Permanent Housing for a Ceramic Oil Filter MIM U702 Capstone Design reNU Design Team Dale Kochevar Kelly Seitz Marco Solia Barrett Straub Matt Whalen MIM U702 Capstone Design reNU Design Team Dale Kochevar Kelly Seitz Marco Solia Barrett Straub Matt Whalen April 15, 2008

Problem Definition Too much motor oil is wasted each year during the oil changing process A significant amount of oil is lost when a traditional paper oil filter is thrown into a landfill A significant amount of oil is lost when a traditional paper oil filter is thrown into a landfill Standard paper oil filters must be replaced after driving about 3,500 miles Standard paper oil filters must be replaced after driving about 3,500 miles A quart of new motor oil can be refined from less volume of recycled motor oil than crude petroleum A quart of new motor oil can be refined from less volume of recycled motor oil than crude petroleum

Environmental Impact Drawbacks of paper filters: Roughly 500M used filters are thrown out each year Roughly 500M used filters are thrown out each year Not recyclable  contaminate landfills with hazardous waste: Not recyclable  contaminate landfills with hazardous waste: Trace metals, chlorinated solvents, gasoline, hydrocarbons, glycols and PCBs Trace metals, chlorinated solvents, gasoline, hydrocarbons, glycols and PCBs Contain up to ¼ gallon of used oil Contain up to ¼ gallon of used oil 1 gallon of improperly managed used oil can contaminate 1M gallons of water 1 gallon of improperly managed used oil can contaminate 1M gallons of water

Environmental Impact Benefits of ceramic filters: Can be crushed, cleaned and recycled Can be crushed, cleaned and recycled Oil trapped in the filter can be reclaimed Oil trapped in the filter can be reclaimed Recycling 2 gallons of used oil can generate enough electricity to run the average household for almost 24 hours Recycling 2 gallons of used oil can generate enough electricity to run the average household for almost 24 hours NEU has used SimaPro to prove the ceramic element housing’s environmental superiority over standard filters NEU has used SimaPro to prove the ceramic element housing’s environmental superiority over standard filters

1. Dirty oil enters honeycomb channels 2. Oil passes through the wall  debris is trapped 3. Clean oil flows out channels through opposite open end Ceramic Filtering Process Dirty Oil Clean Oil Honeycomb cell pattern

NEU Ceramic Oil Filter Background NEU’s previous accomplishments: Confirmed that the ceramic component is recyclable or compactable. Confirmed that the ceramic component is recyclable or compactable. Established that a ceramic oil filter can improve performance over that of a conventional paper oil filter. Established that a ceramic oil filter can improve performance over that of a conventional paper oil filter. Produced a prototype that accomplished most project goals. Produced a prototype that accomplished most project goals.

Project Goals To design the housing of the ceramic oil filter with the following objectives: Ease of filter replacement Ease of filter replacement No special tools required No special tools required Design for the home mechanic Design for the home mechanic Improve Manufacturability Improve Manufacturability Reduce part count Reduce part count Use less costly manufacturing operations Use less costly manufacturing operations Make Production Cost Competitive Make Production Cost Competitive Minimize scrap Minimize scrap Make design robust Make design robust

reNU Housing Design Reduced part count Reduced part count Simpler parts Simpler parts Easier to assemble Easier to assemble reNU Design NEU Design

Engine Interface Adapter (EIA) Inner Element Seal Outer Element Seal Threaded Ring Filter Spring Plate Anti-drainback Valve (ADV) EIA Seal O-Ring Can Spring reNU Design Components

Oil Flow Through Filters NEU prototype Clean Oil Dirty Oil reNU prototype

re NU Housing Design Design Parameters Bypass Valve Activation Pressure: 12 psi Bypass Valve Activation Pressure: 12 psi Equivalent Flow Rate Equivalent Flow Rate at 3 GPM Dimensions ≤ FRAM PH8A Dimensions ≤ FRAM PH8A Exploded reNU Design

Engine Interface Adapter (EIA) Engine Interface Adapter (EIA) Machined Flats Machined Flats 3.0”-8 UNC 2A 3.0”-8 UNC 2A 1018 Low Carbon Stainless Steel 1018 Low Carbon Stainless Steel Threaded Ring Threaded Ring Press Fit FRAM PH8A Can Press Fit FRAM PH8A Can 3.0”-8 UNC 2B 3.0”-8 UNC 2B 1018 Low Carbon Stainless Steel 1018 Low Carbon Stainless Steel Spring Spring ¼” Deflection at 12 psi (~40 lbs) ¼” Deflection at 12 psi (~40 lbs) Can Can FRAM PH8A FRAM PH8A Tin Coated Cold Rolled, Aluminum Killed Drawn Quality Sheet Steel (ASTM A599 and A1008M) Tin Coated Cold Rolled, Aluminum Killed Drawn Quality Sheet Steel (ASTM A599 and A1008M) re NU Housing Design reNU Design

reNU Rubber Components 5 rubber components: 3 Seals 3 Seals EIA seal EIA seal Inner element seal Inner element seal Outer element seal Outer element seal O-ring O-ring Anti-drainback valve (ADV) Anti-drainback valve (ADV) Material Selection: Nitrile rubber Nitrile rubber Most commonly used hydrocarbon elastomer Most commonly used hydrocarbon elastomer Low cost Low cost Oil resistant Oil resistant Temperature range: -40°F - 225°F Temperature range: -40°F - 225°F Peroxide cured: -40°F - 275°F Peroxide cured: -40°F - 275°F High tensile strength High tensile strength Resistance to abrasion, tearing, and compression set Resistance to abrasion, tearing, and compression set Inner Element Seal Outer Element Seal Anti-Drainback Valve (ADV) EIA Seal O-Ring

re NU Pressure Release Method Normal oil flow Filter clogged; Clean Oil Dirty Oil Bypass method in operation

Testing Apparatus

Pressure Drop versus Flow Rate Flow Rate (gpm) Pressure Drop (psi) Pressure Drop at 3 gpm: FRAM PH8A reNU

Filtration Efficiency Efficiency % Particle Size (microns) 91% 89% Average Filtration Efficiency: FRAM PH8A reNU

reNU Prototype vs Ideal Design Weight Decrease to 1.67 lbs Height Decrease to 5.8 in Functionality Spring Ceramic element Rubber components Press-fitting Prototype Ideal Design

Manufacturing Process EIA Assembly EIA Assembly Can Assembly Can Assembly Spring Assembly Spring Assembly Filter Assembly Filter Assembly Deburring Deburring Turning Turning Drilling Drilling Assembling Assembling Painting Painting Press-fitting Press-fitting Packaging Packaging Manufacturing Operations Needed Housing Subassemblies 7 Operations, 14 Total Processing Steps KEYKEY KEYKEY

QuestionsQuestions

Current Crushing Technology

Filtration Efficiency Count per CC Particle Size (microns) Count per CC Particle Size (microns) FRAM Filter re NU Filter

NEU Ceramic Oil Filter Background Traditional paper filter NEU’s latest prototype Clean Oil Dirty Oil

NEU Ceramic Oil Filter Background Traditional FRAM Paper Filter reNU Prototype