Rotary valve

Abstract

A rotary valve includes a rotating component configured to rotate about a rotation axis. The rotating component includes a plurality of fluid openings formed on its outer surface, wherein each fluid opening forms a fluid inlet or fluid outlet leading to one of a plurality of fluid channels formed through the rotating component. The rotating component also includes a valve body therein, rotatably receiving the rotating component. The valve body includes five fluid ports formed therethrough, wherein each fluid port is configured to selectively align with one of the fluid openings of the rotating component depending on the rotational position of the rotating component relative to the valve body, to allow the rotary valve to operate as a five-way switching valve.

Description

Technical Field

[0001] This invention relates to rotary valves. More specifically, the rotary valve includes five different fluid ports to allow it to operate as a five-way switching valve. Furthermore, the rotary valve includes a rotating component rotatable within the valve body, wherein the rotating component has a variable outer peripheral wall radius to generate a variable sealing force between the rotating component and a sealing element associated with the valve body. Background Technology

[0002] A plug valve typically comprises a "plug" having a generally cylindrical or conical outer surface, received within a valve body having a corresponding cylindrical or conical inner surface. The plug typically includes at least one channel formed therethrough, wherein at least one end of each channel intersects the outer surface of the plug. Each channel is configured to allow fluid to communicate through the plug relative to any of a variety of flow configurations. The valve body typically includes one or more ports intersecting the inner surface of the valve body to allow fluid communication between any combination of ports of the valve body and channels of the plug. The plug is operatively connected to a rotary actuator configured to rotate the plug relative to the stationary valve body, thereby repositioning each channel in the channels relative to each stationary port. Depending on the configuration of the plug and valve body, this rotation of the plug relative to the valve body can switch some channels in the channels to fluid communication with their corresponding ports, or can terminate flow through at least one channel by aligning at least one channel with a portion of the inner surface of the valve body that does not have a port. The way the plug rotates relative to the valve body necessitates establishing a proper fluid tightness seal between the outer surface of the plug and the inner surface of the valve body. This ensures that the corresponding fluid does not leak into any relatively small cylindrical or tapered gap that may exist between the plug and the valve body to allow the plug to rotate easily relative to the valve body. Typically, such a seal is established by placing sealing elements around the periphery of each port on the inner surface of the valve body. Each sealing element is typically compressed between the inner surface of the valve body and the outer surface of the plug to ensure a proper seal regardless of the plug's rotational position. For example, these sealing elements can be formed from elastomeric materials, rigid plastic materials, or a combination of both.

[0003] Unfortunately, this sealing element exhibits an unfavorable relationship, where an increase in the sealing effect between the plug and the valve body tends to increase the amount of torque required to rotate the plug relative to the valve body. This is because the amount of compression applied to such a sealing element in the radial direction along the plug valve is directly related to the sealing effect provided. With increasing compression, the radial force existing between the inner surface of the sealing element and the outer surface of the plug also increases. This increased radial force increases the frictional force existing between the outer surfaces of the sealing element and the plug in the circumferential direction about the plug, which in turn increases the amount of torque required to overcome this frictional force when the plug rotates relative to the valve body. Therefore, the type of rotary actuator capable of providing the desired level of sealing effect for a given plug valve configuration may be limited to those with a corresponding rated torque, resulting in more expensive rotary actuators that also require greater power to operate in the desired manner.

[0004] One solution to minimize the amount of torque that must be delivered to the plug for the desired rotation of the plug is to reduce the friction between each of the sealing elements associated with the ports of the plug and the valve body. This can be achieved by forming the mating surfaces of the sealing elements and / or the plug with a relatively low-friction material. However, such low-friction materials are often expensive, require special and more complex manufacturing processes, or lack other properties, such as undesirable thermal expansion characteristics or corrosion resistance.

[0005] Therefore, there is a need in the art to produce a plug (rotating component) that can provide a desired level of sealing effect to each of the associated sealing elements without requiring a corresponding increase in the amount of torque required to rotate the plug relative to the associated valve body.

[0006] Furthermore, existing plug valves typically include only a limited number of possible configurations to define the flow pattern passing through the valve, such as a maximum of two or three suitable configurations. This significantly limits the ability of such plug valves to adapt to more complex flow patterns, in which one or more fluid flows must be directed to more than two or three possible flow paths. Therefore, it may be necessary to combine multiple different valve elements at different locations within a corresponding fluid system or multiple fluid systems to achieve the desired flow pattern of the fluid system. The use of additional valve elements increases the cost, complexity, and packaging space required to achieve such a flow pattern.

[0007] Therefore, there is a need in the art to produce a plug valve that can be repositioned to a greater number of different flow configurations that can be utilized, while maintaining the aforementioned tight fluid seal at each interaction between the plug and the valve body, so as to minimize the cost, complexity and packaging space of the plug valve. Summary of the Invention

[0008] Technical solutions to the problem

[0009] According to an embodiment of the invention, a rotary valve includes a rotating component configured to rotate about a rotation axis. The rotating component includes a plurality of fluid openings formed on its outer surface, wherein each fluid opening forms a fluid inlet or fluid outlet leading to one of a plurality of fluid channels formed through the rotating component. The rotating component also includes a valve body therein, rotatably receiving the rotating component. The valve body includes a plurality of fluid ports formed therethrough, wherein each fluid port is configured to selectively align with one of the fluid openings of the rotating component depending on the rotational position of the rotating component relative to the valve body. Attached Figure Description

[0010] Figure 1 This is an exploded perspective view of a rotary valve according to an embodiment of the present invention;

[0011] Figure 2 It is an exploded front cross-sectional view of the rotary valve taken through the axis of rotation of the rotary valve;

[0012] Figure 3 It is a bottom-view three-dimensional cross-sectional view of the rotary valve taken through one of a pair of layers of the rotary valve;

[0013] Figure 4 This is a partially enlarged perspective view of the rotating component of the rotary valve, showing the variable radius of the outer circumferential surface of the rotating component;

[0014] Figure 5 This is a partially enlarged cross-sectional view showing the interaction between the rotating components, valve body, and sealing elements of a rotary valve;

[0015] Figure 6 This is a schematic diagram of a fluid system utilizing a rotary valve;

[0016] Figure 7A It is a cross-sectional view taken through the first layer of the rotary valve when the rotary valve is operating in the first operating mode;

[0017] Figure 7B It is a cross-sectional view taken through the second layer of the rotary valve when the rotary valve is operating in the first operating mode;

[0018] Figure 8A It is a cross-sectional view taken through the first layer of the rotary valve when the rotary valve is operating in the second operating mode;

[0019] Figure 8B It is a cross-sectional view taken through the second layer of the rotary valve when the rotary valve is operating in the second operating mode;

[0020] Figure 9A It is a cross-sectional view taken through the first layer of the rotary valve when the rotary valve is operating in the third operating mode;

[0021] Figure 9B It is a cross-sectional view taken through the second layer of the rotary valve when the rotary valve is operating in the third operating mode;

[0022] Figure 10A It is a cross-sectional view taken through the first layer of the rotary valve when the rotary valve is operating in the fourth operating mode; and

[0023] Figure 10B It is a cross-sectional view taken through the second layer of the rotary valve when the rotary valve is operating in the fourth operating mode. Detailed Implementation

[0024] The following technical description of the subject matter, manufacture, and use of one or more inventions is merely exemplary in nature and is not intended to limit the scope, application, or use of any particular invention claimed in this application or in any other application filed under the priority of this application or a patent filed under this application. Regarding the disclosed methods, the order of the presented steps is merely exemplary in nature, and therefore the order of steps may differ in various embodiments. As used herein, “a” and “an” indicate the presence of “at least one” item; where possible, multiple such items may be present. Unless otherwise expressly indicated, all numerical values ​​in this description should be understood to be modified by the word “about” when describing the broadest scope of the technology, and all geometric and spatial descriptors should be understood to be modified by the word “substantially.” When applied to numerical values, “about” indicates that the calculation or measurement allows for a slight inaccuracy in the value (approximately to the exact value; about or reasonably close to the value; approximate). If, for some reason, the imprecision provided by “about” and / or “substantially” is not understood in its general meaning in the art, then “about” and / or “substantially” as used herein at least indicate variations that may be caused by common methods of measuring or using these parameters.

[0025] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” or “attached to” another element or layer, the element or layer may be directly on, joined to, connected to, or attached to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” or “directly attached to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.) should be interpreted in a similar manner. As used herein, the term “and / or” includes any and all combinations of one or more of the associated enumerated items.

[0026] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or portion from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence. Therefore, without departing from the teachings of the exemplary embodiments, the first element, first component, first region, first layer, or first portion discussed below may be referred to as a second element, second component, second region, second layer, or second portion.

[0027] Figures 1 to 1 Figure 0 illustrates a rotary valve 10 utilizing a rotating member 50 (plug) according to an embodiment of the present invention. The rotating member 50 has a reduced frictional contact surface to reduce the amount of torque required to rotate the rotating member 50 relative to the corresponding valve body 60. The illustrated rotary valve 10 may alternatively be referred to as a "plug valve" as needed.

[0028] The rotary valve 10 shown and described herein can also be used in any number of different applications and for selectively delivering any kind of different fluids or combinations of fluids through the rotary valve 10. The currently disclosed rotary valve 10 can be used in automotive applications, including, for example, the control of various fluids associated with the operation of the hydraulic, pneumatic, fuel, heating, ventilation, and air conditioning (HVAC) systems or coolant systems of the relevant vehicle. Fluids suitable for use with the rotary valve 10 can, as needed, be air commonly used in such vehicle systems, any hydraulic fluid, any type of fuel, any refrigerant, or any liquid coolant. However, it should also be apparent that the rotary valve 10 can be adapted for use with any fluid associated with any fluid delivery system without departing from the scope of the invention. Figure 6The illustration shows an exemplary application of the rotary valve 10, in which the rotary valve 10 is used to control the flow of various different coolant (water) through the rotary valve 10 according to the heating / cooling requirements of various components of the relevant motor vehicle.

[0029] A rotary valve 10 typically includes a rotating component 50, a valve body 60, and at least one sealing element 20 for providing a tight fluid seal between the rotating component 50 and the valve body 60. The rotating component 50 and the valve body 60 are each generally cylindrical in shape. The valve body 60 also includes a generally cylindrical opening 67 formed therein for rotatably receiving the rotating component 50. However, it should be apparent that the beneficial features of the invention can be maintained if the rotating component and the complementary opening formed in the valve body comprise other substantially axially symmetrical shapes. For example, without departing from the scope of the invention, the rotating component and the complementary opening formed in the valve body may each comprise a truncated conical shape or a truncated elliptical shape.

[0030] The rotating component 50 is configured to rotate relative to the valve body 60 about its axis of rotation. The axis of rotation of the rotating component 50 extends through the center of the rotating component 50 and defines its axial direction. The axis of rotation of the rotating component 50 also coincides with the central axis of the valve body 60, and more specifically, with the central axis of the rotary valve 10. Therefore, subsequent references to the axial direction of any of the rotary valve 10, the rotating component 50, or the valve body 60 refer to a direction arranged parallel to the axis of rotation of the rotating component 50. Furthermore, the radial direction of any of the rotary valve 10, the rotating component 50, or the valve body 60 can refer to any direction that passes through and is perpendicular to the axis of rotation of the rotating component 50.

[0031] The rotating component 50 is operatively coupled to a rotary motor or actuator (not shown) configured to provide the torque required to rotate the rotating component 50 about its axis of rotation relative to a stationary valve body 60. As a non-limiting example, the rotary motor or actuator may be a torque motor, a servo motor, an electric stepper motor, or a brushless DC motor. Without departing from the scope of the invention, any rotary motor or actuator with the torque and precision required to establish the desired rotational position of the rotating component 50 relative to the valve body 60 may be selected.

[0032] The rotating component 50 extends axially from its first end 151 to its second end 152. A first end wall 161 extends substantially perpendicular to the axial direction of the rotating component 50 from the first end 151, and a second end wall 162 extends substantially perpendicular to the axial direction of the rotating component 50 from the second end 152. Figure 1 and Figure 2As shown, the rotating component 50 may include a rod 56 extending from its first end 151 for operatively engaging a corresponding rotary motor or actuator of the rotary valve 10. The rotating component 50 also includes a cylindrical circumferential wall 153 extending between a first end wall 161 and a second end wall 162. The circumferential wall 153 includes an outer circumferential surface 171 radially outwardly facing the periphery of the valve body 60 and an inner circumferential surface 175 radially inwardly facing the axis of rotation of the rotating component 50.

[0033] The rotating component 50 defines a plurality of fluid channels 211, 212, 213 therethrough. Each of the fluid channels 211, 212, 213 provides fluid communication between two or more fluid openings 181, 191 formed on the outer or external surface of the rotating component 50. Specifically, the fluid openings 181, 191 include eight circumferential fluid openings 181 extending through the circumferential wall 153 to the outer circumferential surface 171 of the circumferential wall 153 and a single axial fluid opening 191 extending through the second end wall 162 to the second end 152 of the rotating component 50. Depending on the instantaneous operating mode of the rotary valve 10, each of the fluid openings 181, 191 may represent an inlet or outlet to the corresponding fluid channel 211, 212, 213. The specific arrangement of the fluid openings 181, 191 relative to the fluid channels 211, 212, 213 will be explained in detail below when describing the different possible operating modes of the rotary valve 10.

[0034] As in Figure 4 As best illustrated, the outer circumferential surface 171 of the circumferential wall 153 is divided into at least one sealing region 172 and at least one non-sealing region 173, wherein each circumferential fluid opening 181 is formed along the outer circumferential surface 171 at a position corresponding to a sealing region in the sealing region 172. Therefore, the entire periphery of each circumferential fluid opening 181 is surrounded by a corresponding sealing region in the sealing region 172, while each non-sealing region 173 is spaced apart from the periphery of each circumferential fluid opening 181.

[0035] Each sealing region in sealing region 172 forms a portion of the outer circumferential surface 171 configured to sealably engage with one of the sealing elements 20 with a first sealing force when the rotating component 50 is rotated to one of a plurality of operating positions of the rotating component 50, including operating positions in which a corresponding circumferential fluid opening 181 transmits fluid through the circumferential fluid opening and operating positions in which a corresponding circumferential fluid opening 181 does not transmit fluid through the circumferential fluid opening. Conversely, each non-sealing region in non-sealing region 173 refers to a portion of the outer circumferential surface 171 that does not directly surround one of the circumferential fluid openings 181 when the rotary valve 10 is actuated to one of its plurality of operating positions and therefore does not need to be directly sealed to one of the sealing elements 20. Therefore, each non-sealing region in non-sealing region 173 is configured to engage with one of the sealing elements 20 with a second sealing force less than the first sealing force. The first sealing force may be alternatively referred to as the maximum sealing force, and the second sealing force may be alternatively referred to as the minimum sealing force, as needed.

[0036] The sealing region 172 and the non-sealing region 173 are distinguished from each other by the difference in the radius of the outer circumferential surface 171 along each of the identification regions 172 and 173, as measured from the axis of rotation of the rotating component 50. Specifically, each sealing region in the sealing region 172 may include a first radius, and each non-sealing region in the non-sealing region 173 may include a second radius smaller than the first radius. The first radius may represent the maximum radius of the outer circumferential surface 171 configured to engage with one of the sealing elements 20, while the second radius may represent the minimum radius of the outer circumferential surface 171 configured to engage with one of the sealing elements 20. Thus, the sealing region 172 may alternatively be referred to as the large radius region 172 of the outer circumferential surface 171, and the non-sealing region 173 may alternatively be referred to as the small radius region 173 of the outer circumferential surface 171.

[0037] Figure 5 The illustration shows the transition of the outer peripheral surface 171 from a sealing region 172 with a first (maximum) radius to a non-sealing region 173 with a second (minimum) radius. Figure 5A radial gap 179 is also illustrated between the innermost surface of the radially facing part of the non-sealing region 173 and one of the sealing elements 20. The sealing element 20 is configured to engage with the outer circumferential surface 171 along both the sealing region 172 and the non-sealing region 173. Because the sealing element 20 is sized to be compressed between the rotating member 50 and the valve body 60 regardless of the rotational position of the rotating member 50, the illustrated gap 179 is practically non-existent during the operation of the rotary valve 10. The gap 179 is shown merely to illustrate the difference in radial compression of each sealing element in the sealing element 20, depending on whether the corresponding portion of each sealing element in the sealing element 20 is compressed between the valve body 60 and a sealing region in the sealing region 172 or between the valve body 60 and a non-sealing region in the non-sealing region 173. The radial gap 179 represents a reduction in the radial distance that the corresponding portion of the sealing element 20 must be radially compressed when clamped between the rotating member 50 and the valve body 60. This reduction in radial compression results in a decrease in the sealing force at each unsealed area in the unsealed area 173.

[0038] Each sealing region in sealing region 172 may be offset outwardly by an appropriate distance from the periphery of the corresponding circumferential fluid opening 181 along the outer circumferential surface 171 to form a sealing engagement with a sealing element in sealing element 20 that is momentarily aligned. In the illustrated example, the circular periphery shape of each circumferential fluid opening in circumferential fluid opening 181 results in each sealing region in sealing region 172 having a similar circular periphery shape, which is extended by a constant offset distance relative to the circular periphery shape of the corresponding circumferential fluid opening 181. The offset distance may correspond to the size of the engaging sealing element 20 that is radially aligned with the corresponding sealing region 172 to ensure the desired engagement between the engagement surfaces of sealing region 172 and sealing element 20. For example, as a non-limiting example, each sealing region in sealing region 172 may be offset outwardly by approximately 3 mm from the periphery of the corresponding circumferential fluid opening 181 to maintain engagement with a aligned sealing element in sealing element 20.

[0039] If it is possible Figure 4As observed, the position and size of each circumferential fluid opening in the circumferential fluid opening 181, and the magnitude of the offset of the periphery of each sealing region in the sealing region 172, allow some sealing regions in the sealing region 172 to intersect and thus merge with an adjacent sealing region in the sealing region 172 with respect to the circumferential direction of the rotating component 50. Such merging can occur in a transition region 177 of the outer circumferential surface 171, hereinafter referred to as the transition region 177. In the illustrated embodiment, the transition region 177 is formed by the portion of the outer circumferential surface 171 disposed between adjacent circumferential fluid openings in the circumferential fluid opening 181. The merging of adjacent sealing regions 172 at each transition region in the transition region 177 ensures that a first sealing force is applied to at least a portion of each sealing region in the merged sealing region 172 during the rotational transition of the rotating component 50 from one operating position to another. Although not shown herein, it should be apparent that the sealing area 172 may also be merged along the axial direction of the rotary valve 10 according to the magnitude of the offset and the axial spacing present between adjacent circumferential fluid openings 181, to similarly form the transition area 177.

[0040] As explained in detail below, the circumferential fluid opening 181 of the illustrated embodiment is disposed in two different layers that are axially spaced apart from each other. Therefore, the unsealed area 173 can extend along those axial locations of one of the layers of the outer circumferential surface 171 that does not have the circumferential fluid opening 181, such as those portions of the outer circumferential surface 171 disposed between the axially spaced layers of the circumferential fluid opening 181, or the portions of the outer circumferential surface 171 disposed to extend axially beyond the axial end portions of each layer of the layer in which the circumferential fluid opening 181 is located.

[0041] The presence of both the sealing region 172 and the non-sealing region 173 within the outer circumferential surface 171 distinguishes the rotating component 50 from similar rotating components (plugs) of prior art rotary valves. Specifically, the outer circumferential surface of each rotating component in prior art typically does not include differences between the radii of the outer circumferential surface depending on the presence of any circumferential fluid openings formed on the outer circumferential surface. For example, prior art cylindrical rotating components typically include a constant radius spanning the entire outer circumferential surface, regardless of the presence of one or more circumferential fluid openings intersecting the outer circumferential surface. Therefore, there are no structural features to reduce the radial sealing force applied to the outer circumferential surface, thereby reducing the frictional force present between the outer circumferential surface and any engaging sealing element.

[0042] Although the rotating component 50 is described below as having a specific configuration relative to the valve body 60 to achieve a variety of advantageous operating modes of the rotary valve 10, it should be apparent that the general concept that the radius between the sealing region 172 and the non-sealing region 173 varies depending on the position of each of the corresponding circumferential fluid openings 181 can be used in a variety of different rotary valve configurations without departing from the scope of the invention. For example, the rotating component 50 may include substantially any number and arrangement of circumferential fluid openings 181 opposite to those shown and described herein, while still appreciating the benefits of changing the radius of the outer circumferential surface 171 to the sealing region 172 and the non-sealing region 173. Furthermore, it should also be apparent that the benefits of varying the radius of the outer circumferential surface 171 between the sealing region 172 and the non-sealing region 173 can also be appreciated when the rotary valve 10 utilizes any radially compressible sealing assembly or sealing element other than the sealing element 20 shown and described herein.

[0043] Return to reference Figure 1 and Figure 2 A valve body 60 extends axially from its first end 61 to its second end 62. The first end 61 of the valve body 60 is configured to receive a cover 63 after the valve body 60 has axially received each of the rotating member 50 and the corresponding sealing element 20 therein. The cover 63 includes an opening 64 centered on the axis of rotation of the rotating member 50, wherein the opening 64 is configured to receive the rod 56 of the rotating member 50 passing through the opening 64. An O-ring 65 is provided between the first end 61 of the valve body 60 and the inner axial surface of the cover 63 to form a fluid-tight seal between the first end 61 of the valve body 60 and the inner axial surface of the cover 63. Another pair of O-rings (not shown) may be received between the inner circumferential surface of the cover 63 defining its opening 64 and the outer circumferential surface of the rod 56 of the rotating member 50 to form a fluid-tight seal between the inner and outer circumferential surfaces, including forming a fluid-tight seal during the rotation cycle of the rotating member 50 relative to the valve body 60.

[0044] An opening 67 of the valve body 60 defines each of an axial end wall 68 and a circumferential wall 69 of the valve body 60. The axial end wall 68 is configured to engage with the axial end of the rotating member 50 when the rotating member 50 is rotatably received within the valve body 60, and the circumferential wall 69 is configured to surround the rotating member 50 when the rotating member 50 is rotatably received within the valve body 60.

[0045] The circumferential wall 69 of the valve body 60 includes an inner circumferential surface 70 extending circumferentially around the rotating member 50. A plurality of support elements 71 extend radially inward from the inner circumferential surface 70 toward the axis of rotation of the rotating member 50. The support elements 71 are circumferentially spaced apart from each other at equal angular intervals of 72 degrees as measured from the axis of rotation of the rotating member 50. A recess 72 is circumferentially formed between each pair of adjacent support elements 71. Each recess 72 is shaped to receive one of the sealing elements 20 therein. The recess 72 may include various surface features for establishing and maintaining the position of a corresponding sealing element of the sealing element 20 in the recess 72 during rotation of the rotating member 50 relative to the stationary valve body 60.

[0046] The valve body 60 also defines a plurality of fluid ports 82, 83 passing through it. Each of the fluid ports 82, 83 is located in a component of a related fluid system located outside the rotary valve 10 (e.g., Figure 6 The components shown provide fluid communication with one of the fluid channels 211, 212, 213 formed through the interior of the rotating member 50. Specifically, fluid ports 82, 83 include four circumferential fluid ports 82 extending radially through the circumferential wall 69 to the inner circumferential surface 70 of the circumferential wall 69, and one axial fluid port 83 defined by the opening 67 extending through the axial end wall 68 into the interior of the valve body 60. Each of the circumferential fluid ports 82 is configured to selectively communicate with one of the circumferential fluid openings 181 of the rotating member 50, depending on the rotational position of the rotating member 50 relative to the valve body 60. The axial fluid port 83 is aligned with and in fluid communication with the axial fluid opening 191 of the rotating member 50 along an axis coinciding with the rotational axis of the rotating member 50. The specific arrangement of the fluid ports 82, 83 is described in detail when discussing different operating modes of the rotary valve 10.

[0047] Figure 1 , Figure 2 and Figure 5The best illustration shows the characteristics of each sealing element in sealing element 20. Each sealing element in sealing element 20 includes a first sealing structure 21 and a second sealing structure 22. The first sealing structure 21 may be alternatively referred to as a “hard” sealing structure 21, and the second sealing structure 22 may be alternatively referred to as a “soft” sealing structure 22, as needed. The hard sealing structure 21 is configured to directly engage with the outer circumferential surface 171 of the rotating component 50 to provide a tight fluid seal between the hard sealing structure 21 and the outer circumferential surface 171 when the rotating component 50 rotates to any different predetermined position of the rotating component 50 to induce any predetermined flow configuration through the rotary valve 10. More specifically, the hard sealing structure 21 is configured to engage with either a sealing region in sealing region 172 or a non-sealing region in non-sealing region 173, depending on the operating position of the rotating component 50. Conversely, the soft sealing structure 22 is configured to directly engage with the circumferential wall 69 of the valve body 60 within a recess 72 of the valve body 60. At least one of the soft-seal structures 22 is configured to surround the periphery of the radially innermost end of a corresponding circumferential fluid port 82 of the valve body 60 and form a fluid-tight seal around that periphery. Furthermore, the hard-seal structure 21 is also configured to engage with the soft-seal structure 22 to form a fluid-tight seal between the sealing structures 21 and 22 at a location where the sealing structures 21, 22 are positioned in direct contact with each other. Therefore, the sealing element 20 is configured to provide a fluid-tight seal between a momentarily aligned circumferential fluid opening 181 formed through the rotating member 50 and the radially innermost end of the circumferential fluid port 82 corresponding to the position of the sealing element 20 within the valve body 60. However, it will be apparent to those skilled in the art that alternative configurations of the corresponding sealing elements 20 can be used to maintain a beneficial relationship between each sealing element of the sealing elements 20 and the outer circumferential surface 171 of the rotating member 50, as described below. For example, in the absence of an adjacent rigid (hard) material, each sealing element in the sealing element may be formed only of an elastic compressible (soft) material, such as an elastomer, as needed.

[0048] Each hard seal structure in the hard seal structure 21 includes a pair of axially spaced outer peripheral portions 25. Each outer peripheral portion 25 defines a cylindrical flow opening 24 through which the flow opening 24 is substantially circular in circumferential shape when viewed from the radial direction of the rotary valve 10. Each flow opening 24 includes a peripheral dimension and shape substantially corresponding to the peripheral dimension and shape of any circumferential fluid opening 181 formed through the rotating member 50. Figure 5As shown, each of the outer peripheral portions 25 further includes a radially inner surface 28 and a radially outer surface 29. The radially inner surface 28 is configured to sealably engage with the outer peripheral surface 171 of the rotating member 50 along a sealing region of the sealing region 172 or along a non-sealing region of the non-sealing region 173, depending on the operating position of the rotating member 50 relative to the valve body 60. The radially outer surface 29 is configured to abut against the soft seal structure 22 in the radial direction with respect to the rotating member 50.

[0049] The hard seal structure 21 is formed of a fundamentally rigid material, such as a relatively rigid and relatively hard thermoplastic material. More specifically, the selected material is preferably a semi-crystalline thermoplastic. If a thermoplastic material is used, it is preferably polyphthalamide (PPA) or polyphenylene sulfide (PPS). PPA or PPS is preferred because each of these materials has relatively strong chemical resistance, heat resistance, and resistance to permanent deformation or abrasion. Furthermore, each of PPA and PPS can be provided as a thermoplastic resin, which can be injection molded using a relatively inexpensive manufacturing process to form the aforementioned shape and configuration of the hard seal structure 21, while remaining within the desired tolerances for establishing a desired sealing engagement with the outer circumferential surface 171 of the rotating component 50. Other rigid thermoplastic materials, such as polytetrafluoroethylene (PTFE), can be used to form the hard seal structure 21. However, PTFE cannot be manufactured using injection molding processes, thus requiring more expensive and difficult manufacturing processes to properly shape the hard seal structure 21 into the desired configuration to provide a fluid tight seal with the outer circumferential surface 171 of the rotating component 50. Alternatively, additional rigid materials—including various metals, ceramics, carbon graphite, and even glass—can be used to form the hard seal structure 21, depending on the specific application requirements of the associated rotary valve 10. However, again, such alternative materials besides the preferred thermoplastic materials listed above may be too expensive or increasingly difficult to manufacture within the desired tolerances for maintaining a fluid tight seal between the hard seal structure 21 and the rotating component 50.

[0050] The rotating component 50, and particularly the portion of the rotating component 50 forming its outer peripheral surface 171, can be formed of the same material as described as suitable for forming the hard seal structure 21. For example, as a non-limiting example, the rotating component 50 can be formed of a rigid thermoplastic material, such as PPA or PPS. In some embodiments, the same material may be chosen to form both the rotating component 50 and the hard seal structure 21. However, any rigid material may be chosen to form the rotating component 50 without departing from the scope of the invention.

[0051] Each soft seal structure in the soft seal structure 22 has a shape substantially complementary to the shape of each recess in the recess 72 formed in the valve body 60. The soft seal structure 22 is received within a corresponding recess in the recess 72 to prevent movement of each soft seal structure 22 in the radial or circumferential direction of the valve body 60. Each soft seal structure in the soft seal structure 22 includes a pair of axially spaced flow openings 44 formed therethrough. Each flow opening 44 is cylindrical in shape and extends through the corresponding soft seal structure 22 in the radial direction of the rotary valve 10. When viewed in the radial direction of the rotary valve 10, each flow opening 44 has a circular peripheral shape. Each flow opening 44 has a radius that is slightly reduced relative to each flow opening 24 formed through the hard seal structure 21 to ensure that the radially outer surface 29 of the hard seal structure 21 is supported against the soft seal structure 22.

[0052] As the given name suggests, the hard seal structure 21 is formed of a material that is harder and more rigid than the material selected for forming the soft seal structure 22. More specifically, the soft seal structure 22 is formed of a relatively soft material that is elastically deformable. As used herein, an elastically deformable material is one that is capable of deforming in such a way that it attempts to return to its initial position after deformation, and particularly when compressed in a given direction to reduce its size. The elasticity of the material selected for the soft seal structure 22 should be such that the material applies a radial spring force to the hard seal structure 21 in response to compression of the soft seal structure 22 toward the circumferential wall 69 in the radial direction. As a non-limiting example, the elastically deformable material may preferably be an elastomeric material such as Santoprene® thermoplastic elastomer, ethylene propylene diene monomer (EPDM) rubber, Nylabond® thermoplastic elastomer, EPDM foam, silicone rubber, nitrile, or urethane. The elastomeric material may be selected based on the type of fluid and the operating characteristics of the fluid delivered through the rotary valve 10, including, for example, desired chemical and heat resistance. In a preferred embodiment, the elastomer material can be selected as a low-hardness, Shore A grade soft-seal rubber to provide a low spring force to displacement ratio relative to the soft-seal structure 22. The use of a low-hardness material also helps to address the problems associated with tolerance superposition in any given direction—including the radial direction of the rotary valve 10—because the low spring force to displacement ratio allows for larger and more manufacturable tolerances when forming each sealing element in the sealing element 20.

[0053] The rigid material forming the hard seal structure 21 is selected to have a lower coefficient of friction than the elastic soft material selected for forming the soft seal structure 22. Therefore, compared to the case where the soft seal structure 22 is positioned to directly contact the rotating component 50 during its rotation, the rotation of the rotating component 50 via a corresponding rotary motor or actuator requires less torque to overcome the frictional force present between the radially inner surface 28 of the hard seal structure 21 and the outer circumferential surface 171 of the rotating component 50.

[0054] When the rotary valve 10 is in the fully assembled position, each flow opening 24 formed through one of the hard seal structures 21 engages with one flow opening 44 formed through the corresponding soft seal structure 22 to provide fluid communication between one of the circumferential fluid openings 181 formed through the rotating component 50 and an aligned circumferential fluid port 82 formed through the valve body 60. Each sealing element 20 with corresponding fluid passing through it establishes the necessary fluid tight seal to prevent any fluid leakage outside the desired fluid flow path. A rotary actuator or motor can rotate the rotating component 50 relative to the valve body 60 to any of a variety of different rotational positions, wherein each sealing element 20 maintains the fluid tight seal effect during and after rotation of the rotating component 50 because each soft seal structure 22 applies a continuous spring force to the corresponding hard seal structure 21.

[0055] A more detailed description of the structure of each sealing element in sealing element 20 can be found in co-pending U.S. patent application No. 16 / 939,270 in Graichen, the entire contents of which are incorporated herein by reference.

[0056] Now refer to Figures 7A to 10B The specific configurations of the rotating component 50 and the valve body 60 for achieving different operating modes of the rotary valve 10 are shown and described. For example, it can be seen that... Figures 1 to 3As observed, the rotary valve 10 typically comprises a two-layer configuration, wherein each of the two layers is spaced apart from the other in the axial direction of the rotary valve 10. The first layer includes a first set of circumferential fluid openings 181, a first set of flow openings 24, 44 (formed as by the structures 21, 22 of each sealing element in the sealing element 20), and a first set of circumferential fluid ports 82, all arranged on a first plane. The first plane is arranged perpendicular to the axial direction of the rotary valve 10 and faces towards a first end 151 of the rotating component 50 when the rotary valve 10 is fully assembled. The second layer includes a second set of circumferential fluid openings 181, a second set of flow openings 24, 44, and a second set of circumferential fluid ports, all arranged on a second plane. The second plane is similarly arranged perpendicular to the axial direction of the rotary valve 10 and faces towards a second end 152 of the rotating component 50 when the rotary valve 10 is fully assembled, and is axially spaced from the first plane having the first layer.

[0057] Figure 7A , Figure 8A , Figure 9A and Figure 10A Each of them shows a cross-section through the first layer (first plane) of the rotary valve 10, while Figure 7B , Figure 8B , Figure 9B and Figure 10B Each of the figures shows a cross-section through the second layer (second plane) of the rotary valve 10, and these figures relate to four possible operating modes of the rotary valve 10. Figure 7A and Figure 7B The rotary valve 10 is shown in two layers when operating in the first operating mode. Figure 8A and Figure 8B The rotary valve 10 is shown in two layers when operating in the second operating mode. Figure 9A and Figure 9B The rotary valve 10 is shown in two layers when operating in the third operating mode, and Figure 10A and Figure 10B The diagram shows two layers of the rotary valve 10 when it is operating in the fourth operating mode. The four different operating modes include the possibility of fluid communication between combinations of five different fluid ports 82, 83 formed through the valve body 60, so the rotary valve 10 can be referred to as a five-way valve or a five-way switching valve.

[0058] If it is possible Figures 7A to 10BAs observed, the cylindrical rotary valve 10 can generally be subdivided into five distinct 72-degree circular sectors, each sector comprising a sealing element 20 disposed within a recess 72 in the valve body 60. Each sector also corresponds to a possible location of a circumferential fluid opening 181 formed on the outer circumferential surface 171 of the rotating component 50. Similarly, each circumferential fluid port 82 corresponds in position to a sector within the circular sector, wherein a pair of circumferential fluid ports 82 of a common layer are disposed in adjacent sectors. Two adjacent sectors comprising the circumferential fluid ports 82 of the first layer also coincide with two adjacent sectors comprising the circumferential fluid ports 82 of the second layer, such that each circumferential fluid port 82 of the first layer is aligned and spaced apart from its corresponding circumferential fluid port 82 of the second layer about the axial direction of the rotary valve 10.

[0059] Dividing the rotary valve 10 into five distinct sectors typically results in different similar features forming the rotary valve 10 being angularly separated from each other in increments of 72 degrees about the circumferential direction of the rotary valve 10. Specifically, the circumferential wall 153 of the rotating component 50 can be divided into five equal circumferential segments, each of which extends through an arc of 72 degrees as measured from the axis of rotation of the rotating component 50. Similarly, the circumferential wall 69 of the valve body 60 can be divided into five equal circumferential segments, each of which again extends through an arc of 72 degrees as measured from the axis of rotation of the rotating component 50.

[0060] Therefore, the rotating component 50 is configured to rotate in 72-degree increments to radially align a desired circumferential fluid opening in the circumferential fluid opening 181 with a desired circumferential fluid port in the same layer of the circumferential fluid port 82, thereby providing fluid communication between the desired circumferential fluid opening and the desired circumferential fluid port (via a set of radially aligned flow openings 24, 44 formed through a corresponding sealing element in the sealing element 20). Then, the two different layers of the rotary valve 10 allow corresponding fluids to axially communicate through the interior of the rotating component 50 via different fluid channels 211, 212, 213 formed in the rotating component 50, to achieve different operating modes of the rotary valve 10.

[0061] Now refer to Figure 7A The rotary valve 10, including the rotating component 50, has a first layer with a first circumferential fluid opening 251, a second circumferential fluid opening 252, and a third circumferential fluid opening 253. The position of the first circumferential fluid opening 251 of the first layer corresponds to a first circumferential section of the circumferential wall 153, which faces... Figure 7AThe lower right corner is positioned. The remaining circumferential section of the circumferential wall 153 is relative to the first circumferential direction of the rotating component 50 (relative to...). Figure 7A The rotating components are arranged sequentially (from a clockwise perspective), wherein the second circumferential segment is positioned adjacent to the first circumferential segment, the third circumferential segment is positioned adjacent to the second circumferential segment, the fourth circumferential segment is positioned adjacent to the third circumferential segment, and the fifth circumferential segment is positioned adjacent to the fourth circumferential segment (and the first circumferential segment is located opposite the fourth circumferential segment). Based on this convention, the second circumferential fluid opening 252 of the first layer is positioned corresponding to the second circumferential segment, and the third circumferential fluid opening 253 of the first layer is positioned corresponding to the fourth circumferential segment. The remaining third and fifth circumferential segments do not have a circumferential fluid opening 181, but are instead occupied by a continuous portion (arc) of the circumferential wall 153, thereby preventing any fluid from radially flowing into or out of the rotating component 50.

[0062] Now refer to Figure 7B Meanwhile, utilizing the same naming convention as the circumferential section of the circumferential wall 153, the second layer of the rotary valve 10, including the rotating component 50, has a positional similarity to the first circumferential section ( Figure 7B The rotating component 50 includes a first circumferential fluid opening 261 (located in the lower right corner of the valve body 60), a second circumferential fluid opening 262 (located in the second circumferential section), a third circumferential fluid opening 263 (located in the third circumferential section), a fourth circumferential fluid opening 264 (located in the fourth circumferential section), and a fifth circumferential fluid opening 265 (located in the fifth circumferential section). The first circumferential section of the rotating component 50 correspondingly includes a first circumferential fluid opening 251 of a first layer, which is aligned with and spaced apart from the first circumferential fluid opening 261 of a second layer about the axial direction of the rotary valve 10. Similarly, the second circumferential fluid opening 252 of the first layer is axially aligned with and spaced apart from the second circumferential fluid opening 262 of the second layer, while the third circumferential fluid opening 253 of the first layer is axially aligned with and spaced apart from the fourth circumferential fluid opening 264 of the second layer. These relationships are maintained regardless of the rotational position of the rotating component 50 relative to the valve body 60.

[0063] If it is possible Figure 7A and Figure 7BAs observed, a partition structure 155 extends between different portions of the inner circumferential surface 175 of the rotating component 50 to divide the interior of the rotating component 50 into three distinct fluid channels 211, 212, and 213. Specifically, the partition structure 155 forms a wall extending from the boundary between a first and second circumferential segment formed on the circumferential wall 153 to the boundary between a fourth and fifth circumferential segment formed on the circumferential wall 153. The first fluid channel 211 is formed along the first and fifth circumferential segments on one side of the partition structure 155, while the second fluid channel 212 is formed along the second, third, and fourth circumferential segments on the opposite side of the partition structure 155. The partition structure 155 also defines an opening extending through the interior of the rotating component 50 for forming the third fluid channel 213. The partition structure 155 fluidly separates each of the fluid channels 211, 212, and 213 within the rotating component 50. In other words, the partition structure 155 prevents direct fluid communication between any of the fluid channels 211, 212, and 213. Therefore, within the boundary of the circumferential wall 153 of the rotating component 50, an independent fluid flow passing through any one of the fluid channels 211, 212, and 213 will not mix with or otherwise combine with an independent fluid flow passing through another fluid channel 211, 212, and 213. For example, it can be... Figure 2 As observed, the end walls 161, 162 of the rotating component 50 also define each of the fluid passages 211, 212, 213 relative to the axial direction of the rotary valve 10.

[0064] The first fluid channel 211 provides fluid communication between the first circumferential fluid opening 251 of the first layer and the first circumferential fluid opening 261 of the second layer. The second fluid channel 212 provides fluid communication between any combination of the second circumferential fluid opening 252 of the first layer, the third circumferential fluid opening 253 of the first layer, the second circumferential fluid opening 262 of the second layer, the third circumferential fluid opening 263 of the second layer, and the fourth circumferential fluid opening 264 of the second layer. The third channel 213 formed by the partition structure 155 includes a 90-degree turn therein and provides fluid communication between the axial fluid opening 191 disposed along the rotation axis of the rotating member 50 and the fifth circumferential fluid opening 265 of the second layer.

[0065] Refer again Figure 7AThe first layer of the rotary valve 10, including the valve body 60, has a first circumferential fluid port 281 and a second circumferential fluid port 282. The first circumferential fluid port 281 is positioned along a first circumferential section of the circumferential wall 69 of the valve body 60, which is momentarily radially aligned with a first circumferential section of the circumferential wall 153 of the rotating component 50 in the first operating mode of the illustrated rotary valve 10. Again, the remaining circumferential sections of the circumferential wall 69 are relative to the circumferential direction of the valve body 60 (relative to...). Figure 7A The circumferential sections are formed sequentially (from a clockwise perspective), wherein the second circumferential section is positioned adjacent to the first circumferential section, the third circumferential section is positioned adjacent to the second circumferential section, the fourth circumferential section is positioned adjacent to the third circumferential section, and the fifth circumferential section is positioned adjacent to the fourth circumferential section (and the first circumferential section is positioned opposite the fourth circumferential section). Based on this convention, the second circumferential fluid port 282 of the first layer is positioned along the second circumferential section of the circumferential wall 69, while the remaining third, fourth, and fifth circumferential sections of the circumferential wall 69 are formed by continuous portions (arcs) of the circumferential wall 69 without any circumferential fluid port 82.

[0066] Now refer to Figure 7B Simultaneously, utilizing the same naming convention as the circumferential sections of the circumferential wall 69, the second layer of the rotary valve 10, including the valve body 60, has a first circumferential fluid port 291 corresponding in position to the first circumferential section and a second circumferential fluid port 292 corresponding in position to the second circumferential section. The remaining third, fourth, and fifth circumferential sections of the circumferential wall 69 are also formed by continuous portions (arcs) of the circumferential wall 69 without any circumferential fluid port 82. The first circumferential fluid port 281 of the first layer is aligned and spaced apart from the first circumferential fluid port 291 of the second layer with respect to the axial direction of the rotary valve 10, and similarly, the second circumferential fluid port 282 of the first layer is aligned and spaced apart from the second circumferential fluid port 292 of the second layer with respect to the axial direction of the rotary valve 10.

[0067] like Figure 7A and Figure 7BThe first operating mode shown includes rotating the rotating component 50 to the illustrated position, wherein the first circumferential fluid port 281 of the first layer is radially aligned with the first circumferential fluid opening 251 of the first layer, the second circumferential fluid port 282 of the first layer is radially aligned with the second circumferential fluid opening 282 of the first layer, the first circumferential fluid port 291 of the second layer is radially aligned with the first circumferential fluid opening 261 of the second layer, and the second circumferential fluid port 292 of the second layer is radially aligned with the second circumferential fluid opening 262 of the second layer. A first fluid flow sequentially flows through the first circumferential fluid port 291 of the second layer, the first circumferential fluid opening 261 of the second layer, through the first flow channel 211 formed by the rotating component 50, the first circumferential fluid opening 251 of the first layer, and then flows through the first circumferential fluid port 281 of the first layer. The second fluid flow flows sequentially through the second circumferential fluid port 292 of the second layer, the second circumferential fluid opening 262 of the second layer, through the second flow channel 212 formed by the rotating component 50, the second circumferential fluid opening 252 of the first layer, and then flows through the second circumferential fluid port 282 of the first layer.

[0068] In the illustrated flow configuration, the first circumferential fluid port 291 and the second circumferential fluid port 292 of the second layer serve as fluid inlets for the rotary valve 10, while the first circumferential fluid port 281 and the second circumferential fluid port 282 of the first layer serve as fluid outlets for the rotary valve 10. However, it will be apparent to those skilled in the art that one or both fluid flows may axially pass through fluid channels 211, 212 in a flow direction opposite to the flow direction shown and described, without departing from the scope of the invention, depending on the flow configuration of the fluid passing through the remaining portion of the fluid system with the rotary valve 10. Therefore, as Figure 7A and Figure 7B As shown, regarding the configuration of the rotating component 50 relative to the valve body 60, any of the circumferential fluid ports 281, 282, 291, and 292 can be used as the fluid inlet or fluid outlet of the rotary valve 10.

[0069] like Figure 8A and Figure 8BThe second operating mode shown includes rotating the rotating member 50 by 72 degrees (counterclockwise from the illustrated perspective) from the rotational position of the rotating member 50 associated with the first operating mode. The second operating mode includes the following configuration: the first circumferential fluid port 281 of the first layer is radially aligned with the second circumferential fluid opening 252 of the first layer, the second circumferential fluid port 282 of the first layer is partially blocked by the circumferential wall 153, the first circumferential fluid port 291 of the second layer is radially aligned with the second circumferential fluid opening 262 of the second layer, and the second circumferential fluid port 292 of the second layer is radially aligned with the third circumferential fluid opening 263 of the second layer. A first fluid flow sequentially flows through the first circumferential fluid port 291 of the second layer, the second circumferential fluid opening 262 of the second layer, through the second flow channel 212 formed by the rotating member 50, the second circumferential fluid opening 252 of the first layer, and then flows through the first circumferential fluid port 281 of the first layer. The second fluid flow flows sequentially through the second circumferential fluid port 292 of the second layer, the third circumferential fluid opening 263 of the second layer, through the second flow channel 212 formed by the rotating component 50, the second circumferential fluid opening 252 of the first layer, and then flows through the first circumferential fluid port 281 of the first layer.

[0070] In the illustrated flow configuration, the first circumferential fluid port 291 and the second circumferential fluid port 292 of the second layer serve as fluid inlets for the rotary valve 10, while the first circumferential fluid port 281 of the first layer serves as a fluid outlet for the rotary valve 10. The two fluid flows mix within the second fluid channel 212 before exiting the rotating component 50. However, it will be apparent to those skilled in the art that one or both fluid flows may pass through the second fluid channel 212 with a flow configuration different from the illustrated and described flow configuration without departing from the scope of the invention, depending on the flow configuration passing through the remainder of the fluid system with the rotary valve 10. For example, fluid can enter any two of the circumferential fluid ports 281, 291, and 292, combine within the second fluid channel 212, and then exit through the remaining one of the circumferential fluid ports 281, 291, and 292; or fluid can enter through a single circumferential fluid port 281, 291, and 292, split into two distinct partial flows within the second fluid channel 212, and then exit through the remaining two of the circumferential fluid ports 281, 291, and 292.

[0071] like Figure 9A and Figure 9BThe third operating mode shown includes rotating the rotating member 50 by 72 degrees (counterclockwise from the illustrated perspective) from the rotational position of the rotating member 50 associated with the second operating mode. The third operating mode includes the following configuration: a first circumferential fluid port 281 of the first layer is partially blocked by a portion of the circumferential wall 153; a second circumferential fluid port 282 of the first layer is radially aligned with a third circumferential fluid opening 253 of the first layer; a first circumferential fluid port 291 of the second layer is radially aligned with a third circumferential fluid opening 263 of the second layer; and a second circumferential fluid port 292 of the second layer is radially aligned with a fourth circumferential fluid opening 264 of the second layer. A first fluid flow sequentially flows through the first circumferential fluid port 291 of the second layer, the third circumferential fluid opening 263 of the second layer, through the second fluid channel 212 formed by the rotating member 50, the third circumferential fluid opening 253 of the first layer, and then flows through the second circumferential fluid port 282 of the first layer. The second fluid flow flows sequentially through the second circumferential fluid port 292 of the second layer, the fourth circumferential fluid opening 264 of the second layer, through the second flow channel 212 formed by the rotating component 50, the third circumferential fluid opening 253 of the first layer, and then flows through the second circumferential fluid port 282 of the first layer.

[0072] In the illustrated flow configuration, the first circumferential fluid port 291 and the second circumferential fluid port 292 of the second layer serve as fluid inlets for the rotary valve 10, while the second circumferential fluid port 282 of the first layer serves as a fluid outlet for the rotary valve 10. The two fluid flows mix within the second fluid channel 212 before exiting the rotating component 50. However, it will be apparent to those skilled in the art that one or both fluid flows may pass through the second fluid channel 212 with a flow configuration different from the illustrated and described flow configuration without departing from the scope of the invention, depending on the flow configuration passing through the remainder of the fluid system with the rotary valve 10. For example, fluid can enter any two of the circumferential fluid ports 282, 291, and 292, combine within the second fluid channel 212, and then exit through the remaining one of the circumferential fluid ports 282, 291, and 292; or fluid can enter through a single circumferential fluid port 282, 291, and 292, split into two distinct partial flows within the second fluid channel 212, and then exit through the remaining two of the circumferential fluid ports 282, 291, and 292.

[0073] like Figure 10A and Figure 10BThe fourth operating mode shown includes rotating the rotating member 50 by 144 degrees (counterclockwise from the illustrated perspective) from the rotational position of the rotating member 50 associated with the third operating mode. The fourth operating mode includes the following configuration: a first circumferential fluid port 281 of the first layer is partially blocked by a portion of the circumferential wall 153; a second circumferential fluid port 282 of the first layer is radially aligned with a first circumferential fluid opening 251 of the first layer; a first circumferential fluid port 291 of the second layer is radially aligned with a fifth circumferential fluid opening 265 of the second layer; and a second circumferential fluid port 292 of the second layer is radially aligned with a first circumferential fluid opening 261 of the second layer. A first fluid flow sequentially flows through the first circumferential fluid port 291 of the second layer, the fifth circumferential fluid opening 265 of the second layer, through the third flow channel 213 formed by the rotating member 50, the axial fluid opening 191 of the rotating member 50, and then through the axial fluid port 83 of the valve body 60. The second fluid flow flows sequentially through the second circumferential fluid port 292 of the second layer, the first circumferential fluid opening 261 of the second layer, through the first flow channel 211 formed by the rotating component 50, the first circumferential fluid opening 251 of the first layer, and then through the second circumferential fluid port 282 of the first layer.

[0074] In the illustrated flow configuration, the first circumferential fluid port 291 and the second circumferential fluid port 292 of the second layer serve as fluid inlets for the rotary valve 10, while the second circumferential fluid port 282 and the axial fluid port 83 of the first layer serve as fluid outlets for the rotary valve 10. However, it will be apparent to those skilled in the art that one or both fluid flows may pass through fluid channels 211, 213 with flow configurations different from those shown and described without departing from the scope of the invention, depending on the flow configuration passing through the remainder of the fluid system with the rotary valve 10. Specifically, the flow direction through one or both of fluid channels 211, 213 may be reversed as needed to switch one of ports 83, 282, 291, 292 to serve as both an inlet and an outlet for the rotary valve 10.

[0075] Although the rotary valve 10 is shown and described using a rotating member 50 having an outer circumferential surface 171 with a variable radius to form a sealing region 172 and a non-sealing region 173, it will be apparent to those skilled in the art that different flow configurations disclosed with respect to the rotary valve 10 can be advantageously utilized without departing from the scope of the invention, without forming sealing regions 172 and non-sealing regions 173. That is, novel flow configurations through the rotary valve 10 may be useful without the reduced friction provided by the different regions 172, 173, and therefore the rotary valve 10 is not limited to embodiments including this feature.

[0076] Now refer to Figure 6 The exemplary fluid system 301 is used to discuss four disclosed operating modes of the rotary valve 10 in order to illustrate a possible use of the rotary valve 10 as a five-way switching valve. As previously mentioned, such as Figure 6 The fluid system 301 illustrated represents a coolant system for an electric vehicle that utilizes water as a coolant circulating through the rotary valve 10. However, it should be apparent that the flexibility of the rotary valve 10 in specifying different flow configurations through it can be advantageously suited for use with any fluid system having five different flow paths merging at a single valve element.

[0077] Fluid system 301 includes a radiator coolant circuit 310, a battery coolant circuit 320, and an electronic component coolant circuit 330. The radiator coolant circuit 310 and the battery coolant circuit 320 can be fluidly connected to each other via a rotary valve 10 or via a pair of valves 315 and 325 disposed away from the rotary valve 10 relative to each of the circuits 310 and 320. A pump 303 is disposed immediately upstream of the rotary valve 10 for each of the circuits 310 and 320 to cause water to flow through each of the circuits 310 and 320 in a desired flow direction.

[0078] The battery coolant circuit 320 exchanges heat with the electronic component coolant circuit 330 via a coolant-coolant heat exchanger 305. The electronic component coolant circuit 330 includes at least one electronic component 335 of the electric vehicle for exchanging heat with the coolant circulating through the electronic component coolant circuit 330. The at least one electronic component 335 may be configured to generate heat, which may be transferred to the battery coolant circuit 320 via the coolant-coolant heat exchanger 305.

[0079] Radiator coolant circuit 310 includes a radiator 312, a valve 315, at least one electrically driven unit 314, one of the pumps 303, and a rotary valve 10. A bypass flow path 318 extends from the rotary valve 10 to a location on the radiator coolant circuit 310 downstream of the radiator 312 and upstream of the valve 315. Radiator coolant circuit 310 also includes a pair of temperature sensors 302 for determining the temperature of the coolant immediately upstream of the radiator 312 and downstream of the location where the bypass flow path 318 intersects with the radiator coolant circuit 310, wherein the determination of the coolant temperature can be used to determine an operating mode in which the rotary valve 10 bypasses the radiator 312. Battery coolant circuit 320 includes a coolant-coolant heat exchanger 305, a cooler 321, a valve 325, a battery 322, a battery charger 323, one of the pumps 303, and a rotary valve 10.

[0080] according to Figure 7A and Figure 7BIn the first operating mode disclosed herein, rotary valve 10 delivers a first coolant flow from port 291 to port 281 and a second coolant flow from port 292 to port 282. This operating mode includes causing the coolant flow through the battery 322 and battery charger 323 in the battery coolant circuit 320 to flow through rotary valve 10 and subsequently through the radiator 312 in the radiator coolant circuit 310 to remove heat from the coolant. Furthermore, the coolant flow through at least one electric drive unit 314 bypasses the radiator 312 by flowing through a bypass flow path 318. The first operating mode may also include valve 315 distributing coolant toward valve 325 to distribute coolant through the battery 322 and battery charger 323 and toward at least one electric drive unit 314.

[0081] Figure 8A and Figure 8B The second operating mode disclosed herein includes a rotary valve 10 transferring coolant from each of ports 291, 292 to port 281. This causes portions of coolant passing through at least one electric drive unit 314 and portions of coolant passing through battery 322 and battery charger 323 to be combined within the rotary valve 10 before passing through radiator 312 to remove heat from the combined coolant flow. The second operating mode relies on valve 315 distributing coolant to at least one electric drive unit 314 and valve 325 subsequently allowing coolant to pass through battery 322 and battery charger 323.

[0082] Figure 9A and Figure 9B The third operating mode disclosed herein includes rotary valve 10 delivering coolant from each of ports 291, 292 to port 282. This causes portions of coolant passing through at least one electrically driven component 314 and portions of coolant passing through battery 322 and battery charger 323 to be combined within rotary valve 10 before passing through bypass flow path 318 to bypass radiator 312. The third operating mode relies on valve 315 distributing coolant to at least one electrical component 314 and valve 325 subsequently allowing coolant to pass through battery 322 and battery charger 323.

[0083] Figure 10A and Figure 10BThe fourth operating mode disclosed herein includes rotary valve 10 conveying a first coolant flow from port 291 to an axially arranged port 191 and a second coolant flow from port 292 to port 282. Furthermore, valves 315 and 325 are adjusted such that all coolant encountering each of valves 315 and 325 flows toward the inlet ports 291 and 292 of rotary valve 10, thus no coolant is exchanged between valves 315 and 325. This configuration results in coolant flowing in a figure-eight pattern through both loops 310 and 320. Specifically, the coolant flow through battery 322 and battery charger 323 passes through rotary valve 10 toward radiator 312. The flow exiting radiator 312 then flows through at least one electric drive unit 314 and rotary valve 10 toward coolant-coolant heat exchanger 305. The coolant in battery coolant loop 320 exchanges heat with the coolant in electronic component coolant loop 330 within coolant-coolant heat exchanger 305. Then, the coolant can exchange additional heat energy with another fluid within the cooler 321 before flowing back through the battery 322 and battery charger 323 to restart the cycle.

[0084] The fourth operating mode can be used during periods when the electric vehicle's battery 322 needs to be heated to achieve its desired level of efficiency, such as when the electric vehicle is first started after being exposed to a particularly cold environment. The coolant-coolant heat exchanger 305 advantageously allows heat to be added to the coolant from the electronic component coolant circuit 330 before the coolant passes through the battery 322, thus allowing the battery 322 to be heated more quickly. During the fourth operating mode, the sequential flow of coolant through each of the circuits 310 and 320 also advantageously allows heat generated by at least one electric drive unit 314 to be similarly transferred to the battery 322 before the heat is removed from the coolant within the radiator 312, thereby further contributing to the rapid heating of the battery 322.

[0085] Compared to existing rotating components, the use of a rotating component 50 with a sealing region 172 and a non-sealing region 173 having variable radii allows for a lower total radial force applied to the rotating component 50. Specifically, different operating positions of the rotating component 50 include at least some of the sealing elements 20 compressed between the sealing region 172 and the valve body 60 with a first sealing force, and some of the sealing elements 20 compressed between the non-sealing region 173 and the valve body 60 with a lower second sealing force. By reducing the sealing force relative to at least some of the sealing elements 20 via the smaller radius of the non-sealing region 173, the frictional force between the engaged hard seal structure 21 and the rotating component 50 is reduced at different locations on the outer circumferential surface 171. Therefore, the total frictional force between the rotating component 50 and the sealing elements 20 is reduced, thus requiring less torque to rotate the rotating component 50 relative to the valve body 60. The reduced torque requirement advantageously expands the range of suitable rotary motors or actuators that can be used with the rotary valve 10, while also reducing the amount of energy required to rotate the rotating component 50 relative to the valve body 60. The lower torque requirement also advantageously allows for a smaller size of the rotary motor or actuator, thereby reducing the package space of any components including the rotary valve 10.

[0086] The disclosed configuration of the rotary valve 10 also allows the rotary valve 10 to control the flow of coolant through five different ports 83, 281, 282, 291, and 292 of the valve body 60 using a single rotating component 50. Thus, the rotary valve 10 operates as a five-way switching valve, although it has only a single actuation input. This is possible due to the two-layer configuration of the rotating component 50 and the valve body 60, as the specific configuration of the fluid passages 211, 212, and 213 formed through the rotating component 50 allows axial communication of the coolant between the two layers, thereby expanding the number of possible flow configurations through the rotary valve 10. The rotary valve 10 is therefore compact and can be more easily integrated into any fluid system requiring a valve capable of controlling flow through at least five different flow paths intersecting at the valve. Using a single valve to control multiple different flow paths also simplifies the fluid system while eliminating the potential problems associated with simultaneously controlling multiple valve elements or valve elements with multiple moving parts.

[0087] Based on the foregoing description, those skilled in the art can readily determine the essential characteristics of the present invention, and can make various modifications and alterations to the present invention without departing from its spirit and scope to adapt it to various uses and conditions.

Claims

1. A rotary valve, comprising: a rotary component configured to rotate about an axis of rotation of the rotary component, the rotary component comprising a plurality of fluid openings formed at an outer surface of the rotary component, wherein each of the fluid openings forms a fluid inlet or a fluid outlet to one of a plurality of fluid passages formed through the rotary component; a valve body rotatably receiving the rotary component therein, the valve body comprising a plurality of fluid ports formed through the valve body, wherein each of the fluid ports is configured to selectively align with one of the fluid openings of the rotary component depending on a rotational position of the rotary component relative to the valve body, wherein the plurality of fluid openings comprises a plurality of circumferential fluid openings formed through a circumferential wall of the rotary component, wherein the plurality of fluid ports comprises a plurality of circumferential fluid ports formed through a circumferential wall of the valve body, wherein the circumferential fluid openings and the circumferential fluid ports are arranged in a first layer and a second layer, the first layer having a first plurality of the circumferential fluid openings and a first plurality of the circumferential fluid ports arranged on a first plane, and the second layer having a second plurality of the circumferential fluid openings and a second plurality of the circumferential fluid ports arranged on a second plane, wherein the first plane and the second plane are each arranged perpendicular to the axis of rotation of the rotary component, wherein the first plane is axially spaced from the second plane about the axis of rotation of the rotary component, wherein the circumferential wall of the rotary component is divided into five equal circumferential segments when advancing in a first circumferential direction, the circumferential segments comprising a first circumferential segment, a second circumferential segment, a third circumferential segment, a fourth circumferential segment, and a fifth circumferential segment, wherein a first plurality of the circumferential fluid openings comprises first circumferential fluid openings of the first layer formed within the first circumferential segment, second circumferential fluid openings of the first layer formed within the second circumferential segment, and third circumferential fluid openings of the first layer formed within the fourth circumferential segment, wherein a second plurality of the circumferential fluid openings comprises first circumferential fluid openings of the second layer formed within the first circumferential segment, second circumferential fluid openings of the second layer formed within the second circumferential segment, third circumferential fluid openings of the second layer formed within the third circumferential segment, fourth circumferential fluid openings of the second layer formed within the fourth circumferential segment, and fifth circumferential fluid openings of the second layer formed within the fifth circumferential segment, and wherein the first circumferential segment is axially spaced from the second circumferential segment about the axis of rotation of the rotary component, the third circumferential segment is axially spaced from the fourth circumferential segment about the axis of rotation of the rotary component, and the fourth circumferential segment is axially spaced from the fifth circumferential segment about the axis of rotation of the rotary component. The plurality of fluid passages includes a first fluid passage fluidically coupled to each of the first circumferential fluid opening of the first layer and the first circumferential fluid opening of the second layer, a second fluid passage fluidically coupled to each of the second circumferential fluid opening of the first layer, the third circumferential fluid opening of the first layer, the second circumferential fluid opening of the second layer, the third circumferential fluid opening of the second layer, and the fourth circumferential fluid opening of the second layer, and a third fluid passage fluidically coupled to each of the fifth circumferential fluid opening of the second layer and an axial fluid opening of the plurality of fluid openings formed through an axial end wall of the rotating component.

2. The rotary valve of claim 1, wherein, At least one of the fluid passages formed through the rotating component is in fluid communication with at least one of the circumferential fluid openings of the first layer and at least one of the circumferential fluid openings of the second layer.

3. The rotary valve of claim 1, wherein, At least two of the fluid passages formed through the rotating component are in fluid communication with at least one of the circumferential fluid openings of the first layer and at least one of the circumferential fluid openings of the second layer.

4. The rotary valve of claim 1, wherein, The plurality of fluid passages includes a first fluid passage fluidically coupling at least one of the circumferential fluid openings of the first layer to at least one of the circumferential fluid openings of the second layer, a second fluid passage fluidically coupling at least one of the circumferential fluid openings of the first layer to at least one of the circumferential fluid openings of the second layer, and a third fluid passage fluidically coupling at least one of the circumferential fluid openings of the second layer to an axial fluid opening of the plurality of fluid openings formed through an axial end wall of the rotating component.

5. The rotary valve of claim 4, wherein, The first fluid passage fluidically couples a first one of the circumferential fluid openings of the first layer to a first one of the circumferential fluid openings of the second layer, the second fluid passage fluidically couples a second one and a third one of the circumferential fluid openings of the first layer to a second one, a third one, and a fourth one of the circumferential fluid openings of the second layer, and the third fluid passage fluidically couples a fifth one of the circumferential fluid openings of the second layer to the axial fluid opening.

6. The rotary valve of claim 1, wherein, The first plurality of the circumferential fluid ports of the first layer includes three of the circumferential fluid ports circumferentially spaced about the circumferential wall of the valve body, and the second plurality of the circumferential fluid ports of the second layer includes two of the circumferential fluid ports circumferentially spaced about the circumferential wall of the valve body.

7. The rotary valve of claim 1, wherein, The circumferential wall of the valve body is divided into five equal circumferential segments, wherein the first plurality of the circumferential fluid ports includes a first circumferential fluid port of the first layer and a second circumferential fluid port of the first layer disposed within circumferentially adjacent circumferential segments of the circumferential wall of the valve body, and wherein the second plurality of the circumferential fluid ports includes a first circumferential fluid port of the second layer axially aligned with the first circumferential fluid port of the first layer and a second circumferential fluid port of the second layer axially aligned with the second circumferential fluid port of the first layer.

8. The rotary valve of claim 7, wherein, The first operating mode of the rotary valve includes fluidly coupling the first circumferential fluid port of the first layer to the first circumferential fluid port of the second layer through the first fluid passage and fluidly coupling the second circumferential fluid port of the first layer to the second circumferential fluid port of the second layer through the second fluid passage, the second operating mode of the rotary valve includes fluidly coupling each of the first circumferential fluid port of the second layer and the second circumferential fluid port of the second layer to the first circumferential fluid port of the first layer through the second fluid passage, the third operating mode of the rotary valve includes fluidly coupling each of the first circumferential fluid port of the second layer and the second circumferential fluid port of the second layer to the second circumferential fluid port of the first layer through the second fluid passage, and the fourth operating mode of the rotary valve includes fluidly coupling the second circumferential fluid port of the first layer to the second circumferential fluid port of the second layer through the first fluid passage and fluidly coupling the first circumferential fluid port of the second layer to an axial fluid port of the plurality of fluid ports formed through an axial end wall of the valve body.

9. The rotary valve of claim 1, wherein, All of the fluid passages formed through the rotary component are fluidly isolated from one another within the rotary component.

10. The rotary valve of claim 1, wherein, The valve body includes five of the fluid ports, and the rotary valve operates as a five-way selector valve. The first plurality of the circumferential fluid ports of the first layer includes three of the circumferential fluid ports circumferentially spaced about the circumferential wall of the valve body, and the second plurality of the circumferential fluid ports of the second layer includes two of the circumferential fluid ports circumferentially spaced about the circumferential wall of the valve body.

11. The rotary valve of claim 10, wherein, The five fluid ports include a first inlet port, a second inlet port, a first outlet port, a second outlet port, and a third outlet port, wherein a first operating mode of the rotary valve includes fluidly coupling the first inlet port to the first outlet port and fluidly coupling the second inlet port to the second outlet port, a second operating mode of the rotary valve includes fluidly coupling both the first inlet port and the second inlet port to the first outlet port, a third operating mode of the rotary valve includes fluidly coupling both the first inlet port and the second inlet port to the second outlet port, and a fourth operating mode of the rotary valve includes fluidly coupling the first inlet port to the third outlet port and fluidly coupling the second inlet port to the second outlet port.

12. The rotary valve of claim 1, wherein, A partition structure forms a partition between the fluid passages within the rotary component.

13. The rotary valve of claim 12, wherein, The partition structure extends across a circumferential wall of the rotary component to separate a first fluid passage from a second fluid passage, and wherein the partition structure defines a closed opening forming a third fluid passage.

14. The rotary valve of claim 1, wherein, At least one sealing element is disposed radially between an inner circumferential surface of the valve body and an outer circumferential surface of the rotary component, the outer circumferential surface of the rotary component having at least one sealing zone and at least one non-sealing zone, the at least one sealing zone having a first radius measured from the rotational axis, the at least one non-sealing zone having a second radius measured from the rotational axis, the first radius being greater than the second radius.

15. The rotary valve of claim 14, wherein, Each of the at least one sealing elements applies a first sealing force to the rotary component when engaging one of the sealing zones or a second sealing force to the rotary component when engaging one of the non-sealing zones, the first sealing force being greater than the second sealing force.

16. The rotary valve of claim 14, wherein, The plurality of fluid openings includes a plurality of circumferential fluid openings formed through a circumferential wall of the rotary component, wherein each of the sealing zones surrounds a periphery of one of the circumferential fluid openings and each of the non-sealing zones is spaced apart from a periphery of each of the circumferential fluid openings.

17. A rotary valve, comprising: a rotary component configured to rotate about a rotational axis of the rotary component, the rotary component including a plurality of fluid openings formed at an outer surface of the rotary component, wherein each of the fluid openings forms a fluid inlet or a fluid outlet to one of a plurality of fluid passages formed through the rotary component; a valve body rotatably receiving the rotary component therein, the valve body including a plurality of fluid ports formed through the valve body, wherein each of the fluid ports is configured to selectively align with one of the fluid openings of the rotary component depending on a rotational position of the rotary component relative to the valve body, wherein the valve body includes five of the fluid ports, and the rotary valve operates as a five-way selector valve, wherein the five fluid ports include a first inlet port, a second inlet port, a first outlet port, a second outlet port, and a third outlet port, and wherein a first operating mode of the rotary valve includes fluidly coupling the first inlet port to the first outlet port and fluidly coupling the second inlet port to the second outlet port, a second operating mode of the rotary valve includes fluidly coupling both the first inlet port and the second inlet port to the first outlet port, a third operating mode of the rotary valve includes fluidly coupling both the first inlet port and the second inlet port to the second outlet port, and a fourth operating mode of the rotary valve includes fluidly coupling the first inlet port to the third outlet port and fluidly coupling the second inlet port to the second outlet port.

Images