Coolant distributor flapper valve

Abstract

A fluid valve includes a housing that has a port wall with multiple ports. A drive assembly has first and second output drives that rotate first and second compound gate valves respectively mounted on first and second shafts. The shafts have coaxial shaft axes and rotate about the shaft axes between a first position in which the compound gate valve's first gate seals against one port and a second position in which the second gate seals against another port. A location of the shaft axes remains fixed relative to the port wall during rotation of the shaft between the first and second positions.

Description

Docket No. 67950-318PCT2COOLANT DISTRIBUTOR FLAPPER VALVEPRIORITY CLAIM

[0001] This disclosure claims priority United States Patent Application No. 18 / 970,237 filed December 5, 2024.TECHNICAL FIELD

[0002] This disclosure relates to a fluid distributor valve for use in vehicle cooling systems, for example.BACKGROUND

[0003] A typical modern vehicle includes various components and subsystems for which it is desirable to regulate the 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 cooling fluid at a desired temperature to the components. As vehicles have become more complex, the complexity of the cooling system has increased as well.

[0004] A typical cooling system found in vehicles such as those having electrified and / or hybrid drivetrains tend to be highly distributed architectures with a complex maze of cooling loops, sub-loops, pumps, and heat exchanges. Coolant distributor valves, controllers and temperature sensors used to direct the coolant through these cooling systems are separated from one another and distributed throughout the vehicle. The resultant cooling system is complicated and expensive to implement and maintain, and the coolant temperature may not be as accurately regulated as desired.

[0005] The coolant distributor valves themselves can be relatively complex as well, which is undesirable. One such example is a compound gate valve that rotates eccentrically while translating in a slot. The motion of the compound gate valve complex, which can introduce failure modes and add cost. Moreover, this type ofDocket No. 67950-318PCT2 compound gate valve extends to opposing walls for sliding support, resulting in larger and heavier gates.SUMMARY

[0006] In one exemplary embodiment, a fluid valve includes a housing that has a port wall with first, second, third and fourth ports, the housing provides a first chamber that is in fluid communication with the first and second ports, and the housing provides a second chamber that is in fluid communication with the third and fourth ports, a drive assembly that has a first and second output drives, and a first compound gate valve that is arranged in the first chamber and includes a first shaft that supports first and second gates. The first shaft is operatively coupled to the first output drive. The first shaft has a first shaft axis. The first shaft is configured to rotate about the first shaft axis in response to the first output drive between a first position in which the first gate seals against the first port, and a second position in which the second gate seals against the second port. A second compound gate valve is arranged in the second chamber and includes a second shaft that supports third and fourth gates. The second shaft is operatively coupled to the second output drive. The second shaft has a second shaft axis. The second shaft is configured to rotate about the second shaft axis in response to the second output drive between a third position in which the third gate seals against the third port, and a fourth position in which the fourth gate seals against the fourth port. A location of the first and shaft axes are configured to remain fixed relative to the port wall during rotation of the first and shafts between their respective positions.

[0007] In a further embodiment of any of the above, each of the first and second output drives has a drive axis, and the first and second shaft axes and its respective first and second drive axis are coaxial with one another.

[0008] In a further embodiment of any of the above, the first and second shaft axes are coaxial with one another.

[0009] In a further embodiment of any of the above, the second shaft extends through the first shaft to the second output drive.Docket No. 67950-318PCT2

[0010] In a further embodiment of any of the above, the housing includes a wall that fluidly separates the first and second chambers. The wall operatively rotatably supports the first and second shafts.

[0011] In a further embodiment of any of the above, the wall includes an aperture that permits fluid exchange between the first and second chambers.

[0012] In a further embodiment of any of the above, the drive assembly includes first and second electric motors that are arranged in the housing. The first and second electric motors are configured to respectively rotate the first and second output drives.

[0013] In a further embodiment of any of the above, the first and second shaft axes extend in a first direction, and the first and second gates respectively lie in first and second planes. The first and second planes extend in the first direction, and the third and fourth gates respectively lie in third and fourth planes. The third and fourth planes extend in the first direction.

[0014] In a further embodiment of any of the above, at least one of the gates includes at least one opening that is configured to permit fluid flow through the at least one gate when in a closed position.

[0015] In a further embodiment of any of the above, the first and second ports are arranged at an angle of less than 180srelative to one another, and the third and fourth ports are arranged at an angle of less than 180srelative to one another.

[0016] In a further embodiment of any of the above, a temperature sensor is arranged in at least one of the first and second chambers.

[0017] In a further embodiment of any of the above, the housing includes first and second housing portions. The first housing portion provides the first, second, third and fourth ports, and the second housing portion provides at least another port.

[0018] In a further embodiment of any of the above, the first housing portion includes a wall that fluidly separates the first and second chambers.

[0019] In a further embodiment of any of the above, the at least another port includes fifth and sixth ports, and the wall fluidly separates the fifth and sixth ports.Docket No. 67950-318PCT2

[0020] In a further embodiment of any of the above, a thermal management system includes at least one component that includes a battery, a heat exchanger, and the fluid valve that is fluidly arranged between the battery and the heat exchanger.

[0021] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0023] Figure 1 is a schematic of one example vehicle cooling system.

[0024] Figures 2A and 2B are respectively a side view of an example fluid distributor valve and a perspective view of the same fluid distributor valve with a housing portion removed.

[0025] Figures 3A and 3B respectively are cross-sectional views taken along line 3A-3A in Figure 2B and along line 3B-3B in Figure 2A.

[0026] Figures 4A and 4B are views similar to Figure 3B illustrating a compound gate valve in first and second positions.

[0027] Figure 5 illustrates another compound gate valve and drive assembly configuration.

[0028] Figure 6 is a perspective view of the compound gate valve and drive assembly configuration shown in Figure 5.

[0029] Figure 7 illustrates another example fluid distributor valve having one inlet and multiple outlets.

[0030] Figure 8 is a cross-sectional perspective view of the valve in Figure 7 taken along line 8-8.

[0031] Figure 9 is a cross-sectional side of another example fluid distributor valve having multiple inlets and multiple outlets.Docket No. 67950-318PCT2

[0032] Figures 10A and 10B are respectively an elevational view and a cross-sectional perspective view of a gate with openings for permitting partial fluid flow with the gate in a closed position.

[0033] Figure 1 1 illustrates a temperature sensor integrated into the valve’s housing.

[0034] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.DETAILED DESCRIPTION

[0035] Figure 1 illustrates, in a highly schematic fashion, a vehicle cooling system 10 that includes a heat generation system 12. The heat generation system 12 may comprise multiple heat sources 12a-12c, one of which may be a battery. A cooling fluid is circulated from at least one of the heat sources 12a-12c to a heat exchanger 14 by one or more pumps (not shown). A fan 16 may be used to increase a heat rejection rate from the heat exchanger 14. It should be understood that other forms of heat rejection may be used, such as a liquid-to-air heat exchanger or a liquid-to-liquid heat exchanger for example.

[0036] One or more coolant distributor valves 18 are used to direct the fluid flow through the cooling system 10 to achieve a desired temperature of the various components within the cooling system. In the example, this fluid valve 18 is fluidly arranged between the battery and the heat exchanger 14, although the fluid valve 18 may be arranged in other locations with the system 10. More inlet(s) and / or outlet(s) may be provided by the fluid valve 18, as indicated by the example dashed lines. An electric motor 59 may be used to actuate the fluid valve 18 between multiple positions in response to an input 20 used to regulate the temperature within the system.

[0037] One example fluid valve 18 is shown in Figures 2A-4B. The fluid valve 18 includes a housing 22, which may comprise multiple housing portions, such as first, second, third and fourth housing portions 24, 26, 28, 30. The various housingDocket No. 67950-318PCT2 portions may be secured using fasteners 23 and 31 , sealant, glue, ultrasonic welding and / or with other securing techniques. More or fewer housing portions may be used than shown. In the example, the motor 59 and a drive assembly 58 are arranged in the third and fourth housing portions 28, 30 in a dry cavity separated from the coolant.

[0038] In the example, the fluid valve 18 is a three-port valve having first, second and third fluid connections 32, 34, 36, which are connected to components within the cooling system 10 via coolant lines. A skilled worker would understand the disclosed fluid valve 18 may include more fluid connections for a different arrangement of fluid connections than shown. At least a portion of the housing 22, for example, first and second housing portions 24, 26 provide a fluid cavity 37 in fluid communication with first, second, and third ports 38, 40, 42 that are respectively in fluid communication with the first, second and third fluid connections 32, 34, 36. The fluid cavity 37 is provided by the housing 22 at least in part by a port wall 44 and first and second walls 46, 48 that are spaced apart from one another and adjoin the port wall 44 on opposite sides from one another. The first and second ports 38, 40 are provided in the port wall 44, and arranged at an angle of less than 1802relative to one another but greater than 50efrom one another (that is, canted inward toward the cavity 37 in the example shown).

[0039] With the example housing 22, the second housing portion 26 acts as a cover over the fluid cavity 37, enclosing its compound gate valve 50. The first and second gates 54, 56 are spaced from the first and second walls 46, 48, due to the simplified motion and design of the compound gate valve 50.

[0040] Referring to Figures 2B-3B, the compound gate valve 50 has a shaft 52 supporting first and second gates 54, 56 within the fluid cavity 37. In the example, the first and second gates 54, 56 support first and second seals 39, 41 , respectively, to block its respective first and second port 38, 40. Alternatively, the seals 39, 41 may instead be provided on the port wall 44 circumscribing the first and second ports 38, 40.

[0041] The drive assembly 58 has an output drive 60 is operatively coupled to the shaft 52. The shaft 52 has a shaft axis S and the output drive 60 has a drive axis D that is coaxial with the shaft axis S in the example shown in Figure 3A.Docket No. 67950-318PCT2

[0042] In the example, the port wall 44 includes an arcuate recess 72 in which the shaft 52 is slidably supported during rotation about the shaft axis S between the first and second positions shown in Figures 4A and 4B. The location of the shaft axis S is configured to remain fixed relative to the port wall 44 during rotation of the shaft 52 between the first and second positions (see, Figs. 4A and 4B). That is, the shaft 52 does not move eccentrically or translate, which greatly simplifies the operation of the fluid valve 18 thus increasing is reliability and reducing cost. Additionally or alternatively, the shaft 52 may include an arcuate flange 62 extending radially relative to the shaft axis S that is received in a correspondingly shaped groove 64 in the port wall 44. Cooperation of the arcuate flange 62 with the groove 64 axially locates the compound gate valve 50 relative to the housing 52.

[0043] The drive assembly 58 may include the electric motor 59 either coupled directly to the shaft 52 or by an intervening gear assembly. In the example, the output drive 60 provides a lug 70 that mates with a socket 68 in an end of the shaft. Seals 61 are provided between the output drive 60 and its supporting housing 22.

[0044] A reinforcing gusset 66 may be provided between and bridging the first and second gates 54, 56. In the example shown, the reinforcing gusset 66 is axially aligned with the arcuate flange 62. Either or both of the arcuate flange 62 and the reinforcing gusset 66 may be omitted.

[0045] Another example compound gate valve 150 is shown in Figures 5 and 6. In this example, a sector gear 74 bridges the first and second gates 154, 156. The output drive 76 of drive assembly 158 meshes with the sector gear 74. The sector gear 74 also acts as a reinforcing gusset. The first and second seals 139, 141 are supported by a support 80 having a stem 82 received in a corresponding hole 78 in the first and second gates 154, 156. The stems 82 are retained in the holes 78 such that are supported by the gates, but permitted to rotate relative thereto to provide improved sealing relative to the seal’s respective port.

[0046] In the example shown in Figures 2B-4B, the first and second gates 54, 56 respectively lie in first and second planes that intersect the shaft axis S (planes lie in same direction as shaft axis S), but this configuration need not be the case as shown in the example of Figures 5 and 6.Docket No. 67950-318PCT2

[0047] Additional example fluid valves 118, 218 are shown in Figures 7-9. The fluid valves 118, 218 provide multiple compound gate valves in a common housing in an arrangement that provides a compact design.

[0048] Referring to Figures 7 and 8, there are two compound gate valves 150a, 150b shown respectively in first and second chambers 137a, 137b. The compound gate valves are provided in a common housing provided by the first and second housing portions 124, 126 on a wet side of the fluid valve 118. The first compound gate valve 150a selectively moves between open and closed positions to selectively block / unblock first and second ports 132a, 134a, and the second compound gate valve 150b selectively moves between open and closed positions to selectively block / unblock third and fourth ports 132b, 134b.

[0049] First and second output drives 158a, 158b (e.g., including first and second gears 98a, 98b) respectively operate the first and second compound gate valves 150a, 150b, independently from one another in the disclosed example. For example, a first motor 159a is coupled to the first output drive 158a, and a second motor 159b is coupled to the second output drive 158b. The motors 159a, 159b are arranged in a dry second of the fluid valve 1 18, such as housing portion 130.

[0050] A first shaft 152a supports the first compound gate valve 150a with first and second gates (only 154a shown). The first shaft 152a is operatively coupled to the first output drive 158a and is configured to rotate about its axis between a first position in which the first gate 154a seals against the first port 132a, and a second position in which the second gate (not shown) seals against the second port 134a.

[0051] In a similar manner, a second shaft 152b supports third and fourth gates (only 154b show). The second shaft 152b is operatively coupled to the second output drive 158b and is configured to rotate about its axis between a third position in which the third gate 154(b) seals against the third port 132b, and a fourth position in which the fourth gate (not shown) seals against the fourth port 134b.

[0052] In the example, the axes of the first and second shafts 152a, 152b are coaxial with one another, having a common shaft axis S. The axis of the output drives 158a, 158b are also coaxial with one another and the shaft axis S in this disclosed example. The first and shaft axes are configured to remain fixed relative toDocket No. 67950-318PCT2 the port wall during rotation of the first and shafts 152a, 152b between their respective positions.

[0053] In the example, the first shaft 152a is a two-piece construction to facilitate assembly. A wall 88, which separates the first and second chambers 137a, 137b, supports the first and second shafts 152a, 152b, for example, using a bearing 92 arranged in a bore 90 in the wall 88. A pilot 93 in the housing may be received in a hole 95 in an end of the first shaft 152a to support its other end.

[0054] In the case where a single inlet 136 is provided by the second housing portion 126 of the fluid valve 218, the wall 88 may include an aperture 96 (Fig. 8) so fluid may be communicated from the inlet 136 to both of first and second chambers 137a, 137b. In the example shown in Figure 9, the wall 88 of first housing portion 224 is unbroken so that fluid from first and second inlets 136a, 136b remain separate to provide fluid to each respective compound gate valve.

[0055] Another example gate 154b is shown in Figures 10A-10B. The gate 154b, which may be used at any location on the compound gate valve for any of the disclosed fluid valves 18, 1 18, 218, includes one or more openings 100 to permit fluid flow through the gate 154b when closed. This permits at least some flow to the associated outlet port when closed, but in an a lesser amount than when the gate 154b is opened.

[0056] Referring to Figure 11 , a temperature sensor 106, such as a thermistor, can be integrated into the fluid valve 18, 118, 218 to monitor fluid temperature within the cavity. In the example, a can 104 protrudes through and seals relative to a hole 102 in the housing portion 324 using a seal 108 and / or sealant. The temperature sensor 106 is protected within the can 104 and is connected to an electrical connector on the fluid valve’s housing.

[0057] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.

Claims

Docket No. 67950-318PCT2CLAIMSWhat is claimed is:

1. A fluid valve comprising: a housing having port wall with first, second, third and fourth ports, the housing providing a first chamber in fluid communication with the first and second ports, and the housing providing a second chamber in fluid communication with the third and fourth ports; a drive assembly having a first and second output drives; and a first compound gate valve arranged in the first chamber and including a first shaft supporting first and second gates, the first shaft operatively coupled to the first output drive, the first shaft having a first shaft axis, the first shaft is configured to rotate about the first shaft axis in response to the first output drive between a first position in which the first gate seals against the first port, a second position in which the second gate seals against the second port; a second compound gate valve arranged in the second chamber and including a second shaft supporting third and fourth gates, the second shaft operatively coupled to the second output drive, the second shaft having a second shaft axis, the second shaft is configured to rotate about the second shaft axis in response to the second output drive between a third position in which the third gate seals against the third port, a fourth position in which the fourth gate seals against the fourth port; and wherein a location of the first and shaft axes are configured to remain fixed relative to the port wall during rotation of the first and shafts between their respective positions.

2. The fluid valve of claim 1 , wherein each of the first and second output drives has a drive axis, and the first and second shaft axes and its respective first and second drive axis are coaxial with one another.

3. The fluid valve of claim 1 , wherein the first and second shaft axes are coaxial with one another.Docket No. 67950-318PCT24. The fluid valve of claim 1 , wherein the second shaft extends through the first shaft to the second output drive.

5. The fluid valve of claim 1 , wherein the housing includes a wall fluidly separating the first and second chambers, the wall operatively rotatably supports the first and second shafts.

6. The fluid valve of claim 5, wherein the wall includes an aperture permitting fluid exchange between the first and second chambers.

7. The fluid valve of claim 1 , wherein the drive assembly includes first and second electric motors arranged in the housing, the first and second electric motors configured to respectively rotate the first and second output drives.

8. The fluid valve of claim 1 , wherein the first and second shaft axes extend in a first direction, and the first and second gates respectively lie in first and second planes, the first and second planes extend in the first direction, and the third and fourth gates respectively lie in third and fourth planes, the third and fourth planes extend in the first direction.

9. The fluid valve of claim 1 , wherein at least one of the gates includes at least one opening configured to permit fluid flow through the at least one gate when in a closed position.

10. The fluid valve of claim 1 , wherein the first and second ports are arranged at an angle of less than 180srelative to one another, and the third and fourth ports are arranged at an angle of less than 180srelative to one another.1 1 . The fluid valve of claim 1 , wherein a temperature sensor is arranged in at least one of the first and second chambers.Docket No. 67950-318PCT212. The fluid valve of claim 1 , wherein the housing includes first and second housing portions, the first housing portion providing the first, second, third and fourth ports, and the second housing portion providing at least another port.

13. The fluid valve of claim 12, wherein the first housing portion includes a wall fluidly separating the first and second chambers.

14. The fluid valve of claim 13, wherein the at least another port includes fifth and sixth ports, and the wall fluidly separates the fifth and sixth ports.

15. A thermal management system comprising: at least one component including a battery; a heat exchanger; and wherein the fluid valve of claim 1 is fluidly arranged between the battery and the heat exchanger.

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