Integrated EGR Valve and Heat Exchanger Assembly
Solution Overview
Problem
The existing exhaust gas recirculation circuits in motor vehicles are large and complex, making them difficult to install in restricted engine compartments and limiting cooling options for components exposed to high temperatures.
Innovation Solution
A compact valve assembly is introduced, comprising a body with a movable valve and a flange that serves both as a fixing element and a support for the valve, with surfaces forming a seat for the valve in its positions, allowing for a reduced size and closer proximity to the exchanger, along with a heat exchange device that incorporates this assembly to enhance thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional EGR circuit with separate heat exchanger and bypass valve is used, then the valve can control gas flow, but the overall device size becomes large and installation space is insufficient
Solution Approach 1:
The patent combines the heat exchanger and bypass valve into a single integrated valve assembly. The valve body is directly formed on the heat exchanger, eliminating the need for separate mounting of the valve. This merging of components reduces the overall device volume while maintaining both the heat exchange function and the gas flow control function.
Solution Approach 2:
The heat exchanger body serves multiple functions: it acts as both the heat exchange component and the valve body housing. The flange of the heat exchanger simultaneously provides structural support, mounting attachment, and forms part of the valve seat structure. This multi-functionality reduces the number of separate components needed.
2Reliability
If a conventional EGR circuit with multiple separate components is used, then each component can be optimized independently, but the manufacturing complexity and assembly operations increase
Solution Approach 1:
The valve body and heat exchanger are merged into a single integrated structure. The valve body is directly formed on the heat exchanger body, reducing the number of parts from multiple separate components to a more compact integrated assembly. This reduces manufacturing complexity and the number of assembly operations required.
3Ease of operation
If the valve is positioned far from the exchanger, then there is sufficient space for valve operation, but the heat exchange efficiency decreases due to increased distance
Solution Approach 1:
The valve body is directly formed on the heat exchanger body, positioning the valve as close as possible to the heat exchange channels. This eliminates the need for long connecting passages and ensures that the gas flow path from the heat exchanger to the valve inlet is minimal, maintaining heat exchange efficiency while providing adequate space for valve operation through the integrated design.
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
The compact design facilitates easier installation and improves heat exchange efficiency by reducing the distance between the valve body and the exchanger, while minimizing manufacturing costs and assembly operations.
Implementation Method 1
a heat exchanger to cool the exhaust gases
Implementation Method 2
circuits for transporting fluids such as those used in motor vehicles, in particular for recirculating the exhaust gases
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a valve unit, comprising a body (21), defining at least one first channel and a valve (26) mounted in the body and which is mobile with relation to a seat (25) formed in the first channel, characterised in that a connector flange (30) for a heat exchanger (1) is mounted on the body, a flap (33) being mounted on the flange such as to pivot between a connecting position for the first channel to the heat exchanger and a bypass position in which the first channel is not connected to the exchanger. The invention further relates to a heat exchanger comprising such a valve.