Porous Polymer Matrix Catch Can

Abstract

Disclosed is an oil catch can device employing a porous polymer matrix which filters and collects oil and other combustion byproducts typically found in “blow-by” gasses of an internal combustion engine. Employing a porous polymer matrix is a more effective means of filtering and collecting components of blow-by gasses due to the physical and chemical properties of the matrix. Various polymers can be used to produce the porous polymer matrix. By controlling the polymer type and particle size distribution of the particles that are sintered to create the matrix, filtration and adsorption can be maximized while maintaining a sufficient flow rate of gasses through the device.

What is claimed is: 
     
         1 . A Porous Polymer Matrix Catch Can that removes oil from the blow-by gases that travel through a Positive Crankcase Ventilation (PCV) system, the Porous Polymer Matrix Catch Can comprising:
 A Catch Can and a Porous Polymer Matrix,
 the Porous Polymer Matrix being comprised of a sintered polymer, the sintered polymer being comprised of particles having a size distribution in which 90% of the particles are in a range between 20 μm and 3000 μm in diameter before sintering and said particles having a Melt Flow Rate of less than 5 grams over 10 minutes, the Porous Polymer Matrix having an exterior surface and an interior surface, the sintered polymer forming a plurality of pores opening at the interior surface and a plurality of pores opening at the exterior surface and a plurality of channels within the Porous Polymer Matrix placing at least one or more of the plurality of pores opening at the interior surface in fluid communication with at least one or more of the plurality of the pores opening at the exterior surface, the Porous Polymer Matrix being positioned in such a way that the air from the Positive Crankcase Ventilation (PCV) system is forced through it; the Porous Polymer Matrix being housed in the Catch Can, the Catch Can being hollow and of any geometrical shape, 
 whereby the blow-by-gases are produced by an internal combustion engine, 
 whereby the blow-by gases enter the Catch Can, flow through the Porous Polymer Matrix and then exit the Catch Can, 
 whereby oils from the blow-by-gases are removed by the Porous Polymer Matrix, 
 and whereby the Catch Can is used in conjunction with the Positive Crankcase Ventilation (PCV) system. 
   
     
     
         2 . The Porous Polymer Matrix Catch Can of  claim 1 , where the sintered polymer comprising the Porous Polymer Matrix is selected from a group consisting of polypropylene, polyethylene, and polycarbonate. 
     
     
         3 . The Porous Polymer Matrix Catch Can of  claim 1 , where the sintered polymer comprising the Porous Polymer Matrix is a thermally resistant polymer. 
     
     
         4 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the Melt Flow Rate of the sintered polymer comprising the Porous Polymer Matrix is less than 3 grams over 10 minutes. 
     
     
         5 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the Melt Flow Rate of the sintered polymer comprising the Porous Polymer Matrix is less than 1 gram over 10 minutes. 
     
     
         6 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the sintered polymer comprising the Porous Polymer Matrix is formed from particles having a size distribution in which 90% of the particles are between 20 μm and 1500 μm in diameter. 
     
     
         7 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the sintered polymer comprising the Porous Polymer Matrix is formed from particles having a size distribution in which 90% of the particles are between 20 μm and 200 μm in diameter. 
     
     
         8 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the Porous Polymer Matrix has porosity in a range of from about 30% to about 60%. 
     
     
         9 . The Porous Polymer Matrix Catch Can of  claim 1 , wherein the pores formed in the Porous Polymer Matrix have a median pore diameter of from about 10 μm to about 200 μm.