Oil-purifying device with oil diffusing assembly and high-surface-area structure

Abstract

An oil-purifying device incorporating a housing that includes an evaporation chamber. In one implementation, there are an oil intake port and an oil exit port, both in fluid communication with the evaporation chamber. There are also at least two ventilation ports in gaseous communication with the evaporation chamber. The oil-purifying device may include an oil diffusing assembly to receive oil from the oil intake port and distribute it. In one implementation, the oil diffusing assembly includes perforated oil journals. The oil-purifying device may include a heating device to heat the oil to increase the rate of evaporation of contaminants. The oil-purifying device may also include a high-surface-area structure to increase a surface area of the oil for improved evaporation of contaminants. In one implementation, the high-surface-area structure includes a metallic or synthetic material with a rough filamentous surface upon which to deposit oil.

Description

FIELD

One or more embodiments relate to purifying oil. More specifically, one or more embodiments relate to an oil-purifying device with an evaporation chamber.

BACKGROUND

Oil filters alone do not remove all contaminants from motor oil. They primarily remove particles that become suspended in the oil through engine use. However, motor oil also accumulates non-particulate contaminants that are not removed by oil filters. These non-particulate contaminants include water, fuel, radiator fluid, and other volatile fluids and gases.

Water or motor fuel in motor oil causes the motor oil to lose viscosity, thereby reducing its effectiveness as a lubricant and as a coolant. Further, water can damage engine parts by increasing wear and promoting rust. Water in motor oil may also react with other contaminants, for example, sulfur, to form acids.

Oil purifiers that remove non-particulate contaminants from motor oil promote the longevity of both the motor oil and the engine. Such purifiers are typically used in addition to an oil filter. They often do not receive the full flow of engine oil, but instead receive a smaller oil flow. For example, a small flow of oil may be received through an oil bypass journal. An oil bypass journal diverts a small quantity of oil from a larger flow of oil that otherwise would be going to, for example, an oil filter.

However, an oil bypass journal is just one way an oil purifying device receives a flow of oil. An oil-purifying device may also have a separate direct line to an oil source, such as a pressurized oil journal in the engine.

Evaporation is one of the methods or mechanisms used by oil-purifying devices to remove non-particulate contaminants from motor oil. Contaminants such as water and motor fuel have lower vapor pressures than motor oil and will therefore evaporate more readily.

One design consideration for oil purifiers that use evaporation is how to increase the rate of evaporation of non-particulate contaminants. Increasing the rate of evaporation results in faster removal of non-particulates from the motor oil. This in turn helps prevent more of the harmful effects of such contaminants.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away perspective diagram of one embodiment of an oil-purifying device.

FIG. 1A is a perspective drawing showing an oil-purifying device mounted between an engine and an oil filter.

FIG. 2 is an exploded perspective diagram of one embodiment of an oil-purifying device.

FIG. 3 is a top view showing cross-cuts for FIGS. 4, 8, and 10.

FIG. 4 is a two-dimensional cross-sectional diagram of a portion of one embodiment of an oil-purifying device, showing an oil intake port, a metering jet, and a portion of an evaporation chamber.

FIG. 5 is a two-dimensional top-view diagram of an oil diffuser for use in one embodiment of an oil-purifying device.

FIG. 6. is a perspective diagram of a diffuser cover for use in one embodiment of an oil-purifying device.

FIG. 7A is a perspective diagram of an evaporation chamber base for use in one embodiment of an oil-purifying device.

FIG. 7B is a top-view diagram of an evaporation chamber base for use in one embodiment of an oil-purifying device.

FIG. 7C is a perspective diagram showing one embodiment of an oil-purifying device coupled to an oil source and to a sump.

FIG. 8 is a two-dimensional cross-sectional diagram of one embodiment of an oil-purifying, showing an evaporation chamber and ventilation ports.

FIG. 9 is a perspective diagram of an evaporation chamber cover for use in one embodiment of an oil-purifying device.

FIG. 10 is a two-dimensional cross-sectional diagram of one embodiment of an oil-purifying device, showing a high-surface-area structure, an oil intake port and an interior oil bypass journal.

FIG. 11A is a perspective drawing of an oil heating mechanism disposed in a diffuser for use with one embodiment of an oil-purifying device—also showing a cross-cut for FIG. 11B.

FIG. 11B is a two-dimensional cross-sectional drawing of the oil heating mechanism of FIG. 11A.

FIG. 12 is a perspective drawing of an oil flow reverser for use with certain embodiments of an oil-purifying device.

FIG. 13 is a two-dimensional, cross-sectional, drawing showing the mounting of an oil flow reverser to an evaporation chamber base of an oil-purifying device.

FIG. 14 is a flow chart illustrating a method of manufacturing an oil-purifying device consistent with certain embodiments.

FIG. 15 is a perspective view of a housing of an oil-purifying device according to one embodiment, showing an evaporation chamber base and an evaporation chamber cover rotatably coupled to each other.

FIG. 16 is a perspective view of a high-surface-area structure for use in an oil-purifying device, according to one embodiment.

DETAILED DESCRIPTION

In described embodiments, an oil-purifying device uses evaporation to remove non-particulate contaminants from oil. Evaporation is effective when the non-particulate contaminants have a lower vapor pressure than oil. When the contaminants evaporate, they leave cleaner oil behind.

Although embodiments are described as operating to purify oil, such as motor oil, the devices and methods described are applicable to other fluids having volatile contaminants. Examples of such fluids are hydraulic fluid and water that may have dissolved acids or lightweight petroleum-based contaminants.

In some embodiments, an oil-purifying device includes a housing that defines an evaporation chamber. Oil heated by an engine or other mechanical device and contaminated with non-particulate, volatile contaminants is introduced into the evaporation chamber. The non-particulate contaminants are evaporated and vented to the outside of the chamber. The cleaner oil is then drained from the chamber.

In some embodiments, the rate of evaporation is increased by distributing oil throughout a greater area of the evaporation chamber. The greater area of distribution increases the surface area of that oil that is exposed to the gaseous atmosphere of the evaporation chamber. A greater exposed surface area generally results in a higher evaporation rate.

In some embodiments, the rate of evaporation is increased by heating the oil above the boiling temperature of the contaminants in the oil prior to distributing the oil into the evaporation chamber. The hot oil is exposed to the gaseous atmosphere of the evaporation chamber. A greater temperature generally results in a higher evaporation rate.

In some embodiments, the rate of evaporation is increased by depositing the contaminated oil on filler, sponge-like or filamentous materials. These materials have a greater surface area than a flat smooth surface. Thus, the oil deposited on these materials will have a greater surface area exposed to the gaseous atmosphere of the evaporation chamber. As noted above, a greater exposed surface area generally results in a higher evaporation rate. The filler, sponge-like, or filamentous material will be referred to subsequently as a “high-surface-area structure.”

Referencing FIG. 1, in one embodiment, an oil-purifying device 100 includes a housing 106 that defines an interior evaporation chamber 108. The housing 106 includes an evaporation chamber cover 102 and an evaporation chamber base 104. The evaporation chamber cover 102 and the evaporation chamber base 104 are coupled together to form the housing 106 that defines the interior evaporation chamber 108.

Referencing FIG. 2—an exploded view of the device of FIG. 1—contaminated oil is introduced into the evaporation chamber through an oil intake port 110. The oil is distributed about the chamber by a diffusion assembly 112 that, in one embodiment, includes a diffuser 114 to distribute oil and a diffuser cover 116. The diffuser cover 116 couples to the diffuser 114 to form a seal to prevent unintended spillage of the oil as it flows about the diffuser 114.

In one embodiment, the diffuser 114 includes perforated oil journals that allow the contaminated oil to drip toward a portion of the evaporation chamber 108 that is defined by the interior surfaces of evaporation chamber base 104 (Perforated journals are not shown in this figure, but see FIGS. 4 & 5). At least some of the dripping oil lands on and coats a high-surface-area structure 146. The high-surface-area structure 146 distributes oil deposited on it over an increased surface area thereby greatly increasing the surface area of the deposited oil that is exposed to the gaseous atmosphere of the evaporation chamber.

In one embodiment, the high-surface-area structure 146 includes a sponge-like or filamentous material disposed between the diffuser 114 and the interior surfaces of the evaporation chamber base 104. In another embodiment, the high-surface-area structure includes a filler-type material.

Non-particulate, volatile contaminants in the oil evaporate out of the contaminated oil as it flows from the oil intake port into the diffuser 114 and out of the perforated oil journals onto the lower chamber surfaces and the high-surface-area structure. These evaporated contaminants diffuse into an upper portion of the evaporation chamber defined by the evaporation chamber cover 102 and exit the evaporation chamber via air vents 120 (only one vent shown).

The now cleaner oil remains in the chamber. This oil drains from the high-surface-area structure 146 and the interior surfaces of the evaporation chamber base 104 and exits the chamber through an oil exit port 122.

Referencing FIGS. 1 and 2, in one embodiment the housing 106 is donut or toroid shaped and has a center opening 138 to accept a mounting pipe 124. In a further embodiment, the pipe 124 is threaded to mount to an engine on one end and to attach to an oil filter on the other end.

That is, referencing FIGS. 1A and 2, the mounting pipe 124 allows the oil-purifying device 100 to be mounted between an engine 105 and an oil filter 103. The mounting to the engine 105 is sealed by gasket 121. In one embodiment, oil flows downward from an engine 105 to an oil filter 103 through oil journals 128.

Further referencing FIG. 1, in a particular embodiment, these oil journals 128 are formed in the walls of an evaporation chamber base 104 that surrounds the mounting pipe 124. Oil flows upward from the oil filter (103, FIG. 1A) through the mounting pipe 124 to the engine (105, FIG. 1A).

Alternative embodiments need not be mounted to either an oil filter or an engine. These alternative embodiments may have a variety of shapes and may lack a mounting pipe. While the above embodiments with the mounting pipe may be designed to purify oil as it circulates through an operating engine, the alternative embodiments may purify oil that is not circulating through an engine. In one alternative embodiment, the housing has a rectangular shape and there is no center hole or pipe. This embodiment may be used to purify contaminated oil from, for example, a storage container.

The above is a high-level overview of embodiments of an oil-purifying device. The structure and operation of particular embodiments are now discussed in more detail.

FIG. 4, is a cross-sectional view of one embodiment of an oil purifying device. The view depicted is indicated by the dotted-lines of FIG. 3, a top view of the device.

Referencing FIG. 4, in one embodiment of an oil-purifying device 400, a metering jet 430 is detachably coupled to an oil intake port 110. In a particular embodiment, metering jet 430 is detachably coupled to the oil intake port 110 by a threaded connection. The oil intake port 110 extends inward through a wall of the evacuation chamber base 104 before turning upward to detachably couple with the metering jet 430.

Metering jet 430 controls the rate of flow of contaminated oil into the evaporation chamber 108. This flow rate control is regulated by the size of the inner diameter of metering jet 430, through which the oil flows. In one embodiment, the oil is pumped under pressure through the oil intake port 110. The velocity of the oil increases as the oil enters metering jet 430 due to its smaller inner diameter relative to the inner diameter of the oil intake port 110.

In one embodiment—as shown by the oil flow arrows of FIG. 4—the oil leaving metering jet 430 moves from the metering jet and its coupling with the oil intake port 430 to the diffuser 114. More specifically, the oil leaving the metering jet moves through an opening 132 in diffuser 114. Contaminated oil therefore flows through the metering jet 430, through the opening 132 in the diffuser 114 and into the diffusion assembly 112. As discussed below in reference to FIG. 5, the diffuser includes perforated oil journals with holes through which the oil falls toward the floor of the evaporation chamber 108.

In one embodiment, a phenomenon known as cavitation may occur as contaminated oil leaves the metering jet 430 and travels into the diffusion assembly 112. As discussed above, the oil is pumped through the metering jet 430 under pressure. Air and gases from the interior of the engine are entrapped in the oil. The pressure remains constant, therefore the velocity is increased due to the narrow inner diameter of metering jet 430. The oil pressure in the diffusion assembly 112 is substantially less than that within the oil intake port 110 and metering jet 430 since the evaporation chamber is open to the atmosphere. Cavitation, or vigorous, forceful expansion of entrapped air and gases, takes place as the oil exits the metering jet 430 and enters the diffusion assembly 112. Evaporation of volatile, non-particulate contaminants occurs as the gases expand. Although cavitation evaporates some of the volatile contaminants, it also may erode the interior surface of the metering jet 430 over time.

As discussed above, in one embodiment, the metering jet 430 is detachably coupled to the oil intake port 110 and is therefore replaceable. Replacement of the metering jet 430 may serve several purposes. First, a metering jet 430 that has been eroded by the above-described cavitation may be replaced when its performance falls below an acceptable level. Second, different metering jets may be used with oils of varying viscosity. For example, a metering jet with a relatively large inner diameter may be used with high-viscosity oil. Metering jets of varying inner diameters may then be used to achieve predetermined flow rates with oils of varying viscosity.

A diffuser 114, for use in some embodiments, is now described with reference to FIG. 5. As discussed above, contaminated oil enters the diffuser 114 from a metering jet (430, FIG. 4) through an opening 132 in diffuser 114. The oil then flows from the opening 132 through oil journals 134. In a particular embodiment, as depicted, two primary oil journals 134 flow along an inner and an outer circumference of the diffuser 114. The oil flows from these oil journals 134 into perforated, radial oil journals 136. It then drips through perforations 139 in the direction of one or more inner surfaces of the evaporation chamber base.

In one embodiment, as shown if FIG. 5, the diffuser is planar shaped and the oil journals are disposed in within a plane, the plane positioned to allow oil from the perforated oil journals to drip toward one or more inner surface of the evaporation chamber base. As discussed below in regard to evaporated contaminant vapors, in some embodiments the diffuser includes vapor journals 144A that convey gaseous contaminant vapors between the lower and upper parts of the evaporation chamber. In other embodiments, the diffuser may have a different shape and the oil journals may not be disposed within a plane.

In one embodiment, as shown in FIG. 5, the diffuser 114 has a central hole 138 and a plurality of perforated oil journals 136 are radially aligned about a central axis of central hole 138.

Although in the embodiment shown in FIG. 5, the diffuser has a circular shape, alternative embodiments have different shapes, for example, rectangular. Further, although the diffuser shown in FIG. 5 has a central hole 138, in other embodiments there is no circular hole.

In addition, although in the embodiment shown in FIG. 5 the diffusion assembly (112, FIG. 2) includes perforated oil journals embedded in a flat-shaped diffuser, in alternative embodiments the perforated journals are not embedded in any structure. They may be independent pipe-like structures extending about the evaporation chamber.

In one embodiment, a single perforated pipe is arranged within the evaporation chamber. Oil is sprayed or pumped under pressure through the pipe. The oil leaves the pipe with sufficient velocity to be distributed about the evaporation chamber. In alternative embodiments there may be a plurality of such pipes.

Finally, although in the embodiment shown in FIG. 5 the perforated oil journals 136 are positioned within the evaporation chamber, in alternative embodiments the perforated journals are within the vertical walls of the evaporation chamber base or cover. Oil exits through the perforations and flows down inner vertical surfaces of the evaporation chamber. In another embodiment, the perforated journals are within the floor of the evaporation chamber base. The oil exits upward out of the journals and spreads on the floor of the evaporation chamber base.

Referencing FIG. 6, in some embodiments a diffuser cover 116 may sealingly couple to the planar-shaped diffuser 114 of FIG. 5 to form a container to prevent the unintended leaking of oil from the oil journals of the diffuser 114. In particular, the diffuser cover 116 includes journal cover regions 640 that cover the perforated oil journals 138 of FIG. 5. Also, the diffuser cover 116 likewise has a central hole 138 corresponding the central hole in the diffuser 114. Also, as discussed below in regard to evaporated contaminant vapors, in some embodiments the diffuser cover 116 includes vapor journals 144B that convey gaseous contaminant vapors between the lower and upper parts of the evaporation chamber.

As shown in FIG. 1, in some embodiments, the diffuser cover 116 and the diffuser 114 couple to from the diffusion assembly 112. Although shown in FIGS. 5 and 6 as separate structures, the diffuser and diffuser cover need not be two separate joined structures. Alternative embodiments have a single solitary structure instead of the two structures shown above.

Referencing FIGS. 7A and 7B, in one embodiment oil intake port 110 extends inward from an exterior wall of the evaporation chamber base 104. Referencing FIG. 7C, in some embodiments, the oil intake port 110 of an oil-purifying device 700 is adapted to be coupled, when in use, with an oil conveyance 113 extending from an outer perimeter of evaporation chamber base (104, FIG. 7A)—part of the housing (106, FIG. 1). The oil conveyance 113 may be a hose or rigid pipe coupled to receive oil from an oil source 111, such as a pump (as shown), an oil storage container, an oil pan, or a tap at an oil pressure gauge. The oil is pumped under pressure from the oil source 111, through the oil conveyance 113, to the oil intake port 110. The oil in the intake port 110 is thus, pressurized.

Further referencing FIGS. 7A and 7B, as oil drips from the perforated oil journals, it falls in the direction of a floor 142 of evaporation chamber 108. The oil eventually flows out of the evaporation chamber through oil exit port 122. In one embodiment, the oil is not pressurized as it flows through the oil exit port 122. Referencing FIG. 7C, the oil is returned via a conveyance 115 (for example, a pipe or a hose) to a sump 117 or similar unpressurized reservoir.

In contrast to the oil, the evaporated contaminants diffuse into the gaseous atmosphere of the upper portion of the evaporation chamber 108 defined by the evaporation chamber cover. In some embodiments, as they do so, they encounter the diffusion assembly 112.

Once more referencing FIG. 5, in one embodiment, the evaporated contaminants pass through openings in the diffusion assembly to reach the upper portion of the evaporation chamber. The diffuser 114 has vapor journals (ventilation holes or openings) 144A to allow the passage of the evaporated contaminants through the diffuser 114. Further referencing FIG. 6, the diffuser cover 116 has matching vapor journals 144B to allow passage of the evaporated contaminants through the diffuser cover 116. The evaporated contaminants thus exit the lower portion of the evaporation chamber 108, pass through the vapor journals 144A, 144B of the diffuser 114 and diffuser cover 116, and then enter an upper portion of the evaporation chamber 108.

FIG. 8, is a cross-sectional view of one embodiment of an oil purifying device. The view depicted is indicated by the dotted-lines of FIG. 3, a top view of the device.

Referencing FIG. 8, in one embodiment, an oil-purifying device 800 has at least two ventilation ports 120 (only one shown) for venting evaporated contaminants out of the evaporation chamber. Upon evaporating, contaminants rise to an upper portion of an evaporation chamber 108. This upper portion of the evaporation chamber 108 is defined by an evaporation chamber cover 102—also shown in FIG. 9. After entering the upper portion of the evaporation chamber 108, the evaporated contaminants are vented out of the evaporation chamber 108 by the two or more ventilation ports 120—one ventilation port is also shown in FIG. 9.

In one embodiment, only one ventilation port is provided. In another embodiment, a separate ventilation port is not provided. Instead the oil exit port is also the ventilation port. Oil and evaporated contaminants both exit via the oil exit port.

In one embodiment, evaporation of contaminants causes an increased gaseous pressure with the evaporation chamber forcing evaporated contaminants out of one or more ventilation ports. In another embodiment, a gaseous pressure at one ventilation port is greater than a gaseous pressure at another ventilation port. For example, compressed air could be introduced at one port, or the other port could be connected to a vacuum line. Thus, a gas flow is created in which gas flows into the evaporation chamber through one or more ventilation ports and exits the evaporation chamber through one or more different ventilation ports. Evaporated contaminants are caught in this gas flow as they rise into the upper portion of the evaporation chamber 108. The caught evaporated contaminants are then evacuated from the evaporation chamber by the gas flow out of the above one or more ventilation ports.

FIG. 10, is a cross-sectional view of one embodiment of an oil purifying device. The view depicted is indicated by the dotted-lines of FIG. 3, a top view of the device.

Referencing FIG. 10, a cross-sectional view of a portion of an oil purifying device 1000, in some embodiments an oil-purifying device includes a high-surface-area structure 1046 upon which oil is deposited. As indicated by the oil flow arrows of FIG. 10, oil drips from a perforated oil journal, (136, FIG. 5) falls toward the floor of the evaporation chamber 108 and lands on and coats the high-surface-area structure 1046. The high-surface-area structure presents an increased surface area (relative to a smooth surface) such that the oil deposited on the high-surface-area structure presents a greater surface area to the atmosphere of the evaporation chamber 108. This greater surface area may improve the rate of evaporation of non-particulate contaminants in the oil.

In one embodiment, the high-surface-area structure 1046 includes a sponge-like material with a multiplicity of cavities and a variegated surface that presents an increased surface area upon which to deposit oil. In this and similar embodiments, the high-surface-area structure is positioned within the evaporation chamber 108 to receive oil that drips or flows from the perforated oil journals (136, FIG. 5). In a particular embodiment, the high-surface-area structure is positioned between a diffuser (e.g., 114, FIG. 5) and the floor of the evaporation chamber.

In another embodiment, the high-surface-area structure includes filamentous material such as a coarse metal or non-metal shavings coils or wires, similar to coarse steel wool. The fibers of the metal or non-metal shavings present a substantial surface area to the oil, which results in the oil being spread more thinly. The thinly spread oil presents a greater surface area to the atmosphere of the evaporation chamber. As stated above, a greater surface area generally results in a higher rate of evaporation.

Referencing FIG. 16, in another embodiment, a high-surface-area structure 1646 includes columnar structures 1681 in a steeple-like arrangement disposed on the floor 142 of an evaporation chamber base (e.g., 104, FIG. 7A). The columnar structures 1681 are spaced closely together such that oil falling on the bars tends to spread and form a film suspended between the bars.

In another embodiment, the high-surface-area structure includes the floor and walls of the evaporation chamber, at least some of which have ribbed or rough surfaces that present an increased surface area to the oil.

An embodiment in which an oil intake port receives its oil from an oil bypass journal is now discussed. As discussed in reference to FIG. 1, in one embodiment, a mounting pipe 124 extends through the central hole 138 to transport oil between, for example, an engine and an oil filter. Oil journals (128, FIG. 1) are formed in the interior walls of an evaporation chamber base (104, FIG. 1) that surrounds the mounting pipe 124. The oil journals 128 carry oil in a direction opposite to that of the pipe 124. So for example, if the oil journals 128 carry the oil from the engine to the oil filter, then the pipe 124 carries oil from the oil filter to the engine. An oil bypass journal, similar to the oil journals 128, may carry oil from the engine. But, as discussed below, the oil bypass journal delivers the oil to the oil-purifying device.

Further referencing FIG. 10, in some embodiments, an oil-purifying device 1000 includes an interior oil bypass journal 1058 in which oil is introduced into an evaporation chamber 108 by a metering jet 1030 that receives its oil from an oil bypass journal 1058 that extends from a coupling with an the engine, near the central hole 138 and the mounting pipe (124, FIG. 1). In these embodiments, the interior oil bypass journal 1058 is the oil intake port—it couples with the metering jet to introduce oil into the evaporation chamber. Stated differently, the oil intake port is an oil bypass journal that diverts to a metering jet a portion of oil flowing from an engine to an oil filter. The oil flow is shown by flow-arrows of FIG. 10.

As shown the oil flows from the metering jet 1030 into the diffusion assembly formed by the diffuser 114 and diffuser cover 116. The oil then falls through the holes of the perforations of the perforated journals toward a floor of the evaporation chamber 108.

Unlike the oil journals (e.g., 128, FIG. 1), oil bypass journal 1058 extends only from a coupling with an engine to its coupling to the metering jet 1030. For example, there may be a plurality of oil journals 128 returning oil from an engine to an oil filter, but oil bypass journal 1058 carries oil from the engine to the metering jet 1030—and ends there. The oil bypass journal 1058 does not continue onward toward—in this example—the oil filter. Oil thus flows from, for example, an engine, through oil bypass journal 1058 to metering jet 1030.

Although in the above embodiments, the pipe was described as possibly transporting oil from an oil filter to an engine, in another embodiment, the direction of flow could be just the opposite. That is, the pipe transports oil from the engine to the oil filter and the oil journals transport the oil back to the engine from the oil filter.

Temperature is a factor that may increase the rate of evaporation. Therefore, in some embodiments, it may be advantageous to heat the oil to promote evaporation of volatile, non-particulate contaminants. In some embodiments, the oil is heated as a natural side-effect of a running engine and the oil-purifying device is coupled to the engine to receive this heated oil. In alternative embodiments, the oil-purifying device is mounted on the engine—and warmed by it through conduction—but it does not receive its oil directly from the engine. Regardless, in the above embodiments, the oil is heated either directly or indirectly by an engine. However, in some embodiments, the oil-purifying device is not mounted to an engine.

In oil-purifying devices that are not mounted to or heated by an engine, a separate heating mechanism may be desirable to heat the oil to increase the rate of evaporation. Referencing FIGS. 11A and 11B, in one embodiment, an oil-purifying device includes a heating mechanism 1160. FIG. 11A is a perspective diagram of a diffuser 1114 with a heating mechanism 1160. FIG. 11B depicts a cross-section—as indicated on FIG. 11A—of the diffuser 1114 and heating mechanism 1160.

As shown in FIG. 11B, in a further embodiment, the heating mechanism 1160 includes thin-film metal resistive heating elements (e.g., nickel-chromium alloy) 1161 sandwiched between electrically insulating films 1163 that are thermally conductive. The heating mechanism 1160 may be affixed to body or interior components of the purifier. In another embodiment the heating elements are not thin film but conventional nickel-chromium alloy resistive wire. In various embodiments, the heating mechanism may be affixed to

• • the upper surface of the diffuser where the heating elements make contact with the oil, or
  • the underside surface of the diffuser, where the oil is heated as a secondary effect by conduction of thermal energy through the diffuser material, or
  • the outside of the base, heating the oil as a secondary effect of heating the base by conduction of thermal energy through the base material, or
  • the interior of the center shaft, heating the oil as a secondary effect of heating the base by conduction of thermal energy through the base, or
  • the interior surfaces of one or more oil supply journals heating the oil directly as well as and heating the oil as a secondary effect of heating the base by conduction of thermal energy through the base.

Further referencing FIG. 11B, an electric current is passed through the thin metal resistive heating elements 1161 causing a rise in temperature of the heating elements 1161. The thermal energy transfers readily through the electrical insulation films 1163 and is absorbed by both the diffuser body and oil.

In one embodiment an electrical control or thermostat controls the temperature of the heating elements by monitoring and adjusting the applied current and voltage. In another, the electrical resistance of the heating elements limits the current so no controller is required. In one embodiment, the heating mechanism heats the contaminated oil to a temperature of between about 200 degrees and 250 degrees Fahrenheit.

Under some circumstances it is desirable to mount an oil purifying device to an engine, but without mounting an oil filter to the central pipe. For example, in some engines used in heavy equipment, a special heavy-duty oil filter may be used that is not attached to the engine at the usual pipe used to couple to oil filters. But, it may still be beneficial to couple the oil-purifying device to the engine at the usual pipe to receive heated oil or for other convenience.

Returning to a previous description with reference to FIG. 1 A, an oil purifying device 100 may be mounted to an engine 105 at a mounting pipe. The oil purifying device 100 may have a central pipe 124 to which an oil filter 103 is ordinarily mounted.

Under ordinary circumstances, the oil filter 103 is used to return oil that flows from the engine 105 through oil journals (128, FIG. 1) to the oil filter 103. When the oil enters the oil filter, its flow is reversed and it flows through the central pipe 124 back to the engine. Therefore, a separate flow-reversing device may be needed if an oil-purifying device is mounted to an engine, but no oil filter is mounted to the oil purifying device. A flow-reversing device receives oil from the engine via oil journals (128, FIG. 1) and returns it to the engine via central pipe 124.

Referencing FIG. 12, in one embodiment, a flow reverser 1271 includes a base 1273, a gasket groove 1275, a flow-reversal port 1277, and a return oil journal 1279.

Referencing FIG. 13, in one embodiment, an oil-purifying device 1300 is mounted to a flow reverser 1371. The base 1373 of flow reverser 1371 is sealingly coupled, via a gasket in the gasket groove 1375, to the evaporation chamber base 1304 of oil-purifier device 1300.

As indicated by the oil-flow arrows of FIG. 13, oil flows away from an engine (not shown) toward the base 1373 of flow reverser 1300. The oil flows in an oil journal 1328 defined by a wall of the housing 1306 of the oil-purifying device 1300 and a wall of the oil return journal 1379 of the flow reverser 1371. Upon reaching the vicinity of the flow reverser base 1373, the oil enters the flow-reversal port 1377 of the flow reverser 1300 and proceeds to reverse course and move towards the engine (not shown) through the oil return journal 1371.

Referencing FIG. 14, an exemplary method 1400 of manufacturing an oil purifying device includes forming a housing comprising an oil evaporation chamber. (Process Block 1431). In one embodiment, the housing with the evaporation chamber is formed by machining the housing from a mass of material, such as a block of aluminum. In one embodiment, the housing with the evaporation chamber is formed by casting metal in a mold.

In one embodiment, the housing is formed by forming an evaporation chamber base, forming an evaporation chamber cover and then joining them together. In a further embodiment, the base and the cover are joined by a threaded connection. When the base and evaporation chamber are joined by a threaded connection, the diffuser assembly and high-surface-area structure (if provided) is enclosed by the toroid formed by the interior cavity of the base/top union. The union may be threaded or dimensioned such that a ‘press-fit’ connection is formed that keeps the top in the same position that the two pieces are orientated at the time of joining.

The method 1400 further includes providing the housing with ports. (Process Block 1433). In one embodiment, the housing is provided with an oil intake port in fluid communication with the evaporation chamber. The oil intake port may be adapted to be detachably coupled to a metering jet. In one embodiment, the housing is provided with an oil exit port in fluid communication with the evaporation chamber.

In one embodiment, the housing is provided with at least two ventilation ports in gaseous communication with the evaporation chamber. In a further embodiment, a first-provided ventilation port is adapted to have, when in operation, a gaseous pressure higher than a gaseous pressure at a second-provided ventilation port.

In one embodiment, providing the ports includes drilling holes or openings for the ports into walls of the housing. In an alternative embodiment in which the housing is cast from a mold, the ports are provided in part by having the holes or openings provided as part of the casting process.

The method 1400 further includes providing an oil diffusing assembly in fluid communication with the oil intake port. (Process Block 1435). In one embodiment, providing an oil diffusing assembly includes placing at least one perforated oil journal in fluid communication with the oil intake port. In a further embodiment, the at least one perforated oil journal is at least partly placed inside the evaporation chamber.

The method 1400 further includes providing an high-surface-area structure to present an increased surface area upon which to deposit oil. (Process Block 1437). In some embodiments, providing an high-surface-area structure includes placing a sponge-like or filamentous material within the evaporation chamber. In one embodiment, providing an high-surface-area structure includes placing a dense mesh of material within the evaporation chamber. For example, coarse steel wool is placed within the chamber.

Referencing FIG. 15, in one embodiment, the evaporation chamber base 1504 and an evaporation chamber cover 1502 of an oil-purifying device 1500 are rotatably coupled to each other. This allows the cover 1502 to be rotated during installation of the device for purposes of fitting the device into a cramped area adjacent an engine. In a particular embodiment, hoses may be coupled to the ventilation ports of the evaporation chamber cover and the space next the engine may be constrained. The ability to rotate the cover and any attached hoses may thus allow easier mounting the device 1500 to the engine when space for the device next to the engine is limited.

The ability to rotate the cover also allows the device to be used in a horizontal orientation in which the evaporation chamber base and the evaporation chamber cover are horizontally adjacent. The cover may be rotated during installation such that the ventilation ports are out of regions of the device where oil will flow. The device may be used in a variety of orientations. For some orientations, it is desirable to position the ventilation ports and the oil exit ports so that they function correctly.

At times, oil may flow into the evaporation chamber via the metering jet at a faster rate than the rate at which it is flowing out of the chamber via the oil exit port. For example, a plug or obstruction may develop in the oil exit port. As a safety measure, to prevent oil from spilling out of the device onto, for example, the roadway, an overflow protection mechanism may be used. For example, a t-shaped tube or conveyance may be coupled to each of the ventilation ports. Then, if oil is overflowing from the chamber into the ventilation ports, the oil may be drained via one of the arms of the t-shaped tube back to the engine. For example, it could be drained back into a hose that is carrying oil to the engine from the oil exit port. Meanwhile, the evaporated contaminants could still be vented out of the other arm of the t-shaped tube or conveyance.

At time reference is made to “one embodiment.” All the embodiments referred to as “one embodiment” are not necessarily the same embodiment.

The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. Those skilled in the art can appreciate from the foregoing description that the techniques of the embodiments of the invention can be implemented in a variety of forms. Therefore, while the embodiments of this invention have been described in connection with particular examples thereof, the true scope of the embodiments of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

Claims

1. An oil-purifying apparatus, comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

a ventilation port in gaseous communication with the evaporation chamber; and

an oil diffusing assembly to receive contaminated oil from the oil intake port.

2. The apparatus of claim 1, further comprising at least one of a high-surface-area structure to increase a surface area of the contaminated oil, a heating mechanism to heat the oil, or a metering jet detachably coupled to the oil intake port to control a rate of flow of the oil.

3. The apparatus of claim 1, wherein the oil diffusing assembly includes at least one perforated oil journal.

4. The apparatus of claim 3, wherein the at least one perforated oil journal includes a plurality of perforated oil journals disposed in a radial configuration about a central axis.

5. The oil-purifying device of claim 3, wherein the at least one perforated oil journal comprises a plurality of perforated oil journals disposed within a plane, the plane positioned to allow oil from the perforated oil journals to drip toward a surface of the evaporation chamber.

6. An oil-purifying apparatus, comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

a ventilation port in gaseous communication with the evaporation chamber; and

a high-surface-area structure to increase a surface area of the contaminated oil.

7. The apparatus of claim 6, further comprising at least one of an oil diffusing assembly to receive contaminated oil from the oil intake port, a heating mechanism to heat the oil, or a metering jet detachably coupled to the oil intake port to control a rate of flow of the oil.

8. The apparatus of claim 6, wherein the high-surface-area structure includes filamentous material.

9. The apparatus of claim 6, wherein the high-surface-area structure includes a sponge-like material with a plurality of cavities and a variegated surface for disposing at least some of the oil onto.

10. The apparatus of claim 6, wherein the high-surface-area structure includes at least one rough surface of the evaporation chamber for disposing at least some of the oil onto.

11. The apparatus of claim 6, wherein the high-surface-area structure includes columnar structures that are arranged in a steeple-shaped structure on a floor of the evaporation chamber.

12. An oil-purifying apparatus, comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

a ventilation port in gaseous communication with the evaporation chamber; and

a thin-film resistive metal heating mechanism to heat the oil.

13. The apparatus of claim 12, further comprising at least one of an oil diffusing assembly to receive contaminated oil from the oil intake port, a high-surface-area structure to increase a surface area of the contaminated oil, or a metering jet detachably coupled to the oil intake port to control a rate of flow of the oil.

14. The apparatus of claim 12, wherein the heating mechanism heats the oil to a temperature between about 200 degrees and 250 degrees Fahrenheit.

15. The apparatus of claim 12, wherein the thin-film resistive metal of the heating mechanism is insulated with an electrically-insulating film.

16. An oil-purifying apparatus, comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

a ventilation port in gaseous communication with the evaporation chamber; and

a replaceable metering jet detachably coupled to the oil intake port to control a rate of flow of the oil.

17. The apparatus of claim 16, further comprising at least one of an oil diffusing assembly to receive contaminated oil from the oil intake port, a high-surface-area structure to increase a surface area of the contaminated oil, or a heating mechanism to heat the oil.

18. An oil-purifying device, comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

means for receiving oil from the oil intake port and dispersing it within the evaporation chamber;

means for increasing a surface area of oil dispersed within the evaporation chamber; and

means for venting evaporated contaminants from the evaporation chamber.

19. An oil-purifying device comprising:

a housing defining an evaporation chamber to receive contaminated oil;

an oil intake port in fluid communication with the evaporation chamber;

an oil exit port in fluid communication with the evaporation chamber;

at least two ventilation ports in gaseous communication with the evaporation chamber;

at least one perforated oil journal in fluid communication with the oil intake port;

a metering jet detachably coupled to the oil intake port to control a rate of flow of the oil; and

a high-surface-area structure to increase a surface area of the contaminated oil

wherein the oil intake port is adapted to be coupled, when in use, with an oil conveyance that extends from an oil source toward an exterior of the housing.

20. The device of claim 19, wherein a gaseous pressure at a first port of the at least two ventilation ports is greater than a gaseous pressure at a second port of the at least two ventilation ports.