Abstract:
A crankcase ventilation apparatus of an internal combustion engine of a motor vehicle, including an oil-mist separator for the separation of oil from the crankcase ventilation gas of the internal combustion engine and including an assembly for the return of lubricating oil from the oil-mist separator to an oil pan of the internal combustion engine. The oil-mist separator includes at least one preliminary separator and at least one fine separator, wherein the preliminary separator is connected to the oil pan via a first oil return flow passage allowing a continuous flow of oil there through during operation and wherein an oil collection chamber is provided downstream of an oil outlet of the fine separator, said oil collection chamber being connected to the oil pan via a second oil return flow passage which is equipped with a check valve to discontinue the flow of oil during operation. The first oil return flow passage is designed in the form of a siphon comprising a pipe section which immerses into a siphon reservoir comprising an overflow and the second oil return flow passage ends in the siphon reservoir downstream of the check valve.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a crankcase ventilation apparatus of an internal combustion engine of a motor vehicle, comprising an oil-mist separator for the separation of oil from the crankcase ventilation gas of the internal combustion engine and comprising an assembly for the return of lubricating oil from the oil-mist separator to an oil pan of the internal combustion engine, wherein the oil-mist separator comprises at least one preliminary separator and at least one fine separator, wherein the preliminary separator is connected to the oil pan via a first oil return flow passage allowing a continuous flow of oil there through during operation and wherein an oil collection chamber is provided downstream of an oil outlet of the fine separator, said oil collection chamber being connected to the oil pan via a second oil return flow passage which is equipped with a check valve to discontinue the flow of oil during operation. 
     DE 203 02 220 U1 shows a crankcase ventilation apparatus of the aforementioned type. Therein, the first oil return flow passage is designed in the form of an annular channel, with an oil outlet being provided adjacent to the bottom of the annular channel. The second oil return flow passage which comes from the oil collection chamber and is equipped with the check valve ends in the same oil outlet. This oil outlet is in communication with the oil pan of the associated internal combustion engine in a manner which is not described in more detail in this document. 
     DE 197 00 733 A1 shows a cylinder head cover which incorporates a two-stage oil-mist separator comprising a helical insert as preliminary separator and a fine separator arranged downstream of the preliminary separator. The oil separated in the preliminary separator and in the fine separator is supplied to a common single oil return flow hole in the bottommost part of the fine separator by virtue of gravity and is returned through this hole and into the engine oil circuit. 
     Where apparatuses according to the two documents mentioned above are concerned, crankcase ventilation gas may flow through the oil outlet or the oil return flow hole opposite to the oil flow direction provided and result in failures of the oil-mist separation. In order to prevent such failures, it is known per se to design an oil return line of an oil-mist separator with a siphon which forms a duct which is permeable to oil but tight to gas. To ensure reliable functioning of the siphon, it is, therein, essential that it contains the oil volume required for gas tightness and retains the oil volume during operation of the associated internal combustion engine. 
     To achieve this, DE 195 31 695 B4 proposes a crankcase ventilation of an internal combustion engine wherein an oil return line connects a pressure regulating valve to the crankcase via a check valve, wherein the oil return line comprises an oil collection chamber or siphon which is embedded in the crankcase or in a wheel house, wherein the oil collection chamber or siphon can be automatically filled with oil upon starting of the internal combustion engine, wherein the oil can be delivered by a scoop wheel or gear wheel arranged on a shaft, and wherein the housing encompassing the oil collection chamber or the siphon comprises an oil scraper nose. Although it is true that this arrangement provides for a continuous and automatic filling of the siphon, the internal combustion engine nevertheless requires special embodiments, namely the scoop wheel or gear wheel for delivery of the lubricating oil into the siphon and the oil scraper nose on the housing, which results in a high complexity and, thus, in high costs. Herein, significant inclined positions of the associated motor vehicle may, in addition, cause the oil collection chamber or siphon to be discharged, whereby the gas blocking function gets lost. 
     DE 199 48 163 A1 shows an apparatus for the ventilation of crankcases/cylinder heads of a combustion engine, comprising an oil separator and a return assembly for returning the separated oil into the crankcase. Therein, it is provided that the oil separator is arranged inside a line of an oil filling system of the combustion engine, the line serving to supply fresh oil into the crankcase. Therein, the return assembly, furthermore and preferably, comprises an oil-filled siphon-type section. 
     In this arrangement, the siphon is filled with oil while the engine is filled with lubricating oil for the first time. If required, the siphon is refilled with the oil separated in the oil separator during ongoing operation of the latter. However, this arrangement is considered to be to a disadvantage in that the free flow cross-section for filling in the fresh lubricating oil is considerably restricted by the arrangement of the oil separator and the siphon in the oil filling system, with the result that the oil can only be filled in at a low flow rate of the oil. Herein, there is the risk of fresh lubricating oil overflowing while oil is being filled in, resulting in fouling of the engine and contamination of the environment. 
     SUMMARY OF THE INVENTION 
     The present invention, therefore, aims at creating a crankcase ventilation apparatus of the aforementioned type, which obviates the drawbacks disclosed above and which reliably prevents undesired misdirected flows of crankcase ventilation gas, in particular if the oil separation efficiency is high, without special maintenance or actuation measures being necessary for this purpose, and the proper functioning of which is reliably preserved even in case of a strongly inclined position of the associated internal combustion engine and a motor vehicle equipped therewith. 
     This problem is solved according to the invention by means of a crankcase ventilation apparatus of the aforementioned type, which is characterized in that the first oil return flow passage is designed in the form of a siphon comprising a pipe section which immerses into a siphon reservoir comprising an overflow and that the second oil return flow passage ends in the siphon reservoir downstream of the check valve. 
     Advantageously, the two oil return flow passages are both running into the siphon reservoir, whereby the construction as a whole remains simple because the number of interfaces with the internal combustion engine is kept low. Furthermore, the second oil return flow passage provides for a reliable and automatic first filling of the siphon reservoir after the first start-up of the associated internal combustion engine, without further special measures having to be taken. At the beginning of the first operation run of the internal combustion engine, oil which is separated in the fine separator is collected in the oil collection chamber the check valve of which remains closed as long as the internal combustion engine is in operation. In this first operating phase, there will still be crankcase gas flowing through the first oil return flow passage because the latter is still open. After the internal combustion engine is turned off, the check valve of the oil collection chamber is opened and the oil collected therein and separated in the fine separator flows into the siphon reservoir. Thus, the siphon reservoir is provided with the oil volume required for operation and for gas tightness of the siphon in a fully automatic manner. As soon as the oil volume present in the siphon reservoir is large enough, the siphon is still permeable to oil to allow the return of the lubricating oil separated in the preliminary separator, but it is gas-tight to crankcase gas. The desired function of the siphon is, therefore, automatically ensured after a short operating time. Since further oil is continuously supplied into the siphon reservoir during ongoing further operation of the internal combustion engine, it is ensured that the siphon reservoir always remains filled to a sufficient degree or is quickly and automatically refilled after a discharge which has possibly occurred nevertheless. 
     In order to ensure proper functioning of the siphon even in the event of inclined positions of the associated motor vehicle, it is preferably provided that, in a horizontal position of the motor vehicle, the pipe section extends into the siphon reservoir at an angle in relation to the vertical, that a lower end of the pipe section is positioned in a bottommost region of the siphon reservoir, and that the overflow comes out of the siphon reservoir in an uppermost region of the siphon reservoir, the uppermost region being positioned in an opposite direction in relation to the end of the pipe section. In this embodiment, the distance formed between the end of the pipe section in the bottommost region of the siphon reservoir and the overflow thereof is as far as possible. As a result, an inclined position of the motor vehicle does not cause a considerable discharge of the siphon reservoir either. 
     In a further development with regard thereto, it is provided that with the motor vehicle being in the horizontal position, the overflow is positioned above the upper edge of the lower end of the pipe section either precisely vertically or at an angle of no more than 15°. 
     In particular for reasons of a compact design, it is proposed that the overflow is continued in an overflow channel extending, in essence, in a parallel direction in relation to the pipe section. What is more, a parallel extension of the overflow channel and the pipe section facilitates manufacture of these parts according to the injection-molding method because, in this case, they can be demolded in a favorable manner. 
     For reasons of cost-effective production, it is furthermore proposed that the first oil return flow passage comprising the pipe section and the second oil return flow passage comprising the check valve are combined to form an integral or pre-assembled structural unit. This facilitates and makes less expensive both the production and the assembly. 
     The siphon reservoir may be arranged at different places which depend on the space requirements in the engine compartment of an internal combustion engine and on the conditions of the internal combustion engine itself. Preferably, it is proposed that the siphon reservoir comprising the overflow is arranged in or on a cylinder head cover or a cylinder head or a cylinder bank or a crankcase of the internal combustion engine and is connected to or forms an integral part with the cylinder head cover or the cylinder head or the cylinder bank or the crankcase. 
     In a further embodiment, it is provided that the cylinder head cover or the cylinder head or the cylinder bank or the crankcase comprises a connecting flange for connection to the structural unit which comprises a matching companion flange. In this embodiment, the structural unit can be connected to the associated part of the internal combustion engine in a particularly fast and easy manner. 
     In order to prevent the occurrence of disturbing and environmentally harmful misdirected flows of gases and oil and to achieve a simple seal, the connecting flange and the companion flange, preferably, form a cylindrical plug flange connection with a radially acting seal. Herein, it is sufficient to plug the parts of the flange in each other to achieve the sealing connection. Here, it is not necessary to take special measures for generating a sealing force, which would have to be taken for an axially acting seal. 
     In order to prevent assembly errors and to ensure reliable functioning, the plug flange connection comprises positioning means which uniquely locate the structural unit in circumferential direction in relation to the connecting flange. 
     Therein, the positioning means are, preferably, formed by a threaded hole provided in the connecting flange, a screw hole which is formed to fit to the structural unit and can be brought into congruence with the threaded hole, and a screw which can be screwed into the threaded hole through the screw hole. In this manner, it is not only possible to achieve exact positioning but also that the structural unit is reliably secured to the associated connecting flange. If required, it is also possible to provide two or more threaded holes, screw holes and screws. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An exemplary embodiment of the invention will be illustrated below by means of a drawing. In the drawing, 
         FIG. 1  is a vertical section of an oil return assembly forming part of a crankcase ventilation apparatus, in a state prior to a first startup of the associated internal combustion engine; 
         FIG. 2  is a partial view of an oil-mist separator comprising the parts of the oil return assembly present thereon, in perspective; 
         FIG. 3  is a partial view of a cylinder head cover comprising the parts of the oil return assembly present thereon, also in perspective; 
         FIG. 4  is a view of the oil return assembly of  FIG. 1 , now in a state during the first startup of the internal combustion engine; 
         FIG. 5  is a view of the oil return assembly of  FIG. 1 , in a state subsequent to the first startup of the internal combustion engine; 
         FIG. 6  is a view of the oil return assembly of  FIG. 1 , in a state during a later ongoing operation of the internal combustion engine; 
         FIG. 7  is a view of the oil return assembly of  FIG. 1 , in a state during an even later ongoing operation of the internal combustion engine; 
         FIG. 8  is a simplified vertical sectional view of the oil return assembly with an associated motor vehicle being aligned horizontally; 
         FIG. 9  is a view of the oil return assembly of  FIG. 8 , now with the motor vehicle being in a position which is inclined by 45° to the left in relation to  FIG. 8 ; and 
         FIG. 10  is a view of the oil return assembly of  FIG. 8 , with the motor vehicle being in a position which is inclined by 45° to the right in relation thereto. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  is a vertical section of an oil return assembly  1  for the return of lubricating oil that has been separated in an oil-mist separator into the oil circuit of an internal combustion engine. Herein, the oil return assembly  1  is, on the one hand, part of a cylinder head cover  10  which is visible in part and, on the other hand, part of a structural unit  20  which forms a lower part of an oil-mist separator not shown here. 
     A first oil return flow passage  21  coming from a preliminary separator of the oil-mist separator is provided in the structural unit  20 , said preliminary separator separating coarse-particle oil from a crankcase ventilation gas flow. A second oil return flow passage  22  serves to return further lubricating oil to the oil circuit of the internal combustion engine, the lubricating oil being separated in a fine separator of the oil-mist separator. The two oil return flow passages  21  and  22  end in a siphon reservoir  25  which is formed in the cylinder head cover  10 . The structural unit  20  comprising the two oil return flow passages  21  and  22  is inserted in the cylinder head cover  10  by means of a cylindrical plug flange connection, with an intermediate layer of a radially acting seal  17 . 
     Inside the siphon reservoir  25 , the first oil return flow passage  21  passes into a pipe section  26  which extends at an angle of approximately 45° in relation to the vertical and the end  26 ′ of which is positioned in the bottommost region of the siphon reservoir  25 . 
     The second oil return flow passage  22  extends from an oil collection chamber  23  arranged thereabove and through a check valve  24  and also ends in the siphon reservoir  25 . Herein, the check valve  24  is a meander valve which is closed during ongoing operation of an associated internal combustion engine and opens during standstill of the associated internal combustion engine, each in relation to the pressures then prevailing on the two sides of the valve. It is also possible to insert a reed valve or a valve with a valve adjustment shim in the stead of the meander valve. 
     An overflow  27  which is positioned in the uppermost region of the siphon reservoir  25  extends from the siphon reservoir  25  into an overflow channel  27 ′ which extends downwards into the interior region of the cylinder head cover  10  at an angle and approximately in parallel in relation to the pipe section  26 . In this way, lubricating oil coming from the overflow channel  27 ′ can be resupplied to the lubricating oil circuit of the associated internal combustion engine. 
     In order to form the above-mentioned flange connection, the cylinder head cover  10  is provided with a connecting flange  18  which is designed in the form of a ring and into which the structural unit  20  can be inserted with a companion flange  28  formed in matching manner. The structural unit  20  is located in the connecting flange  18  in a detachable manner by means of connecting means which are not shown here. 
       FIG. 2  is a view of a detail of the oil-mist separator  2  comprising the companion flange  28  and the oil return flow passages  21  and  22  extending through the structural unit  20 . The check valve  24  which is positioned in the oil return flow passage  22  and which is, in the illustrated instance, designed in the form of a meander valve is drawn detached here in order to make the second oil return flow passage  22  visible which is positioned behind the check valve  24 . The pipe section  26  through which the first oil return flow passage  21  extends is visible at the bottom of  FIG. 2 . Therein, the lower end  26 ′ of the pipe section  26  faces the viewer. 
     The radially acting seal  17  is attached on the outside of the companion flange  28 , the radially acting seal  17  serving to seal the flange connection, as has already been illustrated in  FIG. 1 . 
       FIG. 3  is a perspective view of a detail of the cylinder head cover  10  comprising the connecting flange  18  arranged therein. The structural unit  20 , along with its companion flange  28 , can be inserted into this annular connecting flange  18 . 
     In  FIG. 3 , the viewer can see into the siphon reservoir  25  inside the connecting flange  18 . The overflow  27  and the overflow channel  27 ′ adjacent thereto are visible at the top of the siphon reservoir  25 . 
     In order to position the structural unit  20  in circumferential direction in relation to the connecting flange  18  and in order to locate the structural unit  20  after it has been connected to the connecting flange  18 , use is made of a threaded hole  19  which, in the illustrated instance, is formed to fit in the lower region of the connecting flange  18 . If the oil-mist separator  2  is positioned correctly with the associated structural unit  20 , a screw hole formed to fit not shown in the drawings comes into congruent position with the threaded hole  19 . In this position, a mounting screw can then be screwed through the screw hole in the structural unit  20  and into the threaded hole  19 . 
       FIG. 4  shows the oil return assembly  1  shortly after a first startup of the associated internal combustion engine, in the same view as in  FIG. 1 . At this point, the fine separator which forms part of the oil-mist separator already separates oil mist from the crankcase ventilation gas, and the separated oil is collected in the oil collection chamber  23  where it remains for the time being because, owing to differences in pressure with the internal combustion engine running, the check valve  24  closes the oil collection chamber  23  and the second oil return flow passage  22  outcoming therefrom. 
     In the illustrated instance, crankcase gas flows, at the same time, out of the interior region of the cylinder head cover  10  through the overflow channel  27 , the siphon reservoir  25 , the pipe section  26  and the first oil return flow passage  21  and to the preliminary separator in the direction of the arrows drawn in  FIG. 4 , which is actually undesired but which is accepted for a limited time on first startup. 
       FIG. 5  shows the oil return assembly  1  in a state immediately after completion of the first operational use of the associated internal combustion engine, in the same view as in  FIG. 4 . Once the internal combustion engine is turned off, the check valve  24  opens and the oil collected in the oil collection chamber  23  flows through the second oil return flow passage  22  and into the siphon reservoir  25 . This results in a rising oil level in the siphon reservoir  25 , wherein said oil level, after having exceeded a specific level height, establishes a gas-tight closure of the first end  26 ′ of the pipe section  26  of the first oil return flow passage  21 . In this manner, the siphon reservoir  25  automatically receives the oil filling required for the siphon function without particular maintenance measures and, in particular, without any modifications to moving parts of the internal combustion engine either. 
       FIG. 6  shows the oil return assembly  1  during a later operation of the associated internal combustion engine, again in the same view as in  FIGS. 4 and 5 . The siphon reservoir  25  is partially filled with oil, whereby the lower end  26 ′ of the pipe section  26  is closed against penetrating gas. Lubricating oil flowing in through the first oil return flow passage  21  flows through the pipe section  26  and the lower end  26 ′ of this pipe section  26  and into the siphon reservoir  25 . Even if there is a difference in pressure between the higher pressure in the interior region of the cylinder head cover  10  and the lower pressure in the upper oil-free region of the first oil return flow passage  21 , as it is present in the state of the oil return assembly  1  shown in  FIG. 6 , the closure of the siphon against penetrating gas remains preserved because the oil present in the siphon reservoir  25  suffices to preserve the desired gas-tight closure even if part of the oil is displaced from the siphon reservoir  25  into the pipe section  26  and the first oil return flow passage  21 . 
     The state of the oil return assembly  1  shown in  FIG. 7  results during continuing operation of the internal combustion engine. In this state, the siphon reservoir  25  is completely filled with oil and further lubricating oil continuously flowing in through the first oil return flow passage  21  is discharged via the overflow  27 , through the overflow channel  27 ′ and into the interior region of the cylinder head cover  10  and is, thus, resupplied to the lubricating oil circuit of the internal combustion engine. 
     If the internal combustion engine is then turned off, the check valve  24  opens and the oil flows from the oil collection chamber  23  into the siphon reservoir  25  and from there via the overflow  27 , through the overflow channel  27 ′ and into the interior region of the cylinder head cover  10  as well, with the result that this oil is also resupplied to the lubricating oil circuit of the internal combustion engine. Therein, the oil flow is continued until the oil level has exactly reached the level of the overflow  27 , both in the first oil return flow passage  21  and in the second oil return flow passage  22 . It is now no longer possible that further oil is discharged from the siphon reservoir  25  whereby the volume of oil remaining in the siphon reservoir  25  is always that required for the siphon function. Appropriately, the volume of the oil collection chamber  23  is selected such that it can reliably receive the oil volume developing if operation of the internal combustion engine is not interrupted for the maximum duration, i.e. between two refueling stops. 
       FIG. 8  is a vertical sectional view of the oil return assembly  1  in a simplified presentation. Therein, a motor vehicle which is equipped with the oil return assembly  1  is aligned horizontally in  FIG. 8 . Therein, the first oil return flow passage  21  initially extends in a vertical direction from top to bottom and passes into the obliquely extending pipe section  26  in the siphon reservoir. Herein, there is a height difference h between an upper edge of the open end  26 ′ of the pipe section  26  of the first oil return flow passage  21  on the one hand and the overflow  27  of the siphon reservoir  25  on the other hand, said height difference h representing the height of the effective oil level for achieving the siphon effect. 
     If the motor vehicle is inclined out of its horizontal position shown in  FIG. 8  and to the left by approximately 45°, the oil return assembly  1  will take the position shown in  FIG. 9 . Due to the inclination made, the first oil return flow passage  21  now extends at an angle from top to bottom and passes into the pipe section  26  which is now extending in a vertical direction. Despite the inclination by approximately 45°, the height difference h′ remaining between the open end  26 ′ of the pipe section  26  on the one hand and the overflow  27  of the siphon reservoir  25  is sufficient to preserve an oil level which suffices to achieve the siphon function. 
       FIG. 10  shows the oil return assembly after an inclination from the state shown in  FIG. 8  by approximately 45° to the right. In this oppositely inclined state, the first oil return flow passage  21  again extends at an angle from top to bottom and passes into the pipe section  26  which is, in essence, then extending in a horizontal direction. In this state, a height difference h″ remains between an upper edge of the open end  26 ′ of the pipe section  26  on the one hand and the overflow  27  of the siphon reservoir  25  on the other hand, said height difference h″ again ensuring an oil level which is high enough to achieve the desired siphon function. 
     Hence,  FIGS. 8 ,  9  and  10  illustrate that the oil return assembly  1  maintains its function even in extremely inclined positions of the associated motor vehicle because a return of the oil separated in the oil separator is always ensured and because an oil level which is high enough to ensure the siphon function is always provided for and an undesired discharge of the siphon reservoir  25  is prevented even in exceptionally inclined positions. 
     As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art. 
     LIST OF REFERENCE SYMBOLS 
     
       
         
               
               
               
             
           
               
                   
                   
               
               
                   
                 Reference symbol 
                 Description 
               
               
                   
                   
               
             
             
               
                   
                  1 
                 Oil return assembly 
               
               
                   
                 10 
                 Cylinder head cover 
               
               
                   
                 17 
                 Radially acting seal 
               
               
                   
                 18 
                 Connecting flange 
               
               
                   
                 19 
                 Threaded hole 
               
               
                   
                  2 
                 Oil-mist separator 
               
               
                   
                 20 
                 Structural unit 
               
               
                   
                 21 
                 First oil return flow passage 
               
               
                   
                 22 
                 Second oil return flow passage 
               
               
                   
                 23 
                 Oil collection chamber 
               
               
                   
                 24 
                 Check valve 
               
               
                   
                 25 
                 Siphon reservoir 
               
               
                   
                 26 
                 Pipe section 
               
               
                   
                 26′ 
                 End of 26 
               
               
                   
                 27 
                 Overflow 
               
               
                   
                 27′ 
                 Overflow channel 
               
               
                   
                 28 
                 Companion flange