Overrun Air Recirculation Valve Sealing Design
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Solution Overview
Problem
Diverter air valves for internal combustion engine compressors face issues with gas and oil contamination leading to coil corrosion and noise during operation, due to inadequate sealing and complex assembly processes.
Innovation Solution
A diverter valve design featuring multiple sealing rings and an elastic plastic ring, injection molded onto the connection housing, which provides comprehensive sealing and reduces noise by acting as a stop surface for the control body, while also simplifying assembly and manufacturing by reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sealing rings and an elastic plastic ring are added to protect the coil from contaminants, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sealing functions into a single elastic plastic ring that integrates both sealing and noise reduction functions. This ring is injection molded directly onto the connection housing, merging what would otherwise be separate sealing components into one integrated element, thus improving reliability without proportionally increasing complexity
Solution Approach 2:
The elastic plastic ring serves multiple functions simultaneously: it provides sealing against contaminants for the coil protection, and acts as a noise-reducing stop surface for the control body. This multi-functionality addresses multiple problems with a single component, improving reliability while minimizing the increase in device complexity
2Object-generated harmful factors
If the control body is equipped with a stop surface for noise reduction, then object-generated harmful factors are reduced, but device complexity increases
Solution Approach 1:
The noise reduction function is merged with the sealing function in the elastic plastic ring. The ring's position and elasticity provide a compliant stop surface for the control body, reducing noise from impact, while simultaneously providing sealing. This integration avoids adding a separate noise reduction component
Solution Approach 2:
The elastic plastic ring utilizes material flexibility to create a compliant stop surface that dampens impact noise. The elasticity of the ring allows it to deform during control body impact, absorbing shock and reducing noise generation, while maintaining its sealing function
3Reliability
If sealing rings are added to prevent gas ingress, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The sealing rings and elastic plastic ring are combined into a single integrated component through injection molding. This single molding operation creates all sealing elements in one process step, eliminating the need for separate assembly of multiple sealing rings, thus improving sealing effectiveness while maintaining ease of manufacture
Solution Approach 2:
The sealing components are pre-formed through injection molding directly onto the connection housing. This preliminary formation of sealing elements during the housing manufacturing process eliminates subsequent assembly steps, improving both sealing reliability and manufacturing ease by integrating sealing into the base manufacturing process
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 design effectively protects the coil from contaminants, reduces noise, and ensures rapid switching with improved sealing, resulting in a cost-effective and efficient diverter valve with enhanced reliability and reduced assembly complexity.
Implementation Method 1
The electromagnetic actuator of this diverter valve is surrounded by a plastic housing... with the valve closing body of the valve being moved by the electromagnetic force via the armature
Implementation Method 2
The plastic ring serves as a stop surface for the control body when open. Due to the elasticity of the stop, it is dampened so that noise and the mechanical stress on the connection housing and the control body are reduced
Data Source
Figure 1
Figure 2
AI summary
Overrun air recirculation valves for compressors on internal combustion engines, having a flow housing (58) with an inlet (60) and an outlet (62), having an electromagnetic actuator (10) arranged in an actuator housing (11), having a control body (66) which can be moved by way of the actuator (10), having a housing interior (82) in which an armature (32) of the electromagnetic actuator (10) is movable, having openings (80) in the control body (66), via which openings the housing interior (82) is fluidically connected to a duct (63), which can be closed off by the control body (66), in the flow housing (58), and having a connector housing (46) which bears axially against the actuator (10) and which at least partially delimits the housing interior (82), are known. To realize a sealed housing interior and to protect the coil on all sides against an ingress of liquids or gases, it is proposed that, on the connector housing (46), there is arranged a first sealing ring (48), which bears against a guide sleeve (26) or an armature sleeve of the actuator (10), and there is arranged a second sealing ring (124), which bears against the flow housing (58) on the axially opposite side of the connector housing (46).