Exhaust Gas Valve Elastomer Seal Leakage Control

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Solution Overview

Problem

Existing low pressure flap valves for internal combustion engines face challenges in precisely controlling exhaust gas return, leading to potential soot formation, increased fuel consumption, and emissions, while also experiencing leakage and corrosion issues.

Innovation Solution

A low pressure flap valve with a metal closure body, elastomer seal, and electromagnetic actuating drive, featuring elongated projections and circular-cylindrical circumferential surfaces for precise control and sealing, reducing leakage and corrosion, and allowing for precise control of exhaust gas mass flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a low pressure flap valve is used to control exhaust gas return, then the mass flow control is improved and emissions are reduced, but leakage occurs leading to soot formation and increased fuel consumption

Engineering Contradiction:

Improveexhaust gas return controlVSAvoidsealing performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs an elastomer seal (flexible membrane) that is radially deformable to create a reliable sealing surface between the closure body and valve seat. The elastomer material allows the seal to conform to the mating surfaces and maintain sealing under varying pressure conditions, preventing exhaust gas leakage while maintaining effective mass flow control

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes the radial deformability parameter of the elastomer seal to adapt the sealing characteristics. By designing the seal with specific radial compliance, it can deform under pressure to ensure contact with the valve seat, dynamically adjusting the sealing parameter to maintain reliability across different operating conditions

Inventive Principle:

Principle #35Parameter changes

2Strength

If the closure body is made of metal for durability, then strength is improved, but corrosion resistance deteriorates in the exhaust gas environment

Engineering Contradiction:

Improveclosure body strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent combines metal closure body (providing structural strength) with elastomer sealing material (providing corrosion resistance). This composite approach allows the metal framework to maintain mechanical integrity while the elastomer components protect against corrosive exhaust gas environments, achieving both strength and corrosion resistance simultaneously

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The elastomer seal acts as an intermediary between the metal closure body and the corrosive exhaust gas environment. It provides a protective barrier that prevents direct contact between the metal surfaces and corrosive gases, thereby protecting the metal components from corrosion while maintaining the structural strength of the closure body

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the shaft is mounted rotatably on only one side of the closure body, then device complexity is reduced, but magnetic forces may affect reliability

Engineering Contradiction:

Improveshaft mounting structureVSAvoidmagnetic force resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces a traditional two-sided mechanical bearing support system with a simplified one-sided mounting configuration. The electromagnetic actuating drive is directly integrated with the shaft, eliminating the need for complex mechanical support structures on both sides while maintaining reliability through direct electromagnetic coupling that can withstand magnetic forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 valve achieves precise control of exhaust gas return, minimizing soot formation, fuel consumption, and emissions, while maintaining low leakage and reducing corrosion, ensuring efficient operation and compliance with tightening emission standards.

Implementation Method 1

The seal is elastic and particularly consists of an elastomer, in particular of a fluororubber (FKM), which is particularly peroxidically cross-linked

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

The valve has an electromagnetic actuating drive connected with the shaft

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS9752687B2Valve for an exhaust gas line of an internal combustion engine

Publication Date: 2017.09.05 BORGWARNER STUTTGART GMBH

AI summary

An exhaust line valve for an internal combustion engine. A closure body is arranged in a duct of the valve and is fastened to a shaft. The closure body when closed separates upstream and downstream duct sections. Two projections extend into the duct, each having a valve seat pointing in an opposite direction of the duct. By pivoting the closure body from its closed position, the sealing surfaces of the closure body are raised from their respective valve seats. A polymer seal is arranged on the valve seats and in the closed position the polymer seal sealingly contacts the associated sealing surface of the closure body. A circumferential surface of the shaft or the closure body is located in an edge region of the closure body. The polymer seal contacts in a sealing manner at least a region of the circumferential surface facing the upstream section of the duct.