Single-Rotor Multi-Way Valve Sealing for Low-Torque Flow Paths
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Solution Overview
Problem
Existing multi-way valves for controlling heating and cooling fluid in vehicles lack improved sealing and increased flow paths, leading to potential leaks and increased manufacturing costs due to complex passageways and excessive seal material usage.
Innovation Solution
A multi-way valve design featuring a valve rotor that rotates within a housing to define multiple flow paths, combined with a sealing system that applies radial force at specific positions to enhance engagement and reduce friction, using less material and torque, thereby improving sealing and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a valve rotor with complex passageways is used to control fluid flow to multiple thermal circuits, then the number of flow paths increases, but the sealing complexity and material usage increase
Solution Approach 1:
The valve housing is divided into multiple separate thermal circuits (first, second, third, and fourth circuits) with dedicated apertures and passageways. Each circuit can be independently controlled by the valve rotor, allowing fluid to be directed to different circuits without requiring complex internal sealing structures within a single housing. This segmentation simplifies the sealing requirements while maintaining multiple flow paths.
Solution Approach 2:
The valve rotor serves multiple functions by rotating to different positions to control fluid flow to different thermal circuits. A single valve rotor with multiple apertures can direct fluid to various circuits, eliminating the need for multiple separate valves or complex multi-layer sealing arrangements. This multi-functionality reduces overall sealing complexity while providing versatile flow control.
2Reliability
If excessive seal material is used to ensure sealing between valve rotor and housing, then sealing reliability improves, but manufacturing cost and friction increase
Solution Approach 1:
Seal material is applied selectively at specific locations where sealing is actually required, such as at the interface between the valve rotor and valve housing, and around specific apertures. Rather than using excessive seal material throughout the entire valve assembly, sealing is concentrated at critical points where fluid pressure and rotation create potential leakage paths. This localized approach reduces material usage and manufacturing cost while maintaining sealing reliability.
3Reliability
If continuous radial force is applied to the valve rotor to maintain seal engagement, then sealing improves, but torque requirement and wear increase
Solution Approach 1:
Radial force application to the valve rotor is made periodic rather than continuous. The biasing assembly applies radial force only when the valve rotor is in specific positions or under specific conditions, allowing the rotor to disengage from the seal at other times during rotation. This periodic engagement reduces the average torque requirement and minimizes wear on the seal while maintaining sealing reliability when needed.
Solution Approach 2:
The radial force application is made dynamic rather than static, allowing the valve rotor to adjust its engagement with the seal based on operating conditions. The biasing assembly can apply variable radial force that adapts to the rotational position and fluid pressure conditions, providing strong seal engagement when required while allowing reduced engagement during rotation to minimize friction and torque requirements.
4Ease of manufacture
If simplified flow paths are used in the valve housing, then manufacturing cost decreases, but sealing effectiveness may be compromised
Solution Approach 1:
The flow paths are segmented into separate, simple passageways for different thermal circuits rather than using complex interconnected channels. Each circuit has its own dedicated aperture and passageway that opens into the valve cavity, allowing fluid to flow directly to the intended circuit without requiring complex routing. This segmentation simplifies manufacturing while maintaining effective sealing through the use of separate, straightforward flow paths.
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 achieves improved sealing and reduced leakage by simplifying flow paths and minimizing seal material usage, while also decreasing the torque required to rotate the valve rotor and reducing wear on seals, thus enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
reduces the friction on the valve rotor
Implementation Method 2
a seal that extends circumferentially partway around the valve axis and is located between the valve rotor and the valve housing body
Data Source
AI summary
A multi-way valve adapted to control a flow of fluid to different thermal fluid circuits includes a valve housing, a valve flow controller, 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.