Active Valve Oiling Module With Buffer Overflow Against Air Ingress

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Solution Overview

Problem

Existing valve modules for hydraulic control systems in motor vehicles are limited by their installation position due to the risk of introducing air into the hydraulic medium through leakage flows, restricting their flexibility and suitability for modern vehicles with limited space.

Innovation Solution

A valve module design featuring a buffer volume with an overflow above the valve piston, allowing it to be installed independently of the oil sump, and incorporating a flow limiter and leakage line to maintain a constant hydraulic medium level, preventing air ingress and foaming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the valve is installed below the normal oil level in the oil sump, then air ingress is prevented, but installation flexibility is restricted

Engineering Contradiction:

Improveprevention of air ingressVSAvoidinstallation flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention separates the valve module from the oil sump by introducing an intermediate buffer volume. The valve can be installed above the oil level while the buffer volume maintains hydraulic connection to the oil sump, segmenting the system into independent installable components while preserving the anti-air-ingress function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The buffer volume acts as an intermediary element between the valve and the oil sump. It receives hydraulic medium from the oil sump through the flow limiter and provides hydraulic connection to the valve, mediating the connection and enabling flexible installation positions while preventing air ingress.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the valve is installed above the oil sump, then installation flexibility is improved, but air ingress risk increases

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidprevention of air ingress

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The buffer volume is pre-filled with hydraulic medium from the oil sump before the valve operates. This preliminary action ensures that the buffer volume contains no air, and the flow limiter continuously replenishes it, preventing air ingress even when the valve is installed above the oil sump.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses hydraulic principles to transfer hydraulic medium from the oil sump through the flow limiter into the buffer volume, creating a hydraulic connection that eliminates air ingress risks. The hydraulic medium acts as a pneumatic barrier preventing air from entering the valve.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If a flow limiter is added to fill the buffer volume, then air ingress is prevented, but device complexity increases

Engineering Contradiction:

Improveprevention of air ingressVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flow limiter is a localized, simple component with a specific function (controlling flow into the buffer volume). By applying local quality - a simple flow-limiting structure at the critical interface between oil sump and buffer volume - the system achieves reliable air prevention without requiring complex system-wide modifications.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables flexible installation and prevents foaming by ensuring hydraulic medium flows contain no air, enhancing operational reliability and usability in diverse vehicle configurations.

Implementation Method 1

the at least one tank connection is fluidly connected to a buffer volume which has an overflow which, when installed in the installation position, is arranged above an upper face of the valve piston

Methodology Applied

Scientific EffectHydraulic medium level maintenance through overflow:

Implementation Method 2

The buffer volume can be fluidly connected to a hydraulic circuit via a flow limiter, via which the buffer volume can be filled. By means of the flow limiter, it can be achieved that a part, for example, a small part, in the amount of the expected maximum valve leakage, of the volume flow of hydraulic medium in the hydraulic circuit can be conveyed into the buffer volume

Methodology Applied

Scientific EffectFlow limitation through orifice:

Implementation Method 3

a valve with a valve piston which can be displaced in an actuating direction in a housing which has a plurality of openings which can be opened and closed by displacement of the valve piston

Methodology Applied

Scientific EffectHydraulic actuation through valve displacement: Hydraulic Press

Data Source

PatentUS12366291B2Valve module with active valve oiling

Publication Date: 2025.07.22 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

The valve module can be installed regardless of an oil level, for example of an oil level of an oil sump of a motor vehicle. By means of a buffer volume having an overflow it is always guaranteed that a leakage flow conveyed past a valve piston includes no air but consists solely of hydraulic medium, since the overflow guarantees a level of hydraulic medium which lies above an upper face of the valve piston in a preferred installation position. As a result, foaming of the hydraulic medium can be prevented. The valve module can also be installed above the oil sump, for example in an upper region of a gearbox of the motor vehicle. In addition, the oil from the overflow can be used for cooling/lubrication of further drive train components.