Improved reed valve and reed valve air box

Abstract

In one embodiment, a reed valve includes a first valve body portion including one or more inlet apertures fluidly coupled to a tapered second valve body portion including one or more outlet apertures. The reed valve includes at least one sealing surface disposed proximate to the one or more outlet apertures and at least one flap continuously, reversibly movable between an open position in which the one or more outlet apertures are open and a closed position in which the one or more outlet apertures are closed. The reed valve has an open position allowing forward flow through the reed valve when fluid pressure proximate the at least one inlet orifice exceeds fluid pressure proximate the at least one outlet orifice, and an open position allowing forward flow through the reed valve when fluid pressure proximate the at least one outlet orifice exceeds fluid pressure proximate the at least one inlet orifice. The closed position prevents reverse flow through the reed valve. The reed valve may be installed in an air tank assembly for use with a turbocharged engine to reduce the occurrence of turbo lag during acceleration.

Description

[0001] This application is a divisional application of the patent application for invention named "Improved Reed Valve and Reed Valve Air Box", with an international filing date of March 11, 2021, an international application number of PCT / US2021 / 070263, and a national application number of 202180029555.7.

[0002] Cross - reference to related applications

[0003] This disclosure claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 988,850, filed on March 12, 2020, which is hereby incorporated by reference in its entirety. Technical field

[0004] This disclosure generally relates to engine components, and more particularly, to the field of reed valve assemblies with improved seals. Background art

[0005] In two - stroke engine applications, reed valves have been used to control the flow of fuel - air mixture from a carburetor to the cylinder(s). When exposed to downstream negative pressure / vacuum (e.g., piston moving downward), the reed valve opens, allowing flow through the reed valve, and when exposed to downstream positive pressure (e.g., piston moving upward), the reed valve closes, preventing flow through the reed valve. The operation of the engine (e.g., movement of the piston within the cylinder) causes changes in the intake pressure. For example, in a two - stroke engine, during the compression stroke, the upward movement of the piston creates a vacuum in the crankcase, drawing the fuel / air mixture into the engine. During the power stroke, the downward movement of the piston draws the fuel / air mixture from the crankcase into the cylinder and increases the pressure in the crankcase, causing the reed valve to close and preventing the fuel / air mixture from flowing into the crankcase.

[0006] Increasing the amount of air introduced into the cylinder(s) can increase the power output of the engine. Turbochargers and superchargers are often used to increase the pressure of the air introduced into the cylinder(s), and thus the volume of air. A turbocharger includes an exhaust - driven turbine coupled to an intake compressor. In contrast, a supercharger is an externally - driven intake compressor. By increasing the power output of the engine, a turbocharger can improve the efficiency of the engine. With a turbocharger, the fuel / air mixture is introduced into the cylinder, compressed by an upward piston stroke, and ignited, causing a downward piston stroke that provides power output via the crankshaft. Exhaust gases leave the cylinder under pressure and flow through the turbocharger. The compressor draws in air (e.g., atmospheric) and forces it into the engine, thus improving the efficiency and / or power output of the engine.

[0007] Although turbochargers are generally effective in increasing the efficiency and / or power output of an engine, a turbocharger may suffer from what is known as "turbo lag." For example, in certain situations (e.g., low engine speeds), the flow of exhaust gas through the exhaust system may be insufficient to drive the turbocharger, resulting in a rotational speed of the turbocharger that is insufficient to provide a sufficient amount of air to significantly increase the power output of the engine. Turbo lag can be particularly problematic when a relatively large turbocharger is used for a given engine application. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other features and advantages will be better understood by reference to the following detailed description when read in conjunction with the accompanying drawings, in which:

[0009] Figure 1 FIG. is a block diagram showing an exemplary illustrative turbocharged engine system in accordance with at least one embodiment described herein, the turbocharged engine system including an air box assembly including a reed valve coupled between a turbocharger assembly and one or more cylinders in an engine;

[0010] Figure 2A FIG. is a perspective view of an exemplary illustrative reed valve in an open position or state in accordance with at least one embodiment described herein, the reed valve including at least one valve body having one or more channels formed therethrough, one or more upper flaps, one or more upper sealing surfaces, and one or more lower sealing surfaces;

[0011] Figure 2B FIG. Figure 2A is a side view of the exemplary illustrative reed valve shown in FIG. in accordance with at least one embodiment described herein;

[0012] Figure 2C FIG. Figure 2A and 2B is a partial detailed view of a portion of the exemplary illustrative reed valve shown in FIGS. and in accordance with at least one embodiment described herein;

[0013] Figure 2D FIG. Figures 2A - 2C is a rear view of the exemplary illustrative reed valve shown in FIG. in accordance with at least one embodiment described herein, the reed valve including a plurality of channels, each channel having a corresponding upper hole and a corresponding lower hole;

[0014] Figure 3A FIG. is a perspective view of an exemplary illustrative reed valve in accordance with at least one embodiment described herein, wherein the upper flap is shown in a closed position or state.

[0015] Figure 3BFor Figure 3A Lower perspective view of an exemplary reed valve according to at least one embodiment described herein, wherein the lower holes of each of the plurality of channels are visible;

[0016] Figure 4A Perspective view of an exemplary reed valve according to at least one embodiment described herein, wherein the upper flap is shown in a slightly open position or state;

[0017] Figure 4B For Figure 4A Side view of an exemplary reed valve according to at least one embodiment described herein, wherein the upper sealing surface and the lower sealing surface are more clearly visible;

[0018] Figure 5A Perspective view of an exemplary reed valve according to at least one embodiment described herein, wherein the upper flap and the lower flap have been removed to more clearly show the upper sealing surface, the lower sealing surface, and details of the sealing assembly, the sealing assembly comprising a sealing surface and a web member that physically couples the sealing surface on three sides of the valve body;

[0019] Figure 5B For Figure 5A Side view of an exemplary reed valve 00 according to at least one embodiment described herein;

[0020] Figure 5C For Figure 5A And 5B Cross-sectional view of an exemplary reed valve according to at least one embodiment described herein, which more clearly shows details of the sealing assembly, the sealing assembly comprising a sealing surface, an external web portion connecting the sealing surface on three sides of the valve body, a first sealing surface portion, a second sealing surface portion, and a connecting member connecting the first and second sealing surface portions;

[0021] Figure 5D For Figures 5A - 5C Enlarged side view of a reed valve according to at least one embodiment described herein;

[0022] Figure 5E Perspective side cross-sectional view of an exemplary sealing surface according to at least one embodiment described herein;

[0023] Figure 5F Partial cross-sectional view of an exemplary sealing surface according to at least one embodiment described herein;

[0024] Figure 6 A block diagram showing another exemplary illustrative engine system in accordance with at least one embodiment described herein, the engine system including one or more reed valves as shown in FIGS. 2, 3, 4, and 5; and

[0025] Figure 7 A block diagram showing another exemplary illustrative engine system in accordance with at least one embodiment described herein, the engine system including a plurality of reed valves as shown in FIGS. 2, 3, 4, and 5. DETAILED DESCRIPTION

[0026] The systems and methods disclosed herein provide a reed valve and / or air box assembly that can beneficially and advantageously help minimize an instantaneous reduction in engine output power caused by turbocharger lag (“turbo lag”). The systems and methods disclosed herein provide a supplemental combustion air inlet that includes a reed valve disposed between a turbocharger and an engine having one or more cylinders. The reed valve opens under a positive pressure differential (inlet pressure > outlet pressure) to provide supplemental combustion air to the engine during a transition period of turbocharger rotation, and the reed valve closes under a negative pressure differential (outlet pressure > inlet pressure) when the turbocharger increases the combustion air pressure. In some embodiments, the reed valve can act as a check valve or non-return valve that permits supplemental combustion air to flow into an air box assembly fluidly coupled to the engine. However, those skilled in the relevant art should readily understand that the reed valve and / or air box assembly disclosed herein can also be used in many different applications, such as replacing a conventional reed valve directly bolted to a two-stroke engine housing or as a reed valve in a four-stroke exhaust device to reduce noise / emissions. The reed valve disclosed herein can include a lip seal type feature just inside the peripheral edge of the reed flap for improved sealing. The lip can also be asymmetric at the top and bottom, having less interference at the base and greater interference at the tip, and additionally having variable interference with the reed flap along the length of the seal.

[0027] The present invention provides a reed valve. The reed valve may comprise: a valve body having one or more channels formed therethrough, each of the one or more channels comprising at least one inlet hole and at least one outlet hole; at least one sealing surface disposed partially around each of the at least one outlet holes; and at least one flap positioned and fixed to the valve body such that the at least one flap moves reversibly and continuously between an open position and a closed position: in the open position, when a positive forward pressure differential is applied between the at least one inlet hole and the at least one outlet hole, a gap is formed between the at least one flap and the at least one sealing surface, thereby allowing forward flow through the one or more channels, and in the closed position, when a negative forward pressure differential is applied between the at least one inlet hole and the at least one outlet hole, the at least one flap is disposed adjacent to the at least one sealing surface, thereby preventing reverse flow through the one or more channels (i.e., the at least one flap is flexibly coupled to the valve body, which means that the flap is fixed to the valve body and flexes / bends relative to the valve body as the flap moves between the open position (OPEN) and the closed position (CLOSED)).

[0028] The present invention provides an air box assembly. The air box assembly may comprise: a housing defining a mixing region having an inlet for receiving combustion air and an outlet for discharging combustion air, the housing having an inlet and an outlet; and a reed valve fluidly coupled to the mixing region to allow ambient air to flow into the mixing region, the reed valve comprising: a valve body having one or more channels formed therethrough, each of the one or more channels comprising at least one inlet hole fluidly coupled to an ambient air inlet and at least one outlet hole; at least one sealing surface disposed partially around each of the at least one outlet holes; and at least one flap flexibly coupled to the valve body, the at least one flap moving reversibly and continuously between an open position and a closed position: in the open position, when a positive forward pressure differential is applied between the at least one inlet hole and the at least one outlet hole, a gap is formed between the at least one flap and the at least one sealing surface, thereby allowing forward flow through the one or more channels, and in the closed position, when a negative forward pressure differential is applied between the at least one inlet hole and the at least one outlet hole, the at least one flap is disposed adjacent to the at least one sealing surface, thereby preventing reverse flow through the one or more channels.

[0029] The present invention provides a turbocharged engine system. The turbocharged engine system may include: an engine having one or more cylinders and a fuel / air inlet system and an exhaust manifold; a turbocharger assembly including: a turbine section fluidly coupled to the exhaust manifold; and a compressor section for supplying combustion air to the engine; an air box assembly fluidly coupled to the turbocharger assembly, the air box assembly receiving combustion air from the turbocharger assembly, the air box assembly including: a housing defining a mixing region having an inlet for receiving combustion air and an outlet for discharging combustion air, the housing having an inlet and an outlet; and a reed valve fluidly coupled to the mixing region to allow ambient air to flow into the mixing region, the reed valve including: a valve body having one or more channels formed therethrough, each of the one or more channels including at least one inlet hole fluidly coupled to an ambient air inlet and at least one outlet hole; at least one sealing surface partially surrounding each of the at least one outlet holes; and at least one flap flexibly coupled to the valve body, the at least one flap reversibly and continuously moving between an open position and a closed position: in the open position, when a positive forward pressure difference is applied between the at least one inlet hole and the at least one outlet hole, a gap is formed between the at least one flap and the at least one sealing surface, thereby allowing forward flow through the one or more channels, in the closed position, when a negative forward pressure difference is applied between the at least one inlet hole and the at least one outlet hole, the at least one flap is disposed adjacent to the at least one sealing surface, thereby preventing reverse flow through the one or more channels; and a throttle body fluidly coupled between the air box assembly and the engine, the throttle body controlling the flow of combustion air to the engine.

[0030] Figure 1 FIG. is a block diagram showing an exemplary illustrative turbocharged engine system 100 according to at least one embodiment described herein, the turbocharged engine system including an air box assembly 110 including a reed valve 112 coupled between a turbocharger assembly 120 and one or more cylinders in an engine 130. As Figure 1As shown, the flow of exhaust gas 108 generated by engine 130 causes turbine 122 in turbocharger assembly 120 to rotate. Turbine 122 is physically coupled to compressor 150, which draws in combustion air 102 through filter 126 and increases the pressure of the discharged combustion air 102. The compressed combustion air flows through throttle body 140, which controls the flow of the fuel / air mixture into engine 130, thereby increasing the power output of engine 130. When the operator increases the throttle valve to provide additional fuel / air mixture to engine 130, the time required for turbocharger assembly 120 to increase the combustion air pressure at the increased throttle valve position is referred to as "turbo lag".

[0031] Using air box assembly 110 as shown Figure 1 can minimize the turbo lag effect. As throttle body 140 opens and the flow of fuel / air mixture to engine 130 increases, the air pressure in conduit 152 that couples turbocharger 120 to engine 130 decreases. The transient sub-atmospheric pressure condition created by the increased air demand in conduit 152 due to the opened throttle valve creates a positive pressure differential (inlet pressure > outlet pressure) across reed valve 112, causing reed valve 112 to open to allow supplemental combustion air 104 to flow through reed valve 112, through throttle body 140, and into engine 130. When the combustion air pressure in conduit 152 increases above ambient atmospheric pressure, a negative pressure differential (outlet pressure > inlet pressure) is created across reed valve 112, causing reed valve 112 to close to allow engine 130 to receive all of the pressurized combustion air provided by turbocharger 120. Advantageously, reed valve 112 opens to allow supplemental combustion air while turbocharger 120 is rotating and closes after turbocharger 120 is rotating and providing pressurized combustion air to engine 130 without any intervention by the vehicle driver.

[0032] The air box assembly 110 may include one or more reed valves 112, one or more air filters 114 that supply air to the one or more reed valves 112, and a mixing region 116 in which the supplementary combustion air 104 provided by one or more improved reed valves 112 is mixed with the combustion air 102 provided by the turbocharger 120. The reed valves 112 are described in more detail in FIGS. 2-5. However, in its most basic form, the reed valve 112 includes a valve body having at least one inlet hole and at least one outlet hole. One or more movable and / or flexible flaps cover the outlet hole. The reed valve 112 includes an enhanced sealing surface between the one or more flaps and the valve body. When the pressure at the outlet hole is less than the pressure at the inlet hole, the one or more flaps open the outlet hole, thereby allowing flow through the reed valve 112. When the pressure at the inlet hole is less than the pressure at the outlet hole of the reed valve 112, the one or more flaps contact the enhanced sealing surface, thereby minimizing or even preventing flow through the improved reed valve 112.

[0033] The reed valve 112 may be coupled, mounted, at least partially disposed within, and / or otherwise secured to, within, on, or around the air box assembly 110. For example, one or more reed valves 112A-112n may be directly coupled to the frame of the air box assembly 110. The reed valve 112 may be secured to the frame / casing of the air box assembly 110 using one or more fasteners such as, but not limited to, bolts, clamps, screws, friction fits, tabs, snap fits, welds, and the like. In one example, at least a portion of the reed valve 112 may be disposed within a cavity formed in the air box assembly 110, such as a cavity at least partially defined by the frame / casing. Alternatively (or additionally), one or more of the reed valves 112 may be disposed outside the air box assembly 110. For example, the reed valve 112 may be coupled to an intake sleeve / conduit or similar structure or component between the turbocharger 120 and the throttle body 140, the intake sleeve / conduit or similar structure or component being coupled to the air box assembly 110. Because of this, the reed valve 112 may be at least partially disposed inside the air box assembly 110, at least partially disposed outside the air box assembly 110, or any combination thereof, while still providing an alternative path for atmospheric air to enter the air box assembly 110 and / or conduit 152.

[0034] When a positive pressure differential is created across the reed valve 112, such as when the pressure in the conduit 152 (i.e., the outlet pressure of the reed valve 112) is less than the ambient pressure (i.e., the inlet pressure of the reed valve 112), the reed valve 112 opens. The pressure in the conduit 152 may be affected by the position of the throttle body 140 - as the throttle position increases (e.g., when engine speed and / or power demand increases), the increased airflow of combustion air through the throttle body 140 may cause an instantaneous pressure drop within the conduit 152. For example, when the pressure in the conduit 152 is under vacuum (e.g., the pressure in the conduit 152 is substantially less than atmospheric pressure), the reed valve 112 opens, allowing the supplemental combustion air 104 to flow into the conduit 152. Allowing the supplemental combustion air 104 to enter the conduit 152 provides the engine 130 with a greater volume of combustion air, thereby increasing the volume of the exhaust gas 108. As the volume of the exhaust gas 108 passing through the turbine 122 increases, the speeds of the turbine 122 and the compressor 150 increase, thereby increasing the volume of the combustion air 102 discharged from the turbocharger assembly 120 into the conduit 152. Once the pressure of the combustion gas 102 in the conduit 152 increases to be higher than the pressure of the supplemental combustion air 104 (e.g., the outlet pressure of the reed valve 112 exceeds the approximate atmospheric inlet pressure at the reed valve 112), the reed valve 112 closes. Thus, the higher-pressure combustion air 102 present in the conduit 152 does not escape through the air box assembly 110 but is forced into the engine 130. As used herein, the term "approximate atmospheric pressure" means + / - 20% of the ambient atmospheric pressure.

[0035] The at least one air filter 114 minimizes the amount of particulate matter and / or other contaminants flowing into the conduit 152 so as not to damage or impair the operation of the throttle body 140 and / or the engine 130. The supplemental combustion air 104 flowing through the reed valve 112 mixes with the combustion air 102 received from the turbocharger assembly 120 in the mixing region 116. In an embodiment, the mixing region 116 may include one or more static flow mixing devices to create turbulence and improve the mixing of the combustion air 102 and the supplemental inlet air 104. The combined combustion air 102 and supplemental combustion air 104 flow through the throttle body 140. A positionable element (such as a butterfly valve) disposed within the throttle body 140 controls the volume of combustion air provided to the engine 130. The throttle body 140 may include various holes or orifices to allow a small amount of combustion air to pass through so that the engine 130 remains running in an "idle" state when the valve in the throttle body is closed. Fuel 106 (such as one or more liquid or gaseous hydrocarbons, such as diesel, gasoline, and / or natural gas) is mixed with the combustion air exiting the throttle body 140 to provide a combustible fuel / air mixture for the engine 130.

[0036] The engine 130 may include a single-cylinder or multi-cylinder two-stroke or four-stroke engine. In at least some embodiments, the engine 130 may include a two-stroke engine having one or more reed valves 112 operatively coupled to the crankcase of the engine 130. Within the engine 130, combustion of the fuel / air mixture produces exhaust gas 108, which is removed from the engine 130. In an embodiment, the exhaust gas 108 may pass through one or more emission control devices and / or one or more noise attenuation devices.

[0037] The exhaust gas 108 flows to the turbine 122 portion of the turbocharger assembly 120. The flow of the exhaust gas 108 through the turbine 122 causes rotation of the turbine 122 and the compressor 150 operatively coupled to the turbine 122. The compressor 150 draws in ambient air (e.g., air having approximately atmospheric pressure) and discharges combustion air 102 having an increased pressure (e.g., air having a pressure greater than atmospheric pressure) into the conduit 152. When compared to a non-turbocharged engine 130, increasing the pressure of the combustion air supplied to the engine 130 increases the oxygen available for combustion in the engine, thereby allowing a greater fuel feed rate to the engine 130 to increase the power output of the engine 130. It should be understood that although the airbox assembly 110 and the throttle body 140 are Figure 1 shown downstream of the turbocharger 120 in, in other embodiments, the airbox assembly 110 and / or the throttle body 140 may be disposed in the conduit 152 at any location and in any configuration.

[0038] Figure 2A A perspective view of an exemplary illustrative reed valve 200 in an open position or state according to at least one embodiment described herein, wherein the reed valve 200 includes at least one valve body 230, one or more upper flaps 220U, one or more upper sealing surfaces 240U, and one or more lower sealing surfaces 240L, and the valve body 230 has one or more channels 210A-210D (collectively referred to as "channels 210") formed therethrough. Figure 2B For Figure 2A A side view of an exemplary illustrative reed valve 200 according to at least one embodiment described herein as shown in, the reed valve 200 having a valve body 230 with a first valve body portion 230A including a reed valve inlet and a second valve body portion 230B including one or more outlet holes. Figure 2C For Figure 2A And 2B A partial detailed view of a portion of an exemplary illustrative reed valve 200 according to at least one embodiment described herein as shown in. Figure 2D For Figures 2A - 2CRear view of an exemplary illustrative reed valve 200 according to at least one embodiment described herein, the reed valve including a plurality of channels 210A-210D, each of which has a corresponding upper hole 212A-212D (collectively "upper holes 212") and a corresponding lower hole 214A-214D (collectively "lower holes 214"). It should be understood that the reed valve 200 may include only one flap 220, either an upper flap or a lower flap.

[0039] In an embodiment, the exemplary illustrative reed valve 200 may include a valve body 230, one or more upper flaps 220U, one or more lower flaps 220L ( Figures 2A - 2D not shown in), one or more upper sealing surfaces 240U, and one or more lower sealing surfaces 240L. In an embodiment, the one or more upper flaps 220U contact and seal the one or more upper sealing surfaces 240U. Similarly, in an embodiment, the one or more lower flaps 220L contact and seal the one or more lower sealing surfaces 240L. By contacting the upper and lower sealing surfaces 240, the upper and lower flaps 220 minimize or even prevent backflow through the reed valve 200. In an embodiment, the valve body 230 may include one or more sealing devices 232 to seal the gap between the reed valve 200 and the air box assembly 110 to prevent flow bypass or leakage around the reed valve 200. In an embodiment, the reed valve 200 may include a first valve body portion 230A and a second valve body portion, the first valve body portion including one or more inlet holes, and the second valve body portion including one or more upper outlet holes 212 and / or one or more lower outlet holes 214. The valve body 230 and the one or more upper flaps 220U and / or the one or more lower flaps 220L may include any reed valve design known to those skilled in the art. For example, the valve body 230 and the one or more flaps 220 may include any design described in U.S. Patent Nos. 6,880,577, 7,614,422, and 7,963,265, all of which are incorporated herein by reference in their entirety. It should be understood that the exemplary illustrative reed valve 200 is in Figures 2A - 2Dis shown as having only a single upper flap 220U disposed above upper holes 212A - 212D in each of a plurality of channels 210A - 210D formed in a valve body 230. However, it should be understood that the reed valve 200 may include one or more additional lower flaps 220L disposed below or beneath each of some or all of the lower holes 214A - 214D such that fluid flow can exit from the upper holes 212 in each channel 210 and the lower holes 214 in each channel 210. Illustrated is an exemplary improved reed valve 112. The flaps may have alternative geometries as needed to meet the desired design and performance requirements of the application. Figures 2A - 2C The reed valve 200 shown in includes a plurality of channels 210A - 210D, each of the plurality of channels having upper holes 212A - 212D and lower holes 214A - 214D. The upper flap 220U covers the upper holes of each of the plurality of channels 210A - 210D and seals against an upper sealing surface 240U extending around the perimeter of the plurality of channels 210A - 210D. For better illustration of the lower sealing surface 240L, the lower flap 220L is omitted in Figures 2A - 2D each of.

[0040] The channels 210A - 210D permit fluid flow (e.g., air and / or air - fuel, and / or air - oil and / or air - fuel - oil mixture) through the valve body 230. The one or more upper flaps 220U and the one or more lower flaps 220L can move independently, reversibly, and continuously between an open (OPEN) state or position (as shown in Figures 2A - 2D and a closed (CLOSED) state or position (e.g., as shown in Figure 3A and 3B ), in the open state or position, allowing forward fluid flow 280 through the channels 210A - 210D, and in the closed state or position, preventing reverse fluid flow 282 through the channels 210A - 210D. In an embodiment, the reed valve 200 may include one or more channels 210 having upper holes 212A - 212D through which fluid can flow, lower holes 214A - 214D through which fluid can flow, or both upper and lower holes through which fluid can flow. In the exemplary reed valve 200 shown in Figures 2A - 2D , the reed valve 200 includes a plurality of channels 210A - 210D, each channel having a corresponding upper hole 212A - 212D and a corresponding lower hole 214A - 214D.

[0041] The one or more upper sealing surfaces 240U seal the one or more upper flaps 220U to the valve body. The one or more lower sealing surfaces 240L seal the one or more lower flaps 220L to the valve body 230. This is particularly advantageous in forced ventilation (e.g., pressurized) systems, such as engine intake systems, e.g., an air box assembly 110 used in combination with a turbocharged engine 130. The upper and / or lower sealing surfaces 240 may include a material overmolded around a portion of the valve body 230. The overmolded material used to provide the one or more upper sealing surfaces 240U and the one or more lower sealing surfaces 240L may include one or more elastomeric or flexible materials. The overmolded material may include, but is not limited to: epichlorohydrin, nitrile rubber, silicone, or elastomeric compounds that have similar properties and the ability to achieve various hardnesses and have minor compound variations to alter performance. The overmolded material selected to provide the one or more upper sealing surfaces 240U and the one or more lower sealing surfaces 240L is selected to withstand the temperature and pressure of the application, be compatible with any chemicals or compounds to which it will be exposed, and be soft enough not to damage the surfaces of the one or more upper flaps 220U and / or the one or more lower flaps 220L after repeated cycling, closing, sealing, and / or contact.

[0042] In some embodiments, the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L may extend around all or a portion of the interface surface between the valve body 230 and the one or more upper flaps 220U and / or the one or more lower flaps 220L, respectively. The interface surface is defined as the portion where the one or more upper flaps 220U and / or the one or more lower flaps 220L will contact the valve body 230 when the reed valve 200 is in the CLOSED state or position. When the reed valve 200 is in the CLOSED state or position, the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L may be disposed at least within the interface surface between the one or more upper flaps 220U and / or the one or more lower flaps 220L and the valve body 230.

[0043] In some embodiments, the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L may be disposed around at least a portion of the peripheral region 260 of the valve body 230. The upper peripheral region 260 may include a region extending around the upper hole(s) 212A - 212D formed in the one or more channels 210A - 210D in the valve body 230. Similarly, although Figures 2A - 2DNot shown, the lower peripheral region 260 may include a region extending around the lower hole(s) 214A - 214D of the one or more channels 210 formed in the valve body 230.

[0044] In Figures 2A - 2D In the example reed valve shown in, a single continuous upper sealing surface 240U extends around the entire upper peripheral region 260 of the valve body 230, and a single continuous lower sealing surface 240L extends around the entire lower peripheral region 260 of the valve body 230. As Figures 2A - 2D shown in, in an embodiment, the upper sealing surface 240U and the lower sealing surface 240L may be physically joined together using a web member that extends at least partially around the peripheries of the upper sealing surface 240U and the lower sealing surface 240L. In other embodiments, all or part of either or both of the upper sealing surface 240U and / or the lower sealing surface 240L may extend on only a portion of the upper peripheral region 260 of the valve body 230, around or across said portion. For example, in some embodiments, the upper sealing surface 240U may extend around only a portion of the upper peripheral region 260, such as along the distal region of the peripheral region 260 (e.g., the portion of the peripheral region 260 opposite the attachment fixtures 222A - 222D that couple the upper flap 220U to the valve body 230), around only the adjacent region of the peripheral region 260 (e.g., the portion of the peripheral region 260 adjacent to the attachment fixtures 222A - 222D that couple the upper flap 220U to the valve body 230), and / or around only one or more side regions of the peripheral region 260 (e.g., the region disposed between the distal region and the adjacent region), and / or extend between the proximal region and the distal region of the peripheral region adjacent to one or more channels. In some embodiments, one or both of the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L may be asymmetric. For example, the height and / or width and / or cross-sectional shape of one or both of the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L may gradually decrease. In one embodiment, the height of one or both of the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L in the adjacent region of the peripheral region 260 may be less than the height of one or both of the one or more upper sealing surfaces 240U and / or the one or more lower sealing surfaces 240L in the distal region of the peripheral region 260.

[0045] Figure 3AA perspective view of an exemplary reed valve 300 according to at least one embodiment described herein, where the upper flap 220U is shown in a closed position or state. Figure 3B As shown in Figure 3A A bottom perspective view of an exemplary reed valve 300 according to at least one embodiment described herein, where the lower holes 214A - 214D of each of the plurality of channels 210A - 210D are visible. In Figure 3A and 3B the lower flap 220L has been omitted to more clearly show the lower sealing surface 240L.

[0046] As Figure 3A and 3B shown, when the upper flap 220U of the reed valve 300 is in a closed state or position, the lower surface of the upper flap 220U contacts the upper sealing surface 240U, which is provided, recessed in all or part of the second valve body portion 230B or otherwise formed within, on, around, or across all or part of the second valve body portion 230B, thereby preventing reverse fluid flow through the reed valve 300. In an embodiment, when the pressure on the downstream side of the reed valve 300 exceeds the pressure on the inlet side of the reed valve 300, the upper flap 220U of the reed valve 300 is in a closed state or position. For example, as Figure 1 shown, this may occur when there is a negative pressure difference (outlet pressure > inlet pressure) across the reed valve 300.

[0047] Figure 4A A perspective view of an exemplary reed valve 400 according to at least one embodiment described herein, where the upper flap 220U is in a slightly open (OPEN) position or state. Figure 4B As Figure 4A shown in a side view of an exemplary reed valve 400 according to at least one embodiment described herein, where the upper sealing surface 240U and the lower sealing surface 240L are more clearly visible.

[0048] As Figure 4A and 4B shown, when the upper flap 220U of the reed valve 400 is in a slightly open state or position, only a portion of the lower surface of the upper flap 220U contacts the upper sealing surface 240U, thereby allowing forward fluid flow through the reed valve 400. In an embodiment, when there is a slight positive pressure difference (inlet pressure > outlet pressure) across the reed valve 400, the upper flap 220U of the reed valve 300 is in a slightly open state or position.

[0049] Figure 5AA perspective view of an exemplary illustrative reed valve 500 in accordance with at least one embodiment described herein, in which the upper flap 220U and the lower flap 220L have been removed to more clearly show the upper sealing surface 240U and the lower sealing surface 240L and the details of the sealing assembly 510, the sealing assembly comprising the sealing surface 240 and the web member 520, the web member physically coupling the sealing surface 240 on three sides of the second part of the valve body 230B. Figure 5B Is Figure 5A A side view of the exemplary illustrative reed valve 500 shown in accordance with at least one embodiment described herein. Figure 5C Is Figure 5A And 5B A cross-sectional view of the exemplary illustrative reed valve 500 shown in accordance with at least one embodiment described herein, which more clearly shows the details of the sealing assembly 510, the sealing assembly comprising the sealing surface 240, an external web portion 520 connecting the sealing surface on three sides of the second part of the valve body 230B, a first sealing surface portion 530, a second sealing surface portion 540, and a connecting member 550 connecting the first and second sealing surface portions. Figure 5D Is Figures 5A - 5C An enlarged side view of the reed valve shown in accordance with at least one embodiment described herein. Figure 5E A perspective side cross-sectional view of an exemplary sealing surface 240 in accordance with at least one embodiment described herein. Figure 5F A partial cross-sectional view of an exemplary sealing surface 240 in accordance with at least one embodiment described herein.

[0050] First referring to Figure 5A And 5B , in at least some embodiments, the external web portion 520 may physically couple at least a portion of the perimeter of the upper sealing surface 240U to at least a portion of the perimeter of the lower sealing surface 240L. For example, the external web portion 520 may extend from both sides and the distal ends of the perimeters of both the upper sealing surface 240U and the lower sealing surface 240L such that the second part of the valve body 230B can be at least partially inserted into the three-sided one-piece sealing assembly 510, as Figure 5A Shown in.

[0051] Next referring to Figures 5C - 5E , the three-sided "pocket" configuration of the one-piece sealing assembly 510 includes the upper sealing surface 240U, the lower sealing surface 240L, and the external web portion 520 that physically couples the upper sealing surface 240U to the lower sealing surface 240L. In Figure 5CThe construction details of the upper sealing surface 240U and the lower sealing surface 240L can also be seen. Each of the upper sealing surface and the lower sealing surface includes a first sealing surface portion 530 and a second sealing surface portion 540 physically connected by a connecting member 550. As Figure 5C shown, in some embodiments, the first sealing surface portion 530 may include a member extending outward at an angle from the connecting member 550, and the second sealing surface portion 540 may include a generally conical or trapezoidal member physically connected to the connecting member 550.

[0052] Next, referring to Figure 5E , in at least some embodiments, the first sealing surface portion 530 may have a thickness of about 0.01 inches to about 0.25 inches. In at least some embodiments, as Figure 5E shown, the first sealing surface portion 530 may have a thickness of about 0.015 inches. In at least some embodiments, the second sealing surface portion 540 may have a thickness of about 0.01 inches to about 0.25 inches. In at least some embodiments, as Figure 5E shown, the second sealing surface portion 540 may have a thickness of about 0.02 inches. In at least some embodiments, the connecting member 550 may have a thickness of about 0.01 inches to about 0.25 inches. In at least some embodiments, as Figure 5E shown, the connecting member 550 may have a thickness of about 0.03 inches. It should be understood that the reed valve 500 according to the present disclosure is not limited to these dimensions, unless specifically stated. The dimension of 0.013 of the second sealing surface portion 540 may gradually vary from about 0 to any dimension less than 0.013 at the base. It should be understood that any of these dimensions may be increased and / or decreased by 25% or more.

[0053] Referring to Figure 5F , in at least one embodiment, the sealing profile is conceptually similar to a hydraulic seal. In the closed position, as the pressure of the exhausted combustion air 102 increases, the first sealing surface portion 530 is pushed into the mating component (e.g., the flap 220) with an increasing force, while the flap 220 is pushed more forcefully into the sealing surface portion 530 and / or the second sealing surface portion 540. For example, when the reed valve is in the closed position, as the pressure of the exhausted combustion air 102 increases, the first sealing surface portion 530 and / or the second sealing surface portion 540 are pushed into the mating component (e.g., the flap 220) with an increasing force, while the flap 220 is pushed more forcefully into the sealing surface portion 530 and / or the second sealing surface portion 540. In short, the seal is enhanced as the operating pressure increases.

[0054] Figure 6FIG. 0 is a block diagram showing another exemplary illustrative engine system 600 in accordance with at least one embodiment described herein, the engine system including one or more reed valves as shown in FIGS. 2, 3, 4, and 5. As Figure 6 shown, in an embodiment, combustion air may enter the engine system 600 via one or more airbox assemblies 110, each airbox assembly including one or more reed valves 112 and / or one or more air filters 114. As Figure 6 shown, in some embodiments, the engine system 600 may include multiple throttle bodies 140A and 140B. In such an embodiment, a second reed valve 112B may be disposed between the throttle body 140A and the throttle body 140B to prevent reverse flow through the engine system 140, such as when the throttle valve coupled to the throttle body 140A is opened before the throttle valve coupled to the throttle body 140B is opened or is opened at the same time as the throttle valve coupled to the throttle body is opened.

[0055] Figure 7 FIG. 8 is a block diagram showing another exemplary illustrative engine system 700 in accordance with at least one embodiment described herein, the engine system including multiple reed valves as shown in FIGS. 2, 3, 4, and 5. As Figure 7 shown, in some embodiments, a first reed valve 112A may be disposed in the airbox assembly 110 and a second reed valve 112B may be disposed on the exhaust side of the engine 130. Ambient combustion air is drawn in through the first reed valve 112A. The second reed valve 112B prevents exhaust gas flow from returning into the engine 130.

[0056] Although the principles of the present invention have been described herein, those skilled in the art should understand that this description is merely an example and not a limitation on the scope of the present invention. In addition to the exemplary embodiments shown and described herein, other embodiments are contemplated within the scope of the present invention. Modifications and substitutions made by those of ordinary skill in the art are considered to be within the scope of the present invention, which is limited only by the claims.

Claims

1. A reed valve, comprising: A valve body having one or more channels formed therethrough, each of the one or more channels including at least one inlet hole and at least one outlet hole; A first seal extending completely around the at least one outlet hole; A second seal extending completely around the at least one outlet hole, wherein the first seal is spaced apart from and extends completely around the second seal; and At least one flap flexibly coupled to the valve body, the at least one flap configured to transition between an open position and a closed position: the open position allowing fluid to flow through the at least one outlet hole; in the closed position, the at least one flap contacts the first seal and the second seal to prevent fluid from flowing through the at least one outlet hole.

2. The reed valve according to claim 1, characterized in that, The first seal includes a lip.

3. The reed valve according to claim 2, characterized in that, The lip extends away from the second seal.

4. The reed valve according to claim 2, characterized in that, The lip extends from a base configured to be disposed adjacent to the valve body to a distal end configured to be further away from the first outlet than the base.

5. The reed valve according to claim 4, characterized in that, The lip is configured to deform towards the valve body when the at least one flap is in the closed position.

6. The reed valve according to claim 3, characterized in that The second seal has a conical or trapezoidal cross-section.

7. The reed valve according to claim 1, characterized in that, The second seal has a conical or trapezoidal cross-section.

8. The reed valve according to claim 7, characterized in that, The cross-section of the second seal tapers from a larger cross-section adjacent to the valve body to a smaller cross-section at the distal end of the second seal.

9. The reed valve according to claim 1, characterized in that, The second seal is closer to the at least one outlet hole than the first seal.

10. A reed valve, comprising: A valve body having at least one inlet hole and at least one outlet hole; A first seal extending completely around the at least one outlet hole, the first seal having a conical or trapezoidal cross-section; And At least one flap flexibly coupled to the valve body, the at least one flap configured to transition between an open position and a closed position: the open position allowing fluid to flow through the at least one outlet hole; In the closed position, the at least one flap contacts the first seal to prevent fluid from flowing through the at least one outlet hole.

11. The reed valve according to claim 10, characterized in that, The cross-section of the first seal tapers from a larger cross-section adjacent to the valve body to a smaller cross-section at the distal end of the first seal.

12. The reed valve according to claim 10, characterized in that, The reed valve further includes a second seal extending completely around the at least one outlet hole, wherein the first seal is disposed between the second seal and the at least one outlet hole.

13. The reed valve according to claim 12, characterized in that, The second seal extends outwardly away from the valve body and the first seal.

14. The reed valve according to claim 12, characterized in that, The second seal is disposed between the first seal and the first outlet.

15. The reed valve according to claim 14, wherein The second seal has a conical or trapezoidal cross-section.

16. A reed valve, comprising: A valve body including a first inlet and a first outlet; A first seal forming a lip extending completely around the first outlet; And At least one flap, the at least one flap being configured to cover the first outlet, the at least one flap being configured to move between an open position and a closed position: the open position allowing fluid to flow through the first outlet; In the closed position, the at least one flap contacts the first seal, thereby preventing fluid from flowing through the first outlet.

17. The reed valve according to claim 16, characterized in that, The lip extends from a base portion configured to be disposed near the valve body to a distal end, the distal end being configured to be disposed farther from the first outlet than the base portion.

18. The reed valve according to claim 17, wherein The lip is configured to deform toward the valve body when the at least one flap is in the closed position.

19. The reed valve according to claim 17, characterized in that, The reed valve further includes a second seal that extends completely around the first outlet.

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