PCV heater and method for manufacturing same

• US 6,062,206 A
• Filed: 07/31/1998
• Issued: 05/16/2000
• Est. Priority Date: 03/19/1998
• Status: Expired due to Term

• Current Assignee: Phillips & Temro Industries, Inc.
• Original Assignee: Phillips & Temro Industries, Inc.
• Inventors: Wicks, Brian E., Edwards, Gary C., Nelson, Kirk A.
• Primary Examiner(s): MCMAHON, MARGUERITE J
• Application Number:
  US09/127,060
• Time in Patent Office: 655 Days
• Field of Search: 123/572-573, 123/574, 123/41.86, 123/549, 123/556
• US Class Current: 123/573
• CPC Class Codes: F01M 13/00 Crankcase ventilating or breathing
• CPC Class Codes: F01M 2013/0027 with a de-icing or defrosting system
• CPC Class Codes: F01M 2013/0455 with a de-icing or defrosting system for breathing valves F01M2013/0027
• CPC Class Codes: F01M 2013/0472 using heating means
• CPC Class Codes: F01M 5/001 Heating

Abstract

A PCV heater including a fitting having a plug and a heat sink coupled to the fitting. The fitting and the heat sink define a gas flow path having a first end and a second end. The second end of the gas flow path defines a discharge port and the heat sink is proximate to the discharge port. The heater also includes a heating element coupled to the plug and electrically connectable to a power source. The heating element thermally engages the heat sink to communicate heat from the heating element to the heat sink when the heating element is electrically connected to the power source.

Claims

1. An internal combustion engine comprising:

a crankcase;

an intake manifold; and

a positive crankcase ventilation system for selectively circulating gases from the crankcase to the intake manifold, said positive crankcase ventilation system communicating with said intake manifold to define a mixing zone where said circulated gases are mixed with ambient air from said intake manifold, said positive crankcase ventilation system including a heater coupled to said engine proximate to said mixing zone, said heater having

a fitting having a plug,

a heat sink coupled to said fitting, said fitting and heat sink defining a gas flow path having a first end and a second end, said second end defining a discharge port communicating with the mixing zone, said heat sink being in heat exchange relationship with said discharge port, and

a heating element coupled to said fitting and being electrically connectable to a power source, said heating element thermally engaging said heat sink to communicate heat from said heating element to said heat sink.

2. The internal combustion engine of claim 1 wherein said heating element is a positive temperature coefficient ceramic.

3. The internal combustion engine of claim 1 wherein said fitting is formed of a high temperature plastic that thermally isolates said heat sink from said manifold.

4. The internal combustion engine of claim 1 wherein said plug includes a groove and wherein said heater includes a sealing element disposed in said groove sealingly engaging said intake manifold.

5. The internal combustion engine of claim 1 wherein said heat sink includes a tapered surface coupled to said plug to retain said heat sink within said plug.

6. The internal combustion engine of claim 1 wherein said heater includes a clamp coupling said heating element in thermal engagement with said heat sink.

7. The internal combustion engine of claim 6 wherein said heater includes a non-conductive housing positioned between said heat sink and said clamp, said housing having a wall defining a cavity and an opening in said wall that communicates with said cavity, said heat sink disposed in said cavity and said heating element disposed in said opening to thermally engage said heat sink.

8. The internal combustion engine of claim 7 wherein said housing includes a groove and wherein said clamp includes a tab coupled to said groove.

9. The internal combustion engine of claim 7 wherein said heat sink includes a heating surface in planar engagement with said heating element.

10. The internal combustion engine of claim 7 wherein said clamp has a first terminal and said heat sink has a second terminal such that a current circuit flows from said power source through said first terminal, said clamp, said heating element, said heat sink, and said second terminal.

11. The internal combustion engine of claim 7 wherein said heater includes a locking element engaging said plug and said intake manifold to couple said heater to said intake manifold.

12. A positive crankcase ventilation heater comprising:

a fitting having a plug;

a heat sink coupled to said fitting, said fitting and heat sink defining a gas flow path having a first end and a second end, said second end defining a discharge port, said heat sink being in heat exchange relationship with said discharge port; and

a heating element coupled to said fitting and being electrically connectable to a power source, said heating element thermally engaging said heat sink to communicate heat from said heating element to said heat sink.

13. The heater of claim 12 further including a clamp and a non-conductive housing, said housing having a wall defining a cavity and an opening in said wall that communicates with said cavity, said heat sink disposed in said housing cavity, said heating element disposed in said opening, and said clamp coupled to said housing to urge said heating element into engagement with said heat sink.

14. The heater of claim 13 wherein said heating element engages said heat sink along a planar contact surface.

15. The heater of claim 12 wherein said plug is formed of a high temperature plastic.

16. The heater of claim 12 wherein said heat sink is formed of a material having a heat conductivity of at least about 60 BTU/hour·

ft² ·

°

F.·

ft and an electrical resistivity of less than about 40 ohms (mil;

ft).

17. The heater of claim 12 wherein said heating element is a positive temperature coefficient ceramic.

18. A method for manufacturing a positive crankcase ventilation heater comprising the steps of:

forming a heater subassembly including coupling a heating element in heat transfer relationship to a heat sink and electrically connecting a first terminal and a second terminal to said heating element;

placing said heater subassembly in a mold defining a cavity; and

providing an electric insulating material to said cavity to overmold said heater subassembly and form a fitting about said heater subassembly.

19. The method of claim 18 further including coupling a nonconductive housing to said heat sink prior to placing said heater subassembly in said mold cavity.

20. The method of claim 19 further including coupling a clamp to said nonconductive housing to urge said heating element into engagement with said heat sink.