Multi-Way Valve Rotor Sealing for Low Pressure Drop
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Solution Overview
Problem
Existing multi-way valves for vehicle thermal management systems face challenges in efficiently controlling fluid flow to various thermal fluid circuits due to complex passageways, which increase pressure drop, potential leaks, and manufacturing costs.
Innovation Solution
The multi-way valve design includes a valve housing with a lower and upper housing body, a housing cover, and a valve flow controller with first and second valve rotors. The valve rotors are configured to rotate about respective axes, defining multiple flow paths, and a sealing system with press-fit seals and a biasing assembly to improve sealing and reduce torque requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex passageways are used in multi-way valves, then fluid flow control capability is improved, but pressure drop increases
Solution Approach 1:
The valve is divided into multiple independent valve rotors (first valve rotor, second valve rotor) that can rotate independently. Each rotor contains through holes that create separate flow paths. This segmentation allows fluid to flow through multiple parallel paths simultaneously, reducing pressure drop while maintaining versatile flow control capability to different thermal circuits.
2Adaptability or versatility
If complex passageways are used in multi-way valves, then fluid flow control capability is improved, but potential leaks increase
Solution Approach 1:
The sealing function is extracted and implemented through a dedicated sealing system comprising multiple seals positioned at critical interfaces (between valve rotors and housing, between housing sections). This separate sealing system isolates potential leak paths from the complex flow control passages, allowing versatile flow control while maintaining reliability through focused sealing at discrete locations.
3Adaptability or versatility
If complex passageways are used in multi-way valves, then fluid flow control capability is improved, but manufacturing costs increase
Solution Approach 1:
Multiple valve rotors are nested within the valve housing, with each rotor containing flow control features. The valve rotors are positioned within valve cavities that are formed within the housing structure. This nested arrangement achieves complex multi-circuit flow control capability while using a compact, integrated housing design that simplifies manufacturing compared to assembling multiple separate valve bodies.
4Reliability
If sealing system with press-fit seals is used, then sealing performance is improved, but torque requirements increase
Solution Approach 1:
The biasing assembly applies axial force to the first valve rotor only when it is in specific predetermined positions (such as when through holes align with housing apertures for sealing). This partial application of force provides enhanced sealing performance at critical moments while avoiding continuous high force that would increase torque requirements during normal rotation operations.
5Reliability
If biasing assembly is used to improve sealing, then leakage is reduced, but device complexity increases
Solution Approach 1:
The biasing assembly is designed to automatically engage and apply axial force to the first valve rotor when it reaches predetermined positions during rotation. The cam surface and cam ramps work together in a self-actuating manner, using the rotational motion itself to trigger the sealing action. This self-service mechanism reduces leakage without requiring complex external control systems or additional actuators.
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
This design reduces pressure drop, minimizes leaks, and lowers manufacturing costs by simplifying the flow path and using a sealing system that reduces friction and torque requirements, while maintaining effective control over fluid flow to various thermal fluid circuits.
Implementation Method 1
a biasing assembly configured to selectively apply an axial force on the first valve rotor when the first valve rotor is in preselected positions relative to the upper housing body
Implementation Method 2
The seals are axially press-fit into the upper housing body around the apertures formed in the floor so that each of the seals engage an axially facing surface of the first valve rotor
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A multi-way valve (10) adapted to control a flow of fluid to different thermal fluid circuits includes a valve housing (12), and a valve flow controller (14), and a sealing system. The valve flow controller is arranged in the valve housing to control flow through the valve housing. The sealing system is configured to seal between the valve housing and the valve flow controller.