WO2010087901A1

WO2010087901A1 - Regulator valve assembly and apparatus having a regulator valve assembly

Info

Publication number: WO2010087901A1
Application number: PCT/US2009/067344
Authority: WO
Inventors: Chris Johnson
Original assignee: Solberg Manufacturing, Inc.
Priority date: 2009-01-30
Filing date: 2009-12-09
Publication date: 2010-08-05

Abstract

A regulator valve assembly is in fluid communication with a crank case and vacuum source. The assembly includes a housing defining a valve chamber. A valve of the assembly has a first valve open position and a second valve open position. The valve in the first open position defines a first and second volume. The valve in the second open position defines a third and fourth volume. The fourth volume is less than the first volume and the third volume is less than the second volume.

Description

REGULATORVALVEASSEMBLYANDAPPARATUS HAVINGA REGULATORVALVEASSEMBLY

FIELD OF INVENTION

The present invention concerns a regulator valve in fluid communication with a crankcase and a vacuum source such as a blower.

BACKGROUND

U.S. Patent 5,347,973, Walker, discloses a vacuum relief valve for use with internal combustion engines. The valve is connected to the breathing tubes of an engine on one side and to the air induction system of the engine on the opposite side. Under certain conditions during engine operation, the induction system has a tendency to reduce the pressure within the crankcase creating a partial vacuum. The vacuum relief valve is interposed between the induction system and the crankcase and controls or limits the amount of partial vacuum thus created to a maximum of 7 inches of vacuum or less. This is accomplished by providing means for limiting the size of a passageway through the valve and thereby limit the amount of suction that can be communicated by the induction system to the crankcase. In one embodiment, a spring biased piston is used to control the size of the passageway. An auxiliary pathway to atmosphere is also incorporated in the valve so that the breather tubes can be vented when the passage way through the valve is partially or fully closed.

U.S. Patent 5,542,401, Newarski, concerns an apparatus and method for maintaining a substantially constant partial vacuum in the crankcase of an internal combustion engine. Maintaining the partial vacuum, in addition to essentially eliminating crankcase emissions, substantially reduces tail pipe emissions of carbon monoxide and unburned hydrocarbons as evidenced by a test conducted according to California Air Research Board Test Method 505 (Hot). The crankcase partial vacuum also has the added benefit of reducing the rate at which the engine lubricating oil is contaminated. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of an apparatus embodying principles of the present invention wherein an inlet of the valve assembly is coupled to an outlet of a vacuum pump and wherein an outlet of the valve assembly is fluidly coupled to an intake of an air oil separator.

FIG. 2 is a side view of a housing of the regulator valve assembly of FIG. 1 ; the side view exemplifies the stepped internal diameters of the assembly housing with dashed lines.

FIG. 3 A is a cross-sectional view of the valve assembly taken along the diameter of the valve assembly's housing, wherein the valve assembly is in a closed position, and wherein 0 cfm is passing through the valve assembly.

FIG. 3B is a cross-sectional view of the valve assembly taken along the diameter of the valve assembly's housing, wherein the valve assembly is in a partially open position, and wherein 15 cfm is passing through the valve assembly.

FIG. 3C is a cross-sectional view of the valve assembly taken along the diameter of the valve assembly's housing, wherein the valve assembly is in a fully open position, and wherein 25 cfm is passing through the valve assembly.

FIG. 3D is a cross-sectional view of the valve assembly taken along the diameter of the valve assembly's housing, wherein the valve assembly is in a by-pass position, and wherein air is exiting the valve assembly at the inlet of the valve assembly.

FIG. 4A is a top plan view of a base of the valve assembly.

FIG. 4B is a cross-sectional view of the base taken along view lines 5 A.

FIG. 5 A is a top plan view of the valve of the valve assembly.

FIG. 5B is a cross-sectional view of the valve taken along view lines 6 A. DETAILED DESCRIPTION

Now referring more particularly to FIG. 1, an air oil separator 20 has an intake 22 which is fluidly coupled to an outlet 32 of a crankcase 30. The separator intake 22 includes an inlet 22a through the housing 23 of the separator 20. The outlet 24 of the air oil separator 20 is fluidly coupled to an inlet 51 of vacuum pump 50. A conduit 40 couples the air oil separator outlet 24 to the vacuum pump inlet 51. The vacuum pump inlet 51 includes an opening into the vacuum pump. The separator outlet 24 includes an opening through the housing of the air oil separator 20.

Accordingly, the vacuum pump 50 when in operation draws air contaminated with oil out from the crankcase 30 and through the air oil separator 20. Cleaner air is then drawn into the vacuum pump 50. The air oil mixture and air travels in the direction of the arrows. Arrow 61 is for the air oil mixture. Arrow 62 is for the cleaner air.

The inlet 71 of valve assembly 70 receives air from the vacuum pump outlet 52. The inlet 71 of valve assembly 70 includes an opening into valve housing 72. The outlet 52 of the vacuum pump 50 includes an opening from the vacuum pump 50. A conduit 42 couples the vacuum pump outlet to the valve assembly inlet.

Air received by valve housing 72 exits valve assembly at its outlet 73. The air exiting the valve assembly housing is directed into the intake 22 of air oil separator 20. The valve assembly outlet is coupled to air oil intake 22 by conduit 43. Thus, all of the air entering the valve assembly at its intake 71 is ported to the air oil separator via conduit 43. The entire fluid passage from the valve outlet to the separator intake can be referred to as fluid circulation conduit.

In the present apparatus, it is understood that the volume of air passing through the fluid circulation conduit measured in cubic feet per minute, cfrn, is equal to A-B where A is the capacity in cfrn of the blower and B is the volume of air being pulled from the crankcase. Thus, for example, if the blower has a capacity of 55 cfrn, and the volume pulled from the crankcase is 30 cfrn, the volume passing through the circulation conduit will be 25 cfrn. It is understood that in the present example the capacity of the blower, when the air oil separator 20 is clean, is 55 cfrn; and the volume removed from the crankcase is 30 cfrn. Accordingly, the volume traveling through the fluid circulation conduit and valve assembly 70, when the compressor is clean, is 25 cfrn. It is understood in the present example that when the air oil separator is saturated, the blower has a capacity of 45 cfin. There is still 30 cfin being removed from the crankcase. The volume passing through the fluid circulation conduit and valve assembly, however, declines to 15 cfin.

FIG. 4B shows the valve assembly at 15 cfin and FIG. 5C shows the valve assembly at 25 cfin. As can be seen, the axial position of the valve 79, relative to the valve inlet 71 and outlet 73 changes as the cfin passing through the valve drops from 25 cfin to 15 cfin. The change in the position of the valve 74 and the stepped interior of the valve housing 72 ensures that the drop in cfin does not cause a change in the negative pressure maintained in the fluid circulation conduit. Maintaining a constant pressure in the conduit helps ensure a constant pressure in the crankcase. In the present example, it is understood the pressure in the circulation conduit is negative. The term pressure can refer to both a positive and a negative pressure. A negative pressure means there is a pressure drop.

As shown and described in the drawings it is the valve assembly structure that ensures constant negative pressure in the valve assembly and fluid circulation conduit even though the cfin passing through the valve assembly drops from 25 cfin to 15 cfin. The valve assembly structure includes the valve assembly housing 72. The housing forms a chamber 74 through which air entering and exiting the valve assembly must pass. The chamber is formed by a stepped internal surface of the housing. The stepped internal surface forms chamber regions within the chamber. Each of the chamber regions have internal diameters which differ from each other. The shown housing has four chamber regions 74a-74d. The first region 74a defines the housing inlet 71. The first region has the largest diameter of the four regions. A second region 74b, immediately adjacent the first, has a reduced diameter. The diameter of the second region is the smallest of all the four regions. A third chamber region 74c is adjacent the second region and axially spaced from the first region by the axial width of the second region. The third region 74c has an internal diameter smaller than the first region and larger than the second. A fourth region 74d, adjacent to the third region, is at the outlet 73 of valve assembly 70. The fourth region has a larger diameter than the third region. Accordingly, the length of the diameters of each region are compared as follows: 74a > 74d > 74c > 74b. The regions rather than being formed by steps could be formed by a gradual change, such as a slope.

The valve assembly has a valve support disposed in the chamber of the valve housing. The support includes an open base 75 threadably secured into valve outlet 73. A shaft 76 is press fit into center bore 75a of open base 75. The shaft extends axially upward from base 75 through the third and second regions and into the first region.

A compression spring 77 is disposed around shaft 76. A valve is slidably coupled to the shaft through a central hole in the valve. The spring biases the valve upward away from the base of the shaft. When the spring is in a non-compressed, resting state, the valve assembly is in the closed position as shown in FIG. 3A. The valve is generally in this position when there is 0 cfin passing through the valve assembly. In the closed position, the valve is at a point in the second chamber region which immediately adjoins the first chamber region. The valve is thus at the top of the second region.

When the blower is operating at full capacity, FIG. 3C, and the separator is clean as stated above, there is 25 cfrn passing through the valve assembly. The air pushes the valve against the spring into a fully open position. In the fully open position, the spring is compressed so that the valve rests in the third region. There is volume X between a bottom ledge of the second region (top of the third region) and the upper surface 79a of valve 79. There is a volume Y between the valve upper surface and the top of the valve inlet 71.

When the blower is operating at full capacity, but the separator is saturated, as stated above, there is 15 cfin passing through the valve assembly. The reduction in cfrn from 25 to 15 means less force pushing valve 79 towards valve outlet 73. The spring thus pushes the valve upward toward valve inlet 71 into a partially open position. As can be seen in FIG. 3B the volume X' between a bottom ledge of second region (top of the third region) and the upper (top) surface of valve 79 decreases. Also the volume Y' between the valve upper surface and the top of the valve inlet 71 decreases. The decrease in volume ensures that although the cfrn has dropped, the negative pressure remains constant in the fluid circulation conduit leading from the vacuum outlet to the separator intake and also across the valve assembly. This in turn makes sure the pressure, including negative pressure, remains constant in the crankcase.

The valve assembly also operates as a pressure relief valve to allow positive pressure which may build up in the crankcase, if the separator becomes fouled, to escape from the crankcase and exit through conduit 43, assembly 70, conduit 42 and onto exit at outlet 80. As shown in FIG. 3D when the air exits it pushes valve 79 up into the first chamber region 74a. Although certain embodiments and examples have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such examples may be made without departing from the true spirit and scope of the invention.

Either of the written description, the drawings and written description and the drawings, each alone or in combination disclose the features of the invention. The terms used in the written description is not to limit the scope of the invention as shown in the drawings.

Claims

Claims:

1. A valve assembly of an apparatus to regulate pressure in a crankcase, the apparatus comprising an air oil separator, said separator having an inlet and an outlet; a vacuum source having an inlet and an outlet; said inlet of said separator fluidly coupled to said crankcase; said outlet of said separator fluidly coupled to said inlet of said vacuum source; said outlet of said vacuum source fluidly coupled to an inlet of said valve assembly; an outlet of said valve assembly fluidly coupled to said inlet of said separator or to an inlet of said crankcase, said valve assembly comprising: a housing, said housing having an internal surface which defines a chamber, said chamber having a plurality of at least three different internal diameters, a first region of said chamber has a first diameter of said plurality, a second region of said chamber has a second diameter of said plurality, a third region of said chamber has a third diameter of said plurality; a valve within said chamber, said valve having a diameter slightly less than the diameter in said second region such that the perimeter of said valve is almost flush with a surface of the second region forming the second diameter; a first valve open position wherein said valve is in said third region having said third diameter, said valve, in said first position, defining a first volume within said housing chamber, said first volume measured from a valve top surface to a top of said valve inlet, said valve in said first position also defining a second volume in said chamber, said second volume measured from the top of said valve surface to a top of said third region; a second valve open position wherein said valve is in said third region, said valve defines a third volume, said third volume is measured from said valve top surface to the top of said third region, said valve defines a fourth volume, said fourth volume measured from said valve top surface to the top of said valve inlet, said fourth volume is less than said first volume, said third volume is less than said second volume; and wherein said valve moves from said first position to said second position when said air oil separator becomes saturated;

2. A valve assembly of an apparatus to regulate pressure in a crankcase, the apparatus comprising an air oil separator, said separator having an inlet and an outlet; a vacuum source having an inlet and an outlet; said inlet of said separator fluidly coupled to said crankcase; said outlet of said separator fluidly coupled to said inlet of said vacuum source; said outlet of said vacuum source fluidly coupled to an inlet of said valve assembly; an outlet of said valve assembly fluidly coupled to said inlet of said separator or to an inlet of said crankcase, said valve assembly comprising: a first valve open position; a second valve open position and wherein; said valve moves from said first valve position to said second position when a volume of air passing through said valve assembly drops, and wherein a negative pressure in a conduit extending from said valve outlet to said separator inlet remains constant.

3. The valve assembly of claim 1 further comprising: a valve support.

4. The valve assembly of claim 3 wherein said support comprises: a base.

5. The valve assembly of claim 4 wherein said base is secured to said housing at said valve assembly outlet.

6. The valve assembly of claim 5 wherein said support is threadably secured to said housing.

7. The valve assembly of claim 4 further comprising: a shaft extending upward from said base.

8. The valve assembly of claim 7 further comprising: a compression spring around said shaft.