Fluid distribution valve housing and sealing device

Abstract

A coolant distribution valve for a vehicle cooling system includes a housing including a shaft support housing portion that provides a unitary unitary structure. The shaft support housing portion has a first side opposite the second side. The first side and the second side include a first hole and a second hole, respectively. A valve is disposed in the housing adjacent the first side. An electronic component is disposed in the housing adjacent the second side. The electronic component is configured to move the valve between a plurality of positions. First and second seals are mounted in the first and second bores, respectively. The shaft extends through and engages the seal. A shaft operably connects the electronic component to the valve.

Description

Technical Field

[0001] The present disclosure relates to a fluid distribution valve for, for example, a vehicle cooling system. Background Art

[0002] Typical modern vehicles include various components and subsystems that desire to regulate temperature (i.e., heat and / or cool to a desired temperature). One or more cooling circuits include one or more heat exchangers through which one or more fluids circulate in a controlled manner to provide coolant at a desired temperature to the components. As vehicles become more complex, the complexity of the cooling system also increases.

[0003] Typical cooling systems found in vehicles (such as vehicles with electrified and / or hybrid powertrains) tend to be highly distributed architectures with complex mazes of cooling circuits, sub-circuits, pumps, and heat exchangers. The coolant distribution valves, controllers, and temperature sensors for guiding coolant through these cooling systems are separated from each other and distributed throughout the vehicle.

[0004] The coolant distribution valve includes a valve disposed within a coolant passage that regulates the flow of fluid between fluid paths within the cooling system. One or more seals may be present to hold the fluid within its coolant passage. If electronics are also housed within the coolant distribution valve, any leakage through the seals can reach the electronics and damage them. Summary of the Invention

[0005] In one exemplary embodiment, a coolant distribution valve for a vehicle cooling system includes a housing that includes a shaft support housing portion providing a single integral structure. The shaft support housing portion has a first side opposite a second side. The first side and the second side include a first hole and a second hole, respectively. The valve is disposed adjacent the first side within the housing. Electronic components are disposed adjacent the second side within the housing. The electronic components are configured to move the valve between a plurality of positions. A first seal and a second seal are respectively installed within the first hole and the second hole. A shaft extends through and engages the seals. The shaft operably connects the electronic components to the valve.

[0006] In another embodiment of any of the above, the shaft support housing portion is provided by a single-piece part that is molded, cast, and / or machined.

[0007] In another embodiment of any of the above, the housing includes an electronics housing portion that is fixed to the shaft support housing portion to enclose the electronic components.

[0008] In another embodiment of any of the above, the shaft support housing portion provides a valve housing portion for receiving the valve, and the housing includes a cover that is fixed to the valve housing portion to enclose the valve.

[0009] In another embodiment of any of the above, the valve housing portion is fixed to the shaft support housing portion. The valve is disposed in the valve housing portion.

[0010] In another embodiment of any of the above, the housing includes a cover fixed to the valve housing portion to enclose the valve.

[0011] In another embodiment of any of the above, a cavity is provided between the first seal and the second seal, and a vent hole is provided in the shaft support housing portion. The vent hole is configured to fluidly connect the cavity to the atmosphere.

[0012] In another embodiment of any of the above, the coolant distribution valve includes a printed circuit board (PCB) disposed in the electronic device housing portion and an electric actuator electrically connected to the printed circuit board and disposed in the electronic device housing portion.

[0013] In another embodiment of any of the above, the electric actuator is a motor, and a gear train is coupled between the motor and the valve.

[0014] In another embodiment of any of the above, the shaft is provided by a first shaft and a second shaft coupled to each other. The first shaft extends from the valve, and the second shaft extends from the gear train.

[0015] In another embodiment of any of the above, the first shaft and the second shaft are nested relative to each other in a splined connection relationship.

[0016] In another embodiment of any of the above, the first shaft and the second shaft respectively include a first outer diameter portion and a second outer diameter portion. The first outer diameter portion and the second outer diameter portion respectively engage the first seal and the second seal.

[0017] In another embodiment of any of the above, a vehicle cooling system includes a coolant distribution valve, and the vehicle cooling system includes a plurality of cooling circuits. The coolant distribution valve interconnects at least two of the plurality of cooling circuits, and the valve is configured to move between a plurality of positions to direct a desired cooling flow through the at least two of the plurality of cooling circuits.

[0018] In another embodiment of any of the above, the cooling circuit includes at least two of a battery, a passenger compartment, charging electronics, and a motor.

[0019] In another exemplary embodiment, a method of assembling a coolant distribution valve includes providing a housing that includes a shaft support housing portion providing a single integral structure. The shaft support housing portion has a first side opposite a second side. The first side and the second side each include a first hole and a second hole, respectively. A first seal is installed in the first hole. A second seal is installed in the second hole. A valve is inserted into the housing adjacent the first side. Electronic components are disposed in the housing adjacent the second side and are configured to move the valve between a plurality of positions. A shaft extends through and engages the first seal and the second seal, and the shaft operably connects the electronic components to the valve.

[0020] In another embodiment of any of the above, the step of installing the first seal is performed before the step of inserting the valve.

[0021] In another embodiment of any of the above, the step of installing the second seal is performed before the step of disposing the electronic components.

[0022] In another embodiment of any of the above, the inserting step includes a shaft extending step of extending through and engaging the first seal, and includes a step of assembling a gear train in the housing. The gear train assembling step includes a shaft extending step of extending through and engaging the second seal.

[0023] In another embodiment of any of the above, the extending step includes extending a first shaft from the valve to engage the first seal, and extending a second shaft from the gear train to engage the second seal. The first shaft and the second shaft are coupled to each other.

[0024] In another embodiment of any of the above, the method includes a step of forming a cavity using the first seal and the second seal, the shaft support housing portion, and the shaft. The shaft support housing includes a vent hole in fluid communication with the atmosphere. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure can be further understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0026] Figure 1 is a schematic diagram of an exemplary vehicle cooling system.

[0027] Figure 2 is a perspective view of the disclosed coolant distribution valve.

[0028] Figure 3 is along Figure 2 a cross-section of the coolant distribution valve taken along line 3-3 in

[0029] Figure 4 is along Figure 2 a cross-section of the coolant distribution valve taken along line 4-4 in

[0030] Figure 5 is Figure 4 an enlarged view of.

[0031] Figure 6 shows Figure 5 a portion of the housing shown, but with no other components installed.

[0032] Figure 7 shows a portion of another exemplary housing similar to Figure 6 .

[0033] Figure 8 is a cross-section similar to Figure 4 but with the housing shown in Figure 7 .

[0034] Figure 9 is Figure 8 an enlarged view of.

[0035] The embodiments, examples, and alternatives (including any one of their respective aspects or individual features) of the foregoing paragraphs, claims, or the following description and drawings may be employed independently or in any combination. Features described in connection with one embodiment apply to all embodiments unless those features are incompatible. Detailed Description

[0036] Figure 1 Depicts some aspects of a typical exemplary vehicle cooling system 100, which is highly schematic and for illustrative purposes only. System 100 tends to be relatively complex and includes multiple loops, sub-loops, and branches for transporting a cooling fluid (such as a liquid coolant (e.g., water glycol)). One type of vehicle includes one or more motors 102, an occupant compartment temperature regulation system 104, a charging system 106, and a battery 108. One or more cooling loops 110 circulate coolant through these components. Typically, multiple heat exchangers 112 are distributed throughout the cooling loop 110 to provide heat exchange from the coolant to another fluid (such as air or another liquid coolant). One or more pumps 114 circulate coolant through the cooling loop 110.

[0037] Multiple fluid distribution valves 115 connect multiple channels to selectively regulate the flow of coolant through the cooling loop 110 and thus regulate its temperature. The fluid distribution valves 115 are distributed throughout the cooling loop 110 and throughout the vehicle. Many temperature sensors 116 are also distributed throughout the cooling system 100 to monitor the temperature at various locations in order to be able to coordinate the various components to achieve a desired temperature throughout the system.

[0038] Figure 2The disclosed coolant distribution valve 10 shown is designed to provide improved internal sealing to prevent internal coolant leakage that could damage sensitive electronic components or otherwise cause premature failure. The coolant distribution valve 10 has a multi-piece housing 12 having multiple parts that are fixed to each other by one or more attachment techniques (e.g., welding, fasteners, glue, sealants, etc.). In this example, there are two main housing parts: a valve body part 11 and an electronics part 13 that are fluidly separated from each other. In Figures 2 to 6 In one example shown, the electronics part 13 is provided by a first housing part 14 and a second housing part 16, and the valve body part 11 is provided by a third housing part 18 and a fourth housing part 20.

[0039] The coolant distribution valve 10 is designed to be configurable to provide flexibility in terms of packaging and versatility when it is used within a cooling system. An example of this flexibility is a reconfigurable bracket 22 that is operably mounted to the housing 12, and the bracket 22 can be oriented at several different discrete positions relative to the housing 12. The bracket 22 includes mounting features (e.g., a pair of mounting ears 28) for securing the coolant distribution valve 10 to a vehicle. Referencing the bracket 22, the bracket 22 is rotated (clock) to a desired orientation based on packaging constraints within the vehicle.

[0040] The valve body part 11 can also be rotated to a desired orientation relative to the electronics part 13. Fasteners fix the valve body part 11 and the electronics part 13 (e.g., the second housing part 16 and the third housing part 18) to each other, which captures the bracket 22.

[0041] Any number of techniques are used to fix and seal the various parts of the housing 12 to each other. In Figure 3 In one example shown, the first housing part 14 and the second housing part 16 are welded to each other at 40, and the third housing part 18 and the fourth housing part 20 are also welded to each other (at 44). The second housing part 16 and the third housing part 18 are sealed with an O-ring 42 and fixed using fasteners 36 ( Figure 2 ).

[0042] Referring to Figures 3 to 5 , a valve 54 is disposed in a coolant passage within the valve body part 11 and is configured to rotate between multiple positions to fluidly connect and disconnect fluid connectors 32 from each other and regulate the flow of coolant (e.g., water glycol) through the cooling system 100. The coolant distribution valve 10 transfers coolant from an input port to a selected output port provided by the fluid connectors 32, thereby connecting at least two cooling circuits (e.g., including at least two of a battery, a cabin, charging electronics, and a motor) based on, for example, a detected coolant temperature or component temperature.

[0043] The electronic device portion 13 includes sensitive electronic components, such as a motor 46 electrically connected to a printed circuit board (PCB) 72. A controller (e.g., PCB 72) can be a hardware device for executing software, particularly software stored in a memory. The controller (e.g., PCB 72) can be a custom or commercially available processor, a central processing unit (CPU), a co-processor among several processors associated with the controller, a semiconductor-based microprocessor (in the form of a microchip or chipset), or any device commonly used to execute software instructions.

[0044] The memory can include any one or combination of volatile memory elements (e.g., random access memory (RAM), such as DRAM, SRAM, SDRAM, VRAM, etc.) and / or non-volatile memory elements (e.g., ROM, hard disk drive, magnetic tape, CD-ROM, etc.). Additionally, the memory can comprise electronic, magnetic, optical, and / or other types of storage media. The memory can also have a distributed architecture where various components are located far from each other but can be accessed by a processor.

[0045] In terms of the hardware architecture, such a computing device can include a processor, a memory, and one or more input and / or output (I / O) device interfaces communicatively coupled via a local interface. The local interface can include, for example but not limited to, one or more buses and / or other wired or wireless connections. The local interface can have additional elements, which are omitted for simplicity, such as controllers, buffers (caches), drivers, repeaters, and receivers for implementing communication. Additionally, the local interface can include address, control, and / or data connections for enabling proper communication among the aforementioned components.

[0046] The software in the memory can include one or more separate programs, where each program includes an ordered list of executable instructions for implementing a logical function. System components embodied as software can also be interpreted as a source program, an executable program (object code), a script, or any other entity including a set of instructions to be executed. When constructed as a source program, via a translator program such as a compiler, assembler, interpreter, etc., the compiler, assembler, interpreter, etc. can be included in the memory or not included in the memory.

[0047] The disclosed input and output devices that can be coupled to one or more system I / O interfaces can include input devices such as, but not limited to, keyboards, mice, scanners, microphones, cameras, mobile devices, proximity devices, etc. Additionally, output devices such as, but not limited to, printers, displays, etc. Finally, the input and output devices can also include devices that communicate as both an input and an output, such as, but not limited to, modulators / demodulators (modems; for accessing another device, system, or network), radio frequency (RF) or other transceivers, telephone interfaces, bridges, routers, etc.

[0048] When the controller (e.g., PCB 72) is in operation, the processor can be configured to execute software stored in the memory, transfer data to and from the memory, and generally control the operation of the computing device according to the software. The software in the memory is read in whole or in part by the processor, possibly buffered within the processor, and then executed.

[0049] The electronic component section 13 houses an electric actuator, such as a motor 46, which includes a drive gear 48 that rotationally drives a valve 54 via a coupler. Since this coupler operably connected between the motor 46 and the valve 54 must extend between the valve body section 11 containing coolant and the electronic component section 13 that must remain dry, it is important to reliably seal the coupler.

[0050] Typically, coolant distribution valves are provided by multiple housings fixed by welding and fasteners. One housing section carries one seal that seals one end of the coupler, and another separate housing section carries another seal that seals the other end of the coupler. During assembly, the housing sections carrying the seals must be concentric between the two seals. Any deviation can cause misalignment of the coupling shaft relative to the seals, which can result in seal wear, gear wear, excessive torque, and / or binding or slow movement (response time) in the assembly. To address this problem, the disclosed first seal 58 and second seal 60 are supported by a housing section provided by a common single integral structure, which helps prevent coolant from passing through the coupler due to misalignment. The shaft support housing section is provided by a single-piece part formed by molding, casting, and / or machining.

[0051] In Figures 3 to 6 the example shown, the integral shaft support housing is provided by the second housing section 16. In Figures 7 to 9 the example shown, the integral shaft support housing is provided by the housing section 17, which is a combination of the second housing section 16 and the third housing section 18.

[0052] Returning to Figures 4 to 6, the shaft support housing portion (i.e., the second housing portion 16) includes an outer wall 150 that is connected to an inner wall 152 by a web 154, and the inner wall 152 is generally annular in shape. The shaft support housing portion has a first side 156 (near which the valve 54 is disposed) opposite to a second side 158 (near which the electronic components are disposed). The first side 156 and the second side 158 of the inner wall 152 respectively have a first hole 160 and a second hole 162, and the first hole 160 and the second hole 162 are formed concentrically with each other in the same part during machining or molding, thereby ensuring alignment. A first seal 58 and a second seal 60 are respectively installed in the first hole 160 and the second hole 162. In this way, the disclosed seal concentricity does not depend on a less precise assembly process.

[0053] As Figure 6 Best shown in, the cavity 163 is provided by the inner wall 152 and is between the first seal 58 and the second seal 60. A vent hole 62 extends through the inner wall 152 to fluidly connect the cavity 163 to the atmosphere. During operation, the coolant is at a higher pressure than the atmosphere. In the case where the coolant undesirably leaks through the first seal 58, the coolant can escape from the cavity 163 through the vent hole 62. The coolant in the cavity 163 will not be under pressure and will thus be less likely to leak through the second seal 60 to the second side 158 having the electronic components.

[0054] The inner wall 152 has a central hole 164, and a coupler or shaft between the valve 54 and the gear train 50 extends through the central hole 164. The gear train 50 has a drive lug 52. The coupler includes a first shaft and a second shaft coupled to each other, such as a first shaft 56 extending from the valve 54, and the first shaft 56 is nested in a splined coupling relationship in a sliding fit with respect to a second shaft 64 extending from the drive lug 52. The first shaft 56 and the second shaft 64 respectively include a first outer diameter portion 166 and a second outer diameter portion 168 that respectively engage the first seal 58 and the second seal 60. The slight sliding fit also helps to accommodate any misalignment in the coupler, and such misalignment will unevenly load the first seal 58 and the second seal 60, which may cause them to leak.

[0055] In one example, the coolant distribution valve 10 is assembled by installing the first seal 58 and the second seal 60 into the first hole 160 and the second hole 162 in the shaft support housing portion. The valve 54 is inserted into the housing and adjacent to the first side 156, thereby sealing the first outer diameter portion 166 with respect to the first seal 58. The drive lug 52 is coupled to the valve 54 at the second side 158, which seals the second outer diameter portion 168 with respect to the second seal 60.

[0056] The remainder of the gear train 50, the motor 46, and other electronic components are arranged on the second side 158 and are electronic components fixed between the first housing part 14 and the second housing part 16 or the first housing part 14 and the housing part 17. The first housing part 14 may provide a guide 68 that mates with a projection 69 on the drive lug 52 to support one end of the coupler. The fourth housing part 20 or the cover is fixed to the third housing part 18 or the housing part 17 to enclose the valve 54. The fourth housing part 20 includes a projection 71 that is received in a hole 70 in the valve 54 to support the opposite end of the coupler.

[0057] Figures 7 to 9 The example shown is assembled in a manner similar to Figures 3 to 6 the example shown.

[0058] It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiments, other arrangements will benefit therefrom. Although a particular order of steps is shown, described, and claimed, it should be understood that the steps may be performed, separated, or combined in any order, unless otherwise stated, and still benefit from the present invention.

[0059] Although the different examples have the specific components shown in the drawings, the embodiments of the present invention are not limited to those specific combinations. Some components or features from one example may be used in combination with features or components from another example.

[0060] Although example embodiments have been disclosed, those of ordinary skill in the art will recognize that certain modifications will fall within the scope of the claims. For this reason, the appended claims should be studied to determine their true scope and content.

Claims

1. A coolant distribution valve for a vehicle cooling system, comprising: a housing including a shaft support housing portion providing a unitary, unitary structure, the shaft support housing portion having a first side opposite a second side, the first side and the second side including a first aperture and a second aperture, respectively; a valve disposed in the housing adjacent the first side; an electronic component disposed in the housing adjacent the second side, the electronic component configured to move the valve between a plurality of positions; a first seal and a second seal installed in the first hole and the second hole respectively; as well as A shaft extends through and engages the first seal and the second seal, the shaft operably connecting the electronic component to the valve.

2. The coolant distribution valve according to claim 1, wherein: The shaft support housing portion is provided as a single-piece component that is molded, cast and / or machined.

3. The coolant distribution valve according to claim 1, wherein: The housing includes an electronics housing portion secured to the shaft support housing portion to enclose the electronic components.

4. The coolant distribution valve according to claim 3, wherein: The shaft supporting housing portion provides a valve housing portion that receives the valve, and the housing includes a cover secured to the valve housing portion to enclose the valve.

5. The coolant distribution valve according to claim 3, wherein: A valve housing part is fixed to the shaft support housing part, the valve being arranged in the valve housing part.

6. The coolant distribution valve according to claim 5, wherein: The housing includes a cover secured to the valve housing portion to close the valve.

7. The coolant distribution valve according to claim 1, wherein: A cavity is disposed between the first seal and the second seal, and a vent is disposed in the shaft support housing portion, the vent being configured to fluidly connect the cavity to atmosphere.

8. The coolant distribution valve of claim 3, comprising a printed circuit board (PCB) disposed in the electronics housing portion and an electrical actuator electrically connected to the PCB and disposed in the electronics housing portion.

9. The coolant distribution valve according to claim 8, wherein: The electric actuator is a motor, and a gear train is coupled between the motor and the valve.

10. The coolant distribution valve according to claim 9, wherein: The shaft is provided by a first shaft and a second shaft coupled to each other, the first shaft extending from the valve, and the second shaft extending from the gear train.

11. The coolant distribution valve according to claim 10, wherein: The first shaft and the second shaft are nested relative to each other in a splined relationship.

12. The coolant distribution valve according to claim 10, wherein: The first shaft and the second shaft include first and second outer diameter portions, respectively, and the first and second outer diameter portions engage the first and second seals, respectively.

13. A vehicle cooling system comprising the coolant distribution valve according to claim 1, the vehicle cooling system comprising a plurality of cooling circuits, the coolant distribution valve interconnecting at least two cooling circuits of the plurality of cooling circuits, and the coolant distribution valve being configured to move between a plurality of positions to direct a desired cooling flow through the at least two cooling circuits of the plurality of cooling circuits.

14. The vehicle cooling system according to claim 13, wherein: The cooling circuit includes at least two of a battery, a vehicle cabin, charging electronics, and a motor.

15. A method of assembling a coolant distribution valve, comprising: providing a housing including an axle support housing portion providing a unitary unitary structure, the axle support housing portion having a first side opposite a second side, the first side and the second side including a first aperture and a second aperture, respectively; installing a first seal in the first hole; installing a second seal in the second hole; inserting a valve into the housing adjacent the first side; disposing an electronic component in the housing adjacent the second side, the electronic component configured to move the valve between a plurality of positions; as well as A shaft is extended through and engages the first seal and the second seal, the shaft operably connecting the electronic component to the valve.

16. The method according to claim 15, wherein: The step of installing the first seal is performed before the step of inserting the valve.

17. The method according to claim 15, wherein: The step of mounting the second sealing member is performed before the step of arranging the electronic components.

18. The method according to claim 15, wherein: The inserting step includes the step of extending the shaft through and engaging the first seal, and includes the step of assembling a gear train in the housing, the step of assembling the gear train including the step of extending the shaft through and engaging the second seal.

19. The method according to claim 18, wherein: The extending step includes extending a first shaft from the valve to engage the first seal and extending a second shaft from the gear train to engage the second seal, the first shaft and the second shaft being coupled to each other.

20. The method of claim 15 including the step of forming a cavity with the first and second seals, the shaft support housing portion and the shaft, the shaft support housing portion including a vent in fluid communication with atmosphere.

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