Two-stage valve assembly

Abstract

A two-stage valve assembly is provided. The two-stage valve assembly for a vehicle lift system includes an outer sleeve extending along an axis between a first end and a second end. A stator is located at the first end and a valve opening is located at the second end. The two-stage valve assembly includes an armature assembly for selectively closing the valve opening and opening the valve opening in a first stage open position and a second stage open position. The armature assembly includes a plunger movable along the axis, the plunger including a poppet portion having a poppet seal oriented toward the second end. A plunger seat is movable along the axis and is located between the poppet portion and the valve opening. The plunger seat includes a seat seal for sealing the valve opening. A seat passage extends through the seat seal and the plunger seat and is in fluid communication with the valve opening.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to a two-stage valve assembly for redistributing fluid in a lift system of a vehicle. BACKGROUND

[0002] It is often beneficial to adjust the height of a vehicle body. For example, by raising the vehicle body to an extended position or lowering the vehicle body to a collapsed position, the ground and roof clearance can be modified, allowing travel under conditions that would otherwise be impossible or undesirable. Devices that facilitate such adjustments are traditionally provided in or around the suspension struts of a motor vehicle. Typically, such devices include a lift housing disposed on a central axis that defines a chamber. A support tube is disposed in the chamber, and the lift housing is movable relative to the support tube along the central axis. Movement of the lift housing is typically driven using a hydraulic or pneumatic actuator. These actuators typically include a solenoid lift valve to control the pressure in the chamber. The lift valve must be designed to meet system flow, pressure, temperature, and voltage specifications while exhibiting robustness to run under multiple operating cycles.

[0003] In operations with higher flow requirements, greater flow and greater sealing area reduce pressure capability. Therefore, valves in the closed position typically require greater return springs to be able to meet increased backseal leakage and pressure. To overcome these limitations, the power input of the solenoid can be increased. However, the increase in solenoid operation is limited by constraints of the system, such as the physical size of system components. Therefore, some operating parameters will require an overall increase of the solenoid valve assembly.

[0004] Accordingly, it is always desirable to improve the operating framework and efficiency of devices that adjust the height of a vehicle body. SUMMARY

[0005] The foregoing has outlined rather broadly the features and technical advantages of the present invention so as to provide an overview of the detailed description of the invention that follows. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art will appreciate that the conception, upon which, the disclosure is based, can be readily utilized as the basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present invention. It will also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. This section provides a general summary of the disclosure, and no

[0006] The present invention provides a two-stage valve assembly that provides first stage fluid flow and second stage fluid flow, improving the operational framework and efficiency of conventional devices that have been used to selectively provide fluid flow. Further, the present invention provides a two-stage valve assembly with a simple design and low production cost.

[0007] One aspect of the present invention is to provide a two-stage valve assembly including a sleeve extending along an axis between a first end and a second end. A stator is located at the first end and a valve opening is located at the second end. The two-stage valve assembly includes an armature assembly for selectively closing and opening the valve opening in a first stage open position and a second stage open position. The armature assembly includes a plunger movable along the axis, the plunger including a poppet portion having a poppet seal oriented toward the second end. A plunger seat is movable along the axis and is located between the poppet portion and the valve opening. The plunger seat includes a seat seal for sealing the valve opening. A seat passage extends through the seat seal and the plunger seat and is in fluid communication with the valve opening. In a closed position, the poppet seal closes the seat passage and the seat seal closes the valve opening, in a first stage open position, the poppet seal is spaced apart from the seat passage, and in a second stage open position, the seat seal is spaced apart from the valve opening.

[0008] Another aspect of the present invention is to provide a two-stage valve assembly. The two-stage valve assembly includes a sleeve extending along an axis between a first end and a second end. A stator is located at the first end and a valve opening is located at the second end. A center body is located in the sleeve and extends between the stator and the valve opening, the center body defining a passage extending along the axis. The two-stage valve assembly includes an armature assembly for selectively opening and closing the valve opening. The armature assembly includes a poppet portion having a poppet seal located between the center body and the valve opening and movable along the axis. A plunger seat is movable along the axis and is located between the plunger and the valve opening. The plunger seat includes a seat seal for sealing the valve opening, a seat passage extending through the seat seal and the poppet portion, and in fluid communication with the valve opening. In a closed position, the poppet seal closes the seat passage and the plunger seat closes the valve opening.

[0009] Other applications will become apparent in light of the description provided herein. All statements herein reciting principles, aspects, and embodiments of the application, as well as specific examples thereof, are intended to be illustrative of the application and are not intended to limit the scope of the application. BRIEF DESCRIPTION OF DRAWINGS

[0010] Other advantages of the present application will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0011] Figure 1 is a side view of a two-stage valve assembly for raising and lowering the height of a vehicle in accordance with the principles of the present disclosure;

[0012] Figure 2 is an enlarged view of an armature assembly of the two-stage valve assembly in a closed position;

[0013] Figure 3 is an enlarged view of an armature assembly of the two-stage valve assembly in a first stage open position;

[0014] Figure 4 is an enlarged view of an armature assembly of the two-stage valve assembly in a second stage open position;

[0015] Figure 5 is an exploded view of certain features in the two-stage valve assembly;

[0016] Figure 6 is an exploded view of the armature assembly illustrating a first side of a plunger seat; and

[0017] Figure 7 is a perspective view of a second side of the plunger seat. DETAILED DESCRIPTION

[0018] Example implementations will now be described more fully with reference to the accompanying drawings. In general, the subject matter of example implementations involves a two-stage valve assembly for raising and lowering the height of a vehicle. However, these example implementations are provided merely to enable the present disclosure to be thorough and complete, and fully convey the scope of the disclosure to those skilled in the art. Numerous specific details are set forth in order to provide a thorough understanding of the example implementations of the present disclosure. Those skilled in the art having the benefit of this description will appreciate that one or more of the specific details are not required. It is possible, however, to practice example implementations in a variety of ways, and the description of example implementations should not be construed as limiting the scope of the present disclosure. In some example implementations, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0019] Referring to the drawings in which like reference numerals designate corresponding parts throughout the several views, a two-stage valve assembly is provided for raising and lowering the height of a vehicle by re-distributing fluid. The two-stage valve assembly improves the operational framework and efficiency of conventional devices for adjusting the height of a vehicle body.

[0020] Referring first to Figure 1The valve assembly 20 has a sleeve 24 extending along an axis A between a first end 26 and a second end 28. The valve assembly 20 includes a stator 30 at the first end 26 and an armature assembly 32 within the sleeve 24 and movable along the axis A. A valve cup 34 is located around the outside of the second end 28 and defines a generally annular shape that is closed around the second end 28. The valve cup 34 includes a valve body 36 that extends around the sleeve 24 toward the second end 28 and narrows to a valve structure 38 that enters the second end 28 and extends within the sleeve 24 along the axis A toward the first end 26. In some embodiments, the valve structure 38 can be tubular. The valve structure 38 defines a valve opening 40 that extends along the axis A for interfacing with the armature assembly 32. The sleeve 24 can include one or more outer apertures 33 near the end of the valve cup 34. A lower seal 42 is located around the outside of the valve body 36 in axial alignment with the second end 28, and an upper seal 44 is located around the sleeve 24 near the end of the valve cup 34 facing the first end 26. Both the lower seal 42 and the upper seal 44 can be annular and formed of an elastic material, and the lower seal 42 can define a larger gauge than the upper seal 44.

[0021] With continued reference to Figure 1 , a mounting ring 46 is located near the valve cup 34 facing the first end 26 and includes a main portion 48 that encircles the sleeve 24 and a flange portion 50 that extends radially outward from the main portion 48. The upper seal 44 encircles the outside of the main portion 48. An inner surface of the sleeve 24 can define a cylindrical chamber that extends around the axis A. The stator 30 enters the first end 26 of the sleeve 24. The stator includes a recess 58 that is aligned with the axis A. A bushing 60 is located in the recess 58 and can extend axially toward the second end 28. A center body 52 is located in the sleeve 24 and extends between the stator 30 and the second end 28. The center body 52 defines a passage 54 that extends through the center body 52 along the axis A. As will be described in greater detail below, the passage 54 guides certain features of the armature assembly 32. The valve assembly 20 includes a closed position Figure 1 , a first stage open position Figure 3 , and a second stage open position Figure 4 . In the closed position, the gap 56 can be located between the center body 52 and the stator 30.

[0022] As Figure 2As best illustrated, the armature assembly 32 includes a plunger 62 extending along the axis A between a stem 64 oriented toward the first end 26 and a poppet portion 66 oriented toward the second end 28. The armature assembly 32 is preloaded with a pair of springs including a first stage pre-load spring 68 and a second stage pre-load spring 70. The first stage pre-load spring 68 abuts a face end 69 of the stem 64 and extends through the bushing 60 into the recess 58 and into abutment with the stator 30. The second stage pre-load spring 70 extends from a plunger seat 72, around the stem 64, around the first stage pre-load spring 68, into the recess 58, through the bushing 60 and into abutment with the stator 30. The plunger seat 72 is located within the outer sleeve 24 between the poppet portion 66 and the second end 28. A seat sleeve 74 surrounds and locates the plunger seat 72 within the outer sleeve 24. The second stage pre-load spring 70 extends between and into abutment with the stator 30 and a front face 73 of the plunger seat 72. The center body 52 extends between the stator 30 and the front face 73 of the plunger seat 72. In operation, the passage 54 in the center body 52 locates and guides the first stage pre-load spring 68, the second stage pre-load spring 70 and the stem 64.

[0023] The poppet portion 66 includes a poppet body 67 and a plurality of fins 76 extending radially outward from the poppet body 67. In some embodiments, the plurality of fins 76 can include three or more circumferentially equidistant fins 76. The plunger seat 72 includes a plurality of fin channels 78 for slidably receiving the fins 76 and a central opening 80 for slidably receiving the poppet body 67 between the fins 76. The front face of the poppet portion 66 includes a poppet seal 82 and the front face of the plunger seat 72 includes a seat seal 84. A seat channel 86 extends through the seat seal 84 and the plunger seat 72 and is in fluid communication with the valve opening 40. The seat channel 86 is aligned with and extends into the central opening 80 for direct interfacing with the poppet portion 66. A surface 90 of the plunger seat 72 within the central opening 80 interfacing with the poppet seal 82 can include a non-planar shape. For example, the surface 90 can include a wall 92 having a tapered shape that outlines a portion of the seat channel 86 and narrows to an interface surface 94 facing the poppet seal 82. The seat channel 86 can widen near the interface surface 94. Thus, when the valve assembly 20 is in the closed position, the poppet seal 82 can be pressed against the interface surface 94, at least partially into the seat channel 86, and around a portion of the exterior of the wall 92. In some embodiments, the seat channel 86 has a different cross-sectional dimension than the valve opening 40, for example, a smaller cross-sectional dimension providing a slower flow rate.

[0024] Reference is now made to Figure 3, illustrating the armature assembly 32 in a first stage open position. In the first stage open position, the stator 30 attracts the plunger 62 and overcomes the preload of the first stage preload spring 68, moving the poppet seal 82 from the plunger seat 72 in a spaced apart relationship from the interface surface 94. The first stage open position allows fluid flow through the valve opening 40, the seat channel 86, and the fin channel 78 for a first stage pressure reduction.

[0025] Referring now to Figure 4 , the armature assembly 32 is illustrated in a second stage open position. After the first stage pressure reduction, the stator 30 attracts the plunger seat 72 and overcomes the preload of the second stage preload spring 70, moving the valve seat seal 84 away from the valve opening 40 to allow greater fluid flow and pressure reduction in the second stage open position. With the first stage pressure reduction, the need for a larger return spring to accommodate increased backseal leakage and pressure is eliminated.

[0026] Figure 5 is an exploded view of the armature assembly 32. The seat sleeve 74 includes at least one sleeve aperture 96 for allowing fluid flow therethrough. The at least one sleeve aperture 96 can be positioned in circumferential alignment with one or more fin channels 78. The seat sleeve 74 further includes a first sleeve wall 98 and a step 100 extending radially inward into a second sleeve wall 102. The plunger seat 72 includes a body portion 104 extending between a flange portion 106 and a seal retention portion 108. The flange portion 106 is adjacent the front face 73 and extends radially outward from the body portion 104 and the seal retention portion 108 is positioned proximate the seat seal 84 and extends radially inward from the body portion 104.

[0027] When assembled, the first sleeve wall 98 can define a first opening 110 sized to receive and guide the fin 76 and the flange portion 106. In some embodiments, the first opening 110 is cylindrical in shape and the first sleeve wall 98 slidably interfaces with the radially outermost portion 107 of the fin 76 and the flange portion 106. The second sleeve wall 102 can define a second opening 112 sized to receive the body portion 104. In some embodiments, the body portion 104 slidably interfaces with the second sleeve wall 102. A sleeve flange 114 can extend radially inward from the second sleeve wall 102 opposite the step 100 for receiving the seal retention portion 108. In some embodiments, the seal retention portion 108 slidably interfaces with the sleeve flange 114. In some embodiments, the center body 52 can include a step portion 116 extending radially inward toward the seat sleeve 74 such that the step portion 116 can be positioned within the first opening 110 and a non-step portion of the center body 52 can abut the first sleeve wall 98.

[0028] Referring to Figure 3 and Figure 5 Valve body 36 includes a series of valve body passages 118 in fluid communication with at least one of outer bore 33 and at least one of sleeve bore 96 for allowing fluid transfer in the first stage open position and the second stage open position. Valve cup 72 can also include an inner cup wall 120 that in turn defines a first cup portion 122, a second cup portion 124, a third cup portion 126, and a fourth cup portion 128 that terminates about a base 130 for abutting second end 28 of outer sleeve 24. Each of cup portions 122, 124, 126, and 128 can be spaced apart by cup steps 132 that can be conical in shape. Accordingly, first cup portion 122 can extend to one of cup steps 132 that extends radially inward to second cup portion 124, which can extend to another cup step 132 that extends radially inward to third cup portion 126, and third cup portion 126 can extend to another cup step 132 that extends radially inward to fourth cup portion 128. As best illustrated in Figure 3 Outer sleeve 24 proximate second end 28 can taper between a series of outer steps 134 to match the profile of cup steps 132 in order with cup portions 122, 124, 126, and 128, as best illustrated in

[0029] Figure 6 is an exploded view of armature assembly 32 illustrating a side of plunger seat 72 oriented toward second end 28. In some embodiments, poppet seal 82 includes a tab portion 136 molded into fin 76. Each of fins 76 can include a rounded outer edge 138 to facilitate assembly and sliding movement. Figure 7 is a perspective view of plunger seat 72 oriented toward first end 26. Center opening 80 can include a rounded surface 140 between fin passages 78 for facilitating slidable movement and contact of poppet body 67.

[0030] The two-stage valve assembly 20 can be integrated in various vehicle systems. In some embodiments, the two-stage valve assembly 20 can be integrated into a vehicle lift system, such as an air lift system. As such, the two-stage valve assembly 20 can selectively allow fluid transfer between two or more chambers. For example, in one open position, fluid can flow from the first chamber through the valve opening 40, and then the fluid can be transferred to the second chamber through the valve body passage 118, the outer bore 33, and the sleeve bore 96. In operation, the two-stage valve assembly 20 can generally operate in a closed position. The magnetic force generated from the stator 30 attracts the armature assembly 32 to overcome the force (e.g., pneumatic pressure) and the preload of the springs 68, 70. Because increased flow demand traditionally requires larger valve openings and increased pressure, the present disclosure provides a first stage open position to provide an initial pressure reduction. In the first stage open position, the poppet valve seal 82 is spaced apart from the seat passage 86. Once the pressure reduction is achieved, the stator 30 can move the seat seal 84 and the two-stage valve assembly 20 moves to a second stage open position that allows greater fluid flow. In some embodiments, the poppet valve seal 82 can be spaced apart from the seat passage 86, sealingly engaged with the seat passage 86, or move between spaced apart engagement and sealing engagement during the second stage open position.

[0031] It is to be understood that the description of the above-described embodiments is provided for illustrative purposes. In other words, the subject disclosure is not intended to be exhaustive or limited to the specific embodiments described. The various elements or features of a particular embodiment are generally not limited to that particular embodiment but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The various elements or features of a particular embodiment can also differ in many respects. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A two-stage valve assembly comprising: an outer sleeve extending along an axis between a first end and a second end; a stator located at and into the first end, the stator defining a recess aligned with the axis, and a valve opening located at the second end; a center body located in the outer sleeve and extending between the stator and the valve opening, the center body defining a center body passage extending along the axis; and an armature assembly for selectively closing the valve opening and opening the valve opening in a first stage open position and a second stage open position, the armature assembly comprising: a plunger movable along the axis and comprising a poppet portion having a poppet seal oriented toward the second end; a plunger seat movable along the axis and located between the poppet portion and the valve opening, the plunger seat comprising a seat seal for sealing the valve opening, a seat passage extending through the seat seal and the plunger seat, the seat passage being in fluid communication with the valve opening; and wherein, in a closed position, the poppet seal closes the seat passage and the seat seal closes the valve opening, in the first stage open position, the poppet seal is spaced apart from the seat passage, and in the second stage open position, the seat seal is spaced apart from the valve opening, wherein the plunger seat comprises a non-planar surface facing the poppet seal and surrounding the seat passage, the surface comprising a wall having a tapered shape that narrows toward the poppet seal, wherein a first stage pre-load spring extends from the stator through the center body passage to the plunger and biases the plunger toward the seat passage, wherein a second stage pre-load spring extends from the stator around the first stage pre-load spring and through the center body passage to the plunger seat and biases the plunger seat toward the valve opening, wherein the first stage pre-load spring and the second stage pre-load spring extend into the recess of the stator and abut the stator, and, in operation, the center body passage positions and guides the first stage pre-load spring and the second stage pre-load spring, wherein the first stage pre-load spring defines a smaller pre-load than the second stage pre-load spring. the poppet portion defines a plurality of radially outwardly extending fins on a side facing the valve opening, and the plunger seat defines a plurality of fin passages for receiving the fins and guiding the poppet portion along the axis.

2. The two-stage valve assembly of claim 1, wherein, the plunger seat is located in a seat sleeve, and wherein the plunger seat comprises a body portion and a flange portion extending radially outwardly from the body portion.

3. The two-stage valve assembly of claim 2, wherein, the seat sleeve comprises a first sleeve wall sized for slidable contact with the flange portion.

4. The two-stage valve assembly of claim 3, wherein, the seat sleeve comprises a second sleeve wall sized for slidable contact with the body portion.

5. The two-stage valve assembly of claim 4, wherein, ​ 6. The two-stage valve assembly of claim 5, wherein, The fins each include a radially outermost portion sized to be in slidable contact with the first sleeve wall.

7. A two-stage valve assembly comprising: an outer sleeve extending along an axis between a first end and a second end; a stator located at and into the first end, the stator defining a recess aligned with the axis, and a valve opening located at the second end; a center body located in the outer sleeve and extending between the stator and the valve opening, the center body defining a center body passage extending along the axis; and an armature assembly for selectively opening and closing the valve opening, the armature assembly comprising: a plunger movable along the axis and including a poppet portion having a poppet seal located between the center body and the valve opening and movable along the axis; a plunger seat movable along the axis between the plunger and the valve opening, the plunger seat including a seat seal for sealing the valve opening, a seat passage extending through the seat seal and poppet portion, the seat passage being in fluid communication with the valve opening; and wherein, in a closed position, the poppet seal closes the seat passage and the plunger seat closes the valve opening, wherein the plunger seat includes a non-planar surface facing the poppet seal and surrounding the seat passage, the surface including a wall having a tapered shape that narrows toward the poppet seal, wherein a first stage pre-load spring extends from the stator through the center body passage to the plunger and biases the plunger toward the seat passage, wherein a second stage pre-load spring extends from the stator around the first stage pre-load spring and through the center body passage to the plunger seat and biases the plunger seat toward the valve opening, wherein the first stage pre-load spring and the second stage pre-load spring extend into the recess of the stator and abut the stator, and, in operation, the center body passage positions and guides the first stage pre-load spring and the second stage pre-load spring, wherein the first stage pre-load spring defines a smaller pre-load than the second stage pre-load spring.

8. The two-stage valve assembly of claim 7, wherein, the poppet portion defines a plurality of radially outwardly extending fins on a side facing the valve opening, and the plunger seat defines a plurality of fin passages for receiving the fins and guiding the poppet portion along the axis.

9. The two-stage valve assembly of claim 7, wherein, a valve cup is sealed to the second end of the outer sleeve, the valve cup including a valve structure that is tubular and extends from the second end of the outer sleeve toward the first end, the valve opening being defined by the valve structure.

10. The two-stage valve assembly of claim 9, wherein, the outer sleeve defines at least one outer bore, and the valve cup defines at least one valve body passage in fluid communication with the at least one outer bore.

11. The two-stage valve assembly of claim 10, wherein, the plunger seat is located in a seat sleeve, and wherein the seat sleeve defines at least one sleeve bore in communication with the outer bore and the valve body passage. the plunger seat is located in a seat sleeve, and wherein the seat sleeve defines at least one sleeve bore in communication with the outer bore and the valve body passage.

12. The two-stage valve assembly of claim 7, wherein, The armature assembly opens the valve opening in an open position, the open position including a first stage open position when the poppet valve seal is moved by the stator in spaced relation from the seat passage, and wherein the open position includes a second stage open position when the seat seal is moved by the stator in spaced relation from the valve opening.

13. The two-stage valve assembly of claim 12, wherein, The first stage open position includes a first flow rate, and the second stage open position includes a second flow rate greater than the first flow rate.

14. The two-stage valve assembly of claim 7, wherein, The plunger includes a stem, and the first stage pre-load spring abuts an end face of the stem, and the second stage pre-load spring extends around the stem to the plunger seat.

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