Fluid distribution valve housing and seal arrangement

Abstract

To prevent damage to electronic equipment in a coolant distribution valve.SOLUTION: A coolant distribution valve 10 for a vehicle cooling system includes a housing 12 including a shaft support housing portion 16 that provides a monolithic unitary structure. The shaft support housing portion has a first side and, on the opposite side thereof, a second side. The first side and the second side respectively include a first bore and a second bore. A valve 54 is arranged in the housing adjacent to the first side. Electronic components 13 are arranged in the housing adjacent to the second side. The electronic components are configured to move the valve between multiple positions. First and second seal materials 58, 60 are respectively mounted in the first and second bores. A shaft extends through and engages the seals. A shaft operably connects the electronic components to the valve.SELECTED DRAWING: Figure 3

Description

Technical Field

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

Background Art

[0002] Typical modern vehicles include various components and subsystems for which it is desirable to regulate temperature (i.e., heating and / or cooling to a desired temperature). One or more cooling loops include one or more heat exchangers through which one or more fluids are circulated in a controlled manner to provide a coolant to components at a desired temperature. As vehicles become more complex, the complexity of the cooling system has similarly increased.

[0003] Typical cooling systems found in vehicles having electric and / or hybrid drive systems tend to have a highly distributed architecture with complex mazes of cooling loops, sub-loops, pumps, and heat exchanges. The coolant distribution valves, controllers, and temperature sensors used to direct coolant through these cooling systems are separated from each other and distributed throughout the vehicle.

[0004] A coolant distribution valve includes a valve disposed within a coolant passage that controls the flow of fluid between fluid paths within the cooling system. There may be one or more sealing materials used to hold fluid within the coolant passage. If an electronic device is also housed within the coolant distribution valve, leakage through the sealing material can reach the electronic device and damage the electronic device.

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 that provides a monolithic, integral structure. The shaft support housing portion has a first side and a second side opposite thereto. The first side and the second side each include a first bore and a second bore, respectively. A valve is disposed within the housing adjacent the first side. Electronic components are disposed within the housing adjacent the second side. The electronic components are configured to move the valve between a plurality of positions. A first sealing material and a second sealing material are attached to the first bore and the second bore, respectively. A shaft extends through and engages the sealing materials. The shaft operably connects the electronic components to the valve.

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

[0007] In any further embodiment of the above, the housing includes an electronic device housing portion that is fixed to the shaft support housing portion so as to surround the electronic components.

[0008] In any further embodiment of the above, the shaft support housing portion provides a valve housing portion that receives the valve, and the housing includes a cover that is fixed to the valve housing portion so as to surround the valve.

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

[0010] In any further embodiment of the above, the housing includes a cover that is fixed to the valve housing portion so as to surround the valve.

[0011] In any further embodiment of the above, a cavity is provided between the first sealing material and the second sealing material, 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 any further embodiment 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 PCB and disposed in the electronic device housing portion.

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

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

[0015] In any further embodiment of the above, the first shaft and the second shaft are nested with each other in a spline connection relationship.

[0016] In any further embodiment of the above, the first shaft and the second shaft each include a first outer diameter and a second outer diameter. The first outer diameter and the second outer diameter engage with the first sealing material and the second sealing material, respectively.

[0017] In any further embodiment of the above, the vehicle cooling system includes a coolant distribution valve including a plurality of cooling loops. The coolant distribution valve interconnects at least two of the plurality of cooling loops, 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 loops.

[0018] In any of the further embodiments described above, the cooling loop includes at least two of the battery, the vehicle cab, the charging electronics, and the 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 that provides a monolithic integral structure. The shaft support housing portion has a first side and a second side opposite thereto. The first side and the second side each include a first bore and a second bore, respectively. The first sealing member is attached to the first bore. The second sealing member is attached to the second bore. A valve is inserted into the housing adjacent to the first side. Electronic components are disposed in the housing adjacent to the second side, and the electronic components are configured to move the valve between a plurality of positions. A shaft extends through and engages the first and second sealing members, and the shaft operably connects the electronic components to the valve.

[0020] In any of the further embodiments described above, the step of attaching the first sealing member is performed prior to the step of inserting the valve.

[0021] In any of the further embodiments described above, the step of attaching the second sealing member is performed prior to the step of disposing the electronic components.

[0022] In any of the further embodiments described above, the inserting step includes extending the shaft through the first sealing member to engage the first sealing member. The step of assembling the gear train includes extending the shaft through the second sealing member to engage the second sealing member.

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

[0024] In any further embodiment of the above, the method includes forming a cavity by the first sealing material and the second sealing material, 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 referring to the following detailed description when considered in connection with the accompanying drawings.

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[0026] The embodiments, examples, and alternatives of the above paragraphs, claims, or the following description and drawings include any of their various aspects or their respective individual features, and may be employed independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments as long as such features are not incompatible.

Best Mode for Carrying Out the Invention

[0027] FIG. 1 shows 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 numerous loops, sub-loops, and branches for conveying a cooling fluid such as a liquid coolant (e.g., water ethylene glycol). One type of vehicle includes one or more motors 102, a passenger compartment thermal regulation system 104, a charging system 106, and a battery 108. One or more cooling loops 110 circulate the coolant through these components. Typically, a plurality of 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 the coolant through the cooling loop 110.

[0028] A plurality of fluid distribution valves 115 connect a plurality of passages to selectively regulate the flow of the coolant, and thus its temperature, through the cooling loop 110. The fluid distribution valves 115 are distributed throughout the cooling loop 110 and the vehicle. Also, a number of temperature sensors 116 are distributed throughout the cooling system 100 to monitor the temperature at various locations to enable adjustment of the various components to achieve a desired temperature throughout the system.

[0029] The coolant distribution valve 10 of the present disclosure shown in FIG. 2 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 a plurality of parts fixed to each other by one or more attachment techniques (e.g., welding, fasteners, adhesives, sealants, etc.). In this example, there are two main housing parts.

[0030] That is, a valve body portion 11 and an electronic component portion 13, which are fluidly separated from each other. In an example shown in FIGS. 2-6, the electronic component portion 13 is provided by first and second housing parts 14, 16, and the valve body portion 11 is provided by third and fourth housing parts 18, 20.

[0031] The coolant distribution valve 10 is designed to be configurable to provide both flexibility in the package and versatility in use within a cooling system. An example of this flexibility is a reconfigurable bracket 22 operably attached to the housing 12, which can be oriented in several different individual positions relative to the housing 12. The bracket 22 includes attachment mechanisms (e.g., a pair of mounting ears 28) used to secure the coolant distribution valve 10 to a vehicle. Referring thereto, the bracket 22 is rotationally adjusted (clocked) in a desired direction based on the package constraints within the vehicle.

[0032] The valve body portion 11 may be rotationally adjusted in a desired direction relative to the electronic component portion 13. Fasteners secure the valve body portion 11 to each other to the electronic component 13 (e.g., the second and third housing parts 16, 18), thereby capturing the bracket 22.

[0033] The various parts of the housing 12 are fixed to and sealed with each other using any number of techniques. In one example shown in FIG. 3, the first and second housing parts 14, 16 are welded to each other at 40, similar to the third and fourth housing parts 18, 20 (at 40). The second and third housing parts 16, 18 are sealed with an O-ring 42 and fixed using fasteners 36 (FIG. 2).

[0034] Referring to FIGS. 3-5, the valve 54 is disposed within a coolant passage in the valve body portion 11 and is configured to rotate between a plurality of positions to fluidly connect and disconnect the fluid connectors 32 from each other and to regulate the flow of coolant (e.g., water ethylene glycol) through the cooling system 100. The coolant distribution valve 10 directs the coolant, for example, based on a detected coolant temperature or component temperature, from an input port to a selected output port provided by the fluid connection 32, thereby connecting at least two cooling loops (e.g., including at least two of a battery, a vehicle cab, charging electronics, and a motor).

[0035] The electronics part 13 includes sensitive electronics such as a motor 46 electrically connected to a printed circuit board (PCB) 72. The controller (e.g., PCB 72) may be a hardware device for executing software, particularly software stored in memory. The controller (e.g., PCB 72) may be a custom-made or commercially available processor, a central processing unit (CPU), an auxiliary processor between a plurality of processors associated with the controller, a semiconductor-based microprocessor (in the form of a microchip or chipset), or any device generally for executing software instructions.

[0036] The memory may include any one or combination of volatile memory elements (such as random access memories (RAMs) like DRAM, SRAM, SDRAM, VRAM, etc.) and / or non-volatile memory elements (such as ROM, hard drive, tape, CD-ROM, etc.). Further, the memory may incorporate electronic, magnetic, optical, and / or other types of storage media. Also, the memory may have a distributed architecture where various components are located apart from each other but can be accessed by a processor.

[0037] From a hardware architecture perspective, such a computing device may include one or more input and / or output (I / O) device interfaces communicatively coupled via a processor, memory, and a local interface. The local interface may include, for example, but not limited to, one or more buses and / or other wired or wireless connections. The local interface may have additional elements such as controllers, buffers (caches), drivers, repeaters, and receivers for enabling communication, but these are omitted for simplicity. Further, the local interface may include address, control, and / or data connections for enabling proper communication between the aforementioned components.

[0038] The software in the memory may include one or more separate programs, each including an ordered list of executable instructions for implementing a logical function. Also, system components embodied as software may be interpreted as any other entity including a source program, an executable program (object code), a script, or a set of instructions to be executed. When constructed as a source program, the program is translated via a compiler, assembler, interpreter, etc., which may or may not be included in the memory.

[0039] The input and output devices of the present disclosure that can be coupled to a (plurality of) system I / O interfaces may include input devices such as, but not limited to, a keyboard, a mouse, a scanner, a microphone, a camera, a mobile device, a proximity device, etc. Further, output devices such as, but not limited to, a printer, a display, etc. may be included. Finally, the input and output devices may further include devices that communicate as both input and output, such as, but not limited to, a modem (for accessing other devices, systems, or networks), a radio frequency (RF) or other transceiver, a telephone interface, a bridge, a router, etc.

[0040] When the controller (e.g., PCB 72) is operating, the processor may be configured to execute software stored in the memory, communicate data with the memory, and generally control the operation of the computer device according to the software. The software in the memory may be wholly or partially read by the processor, perhaps buffered in the processor, and then executed.

[0041] The electronic component portion 13 houses an electric actuator such as a motor 46 that includes a drive gear 48 for rotationally driving the valve 54 via a coupling. Since this coupling, which is operably connected between the motor 46 and the valve 54, must extend between the valve body portion 11 that houses the coolant and the electronic component portion 13 that must remain dry, it is important to reliably seal this coupling.

[0042] Typically, a coolant distribution valve is provided by a plurality of housings secured by welding and fasteners. One housing portion carries one sealing material that seals one end of the coupling, and another separate housing portion carries another sealing material that seals the other end of the coupling. During assembly, the housing portions carrying the sealing materials must maintain concentricity between both sealing materials. Any misalignment of the coupling shaft relative to the sealing materials can occur, which can result in wear of the sealing materials, wear of the gears, excessive torque, and / or binding or slow movement (response time) in the assembly. To address this problem, the first sealing material 58 and the second sealing material 60 of the present disclosure are supported by a housing portion provided by a common monolithic integral structure that helps prevent coolant from passing through the coupling due to misalignment. The shaft support housing portion is provided by a single part that is molded, cast, and / or machined.

[0043] In the example shown in FIGS. 3 - 6, a single shaft support housing is provided by the second housing portion 16. In the example shown in FIGS. 7 - 9, a single shaft support housing is provided by the housing portion 17, which is a combination of the second housing portion 16 and the third housing portion 18.

[0044] Returning to FIGS. 4 - 6, the shaft support housing portion (i.e., the second housing portion 16) includes an outer wall 150 connected by a web 154 to an inner wall 152 that is of generally annular shape. The shaft support housing portion has a first side portion 156 (near the location where the valve 54 is disposed) and a second side portion 158 on the opposite side (near the location where the electronic components are disposed). The first side portion 156 and the second side portion 158 of the inner wall 152 each have a first bore 160 and a second bore 162, which are formed concentrically with each other at the same portion during machining or forming, and thus are surely aligned. The first sealing material 58 and the second sealing material 60 are attached to the first bore 160 and the second bore 162, respectively. In this way, the concentricity of the sealing materials of the present disclosure does not depend on a less accurate assembly process.

[0045] As best shown in FIG. 6, a cavity 163 is provided between the first sealing material 58 and the second sealing material 60 by the inner wall 152. A vent hole 62 extends through the inner wall 152 to fluidly connect the cavity 163 to the atmosphere. The coolant is at a higher pressure than the atmosphere during operation. If the coolant undesirably leaks through the first sealing material 58, the coolant can be released from the cavity 163 through the vent hole 62. The coolant in the cavity 163 is not under pressure and thus is less likely to leak through the second sealing material 60 to the second side portion 158 having the electronic components.

[0046] The inner wall 152 has a central hole 164 through which a coupling or shaft between the valve 54 and the gear train 50 extends. The gear train 50 has a drive lug 52. The coupling includes a first shaft and a second shaft coupled to each other, e.g., a first shaft 56 extending from the valve 54 nested in a splined coupling relationship that slip fits over a second shaft 64 extending from the drive lug 52. The first shaft 56 and the second shaft 64 include a first outer diameter and a second outer diameter 166, 168 that engage the first seal member 58 and the second seal member 60, respectively. Also, a slight slip fit serves to accommodate misalignment of the coupling that can cause non-uniform loading on the first seal member 58 and the second seal member 60 and lead to leakage.

[0047] In one example, the coolant distribution valve 10 is assembled by attaching the first seal member 58 and the second seal member 60 to a first bore 160 and a second bore 162 of the shaft support housing portion. The valve 54 is inserted into the housing and seals the first outer diameter 166 against the first seal member 58 adjacent the first side 156. The drive lug 52 is coupled to the valve 54 at the second side 158, which seals the second outer diameter 168 against the second seal member 60.

[0048] The remaining portion of the gear train 50, the motor 46, and other electronic components are fixed on the second side 158 where the electronic components are disposed, between the first and second housing portions 14, 16, or between the first housing portion 14 and the housing portion 17. The first housing portion 14 may provide a pilot 68 that cooperates with a projection 69 on the drive lug 52 to support one end of the coupling. The fourth housing portion 20 or cover is fixed to the third housing portion 18 or housing portion 17 so as to surround the valve 54. The fourth housing portion 20 includes a projection 71 received in a hole 70 of the valve 54 to support the opposite end of the coupling.

[0049] The example shown in FIGS. 7 - 9 is assembled in the same manner as the example shown in FIGS. 3 - 6.

[0050] Also, although the arrangement of specific components is disclosed in the illustrated embodiments, it should be understood that other configurations may also benefit therefrom. A specific sequence of steps is shown, described, and recited in the claims, but the steps may be performed, separated, or combined in any order, even if not specifically shown, and it should still be understood that the present invention benefits therefrom.

[0051] The different illustrations have specific components shown, but embodiments of the present invention are not limited to these specific combinations. It is also possible to use some of the components or features from one illustration in combination with features or components from another illustration.

[0052] Exemplary embodiments are disclosed, but those skilled in the art will recognize that certain modifications fall within the scope of the claims. Therefore, the following claims should be considered 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 monolithic integral structure, the shaft support housing portion having a first side and a second side opposite thereto, the first side and the second side each including a first bore and a second bore, a shaft support housing portion; a valve disposed in the housing adjacent to the first side; an electronic component disposed in the housing adjacent to the second side, the electronic component being configured to move the valve between a plurality of positions; a first sealing material and a second sealing material respectively attached to the first bore and the second bore; a shaft extending through the sealing material and engaging with the sealing material, the shaft operably connecting the electronic component to the valve A coolant distribution valve comprising.

2. The coolant distribution valve according to claim 1, wherein the shaft support housing portion is provided by a single part formed, cast and / or machined.

3. The coolant distribution valve according to claim 1, wherein the housing includes an electronic device housing portion fixed to the shaft support housing portion so as to surround the electronic component.

4. The coolant distribution valve according to claim 3, wherein the shaft support housing portion provides a valve housing portion for receiving the valve, and the housing includes a cover fixed to the valve housing portion so as to surround the valve.

5. The coolant distribution valve according to claim 3, wherein a valve housing portion is fixed to the shaft support housing portion, and the valve is disposed in the valve housing portion.

6. The coolant distribution valve according to claim 5, wherein the housing includes a cover fixed to the valve housing portion so as to surround the valve.

7. The coolant distribution valve according to claim 1, wherein a cavity is provided between the first sealing material and the second sealing material, and a vent hole is provided in the shaft support housing portion, the vent hole being configured to fluidly connect the cavity to the atmosphere.

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

9. The coolant distribution valve according to claim 8, wherein the electric actuator is a motor, and a gear train is connected 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 connected to each other, the first shaft extends from the valve, and the second shaft extends from the gear train.

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

12. The coolant distribution valve according to claim 10, wherein the first shaft and the second shaft each include a first outer diameter and a second outer diameter, and the first outer diameter and the second outer diameter engage with the first sealing material and the second sealing material, respectively.

13. A vehicle cooling system including the coolant distribution valve according to claim 1, comprising a plurality of cooling loops, wherein the coolant distribution valve interconnects at least two of the plurality of cooling loops, 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 loops.

14. The vehicle cooling system according to claim 13, wherein the cooling loop includes at least two of a battery, a vehicle cab, charging electronics, and a motor.

15. A method of assembling a coolant distribution valve, comprising the step of providing a housing including a shaft support housing portion providing a monolithic integral structure, the shaft support housing portion having a first side and a second side opposite thereto, the first side and the second side each including a first bore and a second bore; the step of attaching a first sealing material to the first bore; the step of attaching a second sealing material to the second bore; the step of inserting a valve into the housing adjacent to the first side; A step of arranging an electronic component in the housing adjacent to the second side portion, the electronic component being configured to move the valve between a plurality of positions; A step of extending a shaft through the first sealing member and the second sealing member and engaging the first sealing member and the second sealing member, the shaft operably connecting the electronic component to the valve; A method comprising. **Claim 16** The method according to claim 15, wherein the step of attaching the first sealing member is performed before the step of inserting the valve. **Claim 17** The method according to claim 15, wherein the step of attaching the second sealing member is performed before the step of arranging the electronic component. **Claim 18** The step of inserting includes a step of extending the shaft through the first sealing member so as to engage the first sealing member, A step of assembling a gear train in the housing, the method according to claim 15, the step of extending the shaft through the second sealing member so as to engage the second sealing member. **Claim 19** The method according to claim 18, wherein the extending step includes extending a first shaft from the valve so as to engage the first sealing member and extending a second shaft from the gear train so as to engage the second sealing member, the first shaft and the second shaft being connected to each other. **Claim 20** The method according to claim 15, including forming a cavity by the first sealing member and the second sealing member, the shaft support housing portion, and the shaft, the shaft support housing including a vent hole in fluid communication with the atmosphere.

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