Patent Application
20140345709
The invention relates generally to a mounting configuration for a valve assembly which provides a secure connection and isolation from vibration.
Typical air flow systems for a vehicle include both a canister purge valve (CPV) and a turbo purge valve (TPV), each of which have vacuum ports connected to a hose. The CPV and TPV are in-line parts attached to the intake manifold of engines by the use of a rubber isolator mounted on a tab, and a rubber hose connecting the vacuum port to the manifold for fluid communication.
There have been attempts to eliminate this hose and directly mount the valve to the intake manifold, similar to the CPV. Due to the port orientation and overall geometry of the CPV, mounting the TPV in the same mounting configuration (as is used with the isolator and the hose) is both impractical and also quite expensive, since two fasteners and isolators are required. Since the TPV is a turbo engine device, any direct mounting must be capable of withstanding cyclical pressures up to 40 psi. The valve must be completely rubber isolated from the manifold to minimize noise generation. Significant noise transmission occurs if any hard contact occurs between the TPV and the manifold.
It is also important when mounting components to the engine that the center of mass of the part be well supported, as engine roll and vibration can induce significant g-forces on the component, generating unexpected failure modes.
Accordingly, there exists a need for a connection between a TPV and a manifold, or other component, which provides a rigid connection, but also provides isolation from vibration, reducing noise.
The present invention is a mounting assembly which provides for a rigid connection between a valve assembly, such as a TPV or CPV, and a component in an air flow system of a vehicle, such as an intake manifold, air box, or the like. The mounting assembly is also suitable for providing commonality of parts between different types of CPVs that are used for different types of vehicles.
The mounting assembly includes two brackets that are connected to the CPV, and the brackets are used to connect the CPV to an intake manifold, for example. The first bracket includes an isolator having a slot, and a blade or flange extends into the slot, providing only one way of attachment between the CPV and the intake manifold. This blade mount design of the CPV does not change significantly (other than minor mating feature changes), and the rubber isolator remains common to the inline part. The second bracket includes a single bolt through a molded tab providing a second connection capable of withstanding the pressure the CPV/TPV is exposed to. The second bracket also has a second isolator; both isolators are made of rubber or other type of material suitable for isolating the TPV or CPV from vibration.
The CPV includes a port which extends into the intake manifold. Sealing as well as noise isolation between the port and the intake manifold are achieved through the use of a sealing device, such as two large O-rings in the sealing interface of the port, or an alternate sealing method.
The mounting assembly of the present invention allows for proper mass support to the blade mount design, and the elimination of at least one hose, and only requires one fastener to rigidly connect the valve to the manifold.
This mounting configuration of blade and bolt is not limited to engine mount components, or even rubber isolated components, and could be used for other system assemblies.
In one embodiment, the present invention is a mounting assembly for a valve assembly, which includes a housing having at least one port, the housing being part of a valve assembly, a first bracket connected to the housing, and a first bracket aperture formed as part of the first bracket such that a first isolator is disposed in the first bracket aperture. A second bracket is connected to the housing, and an aperture is formed as part of the second bracket such that a second isolator is disposed in the aperture formed as part of the second bracket. A slot is formed as part of the first isolator, and a flange formed as part of a lower housing is disposed in the slot formed as part of the first isolator.
A flow aperture is formed as part of the lower housing, and at least one port of the valve assembly is in alignment with the flow aperture when the flange is aligned with the slot formed as part of the first isolator, such that the port is inserted into the flow aperture as the flange is inserted into the slot formed as part of the first isolator. This configuration allows for the first isolator and second isolator to isolate the housing from vibration from the lower housing.
A first groove is formed as part of the port, and a second groove is also formed as part of the port. A first O-ring is disposed in the first groove, and a second O-ring is disposed in the second groove, such that the first O-ring and the second O-ring are in contact with the inner surface of the flow aperture, providing a seal between the port and the flow aperture, and isolating the port from vibration from the lower housing.
The mounting assembly also includes a washer having an aperture, where the second isolator substantially surrounds the washer, and an aperture is formed as part of the lower housing. The aperture of the washer is in alignment with the aperture of the lower housing when the flange is in alignment with the slot formed as part of the first isolator. A fastener is inserted through the aperture formed as part of the washer and into the aperture formed as part of the lower housing, securing the second isolator and the housing to the lower housing.
As the fastener is inserted into the aperture formed as part of the lower housing, the washer absorbs the compressive stress from the fastener, preventing the second isolator from being exposed to stress from the fastener being inserted into the aperture formed as part of the lower housing. The fastener is substantially parallel to the at least one port disposed in the flow aperture, to ensure that the fastener absorbs tensile stress from the force of the air flow flowing into and out of the port of the lower housing. This configuration substantially eliminates potential from the fastener having to absorb shear stress from the force of the air flowing into or out of the port.
The mounting configuration of the present invention allows for the valve assembly to be connected to different components of an air flow system of a vehicle. For example, the lower housing may be part of an air box, an intake manifold, a vapor canister, or another component in an air flow system. The mounting configuration provides for isolation of vibration from these components, while still providing a rigid connection and proper alignment between the housing and the lower housing during assembly.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
A canister purge valve (CPV) according to the present invention is shown in
The flange 24 protrudes away from a base portion 62 formed as part of the lower housing 26. The first isolator 20 also includes a body portion 64, and an upper isolator flange portion 66 and a lower isolator flange portion 68, where in the first bracket 18a is disposed between the isolator flange portions 66,68 when the isolator 20 is connected to the bracket 18a. As shown in
Also part of the mounting assembly is a second bracket 18b which is connected to the second portion 14b of the housing 12. The second bracket 18b includes an aperture 28, and disposed in the aperture 28 is a second isolator 30 and a washer 32. The aperture 28 is part of a flange portion 74, and the flange portion 74 is partially disposed in a groove 30a formed as part of the second isolator 30. The washer 32 includes an aperture 34, and selectively disposed within the aperture 34 is a fastener, which in this embodiment is a bolt 36. When assembled, the bolt 36 at least partially extends into an aperture 38 formed as part of the lower housing 26.
The second bracket 18b also includes a second port 40, and the second port 40 is surrounded by a sealing device. In this embodiment, the sealing device is a first O-ring 42 disposed in a first groove 44, and a second O-ring 46 disposed in a second groove 48. The second port 40 extends into a flow aperture 50 formed as part of the lower housing 26, and a seal between the second port 40 and the flow aperture 50 is provided by the O-rings 42,46. More specifically, the first O-ring 42 is disposed in the first groove 44 and is in contact with the inner surface of the aperture 50, and the second O-ring 46 is disposed in the second groove 48 and is also in contact with the inner surface of the aperture 50. However, it is within the scope of the invention that other types of seals may be used, other than the O-rings 42,46. The second portion 14b also includes an attachment 52 having a third port 54.
During the assembly of the CPV 10 to the lower housing 26, the flange 24 is inserted into the slot 22. The placement of the flange 24 into the slot 22 ensures that the aperture 34 of the washer 32 is properly aligned with the aperture 38 of the lower housing 26, and provides alignment between the second port 40 and the flow aperture 50. This prevents the CPV 10 from being twisted once the second port 40 is placed in the aperture 50, and therefore prevents the O-rings 42,46 from being stretched or deformed when disposed in the flow aperture 50.
After the flange 24 is inserted into the slot 22 and the second port 40 is positioned in the flow aperture 50, the bolt 36 is inserted through the aperture 34 of the washer 32 and into the aperture 38. The aperture 38 an the bolt 36 are threaded such that the bolt 36 may be tightened. This provides a rigid connection between the CPV 10 and the lower housing 26. As the bolt 36 is tightened, the compressive force generated by the bolt 36 is applied to the washer 32, but the shape of the washer 32 prevents the compressive force from being transferred to the second isolator 30, such that the second isolator 30 is not deformed by any of the compressive force in the washer 32, the bolt 36, or the housing 26. The washer 32 includes an upper flange portion 56 which contacts the bolt 32 and a lower flange portion 58 which contacts the lower housing 26. The second isolator 30 surrounds the washer 32 as shown in
The first bracket 18a does not contact the lower housing 26 because of the first isolator 20, the second bracket 18b does not contact the lower housing 26 because of the second isolator 30 and the washer 32, and the second port 40 does not contact the lower housing 26 because of the O-rings 42,46. Therefore, the CPV 10 is not in contact with the lower housing 26, but is still rigidly connected to the lower housing 26 because of the bolt 36 and the washer 32. This prevents the CPV 10 from contacting the lower housing 26, and therefore prevents any noise generation resulting from vibration in the lower housing 26, and also provides noise isolation to the lower housing 26.
The direction of airflow into the second port 40 is shown is shown by an arrow 60 in
Partially formed as part of the second bracket 18b and the second portion 14b of the housing 12 is a check valve, shown generally at 78. The check valve 78 includes a check valve aperture 80 in fluid communication with a cavity, shown generally at 82 in the second portion 14b of the housing 12. The check valve 78 also includes a valve member 84 surrounded by a seal member 86, where the seal member 86 is selectively in contact with a valve seat 88. When the valve member 84 moves away from the valve seat 88, the cavity 82 is in fluid communication with a check valve cavity, shown generally at 90, through the check valve aperture 80. The check valve 78 also includes a plurality of vents 92 which are in fluid communication with the check valve cavity 90. The direction of the air flow in the flow aperture 50 and the second port 40 determines whether the seal member 86 is in contact with the valve seat 88, and therefore whether the valve 78 is in an open position or a closed position. When the check valve 78 is in an open position, air (and purge vapor) is able to flow from the cavity 82 of the second portion 14b of the housing 12, through the check valve aperture 80, the check valve cavity 90, through the vents 92, and through the second port 40.
Yet another alternate embodiment of the present invention is shown in
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 61/825,649 filed May 21, 2013, U.S. Provisional Application No. 61/825,681 filed May 21, 2013, and U.S. Provisional Application No. 61/825,616 filed May 21, 2013. The disclosures of the above applications are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61825649 | May 2013 | US | |
| 61825681 | May 2013 | US | |
| 61825616 | May 2013 | US |
