Oil Catch Can

This application claims the benefit of and priority to U.S. provisional application No. 63/601,493, filed on Nov. 21, 2023, entitled “OIL CATCH CAN,” the entirety of which is incorporated by reference herein.

The disclosed technology generally relates to an oil catch can for automobiles, motorcycles, or other apparatuses having a combustion engine.

In a combustion engine, pressures are created under the piston as a result of combustion. This pressure is an air/oil mixture. The amount of oil to air can vary in application. Typically, these gases are routed from the lower crankcase/breather system via a hose or tubing to the induction system. The induction system (which is always under vacuum) pulls the air oil mixture into the intake system where it is combined with fuel and air mixture and then reburned. This action deoxygenizes the fuel and creates more carbon on top of the piston and combustion chamber than needed. The excess oil can cause various issues with combustion and causing unwanted and or premature wear to the engine. Including but not limited to cylinder walls, pistons, rings, cylinder heads, valves, valve guides and the combustion chamber. The catch can is constructed and arranged to separate oil and air from the engine's intake system to reduce oil vapors in the engine and allow the oil free air to enter the induction system.

In one aspect, a catch can assembly for a vehicle comprises a quadrilateral housing having a top unit coupled to a bottom unit for forming a quadrilateral interior volume, the housing having an input for receive a mixture of oil and air and an output for outputting the air; a filter at the interior volume for separating the oil from the air so that the oil collects at the bottom unit; a bracket coupled to the quadrilateral housing for aligning the quadrilateral housing relative to a surface of the vehicle; and a window in the bottom unit for viewing a level of the oil collected at the bottom unit.

In another aspect, a catch can assembly for a motorcycle comprises a housing having a top unit coupled to a bottom unit for forming an interior volume, the housing having an input for receive a mixture of oil and air and an output for outputting the air; a filter at the interior volume for separating the oil from the air so that the oil collects at the bottom unit; and a bracket coupled to the quadrilateral housing for aligning the quadrilateral housing relative to a surface of the vehicle, wherein the bottom unit has an extension for coupling to an air filter backing plate of the motorcycle.

In another aspect, a vehicle, comprising: an engine; an intake system; and a catch can, comprising: an inlet from a valve cover or crankcase of the vehicle; an outlet to an induction system, breather, or manifold of the vehicle; a quadrilateral housing having a top unit coupled to a bottom unit for forming a quadrilateral interior volume, the housing having an input for receive a mixture of oil and air and an output for outputting the air a filter at the interior volume for separating the oil from the air so that the oil collects at the bottom unit; a bracket coupled to the quadrilateral housing for aligning the quadrilateral housing relative to a surface of the vehicle; and a window in the bottom unit for viewing a level of the oil collected at the bottom unit.

Reference in the specification to an embodiment or example means that a particular feature, structure or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the teaching. References to a particular embodiment or example within the specification do not necessarily all refer to the same embodiment or example.

The present teaching will now be described in detail with reference to exemplary embodiments or examples thereof as shown in the accompanying drawings. While the present teaching is described in conjunction with various embodiments and examples, it is not intended that the present teaching be limited to such embodiments and examples. On the contrary, the present teaching encompasses various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Moreover, features illustrated or described for one embodiment or example may be combined with features for one or more other embodiments or examples. Those of ordinary skill having access to the teaching herein will recognize additional implementations, modifications, and embodiments, as well as other fields of use, which are within the scope of the present disclosure as described herein.

Referring to, a conventional catch cancomprises a cylindrical top unit, a cylindrical bottom unit, a media or filter element, a screen, a set of fittingsA,B (generally,), a set of brackets,, and at least one boltor other coupling element. The catch canis not limited to these parts and may include other parts that are not shown or described for brevity, for example, hoses or the like.

The top unitincludes two holes for receiving the fittings. Each fittingincludes a machined bore (not shown) extending through a center of the fitting. A first fittingA is coupled to PVC tubing or rubber oil line from the valve cover or area of the engine designed to hold and remove/relocate positive crankcase pressures from the engine, or the like for receiving a source of oil vaper and air from the PVC, valve cover, or the like. A second fittingB is coupled to an air intake system of a combustion engine to permit the catch canto outputting clean air (oil free) (with oil particles received from the first fittingA causing undesirable sludge and residue removed as described below). In some embodiments, the fittingsandare formed of brass or the like. A rubber hose connects to the outlet side and can be ran anywhere to the manifold/engine intake system.

The screenand filter elementare positioned in the bottom unitfor separating the oil particles so that the oil sludge or residue collects at the bottom of the bottom unit.

The oil canis attached to the engine by the brackets,and boltor related hardware, which collectively provide a mount system. In some embodiments, bracketis a generic bracket that is designed to be bolted universally, i.e., to any surface or object, for example, mounted to a chassis or engine. The orientation and positioning of the brackets may prevent the catch can from becoming loose between the locations where the brackets,are located.

The conventional catch canshown inuses a generic style bracket to mount the unit to the engine/chassis. These generic brackets allow for a broad fitment but often result in issues regarding use or clearance. When using the conventional design, the catch cancan easily rotate around its mount(s). Since there is just one boltbetween the bracket and the can assembly and another single bolt used for mounting the assembly to the engine or chassis, both these areas are not clocked or supported in such a way to prevent rotation or loosening from vibration and usage.

are views of an oil catch can, in accordance with some embodiments of the present inventive concept, which addresses the deficiencies described with respect to the conventional catch canof.

Referring to, in some embodiments, the oil catch canhas a quadrilateral or trapezoidal, e.g., square or rectangular, shape to allow for a larger volume for filtering operations due to the corners of the square or rectangular shape of a top unitand a bottom unit, collectively forming a housingof the catch can. The corners may be curved or sharp, but nevertheless forming right angles of the quadrilateral interior volume of the housing. The top unitmay be coupled to the bottom unitby boltsextending through holes in the corners of the top unit, or by other coupling devices or techniques. An o-ringmay be between the top unitand bottom unitto provide a seal and prevent gas, oil, etc. from leaking from an interior of the housingformed by the top unitand the bottom unit. The square or rectangular shape of the housingprovides a volume of the can for filtering that is larger in volume than a conventional cylindrical configuration due to using the corners of the shape. Circular shapes do not add that extra volume. Since the interior volume is larger, the external shape can be made smaller in all dimensions, for example, shown in. For example, the catch caninas a lower unitthat can hold a greater volume than the round cylindrical catch canshown indespite the greater height of the catch canthan the catch can. The shape of the catch canholds more volume because the interior corners of the rectangular design which are not present in the cylindrical design of the catch can. This can also allow for more fitment applications. The smaller unit, that holds the same or more volume of other units, can now be used in applications where others can't fit, due to the overall size of the unit.

In some embodiments, the catch can assemblyhas an upper bracketand a lower bracketthat operate together that utilize multiple positions of linear attachment, preventing any type or rotation or unwanted movement. In particular, the catch can assemblycan use vehicle specific brackets to locate the catch can assemblyto a position of perfect alignment for hose routing and fitting alignment. The brackets are constructed and arranged having specific configurations, e.g., square, rectangular, trapezoidal, and so on, for performing the inventive features herein. This may be achieved by various coupling mechanisms, such as bolts, screws, or the like including but not limited to socket-head screwsfor coupling the upper bracketto holes, i.e., threaded, in a top surface of the lower bracket. Other coupling mechanisms may include hex head screwsparallel to the socket-head screwsand extending from the upper bracketfor coupling to the engine (not shown). The holesin the bracket(see) can be aligned with threaded holes in the manifold or other region of the engine block so that the boltscan be inserted and hold the assemblyin place against the engine, manifold, or other relevant component of the vehicle. In some embodiments, bracketsandare vehicle specific brackets for a particular engine, such as a Dodge Hellcat engine. However, the bracketsandcan be applicable to other engine configurations. The dimensions of the brackets are designed to be in a perfect position for alignment and best overall fitment and orientation for service and installation.

The position specific design maximizes efficiency of the unit by not allowing hoses coupled to the fittings(which may be similar to fittingsof) to kink in anyway while being routed to or from the can assembly. In some embodiments, the top unitincludes two holes (not shown but similar to holes shown in) for receiving the fittings. The holes may be threaded to mate with the threads at the end of the fittings. Each fittingincludes a machined bore (not shown) extending through a center of the fittingso that a fluid path can extend from the inlet or outlet of the fittingto the interior of the housing. This routing and alignment procedure drastically reduces forces on the lines and fittings. In some embodiments, other possible changes are made to the brackets,and mounting points and how this would cause fitting locations to change/move but still provide the same service. This causes less wear to the system, i.e., rubbing hoses, loosening fittings, and possible leaks. The brackets,shown in this design specific to high performance vehicles, for example, manufactured by a Dodge/Chrysler/Jeep hemi performance line, but not limited thereto.

The conventional can design utilizes a single screwon a bottom to top fitment. The bottom must be unscrewed from the top to service (drain oil from bottom) the unit. Additional service, cleaning the screen and filter is also recommended for different service intervals. i.e., drain it every 50-100 hours, clean it every 500 in theory. Additionally, the unscrewing action of the bottom typically results in the entire unitbecoming loose due to the single bolt design.

Embodiments of the present inventive concept on the other hand as shown at least inincludes catch can bottom unitthat includes a drain boltwith a magnet to ease service usage and collect any unwanted ferrous materials from re-entering the induction/combustion cycle. This is two parts, the first being the drain, a needed addition to help ease service and keep messes to a minimum. This drain holein the bottom of the bottom unitcan receive a sealing boltas shown, a bolt with an o-ring, or a self-contained twist style drain, but not limited thereto. The addition of the magnet is incredibly useful. It could either be attached to the drain plugor attached to the catch can bottom surface, or the screen(described below) itself an be magnetized.

Another feature is that the catch can assemblyhas a viewing windowpositioned over an openingin the bottom unitto monitor oil levels and to inspect usage over time etc. In some embodiments, the catch can bottom unitis machined with a viewing area formed by the windowover the opening. The windowcan comprise polycarbonate or acrylic, or other materials that provide strength and transparency. The windowis positioned between sealing o-rings,located on both sides of the windowas shown. The outer bezelis fastened/bolted to the catch can bottomusing threaded bolts, screws, or other coupling devices, which when threaded through the outer bezeland into holes in an indented region of the bottom unit openingcan apply a force thereby squeezing the o-rings,and polycarb windowtherebetween creating a waterproof/leak proof seal. The polycarb/windowcould be color matched the vehicle or branding. i.e., red, blue, green, black, etc. tinted polycarb.

Another feature is that the catch canincludes outer bezel features machined marksto judge/measure usage levels. Indicators similar to a tape measure show changes in volume. Each markon the bezelindicates how many ounces of fluid are in the catch can bottom. The linesare useful to show how much oil is being collected (usage) vs. the time last checked. The more usage could possibly indicate potential problems in the engine itself and provide some type of pre maintenance. More oil usage in the can bottomwould indicate more leak down (pressures escaping combustion). The more the leak down, indicates that the condition of the engine is deteriorating and could use a top end service. i.e., piston rings, cylinder resizing, and so on.

As shown in, the screencan be coupled to a bottom region of the top unitby bolts, screws, or the coupling devices or techniques. During operation, crankcase gases enter the catch canthrough at least one threaded holevia a corresponding fitting. A wall separating the ports forces the gasses, which comprise air and oil particles, gasses, and so on, to move through the screenand/or filter/oil separator(not shown in) causing the filtered oil to fall into the bottom unitof the catch can. This results in oil free air flowing back through the filter and into the intake system, for example, shown in.

For example, a catch can assemblycan include an inletfrom a valve cover or lower crankcase and an outletto an engine induction system or manifold. The catch can assemblycan be similar to a catch assembly ofso repetitive details are omitted for brevity.

In some embodiments, the catch can assemblycan include a first rubber hose or PVC tubingcoupled to the inletand extending to the valve cover or lower crankcase and a second rubber hose or PVC tubingcoupled to the outletand extending to the engine induction system or manifold.

The catch can assemblycan also transfer or otherwise move an oil/air mixture through a flow path that includes a filter. The top unit of the catch can assemblycan include a wallthat forces the oil/air mixture into the bottom and up the outlet side. The oil is removed from the air by the filters and the oil when separated drops into the bottom unit. Holesin the screen can allow the oil to drip down while retaining the filter's air flow through the catch can. In some embodiments, a magnetic drain plugcan remove and hold steel/magnetized particles in the mixture and prevent them from output to the engine.

are views of an oil catch can, in accordance with other embodiments of the present inventive concept. The oil catch canincludes various components-that are similar to or the same the components-of the catch canofso details thereof are not repeated for brevity.

However, the upper bracketand a lower brackethave a different structure and configuration that operate together that utilize multiple positions of linear attachment, preventing any type or rotation or unwanted movement. Also, the top unithas threaded holesextending through opposite sidewalls of the top unitfor receiving corresponding fittings. This configuration allows for insertion of the catch can assemblyinto a vehicle having a different arrangement of hoses and location of the intake system, manifold, and so on.

is a front view of a motorcycle catch can, in accordance with other embodiments of the present inventive concept.is a rear view of the motorcycle catch canof.is an exploded view of the motorcycle catch canof.

As shown in, the motorcycle catch cancomprises a top unitand a bottom unitto form a housing, similar to the vehicle catch can assemblyabove. A top o-ring, a backing plate hardware unitsuch as a screw, a filter/oil separator, a screen, and a screen hardware couplersuch as a bolt or the like may be between the top unitand the bottom unitand may be similar to or the same as counterpart components of the vehicle catch canabove. Similar to components shown in, the motorcycle catch canmay also include an outer bezel, a sign glass o-ring, a windowformed of polycarbonate or the like, and coupling hardware such as a stainless steel button head next drive screw, and plated steel with rubber sealing washer, which may be similar to or the same as the viewing windowofso details are not repeated for brevity. The catch canis not limited to the parts shown inand may include other parts that are not shown or described for brevity, for example, hoses or the like. The bottom unit may have a shape that can be modified and not limited to that shown in. In some embodiments, the bottom unitcan be mounted on either side of the air cleaner assembly. The catch cancan be mounted anywhere on a motorcycle as long as the hoses were routed properly, etc. The function of the sight glass of the viewing windowis to be able to see the total volume you have inside the catch can thereby avoiding the need to separate the upper and lower to visually check the amount. The viewing windowallows a user to monitor the volume per mile, etc. Over time and mileage the internals in the engine wear, when this happens more oil will be caught in the can.

In some embodiments, the catch canincludes a first hosefor coupling between a first holein the top unitand to a crankcase of the motorcycle and a second hosefor coupling between a second holein the top unitand a breather backing plate of the motorcycle. The first and second holes,may be constructed and arranged similar to the arrangement shown and described inso details are not repeated for brevity.

In some embodiments, the catch canincludes additional hardware components such as o-rings, washers, bolts, or the like for coupling the catch can bottom unitto the outer bezel. Some or all of these hardware components may be threaded for removably attaching to the relevant components, such as threaded holes in the bezel.

As shown, the motorcycle catch can assemblycan be coupled to a motorcycle air filter assembly. In some embodiments, the bottom unithas an extensionwith a hole that can receive a boltor the like. This extension hole can be aligned with a threaded hole in the air filter assemblyso that a boltcan be inserted through the extension hole to the threaded filter hole.