Patent Abstract:
An oil management system and oil filter utilized in association with an internal combustion engine. The oil filter comprises high-efficiency filtration media for filtering engine oil associated with the internal combustion engine. At least one type of time release additive can be impregnated into the filtration media, wherein the time release additives are automatically released into the engine oil filter from filtration media in order to replenish additives already present in the engine oil. Additionally, a sensor module can be provided that monitors oil quality and oil filter efficiency through detecting one or more attributes of the engine oil filtered through the filtration media of oil filter in order to efficiently conserve and manage the oil and reduce the interval of oil changes thereof by extending the life of the engine oil through the replenishment of the additives present in the engine oil and higher filtration effectiveness of the filter.

Full Description:
TECHNICAL FIELD 
     Embodiments are generally related to sensor systems and devices. Embodiments are also related to oil filters utilized in internal combustion engines. Embodiments are additionally related to techniques for monitoring oil usage and quality and reducing the frequency of oil changes thereof. 
     BACKGROUND OF THE INVENTION 
     A typical oil change for modern cars or light trucks includes both draining the oil and replacing the filter every 3,000 to 7,000 miles. It is estimated in the U.S., alone, that over 1 billion gallons of engine oil annually are changed in the passenger car/light truck segment every year. An additional 250 Million gallons of oil are consumed in the commercial truck market segment. 
     There is a growing need to minimize the flow of unregulated waste oil in the environment. Extending the useful life of engine lubricating oil can significantly reduce contamination of the air and ground water (through evaporation and landfill seepage, respectively). Also, a reduction in engine oil consumption can help to lessen our dependence on foreign oil. 
     Modern cars, trucks and other transportation vehicles are designed for unprecedented life and reduced maintenance. Fewer components associated with the car/truck require regular replacement. For example, spark plugs and engine coolant now last 100,000 miles or more. Exhaust systems last the life of the vehicle. The chassis no longer requires lubrication. As a result, the ongoing cost of vehicle ownership is going down. This trend will continue. The reduced cost of vehicle ownership is especially important in the heavy-duty truck and off-highway market segments. Initial vehicle investment, reliability, and vehicle up time all contribute to company profitability. Therefore, reduced maintenance costs and more vehicle time on the road are very attractive to a fleet management company. In summary, extended oil change intervals are good for both profitability and the environment. 
     BRIEF SUMMARY OF THE INVENTION 
     The following summary is provided to facilitate an understanding of some of the innovative features unique to the embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments can be gained by taking the entire specification, claims, drawings, and abstract as a whole. 
     It is, therefore, one aspect of the embodiments to provide for improved sensing systems and devices. 
     It is another aspect of the embodiments to provide for an oil management system utilized in internal combustion engines. 
     It is a further aspect of the embodiments to provide a system for monitoring oil quality and oil filter effectiveness thus reducing the frequency of oil changes thereof. 
     The aforementioned aspects and other objectives and advantages can now be achieved as described herein. An oil management system is disclosed, which includes an oil filter utilized in association with an internal combustion engine. The oil filter comprises filtration media for filtering engine oil associated with the internal combustion engine. One or more types of time-release additives can be impregnated into the filtration media. The time release additives are automatically released into the engine oil filter from the filtration media in order to replenish additives already present in the engine oil. 
     Additionally, a sensor module can be provided that communicates with the oil filter and detects one or more attributes of the engine oil filtered through the filtration media of oil filter in order to efficiently conserve and manage the oil and reduce the interval of oil changes thereof by extending the life of the engine oil through the replenishment of the additives present in the engine oil. A housing (e.g., canister) can be provided for maintaining the oil filter. The sensor module is located preferably, but not exclusively within the oil filter housing. The sensor module can continuously or periodically monitor the oil in order to measure multiple parameters of oil quality and/or oil filter condition. The filter can be configured from high efficiency filtration media, such as, for example, nano-fiber based filtration media. Power to the sensor module can be capacitive or wired. 
     Additionally, a wireless module can be associated with and in communication with the sensor module to permit sensor data compiled by the sensor module to be transmitted wirelessly to a receiver. A monitoring device can be utilized, which monitors data transmitted wirelessly from the sensor module. The monitoring device is associated with the receiver and comprises a memory for maintaining the data transmitted wirelessly from the sensor module. Additionally, a GPS device can be associated with and/or integrated with the monitoring device, wherein the GPS device permits the data stored within the memory of the monitoring device to be polled or up-linked. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention. 
         FIG. 1  illustrates an exploded view of an example oil filter apparatus that can be adapted for use in accordance with an embodiment; 
         FIG. 2(   a ) illustrates a side view of the oil filter apparatus depicted in  FIG. 1 ; 
         FIG. 2(   b ) illustrates a general pictorial diagram illustrating the flow of oil filtration and an oil filter basket arrangement, which may be implemented in accordance with the oil filter apparatus depicted in  FIGS. 1 and 2(   a ); 
         FIG. 3  illustrates pictorial diagram of an oil management system that can be implemented in accordance with one embodiment; 
         FIG. 4  illustrates a high-level block diagram of an oil management system that can be implemented in accordance with another embodiment; 
         FIG. 5  illustrates a block diagram illustrating additional components of the system depicted in  FIG. 4 ; 
         FIG. 6  illustrates a side view of an oil sensing system that can be implemented in accordance with an alternative embodiment; 
         FIG. 7  illustrates a block diagram of an oil management system that can be implemented in accordance with an alternative embodiment; and 
         FIG. 8  illustrates a side view of an oil sensing system that can be implemented in accordance with an alternative embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof. 
       FIG. 1  illustrates an exploded view of an example oil filter apparatus  10  that can be adapted for use in accordance with an embodiment. Note that the oil filter apparatus  10  depicted in  FIG. 1  is described herein for illustrative purposes only and is not considered a limiting feature of the embodiments. Instead, oil filter apparatus  10  is provided in order to depict the context in which one embodiment can be implemented. The embodiment of  FIG. 1  is therefore provided for exemplary and edification purposes only and may be modified or varied, depending upon design considerations. The embodiments disclosed herein can be implemented in the context of a wide variety of automotive systems, such as, for example, heavy duty trucks, tractor trailers, conventional automobiles, and so forth. 
     The example oil filter apparatus  10  depicted in  FIG. 1  can incorporate a housing  12 , which may be formed as a steel filter body covered, for example, by an epoxy powder paint. An oil filter  16  can be provided in the form of a filter cartridge. Oil filter  16  is generally composed of filtration media  14 , which can be implemented, for example, in the form of pleated filter media. The filtration media  14  is preferably implemented as high-efficiency filtration media (i.e., filtration media that is at least 95% efficient at 5 microns and above). 
     Oil filter  16  is maintained within housing  12  below a retainer  20  and a relief valve  22 . A center tube  18  is centrally located within oil filter  16 . End disks  8  and  10  can also be provided to provide additional strength and stability to oil filter  16  within housing  12 . An anti-drain valve  6  can be located below oil filter  16  and adjacent to a tapping plate  4  formed from a bottom assembly  2  and located immediately above a bottom portion  24 . An external gasket  26  can be configured below bottom assembly  2 . 
       FIG. 2(   a ) illustrates a side view of the oil filter apparatus  10  depicted in  FIG. 1 .  FIG. 2(   b ), on the other hand, illustrates a general pictorial diagram illustrating the flow of oil filtration and an alternative oil filter basket arrangement, which may be implemented in accordance with the oil filter apparatus depicted in  FIGS. 1 and 2(   a ). Note that in  FIGS. 1 ,  2 ( a ) and  2 ( b ), identical or similar parts or elements are generally indicated by identical reference numerals. Thus, oil filter  16  with filtration media  14  is depicted in  FIG. 2(   a ). 
     In  FIG. 2(   a ), arrow  26  indicates that oil filter  16  can be located and maintained within oil filter apparatus  10 . In  FIG. 2(   b ), an alternative embodiment is disclosed. Oil filter  16  can be modified for placement within a basket  42  and housed within an oil filter apparatus  40  that includes elements that were depicted in  FIG. 1 . Arrow  51  indicates the placement of basket  42  within oil filter apparatus  40 . Arrows  44 ,  46 ,  49 , and  50  indicate the general flow of filtered oil in association with the functioning of oil filter  16 . Arrows  56 ,  54 , and  52  generally indicate the flow of additized oil within oil filter apparatus  40 . Note that oil filter apparatus  40  depicted in  FIG. 2(   b ) represents a modified implementation of oil filter apparatus  10  depicted in  FIGS. 1-2(   a ). 
       FIG. 3  illustrates pictorial diagram of an oil management system  300  that can be implemented in accordance with one embodiment. System  300  generally includes an oil filter container or housing  302  that maintains oil filter  303  that contains filtration media  304 , which can be implemented as high-efficiency filtration media. For example filtration media  304  can be configured as nano-fiber based filtration media that possess the ability to filter particles at the sub-micron level. Thus such nano-fiber based filtration media addresses two problems. First, such media prevents soot agglomeration that leads to sludge build-up. Second, such media reduces acid built-up created by combination of high soot levels and water (e.g., inherent in diesel fuel). Filtration media  304  depicted in  FIG. 3  is therefore analogous to the high-efficiency filtration media  14  depicted in  FIGS. 1-2(   a ). 
     Oil filter  303  can be implemented in the context of an oil filter assembly or mechanism such as, for example, oil filter apparatus  10  depicted in  FIG. 1-2 . System  300  also incorporates the use of additives  306 . As indicated by arrow  307 , additives  306  can be impregnated into filtration media  304  and housed in a standard replacement oil filter canister or housing  302 . A sensor module  308  can be embedded in the canister or housing  302 . Sensor module  308  generally detects key oil condition attributes associated with oil maintained or filtered by oil filter  303 . 
     In some implementations of the embodiments, additives  306  can be configured as time-release additives. It is important to note, however, that additive(s)  306  are not restricted to time-release or are necessarily impregnated into the filtration media. The additive(s)  306  can also be released based on need or simply released with no logic involved. The additive can be in the form of a gel, pellets, solid disks, etc. The additive can be presented to the oil similar to that shown in  FIG. 2(   b ) herein with respect to arrows  56 ,  54 ,  52 . In the particular embodiment depicted in  FIG. 2(   b ) with respect to basket  42 , the additive flows by a gel in the basket  42  on the clean side of the filter media thereof. 
       FIG. 4  illustrates a high-level block diagram of an oil management system  400  that can be implemented in accordance with another embodiment. Note that in  FIGS. 3-5  herein, identical or similar parts or elements are generally indicated by identical reference numerals. System  400  indicates that canister  302  can maintain sensor module  308 , additives  306  and oil filter  303 . Sensor module  308  can monitor oil filter  302  and identify and detect additives  306 , depending upon design considerations. 
     It is important to note that the depletion of additives  306  can be anticipated. A solid mixture of additive chemistry can dissolve at a rate based on oil flow, time and temperature. The oil additive concentration levels are maintained throughout the oil filter  303  change intervals. The combination of very high-efficiency filtration (e.g., filtration media implemented via nano-fiber base filtration media) and stable additive concentration levels throughout the filter service interval precludes the need to change the oil in the sump. As indicated previously, such high-efficiency filtration media is preferably filtration media that is at least 95% efficient at 5 microns and above. 
     Depending on oil operating temperatures, small amounts of base oil oxidation may occur. A build up of oxidized oil can eventually result in sludge and reduced lubrication properties. In conventional systems, oxidized oil is removed when the oil is changed. According to the embodiments disclosed herein, however, if the oil filter  303  selectively removes oxidized oil, there is a reduced need to change the oil. 
     There are external variables that can adversely affect oil quality. With the oil change interval being extended by as much as an order of magnitude, according to the embodiments, it is also desirable to monitor oil quality. With appropriate sensors to monitor oil PH etch rate, metal contamination, pressure, temperature, soot loading in filter, and/or the presence of coolant or fuel, additional protection can be provided to systems  300 ,  400 . The oil quality information can be displayed or up-linked on a real time basis utilizing monitoring device  414  disclosed in  FIGS. 4 and 5 . 
     A wireless module  402  can be connected to sensor module  308  in order to transmit data wirelessly from sensor module  308  through antenna  404 , which is incorporated with wireless module  402 . Power  406  to sensor module  308  can be provided as capacitive  408  or wired  410 , depending upon design considerations. Sensor data can therefore be transmitted from wireless module  402  to a receiver  412  associated with an antenna  415 . Wireless communications are represented in  FIG. 4  by dashed line  407 . A monitoring device  414  is associated with receiver  412 . Both the monitoring device  414  and the receiver  412  may be located within a vehicle cabin (e.g., a car, heavy duty truck, etc.). The monitoring device  414  thus monitors data transmitted wirelessly from the sensor module  308 . 
       FIG. 5  illustrates a block diagram illustrating additional components of the system  400  depicted in  FIG. 4 . In  FIG. 5 , sensor module  308  and monitoring device  414  are depicted in greater detail. Sensor module  308  can incorporate a memory unit  502  for storing data collected by sensor module  308 . Similarly, monitoring device  414  can include a memory  408  for storing data transmitted to it wirelessly (e.g., data transmitted as indicated by arrow  407  in  FIG. 4 ). 
     Monitoring device  414  may also incorporate a Global Positioning System (GPS) device  510 . Data stored in memory  508  has the capability of being polled or up-linked utilizing GPS techniques. Note that as utilized herein, the term Global Positioning System (GPS) generally refers to the worldwide radio-navigation system that uses the position of satellites to determine locations on the earth. The GPS is formed generally from a group or constellation of orbiting man-made satellites and their respective ground station, thereby utilizing such satellites as reference points to calculate accurate positions. Monitoring device  414  can also be associated with a management module  512  that collects sensor data input and allows for historical analysis of the oil quality data, allowing for accurate maintenance scheduling and productivity analysis for engine fleet owners. Management module  512  can be implemented as a software module, which is defined and described in greater detail herein. 
       FIG. 6  illustrates a side view of an oil sensing system  600  that can be implemented in accordance with an alternative embodiment. Note that in  FIGS. 1-8 , identical or similar parts or elements are generally indicated by identical reference numerals. Thus, systems  300 - 400  depicted herein can be modified in accordance with the configuration depicted in systems  600 - 700  as described herein. System  600  generally includes a housing or canister  302  in which filter  303  (i.e., having filter media  304 ) is located. Sensor module  308  can be implemented in the context of system  600  as a sensor probe with multiple transducers  611 ,  613 ,  615 . A power component  406  can be implemented as a circuit board with a power supply, signal conditioning components thereof, and wireless input/output capabilities such as that of wireless module  402  and antenna  404  depicted in  FIG. 4 . Engine oil can flow through a central cavity  617  which is surrounded by filter  303  and filter media  304  thereof. 
     System  600  can also be equipped with a bypass filter  605 , which can bypass, for example, approximately, 6%-10% of the total engine oil flow. A plurality of TBN pellets  609  can also be provided above the filter  303 . Note that filter  303  can be configured with filter media  304  (not shown in  FIG. 6 ) that filters, for example, approximately 90%-94% of total engine oil flow, depending upon design considerations and goals. Sensor module  308  can therefore indicate oil conditions, such as, for example, soot, alkalinity TBN, and so forth, thereby preventing the need to actually send the oil out to a third party or location for testing. 
       FIG. 7  illustrates a block diagram of an oil management system  700  that can be implemented in accordance with an alternative embodiment. System  700  incorporates the sensing system  600  depicted in  FIG. 6 , such that data can be transmitted wirelessly as indicated by wireless transmissions  407 ,  721 , and  726  depicted in  FIG. 7 . Data can be transmitted from system  600  to a receiver (e.g., receiver  412 ) located in a heavy-duty truck  720 . Data from the truck  720  can then be transmitted to an antenna  722  and related via a GPS component  510  to a user  728  for further analysis and evaluation. 
       FIG. 8  illustrates a side view of an oil sensing system  800  that can be implemented in accordance with an alternative embodiment. Again, it is important to note that in  FIGS. 1-8 , identical or similar parts or elements are generally indicated by identical reference numerals. System  800  is similar to that of system  600  and incorporates filter media  304  and additionally, an indentation  801  in the existing filter canister  302 . 
     In general, the embodiments, such as systems  300 - 800  can result in the ability to extend oil change intervals through the use of an effective removal of combustion products and replenishments of oil additives (i.e., helps to protect lubricity, reduce corrosion and keep the engine clean). This demand is met through the use of high performance/selective filtration media  304  and through the use of an effective additive replenishment strategy. Depending on their size, soot particle can be captured by filter media  304 . Smaller particles remain suspended in the oil. 
     The engine oil itself can be designed to suspend sub-micron soot particles. If soot concentrations are too high, however, the oil filter  303  can make up the difference. Extending the life of engine oil requires the capture of small soot particles. Also, oil additives are replaced on a timely basis. The base oil goes through very little, if any, degradation. As oil additives are depleted, systems  300 - 800  can “intelligently” refresh the oil with new additives. “Smart” filtering, along with additive replenishment, combines to extend the useful life of engine oil. It is conceivable that that the use of systems  300 - 800 , for example, can increase oil life by a factor in a range of, for example, 4-10. 
     Based on the foregoing it can be appreciated that the combination of oxidized oil and soot removal, additive replenishment (e.g., on a regular basis), and real-time oil quality monitoring can successfully preclude the need for regular oil changes and the unnecessary discarding of millions of gallons of perfectly fine base oil. Such an advantage not only reduces the cost of vehicle ownership, but is also beneficial for the environment. 
     Note that the term “module” as utilized herein can refer to a physical hardware component (i.e., a hardware module), a software component (e.g., a software module) or a combination thereof. A software module can therefore be implemented as one or more instruction modules residing in a computer memory, such as, for example, memory units  508  and/or  502 . the computer programming arts, a “module” can be typically implemented as a collection of routines and data structures that performs particular tasks or implements a particular abstract data type. 
     Software modules generally are composed of two parts. First, a software module may list the constants, data types, variable, routines and the like that can be accessed by other modules or routines. Second, a software module can be configured as an implementation, which can be private (i.e., accessible perhaps only to the module), and that contains the source code that actually implements the routines or subroutines upon which the module is based. Thus, for example, the term module, as utilized herein generally refers to software modules or implementations thereof. Such modules can be utilized separately or together to form a program product that can be implemented through signal-bearing media, such as, for example, transmission media and/or recordable media. 
     Thus, sensor module  308  can be composed of a hardware component (e.g., a sensor) and/or a software component. Similarly, wireless module  402  can also be composed of a hardware component (e.g., a wireless transmitter/receiver) and/or a software component. Management module  512  depicted in  FIG. 5 , which is associated with monitoring module  414 , is preferably implemented as a software module that can be stored in a computer memory of a data-processing system and processed utilizing a microprocessor. 
     It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Technology Classification (CPC): 1