Patent Description:
It is common to provide an oil pan for an internal combustion engine that is bespoke not only to the model of internal combustion engine but also potentially also to the model of machine or vehicle in which the internal combustion engine is intended to be used. This is to accommodate different packaging constraints on different machines and vehicles.

Oil pans are most commonly made of metal, which is generally cast as a unitary component. However, additional fabrication steps are often undertaken, such as machining and/or the addition of some elements by welding.

More recently, composite oil pans have been introduced. Composite oil pans are generally moulded as a single unitary component. Machining of composite oil pans is less common than for metal oil pans. Moreover, fabrication of multiple moulded composite oil pan components by plastic welding would generally be avoided due to limitations in the resultant weld strength relative to metal weld strength.

It is also common that an oil syphon that collects oil from the oil pan for supply to the internal combustion engine is connected to the engine block before the oil pan is fitted to the internal combustion engine and is not mechanically connected directly to the oil pan.

<CIT> discloses a reversible oil pan assembly including an oil suction tube. In one aspect, an oil pan assembly includes an oil pan and a suction tube connected to the oil pan. The suction tube includes an inlet to draw oil from the oil pan, and a plurality of outlets, each outlet configured to output oil that has been moved through the suction tube from the inlet.

<CIT> discloses a tubular body and oil pan having such a tubular body. The tubular body comprises a partial tubular body that extends over a first partial circumference of a tubular section and a partial tubular body complementary thereto that extends over the still free partial circumference, which partial tubular bodies have connecting surfaces that lie against each other along a separating surface that follows a course of the tubular body and are connected to each other along said connecting surfaces by means of joining.

Against this background there is provided an oil pan in accordance with claim <NUM> and a method of manufacturing a composite oil pan assembly in accordance with claim <NUM>.

In this way, a single specification of oil pan may be deployed on an internal combustion engine in either one or two orientations, so as to facilitate differing constraints of different machines that may comprise the engine. Consequently, when the oil pan is attached to an engine block of the engine, the oil tube of the engine, which has a fixed location relative to the engine block, will align with either the first plug portion or the second plug portion.

By enabling the same oil pan to be deployed in two orientations, a larger number of machines and vehicles having different packaging constraints can accommodate the oil pan, which reduces the need for different oil pans to be manufactured for the same specification of engine for use in different machines.

In a further aspect of the disclosure, there is provided an oil pan syphon connector configured for use with the oil pan. The oil pan syphon connector comprises a socket portion configured to correspond both to the first plug portion and to the second plug portion such that the socket portion can be deployed either with the first plug portion or with the second plug portion.

In this way, a single oil pan and a single oil pan syphon connector may be deployed with the engine in either orientation. Thus, neither a different oil pan nor a different oil pan syphon connector is required to use the oil pan with an engine in either orientation.

An embodiment of the disclosure is set out below with reference to the following Figures, in which:.

The disclosure relates to an oil pan for an engine comprising:
a containment portion of unitary construction, the containment portion having:.

<FIG> shows an oil pan <NUM> in accordance with one embodiment of the disclosure for use with an engine (not shown) plus a plurality of fixing bolts <NUM>. The oil pan <NUM> comprises a containment portion <NUM> of unitary construction. The oil pan may be of a composite material and may be formed by moulding.

<FIG> shows an exploded view of the oil pan <NUM> together with an oil syphon connector <NUM>, an oil syphon <NUM> and a transfer tube <NUM>. <FIG> shows the same components as <FIG> in their assembled form.

Referring again to <FIG>, the containment portion <NUM> comprises a circumferential component <NUM> defining a circumferential extent of the containment portion <NUM>. The containment portion <NUM> has a first portion <NUM> and a second portion <NUM>. The first portion <NUM> is a generally lower portion <NUM> while the second portion <NUM> is a generally upper portion <NUM>, relative to the first portion <NUM>. The circumferential component <NUM> comprises a pair of mutually opposing side walls <NUM>, <NUM> and may further comprise a pair of mutually opposing end walls <NUM>, <NUM>. The pair of mutually opposing end walls <NUM>, <NUM> may be perpendicular to the pair of mutually opposing side walls <NUM>, <NUM>.

The containment portion <NUM> further comprises a base wall <NUM> extending inwardly from the first portion <NUM> of the circumferential component <NUM> and defining a lower extent of the containment portion <NUM>.

The oil pan <NUM> has an aperture <NUM> opposite the base wall <NUM> (the top opening in the orientation of <FIG>). As such, the oil pan <NUM> defines a volume bounded by the containment portion <NUM> and the aperture <NUM>, the volume facilitating containment of engine oil.

The containment portion <NUM> has a first end <NUM> and a second end <NUM>. The first end <NUM> may be deeper than the second end <NUM>. A first end wall <NUM> of the pair of mutually opposing end walls <NUM>, <NUM> may be located at the first end <NUM> and a second end wall <NUM> of the second pair of mutually opposing end walls <NUM>, <NUM> may be located at the second end <NUM>. The second end wall <NUM> may be shorter than the first end wall <NUM>.

The pair of mutually opposing side walls <NUM>, <NUM> may each be shorter at the second end <NUM> than at the first end <NUM>.

The base wall <NUM> may comprise a first portion at the first end <NUM>, a second portion at the second end <NUM> and an intermediate portion between the first portion and the second portion. The intermediate portion may be sloped to accommodate a difference in height of the base wall between the first portion and the second portion.

In this way, the containment portion <NUM> may accommodate a greater volume at the first end <NUM> than at the second end <NUM>.

The containment portion <NUM> may comprise an access port <NUM> configured to accommodate a dipstick to facilitate measurement of a level of oil in the containment portion <NUM>.

The containment portion <NUM> further comprises an attachment portion <NUM>. The attachment portion <NUM> comprises an attachment surface <NUM> at the second (upper) portion <NUM> of the circumferential component <NUM> proximate the aperture <NUM>.

The circumferential component <NUM> may comprise a plurality of ribs <NUM> each of which extends substantially perpendicular to the attachment surface <NUM>. The ribs <NUM> may contribute to structural rigidity of the oil pan <NUM>. One or more of the plurality of ribs <NUM> may comprise a fixing aperture in the attachment portion <NUM>, each fixing aperture configured to receive a fixing such as a bolt <NUM>. In this way, the attachment portion <NUM> may be fastened to an underside of an engine block (not shown) using bolts <NUM> when the attachment portion <NUM> is located to meet with a corresponding attachment area on the underside of the engine block.

The attachment portion <NUM> has a rotational symmetry such that the attachment surface <NUM> is connectable to an engine block in a first orientation and in a second orientation. In this way, the oil pan <NUM> can be fastened to an engine block either with the first (deep) end <NUM> pointing in a first direction and the second (shallow) end <NUM> pointing in a second direction or it can be fastened to the same engine block with the first (deep) end <NUM> pointing in the second direction and the second (shallow) end <NUM> pointing in the first direction. This provides flexibility for use in different applications (such as different machines) having different packaging constraints.

The attachment portion <NUM> further comprises a first plug portion <NUM> on an interior of a first one of the pair of mutually opposing side walls <NUM> at a first location <NUM>. The attachment portion <NUM> further comprises a second plug portion <NUM> on an interior of a second one of the pair of mutually opposing side walls <NUM> at a second location <NUM>.

Given the rotational symmetry of the attachment portion <NUM>, either the first plug portion <NUM> or the second plug portion <NUM> is located at the same location relative to the engine block depending upon the orientation in which the oil pan <NUM> is attached to the engine block.

Each of the first and second plug portions <NUM>, <NUM> is configured to receive an oil syphon connector <NUM>, such as the oil syphon connector <NUM> shown in <FIG>.

In this way, an oil tube having a fixed location relative to the engine block aligns adjacent the first plug portion <NUM> on attachment of the attachment portion <NUM> to the engine block in the first orientation and aligns adjacent the second plug portion <NUM> on attachment of the attachment portion <NUM> to the engine block in the second orientation.

With reference to <FIG> and <FIG>, the first plug portion <NUM> comprises a plurality of fingers <NUM>. Each finger of the plurality of fingers <NUM> may protrude from an interior surface of the sidewall <NUM>. Each finger of the plurality of fingers <NUM> may have an elongate direction that runs substantially perpendicular to the attachment surface <NUM>, a length that runs substantially parallel to the attachment surface <NUM>, and a width that runs substantially inwardly from the interior surface of the sidewall <NUM>.

All fingers of the plurality of fingers <NUM> are substantially mutually parallel.

At least one of the fingers of the plurality of fingers <NUM> may taper in one or both of its width and its length so as to be narrower near the attachment surface <NUM> and wider away from the attachment surface. Where a finger tapers in at least one of its width and its length, the finger may be referred to as a wedge portion.

The plurality of fingers <NUM> may comprise a first finger <NUM>, a second finger <NUM>, a third finger <NUM> and a fourth finger <NUM>. The first finger <NUM> may be located on one of the ribs <NUM>. The second finger <NUM>, the third finger <NUM> and the fourth finger <NUM> may each be located on a portion of the interior surface <NUM> of the sidewall <NUM> that is planar and between ribs <NUM>. An inmost face of the second finger <NUM> and an inmost face of the third finger <NUM> may be substantially parallel to an axis of the sidewall <NUM>. An inmost face of the first finger <NUM> may be at an angle to the axis of the sidewall <NUM> and an inmost face of the fourth finger <NUM> may be at an angle to the axis of the sidewall <NUM> such that there is an extent to which the inmost face of the first finger <NUM> and the inmost face of the fourth finger <NUM> face each other.

The first plug portion <NUM> may further comprise a pillar <NUM> configured to cooperate with a leg of the oil syphon connector. The pillar <NUM> may project upwardly from the base wall <NUM>. The pillar <NUM> may comprise a surface <NUM> and an alignment pin <NUM> projecting upwardly from the surface <NUM>. The first plug portion <NUM> may further comprise a lip <NUM> extending from the interior surface of the sidewall <NUM> and having an upper surface that is perpendicular to the interior surface of the sidewall <NUM>.

One or both of the lip <NUM> and the surface <NUM> of the pillar <NUM> may act as an end stop to prevent further downward movement of an oil syphon connector <NUM>.

<FIG> shows an exploded view of the oil pan <NUM> in a different orientation from <FIG> together with an oil syphon connector <NUM> and an oil syphon <NUM> (but with no transfer tube <NUM>). <FIG> shows the same components as <FIG> in their assembled form.

Referring to <FIG>, the second plug portion <NUM> comprises a plurality of fingers <NUM>. Each finger of the plurality of fingers <NUM> may protrude from an interior surface of the sidewall <NUM>. Each finger of the plurality of fingers <NUM> may have an elongate direction that runs substantially perpendicular to the attachment surface <NUM>, a length that runs substantially parallel to the attachment surface <NUM>, and a width that runs substantially inwardly from the interior surface of the sidewall <NUM>.

At least one of the fingers of the plurality of fingers <NUM> may taper in one or both of its width and its length so as to be narrower near the attachment surface <NUM> and wider away from the attachment surface <NUM>. Where a finger tapers in at least one of its width and its length, the finger may be referred to as a wedge portion.

The plurality of fingers <NUM> may comprise a first finger (corresponding to first finger <NUM> but not individually labelled in the figures), a second finger (corresponding to second finger <NUM>), a third finger (corresponding to third finger <NUM>) and a fourth finger (corresponding to fourth finger <NUM>). The first finger may be located on one of the ribs <NUM>. The second finger, the third finger and the fourth finger may each be located on a portion of the interior surface of the sidewall <NUM> that is planar and between ribs <NUM>. An inmost face of the second finger and an inmost face of the third finger may be substantially parallel to an axis of the sidewall <NUM>. An inmost face of the first finger may be at an angle to the axis of the sidewall <NUM> and an inmost face of the fourth finger may be at an angle to the axis of the sidewall <NUM> such that there is an extent to which the inmost face of the first finger and the inmost face of the fourth finger face each other.

It should be noted that the plurality of fingers <NUM> at the first plug portion <NUM> might not be exactly identical to the plurality of fingers <NUM> at the second plug portion <NUM>. However, it is necessary that the plurality of fingers <NUM> at the first plug portion <NUM> and the plurality of fingers <NUM> at the second plug portion <NUM> are compatible with the oil syphon connector <NUM>, meaning there is at least a high degree of similarity between the plurality of fingers <NUM> at the first plug portion <NUM> and the plurality of fingers <NUM> at the second plug portion <NUM>.

The second plug portion <NUM> may further comprise a pillar <NUM> configured to cooperate with a leg of the oil syphon connector. The pillar <NUM> may project upwardly from the base wall <NUM>. The pillar <NUM> of the second plug portion <NUM> may be of a different length to the pillar <NUM> of the first plug portion <NUM> in view of the different depths of the oil pan <NUM> between the first end <NUM> and the second end <NUM>. The pillar <NUM> may comprise a surface <NUM> and an alignment pin <NUM> projecting upwardly from the surface <NUM>. The first plug portion <NUM> may further comprise a lip <NUM> extending from the interior surface of the sidewall <NUM> and having an upper surface that is perpendicular to the interior surface of the sidewall <NUM>.

An oil syphon connector <NUM> in accordance with the present disclosure is described with reference to <FIG> and <FIG>.

The oil syphon connector <NUM> comprises a top face <NUM> that sits in a top plane of the oil syphon connector <NUM>, a mating portion <NUM> on a first side of the oil syphon connector <NUM> perpendicular to the top face <NUM>, an oil channel <NUM> that extends through the oil syphon connector <NUM> from the top face <NUM> to a connector outlet <NUM>, and a leg <NUM> that extends from a second side of the oil syphon connector <NUM>.

The mating portion <NUM> comprises a socket portion <NUM> comprising a plurality of apertures <NUM>. The plurality of apertures <NUM> may comprise a first aperture <NUM> (also referred to as a first finger cavity <NUM>), a second aperture <NUM> (also referred to as second finger cavity <NUM>), a third aperture <NUM> (also referred to as third finger cavity <NUM>) and a fourth aperture <NUM> (also referred to as fourth finger cavity <NUM>). The first aperture <NUM> is configured to correspond to and receive the first finger <NUM> of the first plug portion <NUM> and the first finger of the second plug portion <NUM> (not simultaneously). The second aperture <NUM> is configured to correspond to and receive the second finger <NUM> of the first plug portion <NUM> and the second finger of the second plug portion <NUM> (not simultaneously). The third aperture <NUM> is configured to correspond to and receive the third finger <NUM> of the first plug portion <NUM> and the third finger of the second plug portion <NUM> (not simultaneously). The fourth aperture <NUM> is configured to correspond to and receive the fourth finger <NUM> of the first plug portion <NUM> and the fourth finger of the second plug portion <NUM> (not simultaneously).

Where at least one of the fingers of the pluralities of fingers <NUM>, <NUM> of the first and second plug portions <NUM>, <NUM> has a taper as described above, the corresponding aperture of the plurality of apertures <NUM> may have a corresponding taper.

The mating portion <NUM> may further comprise a lower stop surface <NUM> distributed in between the plurality of apertures <NUM>. The lower stop surface <NUM> may sit in a plane that is parallel to the top face <NUM>.

The top face <NUM> may comprise components of a pip seal channel <NUM> configured to receive a pip seal (not shown). The pip seal channel <NUM> may be fully defined in the top face <NUM>. Alternatively, and as in the illustrated embodiments, the pip seal channel <NUM> may be at least partly defined by the plug portion <NUM>, <NUM> once the oil syphon connector <NUM> is in situ in the oil pan.

<FIG> shows the components of the pip seal channel <NUM> that are provided by the oil syphon connector <NUM>. <FIG> shows the oil syphon connector <NUM> in situ with the oil pan <NUM> showing how the pip seal channel <NUM> is provided in part by the oil syphon connector <NUM> and in part by the plug portion <NUM>, <NUM>.

The leg <NUM> may comprise a buttress <NUM> and a foot <NUM> having a planar lower face. The foot <NUM> may comprise an aperture <NUM>.

When in situ with an oil pan <NUM> in a first configuration using the first plug portion <NUM> (as shown in a first orientation in <FIG>) some or all of the following may take place:.

In this way, the oil syphon connector <NUM> may be held in position at the first plug portion <NUM>.

When in situ with an oil pan <NUM> in a second configuration using the second plug portion <NUM> (as shown in a second orientation in <FIG>) some or all of the following may take place:.

In this way, the oil syphon connector <NUM> may be held in position at the second plug portion <NUM>.

Where at least one of the fingers of the pluralities of fingers <NUM>, <NUM> of the first and second plug portions <NUM>, <NUM> has a taper and the corresponding aperture of the plurality of apertures <NUM> has a corresponding taper, this may facilitate an improved interference fit and elimination of movement of the oil syphon connector <NUM> relative to the oil pan <NUM> when the oil syphon connector <NUM> is in situ in the oil pan <NUM>.

Referring to <FIG>, the oil syphon connector <NUM> may be deployed at the first plug portion <NUM> with an oil syphon <NUM> and a transfer tube <NUM>.

Referring to <FIG>, the oil syphon connector <NUM> may be deployed at the second plug portion <NUM> with the oil syphon <NUM> (but without a transfer tube <NUM>).

The connector outlet <NUM> of the oil syphon connector <NUM> may be connectable either to an inlet <NUM> of the transfer tube <NUM> or to an inlet <NUM> of the oil syphon <NUM>.

An outlet <NUM> of the transfer tube <NUM> may be connectable to the inlet <NUM> of the oil syphon <NUM>.

In this way, exactly the same oil syphon connector <NUM>, and exactly the same oil syphon <NUM> may be deployed regardless of whether the first plug portion <NUM> or the second plug portion <NUM> is in use. The transfer tube <NUM> is only required in the event that the first plug portion <NUM> is in use and is not required if the second plug portion <NUM> is in use.

The oil pan <NUM> and oil syphon connector <NUM> of the present disclosure gives rise to the possibility of using an identical oil pan <NUM> (and oil syphon connector <NUM>) with an engine in two different configurations, depending on the orientation of the oil pan <NUM> relative to the engine.

This means that the same components may be deployed in a different configuration effectively to produce a different assembly of those products in order to facilitate different packaging constraints on different machines that use the same engine and the same oil pan <NUM>.

Manufacturing only a single design of oil pan <NUM>, a single design of oil syphon connector <NUM>, a single design of oil syphon <NUM> and a single design of transfer tube <NUM> (only required for one of the two orientations) in order to produce what are effectively two different oil pan assemblies suitable for different applications brings manufacturing efficiency, minimum number of production lines, reduced manufacturer part count, reduced part count across multiple engine platforms and reduced development costs.

Furthermore, by providing the oil syphon connector <NUM> which is fixed relative to the oil pan <NUM>, it is possible to bring the already fully assembly oil pan assembly to the engine block and fix the entire syphon functionality onto the engine with the oil pan assembly rather than the previously common approach of having to assemble the syphon to the engine block before the assembling the oil pan to the engine block. This removes a step from an engine assembly process as the oil pan assembly can be pre-assembled in the absence of the engine.

Claim 1:
An oil pan (<NUM>) for an engine comprising:
a containment portion (<NUM>) of unitary construction, the containment portion (<NUM>) having:
a circumferential component (<NUM>) defining a circumferential extent of the containment portion (<NUM>) and comprising a pair of mutually opposing side walls (<NUM>, <NUM>);
a base wall (<NUM>) extending inwardly from a first portion (<NUM>) of the circumferential component (<NUM>) and defining a lower extent of the containment portion (<NUM>); and
an attachment portion (<NUM>), the attachment portion (<NUM>) comprising:
an attachment surface (<NUM>) at a second portion (<NUM>) of the circumferential component (<NUM>);
a first plug portion (<NUM>) on an interior of a first one of the pair of mutually opposing side walls (<NUM>, <NUM>) at a first location (<NUM>);
a second plug portion (<NUM>) on an interior of a second one of the pair of mutually opposing side walls (<NUM>, <NUM>) at a second location (<NUM>);
wherein the first and second plug portions (<NUM>, <NUM>) are configured to receive an oil syphon connector (<NUM>); and
wherein the attachment portion (<NUM>) has a rotational symmetry such that the attachment surface (<NUM>) is connectable to an engine block in a first orientation and in a second orientation; and
wherein the first and second plug portions (<NUM>, <NUM>) are located such that an oil tube having a fixed location relative to the engine block aligns adjacent the first plug portion (<NUM>) on attachment of the attachment portion (<NUM>) to the engine block in the first orientation and aligns adjacent the second plug portion (<NUM>) on attachment of the attachment portion (<NUM>) to the engine block in the second orientation;
wherein the first and second plug portions (<NUM>, <NUM>) each comprise a first finger (<NUM>) that extends radially inwardly from the circumferential component (<NUM>) and extends in a direction substantially perpendicular to the attachment surface (<NUM>).