accord with the present disclosure mounted thereon. The particular gas/liquid separator assembly 451 depicted, comprises a crankcase ventilation filter assembly 453, although alternatives are possible.
In general, the crankcase ventilation filter assembly 453 comprises a housing 454 including removable service cover 455. The housing 454 defines: a gas flow outlet 456, gas flow inlet 457 and a collected liquid drain outlet 458, positioned in a bottom 454 b of the housing 454.
The housing 454 defines an interior 454 i in which is positioned a serviceable filter cartridge 460. By “serviceable” in this context, again, it is meant that the cartridge 460 is removable and replaceable with respect to the housing 454.
Referring to FIG. 22, the serviceable filter cartridge 460 comprises media 461 surrounding and defining an open filter interior 462. The media 461, then, defines a media inner perimeter 461 i and a media outer perimeter 461 p. As will be understood from further description below, the assembly 450 is configured, so that the media 461 filters the gases and coalesces oil(s), as the gases pass from the media outer perimeter 461 p to the media inner perimeter 461 i.
For the particular cartridge 460 depicted, the media 461 is positioned around central support 464 in extension between opposite end pieces 465, 466. End piece 465 is an upper end piece, with central aperture 465 a therethrough. End piece 466 is a lower end piece, with open central aperture 466 a therethrough. Apertures 465 a, 466 a, provide for communication with open central interior 460 o surrounded by media 461.
In operation, gas flow enters housing 454 through inlet 457. Seal arrangement 467 on the cartridge 460 (in the example shown on end piece 465) in engagement with the housing 454, defines an inlet gases annulus or region around (higher pressure region) the outside of the media pack 461. The gases flow through the media 461, with filtering and coalescing liquid. The filtered gases reach interior 462 then pass upwardly through end piece 465 through regulator valve arrangement 470 and into the gas flow outlet 456. Liquid which is coalesced within the media 461 drops to housing bottom 454 b and eventually drains from the housing 454 through drain 458.
The liquid, as it reaches housing bottom 454 b, will generally have either passed completely through the media pack 461 (i.e. outwardly through inner perimeter 461 i) or downwardly through the lower end piece 466 via drain arrangement 471 through end piece 466 under media 461.
The gases from outlet 456 can be directed into an air induction system (for a closed or CCV system) or can be vented elsewhere, for example to the atmosphere (for an open or OCV system).
Attention is now directed to the flow control module 452. As the liquid enters drain 458 it is directed into the module 452.
Flow control module 452 comprises a housing 475 defining a transition chamber 476. Beneath the transition chamber 476, the housing 475 defines a bottom chamber 477 having a liquid drain outlet 478 associated therewith. The bottom wall 476 b of the transition chamber 476 includes a drain aperture 479 therein, with drain flow therethrough managed by one-way transition chamber drain control valve arrangement 480, in this instance comprising an umbrella valve, although alternatives are possible.
The housing 452 further defines an inlet or flood arrangement 482 in liquid flow communication with drain 458, and providing for flow of liquid, selectively, into an interior of transition chamber 476. Flow through flood aperture or aperture arrangement 482 is managed by one-way transition chamber flood valve arrangement 483, in the example depicted comprising an umbrella valve, although alternatives are possible.
Positioned within transition chamber 476 is float valve 485 having a head 486 sized to engage valve seat 490 x in selected operation.
Still referring to FIG. 22, at 490 is provided a low pressure side outlet tap for the flow control module 452. The outlet tap 490 comprises a conduit projection 490 p that projects into an interior of the housing 454 to a location above a likely height of collected oil within bottom 454 b in use. Entry to the tap 490 from the chamber 476 is provided with valve seat 490 x. The valve seat 490 x is configured relative to the head 496 so that as the float member 445 rises, it will eventually engage valve seat 490 x inhibiting gas flow through tap 490.
Projection 490 p generally extends upwardly from housing bottom 454 b at least 5 mm usually at least 8 mm and often at least 10 mm. For the example depicted, conduit projection 490 p projects upwardly to a location surrounded by the media 461. For the example depicted, projection 490 p extends through aperture 466 a in lower end piece 466.
Still referring to FIG. 22, at 492 a high pressure side tap providing for gas flow communication with transition chamber 476 is provided.
The high pressure side gases to the inlet tap 492 are provided by conduit 493. Gas pressure within conduit 493 is provided at gas flow or pressure tap 495.
Gas flow or pressure tap 495 in the example depicted in FIG. 22, receives gases that have flowed partially across media 461 from the outer perimeter 461 p to the inner perimeter 461 i, and outwardly through aperture arrangement 455 a in end piece 465 above media 461. Thus, pressure at tap 495 is higher than the pressure at interior 464, which is the region in which tap 490 is in communication. Therefore, the gradient desirable for preferred operation of a liquid control module 452 is provided.
Liquid collected on bottom 454 b drains through aperture 458 to inlet 482. Under appropriate conditions controlled by valve 483, liquid enters interior 476. As this occurs, valve 485 begins to float. When enough liquid has entered transition chamber 476, float valve 485 will have risen sufficiently for head 486 to engage valve seat 490 x. When this occurs, pressure within interior 476 will begin to increase, as a result of gas flow therein through tap 492. In due course, valve 480 will open, allowing for drainage through aperture 476 of liquid contained within transition chamber 476 to bottom 477 and drain outlet 478. As with the previous assemblies, the operation will cycle.
In general terms, the assembly 450 of FIG. 22, can be characterized relative to other assembly previously described, as having a cartridge 460 with an upper end piece 465 and a gas flow aperture arrangement 495 a therethrough at a location partially across the media 461 and in overlap with an end of the media. That gas flow aperture 495 a is in communication with a conduit arrangement 493, in the example depicted having a portion extending exteriorly to the housing to a high pressure side gas flow tap in communication with internal chamber 476 of a flow control module 452 in accord with the present disclosure.

D. Another Variation, FIG. 23

In FIG. 23, a variation of the assembly depicted in FIG. 22 is provided. The componentry of FIG. 23, to the extent it is analogous to that of FIG. 22, is numbered analogously except for the overall reference to the assembly of FIG. 23 being assembly 500 comprising gas/liquid separator 501 and flow control module 502. Like reference numerals in FIG. 23 to FIG. 22, are intended to represent parts with analogous features, construction and operation.
The principal difference between the assembly 500, FIG. 23 and the assembly 450, FIG. 22, relates the conduit that the gas flow is provided with from tap 495 (via aperture arrangement 495 a) into the interior transition chamber 476. Tap 495 is the location at which gas pressures allow to enter the upstream side tap 510 for the flow control module 502. Unlike the arrangement of FIG. 22, the arrangement of FIG. 23 is provided with a conduit 511 that has a portion that engages tap 410 by passage through the interior 464 o of the cartridge 460 rather than an exterior of the housing, as shown in FIG. 22. Thus, conduit section 591 extends through a central apertures 465 a, 466 a in each end cap 465, 466.
Operation of assembly 500, FIG. 23, however, would be analogous to operation of the assembly of FIG. 22

IV. Schematics Depicting a Varity of Systems

In FIGS. 24-27, a schematic representations of various systems further represent the wide variety of applications possible using techniques according to the present disclosure. It will be apparent that the techniques can be applied various systems without specificity as to the direction of gas flow through a filter cartridge if used; the presence or absence of regulator valve arrangements; etc.
Referring first to FIG. 24, a system 600 is depicted comprising an engine 601, a gas/liquid separator arrangement 602 and a liquid flow management system 603. The liquid flow management system 603 may be in general accord with arrangements previously discussed, or variations thereof.
Associated with the engine 601 is depicted in an air induction system 604 comprising an air cleaner 605 and turbo 606. The engine 601 is depicted with a vent 607 for crankcase gases.
The gas/liquid separator assembly 602 depicted comprises a crankcase ventilation filter assembly 610. The assembly 610 comprises a housing 611 including a removable service cover 612 and defining an interior 613 having a serviceable filter cartridge 615 therein.
The housing 611 defines a gas flow inlet 620 and gas flow outlet 621 and a liquid drain outlet 622.
The cartridge 615 is configured for “out-to-in” flow during filtering. The cartridge comprises media 625 surrounding open interior 626. Seal arrangement 627 is provided for removably sealing the cartridge 625 to the housing 611 and separating the housing 611 (in conjunction with the media 625) into an upstream (higher pressure) region and a downstream (lower pressure) region.
In operation, crankcase ventilation gases are directed from outlet 607 of the engine 601 into inlet 620 via lines 630. Gases flow into housing 611, through cartridge 615 from out-to-in and to interior 626. The gases then leave the housing 611 through outlet 621 to line 632. They can either be directed back into the closed system as indicated in 633 or be vented elsewhere by optional line 634.
The flow control module 603 is generally analogous in feature and operation to the flow control module described in connection with FIG. 3A.

B. FIG. 25

In FIG. 25, a variation in the arrangement depicted in FIG. 24 is depicted. The principal difference relates to the fact that as the gas flow enters the housing, it is directed through a regulator valve arrangement 651. In other manners, the arrangement 650 of FIG. 25 is analogous in operation to the arrangement of FIG. 24 and like reference numerals are used for parts of analogous function and operation.

C. The Arrangement of FIG. 26

Still another variation is depicted in FIG. 26 at system 700. The system 700 comprises an engine arrangement 701, a gas/liquid separator arrangement 702 and flow control module 703.
The engine 701 generally comprises a air induction arrangement 704 including an air cleaner 705 and turbo 706. The engine 701 includes a crankcase vent 707 from which crankcase gases leave the engine 701.
The gas/liquid separator arrangement 702 depicted, comprises a crankcase ventilation filter assembly 710, although alternatives are possible. The assembly 710 comprises a housing 711 having gas flow inlet 712, gas flow outlet 713 and liquid drain outlet 714.
The housing 711 includes a service cover 717 removably positioned thereon.
Positioned within an interior 7111 of housing 711 is provided as a serviceable filter cartridge 720. The cartridge 720 comprises media 721 surrounding and defining an open filter interior 722. The cartridge 720 has an upper, open, end piece 723 and a lower, closed, end piece 724. The media 721 is positioned between the end pieces 723, 724.
The cartridge 720 is configured for “in-to-out” flow during operation. In general, then, operation of assembly 700 is with gases from outlet 707 transferred via line 725 to inlet 712. The gases pass through the cartridge 720 to outlet 713. From there they are directed via line 726 back into the assembly or vented to the atmosphere via line 727.
Liquid which collects within the housing 711 is drained via line 714 to the flow control module 703 which can generally be in accord with the arrangements previously described. Various pressure line and drains for the flow control module 703 can be as previously described herein.

D. FIG. 27

In FIG. 27, a system 750 analogous to that of FIG. 26 is depicted, at 750, except configured with a gas regulator valve arrangement 751 at the gas flow outlet. In FIG. 27, analogous reference numerals to those used in FIG. 27, for related features are shown.

V. Additional Comments Regarding Component Materials and Assembly

A. The Filter Cartridge

In general, the filter cartridge (when the invention involves a crankcase ventilation filter assembly) can be assembled using techniques and materials as described in previously incorporated references: PCT WO 2007/053411 A2; WO 2008/147585 A2; WO 2008/115985 A2; WO 2008/157251 A2; WO 2009/018454 A2; U.S. Ser. No. 61/425,869; U.S. Ser. No. 61/503,008; and, in U.S. Ser. No. 61/503,063. Variations from these may relate to specific locations of apertures in the end pieces, to accomplish the intended results of the present application.
A variety of types of seals can be positioned on the cartridges, including molded-in-place seal members and/or preform seal members attached to the filter cartridge. In some instances, o-rings can be used.
Specific features relating the filter cartridge can be as appropriate for the overall filter assembly involved. However, the filter cartridge may be adapted for operational connection with the flow control module as described herein.

B. The Float Valve within the Transition Chamber

The float valve positioned within the transition chamber should be configured to have appropriate weight/density characteristics, for the intended cycling as liquid flows into or out of the internal chamber. This is a matter of selecting the material for the float, and ensuring the appropriate density-type characteristics of the float. Typically, the float valve will be made from plastic, although alternative materials are usable.

C. The Second Gas Flow Conduit or Pilot Aperture

Typically, the assembly is configured so that the flow rate through the second gas flow conduit or pilot aperture into the internal chamber, can occur at a rate between about 0.5 and 10 liters per minute, typically between 50 and 1,000 milliliters per minute. Alternatives are possible.

D. The Media Providing Restriction to the Port (Second Gas Flow Aperture)

The media positioned over the second gas flow aperture will typically be a porous, fibrous, material is appropriate integrity for the intended use. Materials similar to these used for the filter cartridge (if present) can be used.

E. The Housing Materials

Typical housing materials for each of the filter control module and the separator can be plastics or metals, as used in crankcase ventilation filter assemblies described in the art discussed herein. An example plastic is polyomide 66 filled with fiberglass.
Typically, the flow central module will be constructed to withstand pressure of ±20,000 Pa, although alternatives are possible.

VI. General Observations and Principles

According to the present disclosure, features, principles and techniques are described, applicable to manage liquid flow control of liquid collected from crankcase ventilation gases and separated via a gas/liquid separator assembly. The management of flow control is generally from a region of lower pressure, to a region of higher pressure. The region of lower pressure is often a region associated with a region of separation of the gas/liquid separator assembly; and, the region of higher pressure is often a region associated with a engine crankcase. Alternatives are possible.
In accord with the present disclosure, a selected ones of the principles, features, techniques, components and methods relate to the liquid flow control arrangement itself. Examples are described in which the flow control arrangement comprises a housing defining a transition chamber having a transition chamber interior and comprising a sidewall and transition chamber bottom. The transition chamber includes a transition chamber liquid drain outlet aperture arrangement configured for drainage of liquid from an interior of the transition chamber.
The flow control arrangement includes a transition chamber one-way drainage valve arrangement positioned to control liquid drain through the transition chamber liquid drain outlet aperture arrangement and from the transition chamber. That is, the transition chamber includes a drain valve arrangement that allows selectively for drainage from the transition chamber of liquid within the interior of the transition chamber. The valve arrangement is one-way so that liquid is inhibited from passing into the transition chamber via this path.
A first gas flow tap or conduit is provided in gas flow communication with an interior of the transition chamber. The first gas flow conduit or tap generally defines a valve seat positioned within the transition chamber.
A second gas flow tap or conduit is also provided in flow communication with the transition chamber.
A transition chamber one-way flood valve arrangement is positioned to control liquid flow through the liquid flow inlet and into the transition chamber. That is, liquid flow into the transition chamber is managed by a one-way valve arrangement, so that generally liquid is inhibited from leaving the transition chamber via this flow path.
The flow control arrangement includes a transition chamber valve arrangement having a valve member or valve arrangement positioned in the transition chamber interior and movable upon entrance of sufficient liquid through the liquid flow inlet to the transition chamber or sufficient liquid drain flow from the transition chamber between two positions. The first position is one in which both the first gas flow conduit and the second gas flow conduit are open. The second position is one in which the valve seat of the first gas flow conduit is inhibited from gas flow therethrough, by the valve arrangement, while the second gas flow conduit remains open.
The transition chamber one-way flood valve arrangement and the transition chamber one-way drainage valve arrangement are positioned and configured so that:
(a) when the transition chamber valve arrangement is in the first position, the one-way valve arrangement is configured to facilitate liquid flow into the transition chamber through the liquid flow inlet and the transition chamber one-way drainage valve arrangement is configured to inhibit liquid drainage flow from the transition chamber; and,
(b) when the transition chamber valve arrangement is in the second position, the one-way valve arrangement is configured to inhibit liquid flow into the transition chamber through the liquid flow inlet and the transition chamber one-way drainage valve arrangement is configured to facilitate liquid drainage from the transition chamber.
Generally, in operation the liquid flow control arrangement will cycle, so that: liquid can enter the transition chamber from a low pressure region; and, as the liquid floods the chamber, the float valve within the chamber will rise to seat with the first gas flow outlet. As this occurs, pressure within the interior of the transition chamber will increase, closing the flood valve and opening the drainage valve to drainage of liquid therethrough, into a higher pressure region. In short, the transition chamber is a transition chamber for liquid flow between higher and lower pressure regions, the transition chamber and valve being configured to cycle back and forth between circumstances allowing for this flow.
A variety of example systems usable as the liquid flow control arrangement are described and depicted. The general principles of operation, however, remain the same among the various systems. It is noted that the liquid flow control arrangement can be configured as a module, with various valve members and gas and liquid flow conduit arrangements positioned thereon, as a single module. However, this is not required in all applications and principles according to the present disclosure. Further, in some arrangements described, the liquid flow control arrangement can comprise a module secured to the gas/liquid separator assembly.
In examples described the housing of the liquid flow control arrangement can define a housing bottom region having housing liquid drain outlet therein and the transition chamber, at a location positioned so that the liquid drain outlet aperture arrangement is configured for liquid flow from the transition chamber to the housing bottom region. That is, liquid flow from the transition chamber can be directed to another chamber within the housing, if desired.
In some example arrangements described herein, the housing can also include a higher pressure chamber separated from the transition chamber. In an example, the housing includes a higher pressure chamber, separated from the transition chamber, that includes an upper interior volume portion in gas flow communication with the second gas flow conduit; and, the lower interior portion in liquid gas flow communication with the housing bottom region and housing drain liquid outlet.
In arrangements depicted, the transition chamber valve arrangement comprises a float member. The float member generally includes a head or cap thereon, positioned to engage the valve seat, as liquid rises within the interior of the chamber. The float valve member of the transition chamber valve arrangement is configured with an appropriate density so that it will rise to engage the valve seat of the first gas flow conduit or tap, when an appropriate amount of liquid has entered the transition chamber; and, so that it will move out of engagement with valve seat at a selected and desired rate as the pressure within the chamber increases from the second gas flow conduit.
In examples described, the housing defines a liquid flow inlet chamber and the liquid flow inlet to the transition chamber comprises an aperture arrangement in communication between the liquid flow inlet chamber and the transition chamber. In some examples, the aperture arrangement in flow communication between the liquid flow inlet chamber and transition chamber is positioned in extension through a sidewall of the transition chamber. In certain applications described, the aperture arrangement in flow communication between the liquid flow inlet chamber and the transition chamber is positioned in extension through the transition chamber bottom.
An example valve arrangement usable as a transition chamber one-way flood valve arrangement, is an umbrella valve having a valve head positioned in the transition chamber and over the liquid flow aperture. Alternatives are possible.
In an example depicted, the transition chamber includes a plurality of float valve guiding ribs therein, positioned along an inside surface of the transition chamber sidewall. As described, optionally, the second gas flow conduit can comprise a port arrangement through the sidewall of the transition chamber at a location above a maximum extension of the float valve guiding ribs. Alternatives are possible.
In arrangements described, the second gas flow conduit can, optionally, preferably, be a restricted flow port arrangement. By the term “restricted flow” in this context, it is meant that it offers restriction to flow therethrough, into the transition chamber interior, of gas from a gas pressure region, in association, for example, with a higher pressure volume. This restriction in the restricted port arrangement can be provided, for example, by having filter media positioned over or in the second gas flow conduit, and/or by limiting the cross-sectional size or flow area of the restricted flow port arrangement. Typically, both are used, although this is not a requirement.
The restricted flow port arrangement, typically has a total cross-sectional of no greater than 13 sq. mm, usually no greater than 7 sq. mm and often no greater than 4 sq. mm. It can comprise a single aperture having a diameter within the range of 1-2 mm, although alternatives are possible.
Typically, the first gas flow conduit in flow communication with an interior of the transition chamber defines a valve seat at a location above a highest likely normal level of liquid in the transition chamber. By the term “highest likely normal level” and variants thereof in this context, reference is meant to the level of liquid within the transition chamber upon flooding, at the point the transition chamber begins to drain.
Typically, the second gas flow conduit is provided in flow communication with an interior of the transition chamber, also at a location of a highest likely normal level of liquid in the transition chamber.
With respect to the flow control arrangement provided, a variety of specific assemblies are depicted and described, as examples. Principles and features of each can be applied in selected ones of the others, as desired. Further, there is no specific requirement that an assembly include all of the specific features described, in order to obtain some benefit according to the present disclosure. The examples do, however, provide general characterizations of desirable features for desirable operation. Methods of operation and assembly are thus provided.
Also, in accord with the present disclosure, various combinations including a gas/liquid separator assembly and a liquid flow control arrangement to facilitate liquid flow from the gas/liquid separator assembly to an engine crankcase are provided. The gas/liquid separator assembly generally comprises a gas/liquid separator assembly housing defining a gas flow inlet, a gas flow outlet in a gas/liquid separator liquid drain outlet. The liquid flow control arrangement may be as generally as previously described.
The combination is configured for direction of liquid from the gas/liquid separator assembly through the gas/liquid separator assembly liquid drain outlet and to the liquid flow inlet to the transition chamber of liquid flow control arrangement. Operation will be as generally previously described.
The housing of the liquid flow control arrangement can be secured to the housing of the gas/liquid separator assembly. The components can be provided inseparable, partially separable or completely separable.
In an example arrangement described, the first gas flow conduit in flow communication with interior of the transition chamber comprises a conduit projection extending into the housing of the gas/liquid separator assembly. Typically, it projects to a location above a likely level of liquid in the bottom of the gas/liquid separator housing. Usually this amount of extension is at least 5 mm, typically at least 8 mm, and often at least 10 mm.
In some example arrangements described, the gas/liquid separator assembly comprises a crankcase ventilation filter assembly including a filter cartridge removably positioned in an interior of the gas/liquid separator housing. In selected examples, the filter cartridge comprises media surrounding an open filter interior and positioned between first and second end pieces.
In certain selected applications, the first gas flow conduit in flow communication with interior of the transition chamber comprises a conduit projection extending to a location surrounded by the media of the filter cartridge. In some examples, this conduit projection extends through a central aperture in one of the end pieces, and in particular a lower end piece.
Arrangements are described in which each one of the first and second end pieces has a central aperture therethrough, and alternative arrangements are described in which one of the end pieces does not include a central aperture therethrough.
Examples are described in which the first gas flow conduit includes an extension thereon sufficient for the gas flow conduit to extend through the central aperture of both the first and second end pieces. This is indicated for example in FIG. 23.
Typically, the crankcase ventilation filter assembly is divided into an upstream region and an downstream region, by the filter cartridge. In some examples, the first gas flow conduit which is in flow communication with an interior of the transition chamber is also in flow communication with a downstream region of the crankcase ventilation filter housing. The second gas flow conduit may be positioned in gas flow communication with the upstream region of the crankcase ventilation filter assembly housing also. However, in some examples, a gas flow conduit is positioned in gas flow communication with the filter cartridge at a location partially across the filter media, i.e. at a location of pressure between the upstream region of the crankcase ventilation filter housing and the downstream region of the crankcase ventilation filter assembly housing.
This can be accomplished by providing the filter cartridge with a end piece having an aperture arrangement overlap with an end of the media. This can operate as a gas tap for higher pressure gases, at lower pressure gases which can then be transferred via conduit(s) to the flow control arrangement as desired, whether it be to the high pressure side or the low pressure side, depending on specifics. A variety of examples are provided.
Also according to the present disclosure, filter cartridges for use in crankcase ventilation filter assemblies are described. These filter cartridges may be specifically adapted for use in a crankcase ventilation filter assembly in which the assembly is used in combination with a liquid flow control arrangement in accord with the present disclosure. Thus, the cartridge can be configured with features specifically to accommodate: a first low pressure side conduit projection of the flow control arrangement; and/or, a gas pressure take-off through an end piece, positioned partially across the media from a media inner region to the media outer region. Such cartridges are depicted and described, including ones configured for in-to-out flow and ones configured for out-to-in flow.
There is no specific requirement that an assembly, method, feature, component or technique include all of the specific example features, characterizations described herein, in order for some benefit according to the present disclosure be obtained. Further, many of the features of any given embodiment can be applied in other embodiments, with analogous advantages and results.

Claims

1. A filter cartridge for use in a crankcase gas ventilation filter assembly;

the filter cartridge comprising:

(a) filter media positioned in extension between upper and lower end pieces;

(i) the filter media surrounding a cartridge open central interior; and,

(b) a gas aperture arrangement through one of the upper and lower end pieces at a location in overlap with the filter media.

2. A filter cartridge according to claim 1 wherein:

(a) the gas aperture arrangement is through the upper end piece.

3. A filter cartridge according to claim 2 wherein:

(a) the cartridge includes a cartridge gas flow conduit secured to the first end cap in gas flow communication with the gas aperture arrangement.

4. A filter cartridge according to claim 2 wherein:

(a) the cartridge gas flow conduit extends through the cartridge open central interior.

5. A filter cartridge according to any claim 1 wherein:

(a) the upper and lower end pieces each have a central aperture therethrough, in communication with the cartridge open central interior.

6. A filter cartridge according to claim 5 wherein:

(a) the gas aperture arrangement is positioned in the upper end piece at a location in overlap with the filter media and at a location spaced from the central aperture in the upper end piece.

7. A filter cartridge according to claim 6 wherein:

(a) the cartridge includes a cartridge gas flow conduit secured to the first end cap in gas flow communication with the gas aperture arrangement that is spaced from the central aperture in the upper end piece.

8. A filter cartridge according to claim 7 wherein:

(a) the gas flow conduit extends through the central aperture in the upper end piece and then through the central cartridge open interior.

9. A filter cartridge according to claim 8 wherein:

(a) the gas flow conduit extends through the central aperture in the lower end piece.

10.-11. (canceled)

12. A gas/liquid separator assembly comprising:

(a) a housing defining a housing interior and having a gas flow inlet; a gas flow outlet; and, a liquid drain outlet; and,

(b) a filter cartridge according to claim 1 operably positioned in the housing.

13. A gas/liquid separator assembly according to claim 12 wherein:

(a) the filter cartridge is in accord with claim 7; and,

(b) the housing includes a gas flow tap separate from the gas flow inlet, the gas flow outlet and the liquid drain outlet; and,

(c) the cartridge gas flow conduit is in gas flow communication with the gas flow tap.

14.-16. (canceled)

17. A gas/liquid separator assembly according to claim 13 wherein:

(a) the gas flow tap is a tap that provides for gas flow entry to a liquid flow control arrangement for use in facilitating liquid flow from a region of first effective pressure to a region of second, higher, effective pressure.

18. A gas/liquid separator assembly according to claim 17 wherein:

(a) the liquid flow control arrangement comprises:

(i) a housing defining a transition chamber having a transition chamber interior and comprising a sidewall and transition chamber bottom;

(A) the transition chamber including a transition chamber liquid drain outlet aperture arrangement configured for drainage of liquid from the interior of the transition chamber;

(ii) a transition chamber one-way drainage valve arrangement positioned to control liquid drain through the transition chamber liquid drain outlet aperture arrangement and from the transition chamber;

(iii) a first gas flow conduit in flow communication with the interior of the transition chamber; the first gas flow conduit defining a valve seat;

(iv) a second gas flow conduit in flow communication with the interior of the transition chamber;

(v) a liquid flow inlet to the transition chamber;

(vi) a transition chamber one-way flood valve arrangement positioned to control liquid flow through the liquid flow inlet and into the transition chamber;

(vii) a transition chamber valve arrangement including a valve arrangement positioned in the transition chamber interior and moveable upon: entrance of sufficient liquid through the liquid flow inlet to the transition chamber; and, sufficient liquid drain flow from the transition chamber, between:

(A) a first position in which both of the first gas flow conduit and the second gas flow conduit are open; and,

(B) a second position in which the valve seat of the first gas flow conduit is inhibited from gas flow therethrough while the second gas flow conduit remains open; and,

(viii) the transition chamber one-way flood valve arrangement and the transition chamber one-way drainage valve arrangement being configured such that:

(A) when the transition chamber valve arrangement is in the first position: the one-way flood valve arrangement is configured to facilitate liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to inhibit liquid drainage flow from the transition chamber; and,

(B) when the transition chamber valve arrangement is in the second position: the one-way flood valve arrangement is configured to inhibit liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to facilitate liquid drainage flow from the transition chamber.

19. A liquid flow control arrangement for use in facilitating liquid flow from a region of first effective pressure to a region of second, higher, effective pressure; the flow control arrangement comprising:

(a) a housing defining a transition chamber having a transition chamber interior and comprising a sidewall and transition chamber bottom;

(i) the transition chamber including a transition chamber liquid drain outlet aperture arrangement configured for drainage of liquid from the interior of the transition chamber;

(b) a transition chamber one-way drainage valve arrangement positioned to control liquid drain through the transition chamber liquid drain outlet aperture arrangement and from the transition chamber;

(c) a first gas flow conduit in flow communication with the interior of the transition chamber; the first gas flow conduit defining a valve seat;

(d) a second gas flow conduit in flow communication with the interior of the transition chamber;

(e) a liquid flow inlet to the transition chamber;

(f) a transition chamber one-way flood valve arrangement positioned to control liquid flow through the liquid flow inlet and into the transition chamber;

(g) a transition chamber valve arrangement including a valve arrangement positioned in the transition chamber interior and moveable upon: entrance of sufficient liquid through the liquid flow inlet to the transition chamber; and, sufficient liquid drain flow from the transition chamber, between:

(i) a first position in which both of the first gas flow conduit and the second gas flow conduit are open; and,

(ii) a second position in which the valve seat of the first gas flow conduit is inhibited from gas flow therethrough while the second gas flow conduit remains open; and,

(h) the transition chamber one-way flood valve arrangement and the transition chamber one-way drainage valve arrangement being configured such that:

(i) when the transition chamber valve arrangement is in the first position: the one-way flood valve arrangement is configured to facilitate liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to inhibit liquid drainage flow from the transition chamber; and,

(ii) when the transition chamber valve arrangement is in the second position: the one-way flood valve arrangement is configured to inhibit liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to facilitate liquid drainage flow from the transition chamber.

20. A liquid flow control arrangement according to claim 19 wherein:

(a) the housing further defines a housing bottom region having a housing liquid drain outlet therein; and,

(b) the transition chamber is configured with the transition chamber liquid drain outlet aperture arrangement configured for liquid flow from the transition chamber to the housing bottom region.

21. A liquid flow control arrangement according to claim 20 wherein:

(a) the housing further includes a high pressure chamber separated from the transition chamber and including:

(i) an upper interior volume portion in gas flow communication with the second gas flow conduit; and,

(ii) a lower interior portion in liquid and gas flow communication with the housing bottom region and housing liquid drain outlet.

22. A liquid flow control arrangement according to claim 19 wherein:

(a) the transition chamber valve arrangement comprises a float valve member.

23. A liquid flow control arrangement according to claim 19 wherein:

(a) the housing defines a liquid flow inlet chamber; and,

(i) the liquid flow inlet to the transition chamber comprises an aperture arrangement in flow communication between the liquid flow inlet chamber and the transition chamber.

24. A liquid flow control arrangement according to claim 23 wherein:

(a) the aperture arrangement in flow communication between the liquid flow inlet chamber and the transition chamber is positioned in extension through a sidewall of the transition chamber.

25. A liquid flow control arrangement according to claim 23 wherein:

(a) the aperture arrangement in flow communication between the liquid flow inlet chamber and the transition chamber is positioned in extension through a transition chamber bottom.

26. (canceled)

27. A liquid flow control arrangement according to claim 19 wherein:

(a) the transition chamber includes a plurality of float valve guiding ribs along an inside surface of the transition chamber sidewall.

28. A liquid flow control arrangement according to claim 27 wherein:

(a) the second gas flow conduit is in flow communication with an interior of the transition chamber by a port arrangement through a sidewall of the transition chamber at a location above a maximum extension of the float valve guiding ribs.

29. A liquid flow control arrangement according to claim 19 wherein:

(a) the second gas flow conduit is a restricted flow port arrangement.

30. A liquid flow control arrangement according to claim 29 wherein:

(a) restriction to gas flow through the restricted flow port arrangement is at least in part provided by a filter media arrangement positioned over the second gas flow conduit.

31. A liquid flow control arrangement according to claim 29 wherein:

(a) restriction to gas flow through the restricted flow port arrangement is at least in part provided by limiting a cross-sectional size of the restricted flow port arrangement.

32.-34. (canceled)

35. A liquid filter control arrangement according to claim 19 wherein:

(a) the first gas flow conduit in flow communication with the interior of the transition chamber defines a valve seat at a location above a highest likely normal level of liquid in the transition chamber.

36. A liquid filter control arrangement according to claim 19 wherein:

(a) the second gas flow conduit in flow communication with the interior of the transition chamber is positioned to communicate with the interior of the transition chamber at a location above a highest likely normal level of liquid in the transition chamber.

37. A combination including a gas/liquid separator assembly and a liquid flow control arrangement to facilitate liquid flow from the gas/liquid separator assembly to an engine crankcase; the combination comprising:

(a) a gas/liquid separator assembly comprising: a gas/liquid separator assembly housing defining a gas flow inlet, a gas flow outlet, and gas/liquid separator liquid drain outlet; and,

(b) a liquid flow control arrangement comprising:

(ii) a transition chamber one-way drainage valve arrangement positioned to control liquid drain through the transition chamber liquid drain outlet aperture arrangement from the transition chamber;

(iv) a second gas flow conduit in gas flow communication with the interior of the transition chamber;

(v) a liquid flow inlet to the transition chamber;

(vii) a transition chamber valve arrangement including a valve arrangement positioned in the transition chamber interior and moveable upon: entrance of sufficient liquid through the liquid flow inlet to the transition chamber; and, sufficient liquid drain flow from the transition chamber between:

(B) when the transition chamber valve arrangement is in the second position: the one-way flood valve arrangement is configured to inhibit liquid flow into the transition chamber through the liquid flow inlet; and, the transition chamber one-way drainage valve arrangement is configured to facilitate liquid drainage flow from the transition chamber;

(c) the combination being configured for direction of liquid from the gas/liquid separator assembly through the gas/liquid separator assembly liquid drain outlet and to the liquid flow inlet to the transition chamber of the liquid flow control arrangement.

38.-52. (canceled)