Patent Application
20240254900
The invention relates to a poppet valve, in particular a hollow poppet valve. Poppet valves are for example used in combustion engines to open and close the inlet and outlet ports to the cylinders. As the power of combustion engines increases, the heat production also increases. To this end it is known to provide hollow poppet valves, which are filled with for example sodium for better heat exchange.
In order to maximize the heat exchange of hollow poppet valves and with the aim of reducing knocking tendency of gasoline engines, the cavity in the valve head should be as large as possible. A number of manufacturing methods are known to produce such poppet valves.
For example US 2016356186 proposes a valve, in which a valve body is provided with a cavity opening at an axial end. This cavity is closed by a valve cap, which is welded to the valve body. The weld is arranged in the axial end surface of the valve, such that the weld is directly subjected to the heat of the combustion process. This could result in fatigue of the weld and as a result leakage of the sodium in the hollow poppet valve into the cylinders of the combustion engine.
Other manufacturing methods are known, in which the valve head is formed as one piece. For example JP 1995208127 disclosed a method in which a hollow valve head is shaped out of a solid material. The resulting cavity, especially in the head itself, is very limited.
Also US 20120255175 discloses a method in which a rod with a blind hole is shaped into a poppet valve. Also with this method, the size of the cavity of the valve head is limited.
In an embodiment, a poppet valve is disclosed, in particular a hollow poppet valve, comprising: a valve stem; a valve body having along a longitudinal axis, a first end with a neck portion to which the valve stem may be coaxially arranged and having along a longitudinal axis a second end with a first outer contact face portion, the valve body comprising a cavity with a first opening towards the first end and a second opening towards the second end; and a valve cap coaxially arranged to the valve body on the second end configured to close the second opening, the valve cap having a second outer contact face portion to form together with the first outer contact face portion a valve head contact face.
In a particular embodiment, which may combine the features of some or all above embodiments, both the first and second outer contact face portions may comprise a circumferential groove portion to form together a circumferential face groove, which may may provide for a space to arrange a seat facing material, and which may be formed having a shape intended to improve welding process aspects, valve performance, reliability, and/or robustness.
In a particular embodiment, which may combine the features of some or all above embodiments, the valve cap may comprise a cylindrical upright wall, which may extend into the second opening of the cavity and centers the valve cap relative to the valve body.
In a particular embodiment, which may combine the features of some or all above embodiments, a second inner contact face portion of the valve cap may abut the first inner contact face portion of the valve body, and a first and a second weld surface of the valve body and the valve cap, respectively, may contact each other at a welding interface.
In a particular embodiment, which may combine the features of some or all above embodiments, the length of a welding line, which may be defined by joining an inner edge and an outer edge of the welding interface, respectively, in a longitudinal cross-section of the poppet valve, may lie between 0.5 millimeters and 3.5 millimeters, the length of the welding line being inclusive of both end values
In a particular embodiment, which may combine the features of some or all above embodiments, an angle α made by the welding line with an axis that is perpendicular to the longitudinal axis of the valve body in the longitudinal cross-section may lie between −80° and +90°, a being inclusive of both end values.
In a particular embodiment, which may combine the features of some or all above embodiments, the weld surfaces may be formed to enable a weld interface shape intended to improve welding process aspects, valve performance, reliability, and/or robustness.
In a particular embodiment, which may combine the features of some or all above embodiments, inner contact face portions may be formed having a contact shape intended to protect the welding, distribute forces between the valve cap and valve body, and improve other welding process aspects, valve performance, reliability, and/or robustness.
In a particular embodiment, which may combine the features of some or all above embodiments, a space may be formed between the first coupling weld surface of the valve body and the second inner contact face portion of the valve cap, the space being provided for any welding residual materials.
In a particular embodiment, which may combine the features of some or all above embodiments, a space may be formed between the first coupling weld surface of the valve body and the second inner contact face portion of the valve cap, the space being provided for any welding residual materials, the space being obtained in the valve cap portion of the poppet valve, the shape and size of the space being selected and formed to improve welding process aspects, valve performance, reliability, and/or robustness.
In a particular embodiment, which may combine the features of some or all above embodiments, a space may be formed between the first coupling weld surface of the valve body and the second inner contact face portion of the valve cap, the space being provided for any welding residual materials, the space being obtained in the valve body portion of the poppet valve, the shape and size of the space being selected and formed to improve welding process aspects, valve performance, reliability, and/or robustness.
In a particular embodiment, which may combine the features of some or all above embodiments, a space may be formed between the first coupling weld surface of the valve body and the second inner contact face portion of the valve cap, the space being provided for any welding residual materials, the space being obtained in both the valve cap and valve body portions of the poppet valve, the shape and size of the space being selected and formed to improve welding process aspects, valve performance, reliability, and/or robustness.
The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
In an embodiment, the present invention reduces the above mentioned disadvantages.
In an embodiment, the present invention provides a poppet valve according to the invention, which poppet valve comprising:
With the disclosed poppet valve, the valve body may be manufactured with a cavity having a second opening towards the second end. This second opening may be closed by the valve cap. Because the valve cap provides for a second outer contact face portion, which forms together with the first outer contact face portion a valve head contact face, the partition surface between the valve body and the valve cap may no longer be positioned in direct contact with the combustion process in the cylinder. This may ensure that the impact of the combustion process onto the attachment between the valve body and the valve cap is lower, such that the chance on leakage of sodium or the like from the cavity may be reduced.
In an embodiment of the poppet valve, both the first and second outer contact face portions may comprise a circumferential groove portion to form together a circumferential face groove and wherein a layer of seat facing material, for example cobalt based or iron based, may be arranged in the circumferential face groove.
The circumferential groove may provide for a space to arrange a seat facing material and covering the partition surface, such that the partition surface between the valve body and the valve cap may be shielded from any contact with the combustion process in the cylinder.
As seen in a cross-sectional view of the poppet valve, the circumferential groove portion may be formed having a shape intended to improve welding area, welding reliability, other welding process aspects, and/or improve feasible manufacturability. Additionally, as seen in a cross-sectional view of the poppet valve, the circumferential groove portion may be formed having a shape intended to improve valve performance, reliability, and/or robustness. In particular embodiments, by way of example and not limitation, the shape of the circumferential groove portion may be curved or arcuate, as seen in a cross-sectional view of the poppet valve. In particular embodiments, by way of example and not limitation, the shape of the circumferential groove portion may be conical or linear, as seen in a cross-sectional view of the poppet valve.
In a further embodiment of the poppet valve, the valve cap may be welded to the valve body, which weld may be arranged between the first and second outer contact face portions.
In yet another embodiment of the poppet valve, the valve cap may comprise a cylindrical upright wall, which may extend into the second opening of the cavity and centers the valve cap relative to the valve body.
The upright wall may allow for easy positioning of the valve cap into the cavity of the valve body, but may also provide for absorption of forces between the valve cap and the valve body, such that the weld between the valve body and valve cap may be at least partially relieved from stresses between the valve body and the valve cap. In particular embodiments, a tolerance gap may be provided between the upright wall of the valve cap and the corresponding engaging surface of the valve body. The tolerance gap may provide benefits for accommodating manufacturing and operational variations, which may lead to improved valve manufacturability, reliability, and/or performance.
In still another embodiment of the poppet valve, the valve stem may comprise a stem cavity with an opening connecting to the first opening of the cavity of the valve body.
With the stem cavity connected to the cavity of the valve body, the poppet valve may be provided with a cavity extending through the whole poppet valve. This cavity may be filled with sodium or the like to enhance the heat transfer of the valve, which may reduce the chance of leakage compared to conventional poppet valves.
In yet a further embodiment of the poppet valve, the valve body may further comprise a first inner contact face portion arranged coaxial with the longitudinal axis of the valve body and a first weld surface extending under the first outer contact face portion, wherein the first inner contact face portion may transition in a radial outward direction into the first weld surface; and
A welding line may be defined by joining the inner edge of the welding interface with the outer edge of the welding interface in a longitudinal cross-section of the poppet valve. In particular embodiments, a length of the welding line may lie between 0.5 millimeters and 3.5 millimeters, inclusive of both end values.
The welding line may make an angle α with an axis that is perpendicular to the longitudinal axis of the valve body in the longitudinal cross-section, angle α being positive when the inner edge of the welding interface is longitudinally extended away from valve body toward the valve cap relative to the outer edge of the welding interface, angle α being negative when the outer edge of the welding interface is longitudinally extended away from valve body toward the valve cap relative to the inner edge of the welding interface, and angle α being zero when the outer edge of the welding interface and the inner edge of the welding interface lie in an identical plane that is perpendicular to the longitudinal axis of the valve body. In particular embodiments, the angle α may lie between −80° and +90°, a being inclusive of both end values.
As seen in a cross-sectional view of the poppet valve, the weld surfaces may be formed to enable a weld interface shape intended to improve welding area, welding reliability, other welding process aspects, and/or improve feasible manufacturability. Additionally, as seen in a cross-sectional view of the poppet valve, the weld surfaces may be formed to enable a weld interface shape intended to improve valve performance, reliability, and/or robustness. In particular embodiments, by way of example and not limitation, the weld interface shape may be curved or arcuate, as seen in a cross-sectional view of the poppet valve. In particular embodiments, by way of example and not limitation, the weld interface shape may be conical or linear, as seen in a cross-sectional view of the poppet valve.
The contact between both inner contact face portions may ensure that any stresses between the weld surfaces and especially in the weld are reduced or even prevented.
As seen in a cross-sectional view of the poppet valve, the inner contact face portions may be formed having a contact shape intended to protect the welding, distribute forces between the valve cap and valve body, improve valve performance, reliability, robustness, and/or feasible manufacturability. In particular embodiments, by way of example and not limitation, the contact shape of the inner contact face portions may be curved or arcuate, as seen in a cross-sectional view of the poppet valve. In particular embodiments, by way of example and not limitation, the contact shape of the inner contact face portions may be conical or linear, as seen in a cross-sectional view of the poppet valve.
The radius of the outer edge of the first inner contact face portion may be selected to be smaller than the radius of the outer edge of the second inner contact face portion, such that a space may be formed between the first coupling weld surface and the second inner contact face portion.
By providing a space between the first weld surface and the second inner face portion a space for any welding residual may be provided, which may avoid the starting of cracks in the weld. This space, which may also be called a vent chamber, may be obtained in either the valve cap portion of the poppet valve, or the valve body portion of the poppet valve, or both portions (the valve cap and the valve body) of the poppet valve. Consequently, as seen in a cross-sectional view of the poppet valve, the shape of this space or vent chamber may be formed to enable improvements in welding area, welding reliability, other welding process aspects, and/or to improve feasible manufacturability. Additionally, as seen in a cross-sectional view of the poppet valve, the shape of this space or vent chamber may be formed to enable a weld interface shape intended to improve valve performance, reliability, and/or robustness. In particular embodiments, the shape of this space, or vent chamber, may be rounded at one or more locations, as seen in a cross-section view of the valve head. One or more rounded surfaces may provide beneficial reduction of mechanical and/or thermal stresses, and/or stress concentrations, during valve manufacturing and/or valve operation, with corresponding improvements in valve manufacturability, reliability, and/or performance.
The disclosure also relates to a method for manufacturing a poppet valve, which method comprises the steps of:
In an embodiment of the method, the weld may be covered by a layer of seat facing material using plasma transferred arc welding. By way of example and not limitation, plasma transferred arc welding may allow for a variety of materials to be arranged in the circumferential face groove, especially for relatively hard materials, which may be well suited for a valve seat surface. By way of example and not limitation, some other options to arrange the layer of seat facing material may by laser welding and projection welding.
The valve stem 2 has a cavity 5, which connects to a cavity 6 of the valve body 3 via a first opening at the coaxially arranged neck portion at the first end 7 of the valve body 3. The second opening of the valve body 3 is closed by the valve cap 4.
The valve body 3 is provided, along a longitudinal axis L-L, with a second end having a first outer contact face portion 8. The valve cap 4 is provided with a second outer contact face portion 9, with forms together with the first outer contact face portion 8 a valve head contact face.
Each outer contact face portion 8, 9 is provided with a groove portion, which accommodates a layer of seat facing material at 10, which covers the weld 11 between the valve body 3 and the valve cap 4.
The valve cap 4 is provided with a cylindrical upright wall 12, which mates with a circumferential wall 13 of the cavity 6 and ensures that the valve cap 4 is centered relative to the valve body 3. A tolerance gap 14 is provided between the cylindrical upright wall 12 and the circumferential wall 13.
The outer radius r1 of the first inner contact face portion 24 is smaller than the outer radius r2 of the second contact face portion 26, such that a space 27 is provided between the first weld surface 23 and the second inner contact face portion 26. These radii are measured from the the longitudinal axis of the valve body, which should be construed to exist in this figure, and is not explicitly shown due to the magnified scale of enlargement.
The weld to attach the valve body 21 to the valve cap 22 is arranged between the first weld surface 23 and the second weld surface 25. Any residuals of the weld can flow into the space 27, preventing any cracks occurring the in the weld.
A welding line 28 joins the inner edge of the welding interface with the outer edge of the welding interface in this longitudinal cross-section view. The welding line 28 makes a positive angle α with an axis ‘x’ that is perpendicular to the longitudinal axis of the valve body, with the axis marked ‘y’ being parallel to the longitudinal axis of the valve body. The longitudinal axis of the valve body should be construed to exist in this figure, and is not explicitly shown due to the magnified scale of enlargement.
The first and second inner contact face portions 24, 26 may furthermore reduce any stresses in the welding area.
The embodiments illustrated in
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.
The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and/or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.
Numerical ranges recited in this application should be construed to be inclusive of the end points of the stated ranges. The longitudinal axis of the valve body, which may have been omitted in some illustrations for convenience of scale, should be construed to exist in every illustration where it is referred to.
This application is a continuation under 35 U.S.C. § 365(c) of International Patent Application No. PCT/EP2022/025516, filed Nov. 16, 2022, which claims the benefit of priority of U.S. Provisional Patent Application No. 63/279,787, filed Nov. 16, 2021, which are incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63279787 | Nov 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2022/025516 | Nov 2022 | WO |
| Child | 18637109 | US |
