Engine Head Cover Assembly Having An Integrated Oil Separator

Abstract

A head cover assembly for covering a crankcase of an internal combustion engine includes a head cover and an integral oil separator. The oil separator includes a housing that defines a flow path that separates oil from crankcase gases passing therethrough. At least a portion of the housing is integrally formed along an inner surface of the head cover.

1 . A head cover assembly for covering a crankcase of an internal combustion engine, said head cover assembly comprising:
 a head cover having opposite outer and inner surfaces; and   an oil separator for separating oil from crankcase gases passing therethrough, the oil separator having a housing disposed along an inner surface of the head cover, the housing having at least one side wall integral with the head cover, which together with the head cover define an interior space of the oil separator.   
   
   
       2 . A head cover assembly as set forth in  claim 1 , wherein the housing is formed by a plurality of side walls, one of the side walls extending along the inner surface of the head cover. 
   
   
       3 . A head cover assembly as set forth in  claim 2  including a plate releasably attached to the side walls to enclose the interior space of the oil separator. 
   
   
       4 . A head cover assembly as set forth in  claim 3 , wherein the oil separator includes a plurality of guide walls that are integral with the head cover and extend between the inner surface and the plate to define a labyrinth path that causes separation of oil from crankcase gases passing therethrough. 
   
   
       5 . A head cover assembly as set forth in  claim 1 , wherein the at least one side wall is cylindrically shaped to define a cylindrical recess in the head cover. 
   
   
       6 . A head cover assembly as set forth in  claim 5  including a cap releasably attachable to the at least one side wall to define the interior space of the oil separator. 
   
   
       7 . A head cover assembly as set forth in  claim 6 , wherein the cap includes threads for engaging mating threads on the at least one side wall. 
   
   
       8 . A head cover assembly as set forth in  claim 7  including a cover plate disposed between the cap and the head cover to enclose the interior space of the oil separator. 
   
   
       9 . A head cover assembly as set forth in  claim 8  including guide walls extending from the cover plate toward the cap to define an oil path for separating oil from crankcase gases passing therethrough. 
   
   
       10 . A head cover assembly as set forth in  claim 6 , wherein the cap and the at least one side wall are coupled to each other by a tab and slot arrangement, wherein the cap is rotated relative to the at least one side wall to cause locking engagement between a tab and a key slot. 
   
   
       11 . A head cover assembly as set fort in  claim 10 , wherein the tab extends outwardly from the cap and the key slot is formed in the at least one side wall. 
   
   
       12 . A head cover assembly as set forth in  claim 11 , wherein the at least one side wall is generally cylindrical and forms a recess for receiving the cap therein. 
   
   
       13 . A head cover assembly as set forth in  claim 12 , wherein the at least one side wall includes a guide slot that receives the tab from the cap as the cap is inserted into the recess. 
   
   
       14 . A head cover assembly as set forth in  claim 13 , wherein the key slot extends orthogonally from an end of the guide slot so that rotation of the cap within the recess causes locking engagement between the tab and the key slot.