Fuel injection pipe with poppet valve

Abstract

A fuel injector assembly includes a tube having an outer circumferential surface, an inner circumferential surface defining a hollow central portion, a closed distal end, an open proximal end defining an annular seat, and an orifice extending between the inner and outer surfaces. A poppet valve has a radially extending flange and is received in the hollow central portion such that the flange is disposed on the annular seat. The valve defines an inlet, a cylindrical valve chamber in fluid communication with the inlet, an outlet from the valve chamber, and a valve seat between the inlet and the outlet. A ball disposed within the valve chamber is movable between a closed position in which the ball seats on the valve seat to shut off fluid communication between the inlet and the outlet, and an open position in which the ball is spaced from the valve seat to place the inlet and the valve chamber in fluid communication.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. non-provisional application No. 16 / 876,700, filed May 18, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to the thermal management of electric motors, and more specifically, to a thermal management system including an injection pipe with a lift valve. Background Technology

[0004] Electric vehicles include one or more motors, which together form a motor for driving the vehicle and a generator for charging a traction battery. The motors generate heat during operation and require cooling. The motors can be air-cooled or liquid-cooled. Air-cooled motors may include cooling fins that help transfer heat from the motor to the air. Liquid-cooled motors can be cooled using oil or water-based coolants. Motors are often housed in the transmission and can be liquid-cooled using transmission fluid (oil). Summary of the Invention

[0005] According to one embodiment, the oil cooling system of the hybrid power module includes an injection pipe attachable to the housing of the hybrid power module. The injection pipe includes a sidewall having an outer circumferential surface and an inner circumferential surface defining a hollow central portion. The pipe also includes a proximal end defining an axially recessed annular seat and an orifice extending between the inner and outer surfaces. A lift valve is disposed in the hollow central portion. The lift valve includes a cylindrical body seated on the inner surface and having a radially extending flange having a first side portion disposed on the annular seat and a second side portion configured to abut against the housing of the hybrid power module by attaching the injection pipe to the housing. The body defines an inlet, a cylindrical valve chamber in fluid communication with the inlet and having a valve seat, and an outlet passage. The valve has a ball disposed within the valve chamber and movable between a closed position and an open position, in which the ball is seated on the valve seat to cut off fluid communication between the inlet and the valve chamber, and in an open position, the ball is spaced apart from the valve seat to place the inlet and the valve chamber in fluid communication.

[0006] According to another embodiment, an oil cooling system includes an oil jet tube having a sidewall with an outer circumferential surface and an inner circumferential surface defining a hollow central portion. The tube also has a proximal end defining an axially recessed annular seat and an aperture extending between the inner surface and the outer surface. A poppet valve is disposed in the hollow central portion and is configured to be secured to a housing by the tube. The poppet valve includes a cylindrical body seated on the inner surface and having a radially extending flange disposed on the annular seat. The body defines an inlet and a cylindrical valve chamber in fluid communication with the inlet. The valve chamber has a valve seat and an outlet passage. The valve has a ball disposed within the valve chamber. The ball is axially movable between a closed position in which the ball is seated on the valve seat to shut off fluid communication between the inlet and the valve chamber and an open position in which the ball is spaced apart from the valve seat to place the inlet and the valve chamber in fluid communication.

[0007] According to yet another embodiment, a hybrid module includes a housing defining a first oil passage and a second oil passage and a bore having a bottom and a sidewall extending from the bottom and defining a periphery of the bore. The first passage opens to the bottom and the second passage opens to the sidewall. An oil jet tube defines a hollow central portion and an aperture in fluid communication with the hollow central portion and extending completely through the sidewall of the tube. The tube includes an insertion portion, a protruding portion, and a collar between the insertion portion and the protruding portion. A poppet valve is disposed in the hollow central portion. The poppet valve defines an inlet, a valve chamber, an outlet, and a movable ball configured to open and close the chamber. The insertion portion is received in the bore such that the collar is disposed against the housing, the first passage is in fluid communication with the inlet, and the second passage is in fluid communication with the outlet. An electric machine is positioned to receive oil from the second passage. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 FIG. 1 illustrates a schematic cross-sectional side view of an electric machine assembly.

[0009] Figure 2 FIG. 2 illustrates a cross-sectional perspective view of an oil jet tube assembly of the electric machine assembly. DETAILED DESCRIPTION

[0010] Embodiments of the present disclosure are described herein. It should be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features can be exaggerated or minimized for the purpose of clarity and illustration. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those skilled in the art will appreciate, the various features illustrated and described in connection with any one of the figures can be combined with features illustrated and described in connection with one or more other figures, to produce yet other embodiments. Combinations of features illustrated and described in connection with the figures are not limited to only the combinations explicitly illustrated and described.

[0011] Modern motor vehicles can be powered by a number of different drives such as an internal combustion engine, an electric machine, or in the case of a hybrid, a combination of an internal combustion engine and an electric machine. The electric machine requires thermal management to prevent overheating. The thermal management system can employ air cooling or liquid cooling to regulate the temperature of the electric machine. The liquid cooling system can utilize a water-based coolant or oil (e.g., transmission fluid) as the working fluid. In one example embodiment, the thermal management system can spray or otherwise provide oil to the stator, rotor, or both the stator and rotor of the electric machine to regulate the temperature.

[0012] Referring to Figure 1 , a cross-section of the electric machine assembly 20 is schematically illustrated. Depending on the type of vehicle architecture, the electric machine 22 can be disposed in different locations and packaged in different larger assemblies. In the case of a hybrid vehicle, the electric machine 22 can be disposed within a hybrid module (sometimes referred to as a hybrid transmission). In the case of a pure electric vehicle (EV), the electric machine can be packaged as part of an electric axle. Figure 1 The electric machine 22 is illustrated attached to a housing 24. The housing 24 can be a transmission housing, such as in the case of a hybrid architecture, or can be any other suitable housing. That is, the present disclosure is not limited to any particular vehicle type or architecture.

[0013] According to embodiments, the electric machine 22 can be one or more electric machines. The electric machine 22 can be configured to operate as a motor to drive the vehicle or as a generator to charge the traction battery. The electric machine 22 can be an alternating current (AC) electric machine or a direct current (DC) electric machine. In one or more embodiments, the electric machine 22 can be a three-phase AC electric machine. The electric machine 22 can include a housing 23 attached to a housing 24, a stator 25, and a rotor (not shown) supported for rotation within the stator 25. The electric machine assembly 20 includes a centerline 27 extending through a center of the rotor. Directional terms used herein are with reference to the view and orientation shown in the example figures. Terms such as "outer" and "inner" are relative to the centerline 27. For example, an "outer" surface means that the surface faces away from the centerline 27 or is located outward of another "inner" surface. Terms such as "radial," "diameter," "circumferential," and the like are also relative to the centerline 27. The terms "front," "rear," "upper," and "lower" indicate directions in the referenced figures.

[0014] In Figure 1 In the example, the electric machine 22 is cooled by oil delivered through a passage defined in the housing 24. The oil can be transmission fluid controlled by a valve body or other control device of the transmission. An oil jet tube assembly 26 controls the flow of oil from the housing 24 to the electric machine 22. The tube assembly 26 is interposed between the passage of the housing 24 and the downstream electric machine 22 and can include a poppet valve 28 that selectively allows oil to flow from the passage of the housing 24 to the electric machine 22.

[0015] In one or more embodiments, the housing 24 defines an oil passage 30 to the valve 28 and an oil passage 32 from the valve 28 to the electric machine 22. The oil passages 30 and 32 are connected by a bore 34 defined in the housing 24. The bore 34 includes a bottom wall 36 and a sidewall 38 extending from the bottom wall 36 to a face 40 of the housing 24. The passage 30 is open to the bottom wall 36 and the passage 32 is open to the sidewall 38. The passage 32 extends from the bore 34 to a cavity 35 that receives at least a portion of the electric machine 22. The bore 34 receives an insertion portion 42 of the oil jet tube assembly 26. When the poppet valve 28 is open, oil is allowed to flow from the passage 30 to the passage 32, and when the poppet valve 28 is closed, the passages 30 and 32 are fluidly isolated, i.e., their fluid connection is cut off. The oil passage 30 can generally extend axially and the oil passage 32 can generally extend radially or obliquely.

[0016] Referring to Figure 1 and Figure 2The tube assembly 26 includes a tube 50 having a sidewall 52 that defines an outer circumferential surface 54 (outer diameter) and an inner circumferential surface 56 (inner diameter) that defines a hollow central portion 58. The tube 50 can generally extend axially in parallel with the centerline 27 and can be located radially outward of the motor 22. This orientation is not required and can be changed in other embodiments. The tube 50 can be positioned above the motor 22 so that oil can be sprayed from the tube 50 onto the motor 22 (as will be described in detail below). The tube 50 can include an open proximal end 60 and a closed distal end 62 having an end face 64. One or more orifices 66, 68 are defined in the tube 50 and extend from the outer circumferential surface 54 to the inner circumferential surface 56. The orifices 66, 68 allow oil disposed within the hollow central portion 58 to exit the tube 50. The tube 50 includes a collar 70 and a protrusion 72 that extends out of the housing 24. The collar 70 can be in the form of two ears 74. The ears 74 can extend from opposite sides of the tube 50. Each of the ears 74 can define a through hole 76 configured to receive a fastener 78. The fastener 78 can be threaded into a threaded hole 80 of the housing 24. The tube 50 defines a circular recess 82 that is located on the insert portion 42. A seal 84, such as an O-ring, is received in the recess 82. The seal 84 is configured to engage with the sidewall 38 of the bore to form an oil tight interface.

[0017] The poppet valve 28 is secured to the housing through the tube 50 rather than having the poppet valve 28 as a separate assembly that is attached to the housing 24. This arrangement results in a smaller package and can be used in hybrid and motor modules that have limited axial spacing. In the illustrated embodiment, the housing 24 has limited axial spacing between the passage 30 and the motor cavity 35. The poppet valve 28 and the tube 50 are fitted in this limited axial spacing by placing the poppet valve 28 within the tube 50 and using the tube 50 to secure the poppet valve 28 against the housing 24.

[0018] The poppet valve 28 includes a cylindrical body 86 having a base 88, a barrel 90, and a flange 92 that extends radially outward from the base 88. The base 88 has an outer diameter 91 that substantially matches (albeit slightly smaller for clearance) the inner diameter 56 of the tube 50. The barrel 90 extends axially from the base 88 and has an outer diameter 93 that is smaller than the inner diameter 56 of the tube 50 so that an annular gap 95 is formed between the barrel 90 and the inner diameter 56. The base 88 defines a circular recess 94 that is configured to receive a seal 96, such as an O-ring. The seal 96 is configured to engage with the inner circumferential surface 56 when the valve 28 is installed into the tube 50. The recess 94 can be adjacent to the flange 92 so that the seal 96 engages with the flange 92. The proximal end 60 of the tube 50 defines an annular seat 98 that is axially recessed and configured to receive the flange 92.

[0019] The poppet valve 28 can be a passive device that is biased to close and open in response to oil pressure exceeding a threshold. The valve 28 can include a valve chamber 100 that houses a ball 102 and a spring 104. The base 88 defines an inlet 108 and a valve seat 106 that surrounds the inlet 108. The valve seat 106 is sized and shaped to receive the ball 102 and create an oil-tight seal that prevents oil from flowing from the inlet 108 into the valve chamber 100. The spring 104 is disposed between the ball 102 and a spring retainer 108 at a distal end of the barrel 90. The spring 104 biases the ball 102 against the valve seat 106, which can be referred to as a closed position. When the oil pressure acting on the ball 102 exceeds the strength of the spring 104, the spring 104 compresses to allow the ball 102 to move axially along the barrel 90 to one or more open positions. The spring 104 is adjustable to adjust the pop pressure of the valve 28. The barrel 90 defines one or more orifices 110 (outlets) that allow oil to flow out of the valve 28 when the ball 102 is in one or more open positions. The oil exits the orifices 110 and collects within the tube 50. The oil then exits the tube via the orifices 66, 68 to contact the motor 22 and remove heat. The oil exiting the orifice 66 flows into the channel 32, which can be connected to internal wiring within the motor 22, and the oil exiting the orifice 68 can drip or spray onto the housing 23 of the motor 22. In some embodiments, a nozzle can be attached to the orifice 68. The oil eventually drains to an oil sump and is recirculated through the system. In some embodiments, a heat exchanger (not shown) can cool the oil before recirculation to the motor 22.

[0020] While the foregoing describes exemplary embodiments, it is not intended to describe all possible forms of the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, features of various embodiments can be combined to form further embodiments of the present application that can not be explicitly described or illustrated. While various embodiments can have been described as providing advantages or being free from disadvantages when compared with other embodiments or prior art implementations, one of ordinary skill in the art will appreciate that one or more features or aspects of any embodiment can be

[0021] The following is a list of reference numerals shown in the drawings. It should be understood, however, that the use of these terms is for the purpose of illustration only in connection with one embodiment. And, the use of a reference numeral associated with a particular term in the drawings and in the claims is not intended to limit the claims to only the illustrated embodiment.

[0022] Parts List:

[0023] Motor assembly 20

[0024] Motor 22

[0025] Housing 23

[0026] Housing 24

[0027] Stator 25

[0028] Oil injection tube assembly 26

[0029] Centerline 27

[0030] Poppet valve 28

[0031] Passage 30

[0032] Passage 32

[0033] Bore 34

[0034] Cavity 35

[0035] Bottom wall 36

[0036] Side wall 38

[0037] Face 40

[0038] Insert portion 42

[0039] Tube 50

[0040] Side wall 52 outer circumferential surface 54 inner circumferential surface 56 hollow central portion 58 proximal end 60 distal end 62 end face 64 aperture 66 aperture 68 collar 70 protrusion 72 ear 74 bore 76 fastener 78 bore 80 recess 82 seal 84 cylindrical body 86 base 88 barrel 90 outer diameter 91 flange 92 outer diameter 93 recess 94 annular gap 95 seal 96 annular seat 98 valve chamber 100 ball 102 spring 104 valve seat 106 inlet 108 spring retainer 108 aperture 110

Claims

1. An oil cooling system for a hybrid module, the system comprising: an oil jet tube attachable to a housing of the hybrid module and including a sidewall having an outer circumferential surface and an inner circumferential surface defining a hollow central portion, the tube further including a proximal end defining an axially recessed annular seat and an aperture extending between the inner and outer circumferential surfaces; and a poppet valve disposed in the hollow central portion, the poppet valve including: a cylindrical body seated on the inner surface and having a radially extending flange with a first side disposed on the annular seat and a second side configured to be secured against the housing of the hybrid module by attaching the oil jet tube to the housing, the body defining an inlet, a cylindrical valve chamber in fluid communication with the inlet and having a valve seat, and an outlet passage, and a valve having a ball disposed within the valve chamber and axially movable between a closed position in which the ball seats on the valve seat to shut off fluid communication between the inlet and the valve chamber and an open position in which the ball is spaced from the valve seat to place the inlet and the valve chamber in fluid communication, a bore defined in the housing; a first oil passage defined in the housing and extending into the bore; and a second oil passage extending from a sidewall of the bore, wherein the oil jet tube is received in the bore such that the second side of the flange is disposed against the wall of the bore, the inlet is opposite the first oil passage, and the aperture is aligned with the second oil passage.

2. The oil cooling system of claim 1, wherein, the valve further having a spring biasing the ball to the closed position.

3. The oil cooling system of claim 1, wherein, the poppet valve further including a seal disposed against the flange and the inner circumferential surface to form an oil tight seal between the hollow central portion and the poppet valve.

4. The oil cooling system of claim 3, wherein, the seal is an O-ring.

5. The oil cooling system of claim 3, wherein, the sidewall defines a circular groove recessed into the outer circumferential surface and further includes a second seal disposed in the groove.

6. The oil cooling system of claim 1, wherein, the oil jet tube further includes a collar extending radially outward from the sidewall and configured to be attached to the housing of the hybrid module.

7. The oil cooling system of claim 1, wherein, the cylindrical body further has a base portion having an outer diameter substantially matching an inner diameter of the inner circumferential surface and a barrel portion having an outer diameter less than the inner diameter to form an annular gap therebetween.

8. The oil cooling system of claim 1, wherein, the oil jet tube has an end face at a distal end of the tube to close the hollow central portion.

9. The oil cooling system of claim 1, wherein, the sidewall defines a circular groove recessed into the outer circumferential surface and further includes a seal disposed in the groove.

10. An oil jet tube assembly comprising: a tube including an outer circumferential surface, an inner circumferential surface defining a hollow central portion, a closed distal end, an open proximal end defining an axially recessed annular seat, and an aperture extending between the inner and outer surfaces; and a poppet valve disposed in the hollow central portion, the poppet valve including: a cylindrical body seated on the inner surface and having a radially extending flange with a first side disposed on the annular seat and a second side configured to be secured against the housing of the hybrid module by attaching the oil jet tube to the housing, the body defining an inlet, a cylindrical valve chamber in fluid communication with the inlet and having a valve seat, and an outlet passage, and a valve having a ball disposed within the valve chamber and axially movable between a closed position in which the ball seats on the valve seat to shut off fluid communication between the inlet and the valve chamber and an open position in which the ball is spaced from the valve seat to place the inlet and the valve chamber in fluid communication, a bore defined in the housing; a first oil passage defined in the housing and extending into the bore; and a second oil passage extending from a sidewall of the bore, wherein the oil jet tube is received in the bore such that the second side of the flange is disposed against the wall of the bore, the inlet is opposite the first oil passage, and the aperture is aligned with the second oil passage. A poppet valve configured to be secured to a housing by the tube, the poppet valve including a radially extending flange and being received in the hollow central portion such that the flange is disposed on the annular seat, the valve defining an inlet, a cylindrical valve chamber in fluid communication with the inlet, an outlet from the valve chamber, and a valve seat between the inlet and the outlet, wherein a ball is disposed within the valve chamber and is movable between a closed position in which the ball seats on the valve seat to shut off fluid communication between the inlet and the outlet and an open position in which the ball is spaced from the valve seat to place the inlet and the outlet in fluid communication.

11. The fuel rail assembly of claim 10, wherein, The valve further has a spring biasing the ball to the closed position.

12. The fuel rail assembly of claim 10, wherein, The tube has a circular groove recessed into the outer circumferential surface and further includes a seal disposed in the groove.

13. The fuel rail assembly of claim 12, wherein, The tube defines a collar extending radially outward from the outer circumferential surface, wherein the collar defines an axially extending bore.

14. The fuel rail assembly of claim 10, wherein, The poppet valve further includes a seal disposed against the flange and the inner circumferential surface to form an oil tight seal between the hollow central portion and the poppet valve.

15. The fuel rail assembly of claim 14, wherein, The seal is disposed in a groove defined in the poppet valve.

16. A hybrid module comprising: a housing defining a first oil passage and a second oil passage and a bore having a bottom and a sidewall extending from the bottom and defining a periphery of the bore, wherein the first oil passage opens to the bottom and the second oil passage opens to the sidewall; an oil jet tube defining a hollow central portion and an orifice in fluid communication with the hollow central portion and extending completely through the sidewall of the tube, the tube including an insert portion, a protruding portion, and a collar between the insert portion and the protruding portion; a poppet valve disposed in the hollow central portion, the poppet valve defining an inlet, a valve chamber, an outlet, and a movable ball configured to open and close the chamber, wherein the insert portion is received in the bore such that the collar is disposed against the housing, the poppet valve is secured against the bottom of the bore by the oil jet tube, the first oil passage is in fluid communication with the inlet, and the second oil passage is in fluid communication with the outlet; and an electric machine positioned to receive oil from the second oil passage.

17. The hybrid module of claim 16, wherein, The valve chamber includes a valve seat and the poppet valve closes when the ball seats on the valve seat and opens when the ball is spaced from the valve seat.

18. The hybrid module of claim 16, wherein, The insert portion of the tube defines a circular groove and further includes a seal disposed in the groove and seated against the sidewall of the bore.

19. The hybrid module of claim 16, wherein, The poppet valve further includes a seal disposed against the hollow central portion to form an oil tight seal between the hollow central portion and the poppet valve.

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