Separator for liquid and gas

An oil tank for an engine is provided with a separator that reduces the amount of entrained air in the oil tank. The separator includes a body with an outer wall, a divider wall, and an outlet. The divider wall is located between the outer wall and at least a first portion of the outlet. The divider wall is offset from a curved portion of the outer wall, which defines a flow channel through which the oil flows towards the outlet. The oil increases speed as travels around the divider wall. This movement keeps the oil with some and/or more entrained air closer to the outer wall. In contrast, the oil with less or no entrained air moves closer to the divider wall and may travel more directly to the outlet.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of engines. The present invention relates specifically to a separator for liquid and gas, such as for use to separate entrained air from oil in an oil tank.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to an oil tank including a tank body which defines a storage compartment. The storage compartment has an upper portion and a lower portion. A separator is located in the upper portion of the tank body. The separator includes a separator body with a top surface, a bottom surface opposite the top surface, an outer wall located between the top surface and bottom surface, and an internal chamber defined by the top surface, the bottom surface, and the outer wall. Additionally, the separator includes an inlet, an air vent, and an outlet. The inlet provides fluid communication for the oil between an exterior of the separator body and the internal chamber. The air vent provides fluid communication for the air between the internal chamber and the exterior of the body. The outlet provides fluid communication for the oil between the internal chamber and the lower portion of the tank body. Further, the separator includes a divider wall within the internal chamber. The divider wall is spaced by a distance from a curved portion of the outer wall and is convex with respect to the curved portion. The divider wall is positioned between the curved portion of the outer wall and at least a first portion of the outlet. Together, the divider wall and the curved portion of the outer wall define a flow channel through which the oil may flow, and the flow channel directs the oil towards the outlet and out of the internal chamber.

Another embodiment of the invention relates to an air and oil separator. The air and oil separator includes a body with a top surface, a bottom surface opposite the top surface, and an outer wall located between the top surface and the bottom surface. The top surface, bottom surface, and outer wall define an internal chamber. Additionally, the separator includes an inlet for providing fluid communication for the oil between an exterior of the body and the internal chamber, and the separator includes a plurality of apertures for providing fluid communication for the oil between the internal chamber and the exterior of the body. The plurality of apertures is spaced at least 0.75 inches from the outer wall. Further, the separator includes a divider wall located between the outer wall and at least a first portion of the plurality of apertures.

Another embodiment of the invention relates to an air and oil separator with a body and an entrance compartment. The body includes a top surface, a bottom surface opposite the top surface, a first side wall located between the top surface and the bottom surface, a second side wall opposite the first side wall, and an internal chamber defined by the top surface, the bottom surface, the first side wall, and the second side wall. The entrance compartment is located in the internal chamber and has an outer wall and an opening in the outer wall. An air vent is located in the entrance compartment for providing fluid communication for the air between the entrance compartment and the exterior of the body. The separator also includes an inlet for providing fluid communication for the oil between an exterior of the body and the entrance compartment and an outlet for providing fluid communication for oil between the internal chamber and the exterior of the body. Further, the separator includes a divider wall located in the internal chamber. The divider wall includes a first end and a second end. The first end is attached to the outer wall of the entrance compartment adjacent to the opening. The second end is located between the second side wall and at least a first portion of the outlet. As such, the divider wall defines a flow channel through which oil may flow from the opening to the outlet.

Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and/or shown in the accompanying drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments. In addition, alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a separator for separating entrained air from oil in an oil tank of an engine are shown. Engines can receive oil from an oil tank to lubricate various parts of the engine. However, as oil is pumped through the engine, air can become entrained in the oil. Entrained air reduces the lubricating effectiveness of the oil. This can lead to a reduction of engine performance, efficiency, and life.

Applicant has developed various separators for oil tanks that are believed to provide for various advantages over typical oil tanks, including reducing the amount of entrained air in the oil before the oil is pumped from the oil tank into the engine. Specifically, the separators discussed herein provide three stages of separation, while also providing a steady supply of oil to the engine.

Referring generally to the figures, first, the oil enters the separator140through the inlet158. The inlet158directs the oil into an entrance compartment160. The entrance compartment160is cylinder shaped and the inlet158sprays the oil tangentially against a curved outer wall174of the entrance compartment160. As such, the oil travels along the inside surface182of the outer wall174and creates a swirling effect. This swirling effect is the first stage of separation. In this stage, some entrained air is separated from the oil due to the centrifugal force caused by the swirling movement of the oil. The air that has separated from the oil travels up towards the top of the entrance compartment160and out of the separator140. Meanwhile, the force of gravity pulls the oil down towards the bottom of the entrance compartment160and through an opening180in the outer wall174of the entrance compartment160.

Second, as the oil flows out of the entrance compartment160and through the opening180, a divider wall162intercepts the oil directing the oil towards an outlet164. The divider wall162is spaced from the outer walls148,150,152,154of the separator140. The divider wall162and the outer walls148,150,152,154define a flow channel through which the oil may flow from the opening180to the outlet164. The oil flows at a relatively slower rate around the divider wall162in comparison to the flow rate within the entrance compartment160. The movement around the divider wall162allows for additional entrained air to separate from the oil. As the oil travels around the curved portion of the flow channel, the oil containing more entrained air moves closer to the outer walls152,154and defines an outer portion212of the flow channel. In contrast, oil with less or no entrained air moves closer to divider wall162, which defines an inner portion210of the flow channel.

As oil exits the flow channel, the second stage of separation occurs. The flow channel extends a distance past the end of the divider wall162; so, the oil continues to flow without interfacing the divider wall162. The outer portion212of the flow channel carrying the oil mixed with more entrained air continues to travel along the outer walls148,150,152,154in a substantially straight direction. This gives the entrained air more time in the separator, which allows for more entrained air to separate from the oil. On the other hand, the inner portion210of the flow channel continues to curve and intersects at least an outer portion of the outlet164. As such, the oil in the inner portion210of the flow channel can flow more directly towards the outlet164.

Third, the oil travels through the outlet164. The outlet164provides fluid communication for oil between the internal chamber156and the lower portion of storage compartment116of oil tank100. The outlet164is defined by a plurality of apertures204, which in various embodiments are arranged in a circular array. The oil traveling through the outlet164experiences the third stage of separation. As the oil travels to the outlet164, the oil may still contain some air bubbles. These air bubbles may catch on the edges of the plurality of apertures204. As more air bubbles are caught on the apertures204(e.g., the periphery of apertures204, the bubbles may connect with each other and rise out of the oil. This provides a tertiary level of air separation for the oil as it leaves the separator.

Generally, as the oil travels through the separator140, it maintains a rapid flow rate. Applicant has found that the oil flows from the inlet to the outlet in a few seconds. Specifically, in various embodiments, the oil can flow through separator at a flow rate of 8 to 12 gallons per minute. As such, Applicant has found that the separator effectively reduces entrained air in the oil, while also allowing for a steady supply of oil to the engine.

Referring now more specifically toFIGS.1and2, an oil tank100for an engine is shown according to an exemplary embodiment. Oil tank100has a tank body102. Body102has a top surface104and a bottom surface106opposite the top surface. Body102also includes a first side wall108, a second side wall110, a third side wall112, and a fourth side wall114. Each side wall108,110,112, and114is located between and extends between top surface104and bottom surface106. Together, top surface104, bottom surface106, first side wall108, second side wall110, third side wall112, and fourth side wall114define a storage compartment116.

Referring toFIGS.3and4, an air and oil separator140is shown mounted in storage compartment116of tank100. Separator140is mounted to top surface104of tank100with mounting brackets141. Specifically, separator140is located in an upper portion of storage compartment116. Separator140is spaced from bottom surface106such that separator140does not touch bottom surface106. Oil that travels through separator140is held below separator140in a lower portion of storage compartment116.

Referring generally toFIGS.5-12, separator140is shown and described according to an exemplary embodiment. Separator140has a body142. Body142includes a top surface144, a bottom surface146opposite top surface144, a first side wall148located between top surface144and bottom surface146, a second side wall150opposite the first side wall148, a first curved outer wall152located between the top surface144and bottom surface146and between first side wall148and second side wall150, and a second curved outer154wall located opposite the first curved outer wall152. First side wall148, second side wall150, first curved outer wall152, and second curved outer wall154are coupled together to form an outer wall of body142. In certain embodiments, first side wall148, second side wall150, first curved outer wall152, and second curved outer wall154are made of a single, continuous, contiguous piece of material. In other embodiments, two or more of the walls148,150,152, and154may be a single, continuous, contiguous piece of material. Body142defines an internal chamber156, and body142includes a plurality of air holes143that provide fluid communication for air between the internal chamber156and an exterior of body142. Air holes143allow air within oil tank100to move between internal chamber156and storage compartment116of oil tank100, and visa-versa. Air holes143help maintain a pressure between internal chamber156and oil tank100. As shown, an air ventilation tube118passes through separator140to provide fluid communication for air from the lower portion of the tank100to the upper portion. This allows for air to exit the lower portion.

Referring generally toFIGS.13-18, separator140and internal chamber156is shown. As shown, separator140includes an inlet158, an entrance compartment or entrance chamber160, a divider wall162, and an outlet164.

Oil enters separator140through inlet158. Inlet158provides fluid communication for oil between an exterior of the separator body and internal chamber156. More specifically, inlet158provides fluid communication for oil between an exterior of oil tank100and entrance compartment160. Inlet158includes a tube166. Tube166extends between a first end168and a second end170. First end168includes end cap172. End cap172is coupled to top surface104of oil tank100. As such, tube166allows oil to flow from outside of oil tank100through first end168and to second end170. Second end170directs oil into entrance compartment160. Specifically, second end170extends into entrance compartment160. As best shown inFIGS.14and15, second end170is tapered or pinched. Specifically, second end170has a cross-sectional area smaller than a cross-sectional area of the first end. This tapered shape increases the speed at which oil enters entrance compartment160.

Entrance compartment160has an outer wall174, a top176, an air vent178, and an opening180. As oil exits second end170, the oil is sprayed tangentially against outer wall174. This spraying creates a swirling effect as the oil travels along an inside surface182of outer wall174. This allows for some air to separate from the oil. Air that has separated from the oil travels up towards top176of entrance compartment160and through air vent178. Meanwhile, the force of gravity pulls oil down towards bottom surface146and through opening180.

As shown, entrance compartment160is located at least partially within internal chamber156. Specifically, entrance compartment160is located between first side wall148and second side wall150and is closer to second curved outer wall154. Outer wall174of entrance compartment160is convex with respect to second curved outer wall154. As shown, outer wall174of entrance compartment160defines a cylinder shape and inside surface182is curved. Outer wall174has a full circumference.

Air that has separated from oil within entrance compartment160rises towards top176. Air vent178is coupled to top176and provides fluid communication for air between internal chamber156and the exterior of body142and, more specifically, between entrance compartment160and the inside of oil tank100. Air vent178includes housing or cap187and a tube188which directs air away from entrance compartment160. Tube188extends from cap187towards a curved end190which directs the air downwards towards top surface144. Curved end190is angled downward to allow any incidental oil that enters air vent178to travel through tube188and exit through curved end190.

Meanwhile, oil in entrance chamber160travels down towards bottom surface146and opening180. Opening180is located in outer wall174and along bottom edge192of outer wall174. Opening180allows for oil to exit entrance chamber160and enter internal chamber156. Opening180is positioned at an angle relative to second curved outer wall154to direct oil towards divider wall162. As shown, opening is angled towards second side wall150.

In specific embodiments, opening180extends a percentage around the circumference of outer wall174. In certain embodiments, opening extends between 25% and 50% around the circumference and, more specifically, between 40% and 49%. In other embodiments, opening180extends a specific number of degrees around the circumference. In certain embodiments, opening180is less than 180 degrees of the circumference. More specifically, opening180is between 120 degrees and 175 degrees.

Swirling oil from entrance compartment160flows through opening180and is directed by divider wall162towards outlet164. Divider wall162is spaced from body142, which defines a flow channel through which oil flows from opening180to outlet164. Oil flows at a relatively slower rate around divider wall162in comparison to the flow rate within entrance compartment160. The slower movement around divider wall162allows for additional time for air to separate from the oil. Oil with less or no entrained air moves closer to and may attach to divider wall162, while oil with more entrained air, relative to the other oil, moves closer to body142and may be carried by centrifugal force along outer walls148,150,152, and154.

Divider wall162is shaped similar to a portion of body142. Divider wall162is perpendicular to bottom surface146, and a portion of divider wall162is parallel to first side wall148and second side wall150. Divider wall162may be made of multiple panels coupled together or a single, continuous, and contiguous piece of material.

Divider wall162extends between a first end194and a second end196. First end194is adjacent to opening180. As best shown inFIG.14, first end194extends through opening180and extends under outer wall174. Opening180is angled towards first end194. An edge of opening180abuts a portion of first end194. This allows for oil to be more easily directed by divider wall162through the flow channel. In certain embodiments, first end194may be coupled to outer wall174.

Second end196of divider wall162is located opposite first end194and near outlet164. Specifically, second end196is located between first side wall148and at least a portion of outlet164. Second end196ends near where first curved outer wall152is connected to first side wall148. That is, second end196ends where a curved portion of the body142transitions into a straight portion.

A curved section197of divider wall162is located between first end194and second end196. Curved section197is located between first curved outer wall152and at least a portion of outlet164. Curved section197is convex with respect to first curved outer wall152. Curved section197may be positioned substantially equidistant from first curved outer wall152. In some embodiments, curved section197, first curved outer wall152, and outlet164are concentric and share a same center. In other embodiments, curved section197, first curved outer wall152, and outlet164are eccentric and are off center with respect to each other. In other embodiments, at least two of curved section197, first curved outer wall152, and outlet164are concentric with respect to each other.

First side wall148, second side wall150, first curved outer wall152, and second curved outer wall154define a perimeter of separator body142. Divider wall162extends a length shorter than the length of the perimeter of the separator body142. In certain embodiments, divider wall162extends a length that is at least 40% of the length of the perimeter of separator body142. In another embodiment, divider wall162extends a length that is less than 80% of the length of the perimeter of separator body142. More specifically, divider wall162extends a length that is between 50% and 70% of the length of the perimeter.

As shown inFIG.15, divider wall162is spaced from body142. First end194is spaced from second side wall150by a first distance198. Curved section197is spaced from the first curved outer wall152by a second distance200. And, second end196is spaced from first side wall148by a third distance202. As shown, first distance198is greater than second distance200, and second distance200is greater than third distance202.

In a specific embodiment, second distance200is less than 1 inch, and more specifically is less than 0.500 inches. In a certain embodiment, second distance200is 0.375 inches.

As oil passes the second end196of divider wall162, it continues to travel along the flow channel. Flow channel extends a distance past the end of the divider wall162. Specifically, flow channel has an inner portion210and an outer portion212, as shown inFIG.23. Inner portion210is located relatively closer to divider wall162, while outer portion212is located relatively closer to first curved outer wall152and second side wall150. Oil with less or no entrained air travels along inner portion210(e.g., such as by attaching to divider wall162), while oil with some and/or more entrained air, relative to other oil, travels along outer portion212(e.g., such as via the oil infused with air being biased towards the outer portion, such as via centrifugal force). The inner and outer flow channels travel in relatively the same direction until the oil passed the second end196of divider wall162. At that point, the oil with more entrained air traveling along the outer portion212of the flow channel continues to travel along the outer walls in a substantially straight direction for a distance. In contrast, the inner portion210of the flow channel directs the oil with less or no entrained air to continue to curve and to intersect at least an outer portion of the outlet164. As such, oil in the inner portion210of the flow channel can flow more directly towards the outlet164. The oil then exits internal chamber156through outlet164.

As best shown inFIGS.12and17, outlet164is located in bottom surface146and includes a plurality of holes or apertures204. Apertures204provide fluid communication for oil between internal chamber156and the lower portion of storage compartment116of oil tank100. Some air bubbles may catch on the circumference of apertures204, which prevents the air from flowing with the oil into oil tank100. As more air bubbles are caught, the bubbles may connect with each other and rise out of the oil. Hole or vent206is located directly above outlet164to allow air caught by the holes to more easily escape internal chamber156.

In a specific embodiment, apertures204each have a diameter208between 0.100 inches and 0.200 inches. More specifically, apertures have a diameter208of at least 0.125 inches. As shown, apertures204are arranged in a circular array. The circular array has a circumference. In some embodiments, the circumference of the circular array is the same as the circumference of outer wall174. In certain embodiments, circular array has a circumference of between 3.0 inches and 3.5 inches.

Circular array has a surface area which includes apertures204and part of bottom surface146. In certain embodiments, circular array has an aperture to bottom surface ratio of at least 1:4. In other embodiments, apertures204are at least 25% of the surface area of the circular array.

As shown inFIG.17, plurality of apertures204are spaced from body142. Apertures204are spaced from first curved outer wall152by at least a first distance214. Apertures204are spaced from first side wall148by at least a second distance216. And, apertures204are spaced from second side wall150by at least a third distance218. As shown, third distance218is greater than first distance214, and first distance214is greater than second distance216.

In a specific embodiment, third distance218is at least 0.75 inches, and more specifically is 0.80 inches to 0.90 inches. In a certain embodiment, third distance is 0.82 inches.

As shown, separator140also includes a crank case return line220. Crank case return line220provides fluid communication for oil and air between storage compartment116and internal chamber156. Crank case return line220is located near second end196of divider wall162.

Referring toFIGS.19-22, side views of separator140are shown. As shown, entrance compartment160extends through top surface144of body142. Entrance compartment160has a height222which is greater than a height224of body142. First side wall148, second side wall150, first curved outer wall152, and second curved outer wall154all have a height224. Opening180has a height226. Opening180is shorter than height224of body142. Further, opening180is shorter than a height228of divider wall162.

As shown, divider wall162is spaced from top surface144of separator140. Divider wall162has a height228, which extend upwards substantially perpendicular from bottom surface146. In specific embodiments, height228of divider wall is at least 50% of height224of body142. More specifically, divider wall is at least 75% of height224.

For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. As used herein, “rigidly coupled” refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.