EGR Valve with Integrated Actuator and Thermal Barrier
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Solution Overview
Problem
Existing EGR valves for vehicles suffer from unstable operation due to separate driving sources and are prone to degradation from high temperature exhaust gas, leading to inefficient exhaust gas recirculation and potential leakage.
Innovation Solution
A three-way EGR valve design utilizing a single driving source with a rotation shaft and coupled valves for linear control, incorporating a heat cutoff plate and nitrided coating to prevent heat transfer, and a sealing mechanism with an elastic member to minimize leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate driving sources are used for exhaust gas valve and EGR operation valve, then individual control is possible, but operation stability deteriorates due to different driving sources
Solution Approach 1:
The patent combines the exhaust gas valve and EGR operation valve into a single integrated valve body that is controlled by one driving source (motor 120). This merging eliminates the instability caused by multiple independent driving sources while maintaining control versatility through the linear relationship between the two valve openings, which are both proportional to the rotation angle of the single driving source.
2Productivity
If high temperature exhaust gas flows through the EGR valve, then exhaust gas recirculation function is achieved, but the EGR valve degrades due to high temperature exposure
Solution Approach 1:
The patent segments the valve body into distinct functional regions: a first valve body portion that contacts high-temperature exhaust gas and a second valve body portion that remains cooler. This segmentation allows the first portion to withstand thermal exposure while the second portion maintains operational stability, reducing overall thermal degradation of the valve components.
Solution Approach 2:
The patent introduces a heat-resistant coating or thermal barrier as an intermediary layer between the exhaust gas and the valve components. This intermediary protects the valve body from direct thermal contact, reducing heat transfer to sensitive components while allowing the exhaust gas to flow through the valve for recirculation.
3Adaptability or versatility
If non-linear control is used for EGR valve, then control range is flexible, but linear relationship between exhaust gas opening and EGR opening is lost
Solution Approach 1:
The patent changes the control parameter from independent non-linear control of each valve to unified linear control based on rotation angle. Both the exhaust gas valve opening and EGR valve opening are made proportional to the rotation angle of the single driving source, ensuring a linear relationship between the two openings while maintaining flexibility through adjustable proportionality constants that can be tuned for different operating conditions.
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 solution enables stable exhaust gas recirculation, prevents degradation from high temperature exhaust gas, and minimizes leakage, thereby reducing pollutant emissions and improving operational efficiency and longevity.
Implementation Method 1
a heat cutoff plate mounted between the valve housing and the driving unit for preventing the driving unit suffering from damage by the high temperature exhaust gas flowing through the flow line
Implementation Method 2
The rotation shaft includes a first rotation shaft coupled to a gear unit in the driving unit, a coupling coupled to the first rotation shaft for receiving rotation force through the first rotation shaft, and a second rotation shaft coupled to the other side of the coupling having the exhaust control valve and the re-circulation valve mounted thereto
Data Source
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AI summary
The present invention relates to an exhaust gas recirculation (EGR) valve for a vehicle. The EGR valve (1) includes a valve housing (100) connected to an exhaust line (10) for discharging exhaust gas therethrough, having a flow line (110) with an inside area divided for taking and re-circulating a portion of the exhaust gas to a suction manifold, a driving unit (200) on one side of the valve housing (100), and a valve unit (300) mounted in a flow line (110) of the valve housing (100) for receiving driving force from the driving unit (200) directly to control flows of the exhaust gas flowing through the flow line (110) at the same time individually, thereby making stable control of the exhaust gas flowing through the EGR valve, preventing damage caused by the high temperature exhaust gas, and preventing the exhaust gas from leaking to an outside of the EGR valve.