REED VALVE

Abstract

A reed valve assembly includes a retainer, one or more reed cages, and a plurality of reed petals. The retainer includes a flange, first and second openings, and a center retainer separating the first and second openings. The reed cages are configured to be advanced from the bottom of the retainer and partially through the first and second openings of the retainer and have at least two inner openings generally facing each other and at least two outer openings generally facing away from each other. The inner and outer openings are configured to be fluidly coupled to the first and second openings of the retainer. The reed petals are configured to extend over the inner openings and the outer openings. The center retainer and reed cages include one or more reed cage grooves and reed cage flanges configured secure the reed cages to the retainer.

Claims

1. A reed valve assembly comprising: a retainer including a flange, a first and a second openings, and a center retainer separating the first and second openings; one or more reed cages configured to be advanced from the bottom of the retainer and partially through the first and second openings of the retainer, the one or more reed cages having at least two inner openings generally facing each other and at least two outer openings generally facing away from each other, wherein the inner openings and the outer openings are configured to be fluidly coupled to the first and second openings of the retainer; a plurality of reed petals configured to extend over the two or more inner openings and the two or more outer openings; wherein the center retainer and the one or more reed cages include one or more reed cage grooves and reed cage flanges configured secure the one or more reed cages to the retainer.

2. The reed valve assembly of claim 1, wherein the center retainer includes at least one of the reed cage grooves and the one or more reed cages includes at least one of the reed cage flanges.

3. The reed valve assembly of claim 2, wherein the plurality of reed petals includes a plurality of outer reed petals configured to extend over the two or more outer openings and a plurality of inner reed petals configured to extend over the two or more inner openings, each of the plurality of reed petals having at least one hole.

4. The reed valve assembly of claim 3, wherein the retainer and the one or more reed cages include a plurality of outer petal tabs and a plurality of petal slots, the outer petal tabs configured to extend through the holes of the outer reed petals and into the petal slots.

5. The reed valve assembly of claim 4, wherein the retainer includes a plurality of petal stops defining the petal slots and the reed cage include the outer petal tabs.

6. The reed valve assembly of claim 3, wherein the center retainer and the one or more reed cages include a plurality of inner petal tabs and a plurality of petal grooves, the inner petal tabs configured to extend through the holes of the inner reed petals and into the petal grooves.

7. The reed valve assembly of claim 6, wherein the center retainer includes the petal grooves and the reed cage include the inner petal tabs.

8. The reed valve assembly of claim 3, wherein the retainer and the one or more reed cages include a plurality of outer petal tabs, a plurality of inner petal tabs, a plurality of petal slots, and a plurality of petal grooves, the outer petal tabs configured to extend through the holes of the outer reed petals and into the petal slots and the inner petal tabs configured to extend through the holes of the inner reed petals and into the petal grooves.

9. The reed valve assembly of claim 8, wherein the plurality of petal grooves are disposed above the reed cage grooves and wherein the plurality of inner petal tabs are disposed above the reed cage flanges.

10. The reed valve assembly of claim 1, wherein the one or more reed cages have a W cross-sectional shape.

11. The reed valve assembly of claim 1, wherein the one or more reed cages includes a single reed cage.

12. The reed valve assembly of claim 1, wherein the single reed cage has a W cross-sectional shape.

13. The reed valve assembly of claim 1, wherein the one or more reed cages includes a first and a second reed cage.

14. The reed valve assembly of claim 1, wherein the first and second reed cages collectively have a W cross-sectional shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features and advantages will be better understood by reading the following detailed description, taken together with the drawings, wherein:

[0010] FIG. 1 is a cross-sectional view of a prior art reed valve;

[0011] FIG. 2 shows an assembled reed valve assembly consistent with at least one example of the present disclosure;

[0012] FIG. 3 shows the reed valve assembly of FIG. 2 without the reed petals;

[0013] FIG. 4 shows an exploded view of the reed valve assembly of FIG. 2 without the reed petals;

[0014] FIG. 5 is a cross-sectional view of the reed valve assembly of FIG. 2 without the reed petals;

[0015] FIG. 6 is a side view of one example a reed petal consistent with the present disclosure;

[0016] FIG. 7 is a perspective view of one example a retainer consistent with the present disclosure;

[0017] FIG. 8 is a first cross-sectional view of the retainer of FIG. 7;

[0018] FIG. 9 is a first cross-sectional view of the retainer of FIG. 7;

[0019] FIG. 10 is a perspective view of one example a reed cage consistent with the present disclosure;

[0020] FIG. 11 is another perspective view of the reed cage of FIG. 10;

[0021] FIG. 12 is a side view of another example a reed cage consistent with the present disclosure;

[0022] FIG. 13 is a bottom view of the reed cage consistent of FIG. 12;

[0023] FIG. 14 is an exploded view of another example of a reed valve assembly including an air guide consistent with the present disclosure;

[0024] FIG. 15 is an assembled top view of the reed valve assembly of FIG. 14;

[0025] FIG. 16 is an assembled bottom view of the reed valve assembly of FIG. 14;

[0026] FIG. 17 is an assembled bottom view of the reed valve assembly of FIG. 14;

[0027] FIG. 18 is a top view of the air guide of FIG. 14; and

[0028] FIG. 19 is a bottom view of the air guide of FIG. 14.

DETAILED DESCRIPTION

[0029] By way of a general overview, the present disclosure is generally directed to an improved reed valve. The improved reed valve may include a retainer, one or more reed cages, and a plurality of reed petals. The retainer may include a flange, a first and a second openings, and a center retainer separating the first and second openings. The reed cages may be configured to be advanced from the bottom of the retainer and partially through the first and second openings of the retainer. The reed cages may have at least two inner openings generally facing each other and at least two outer openings generally facing away from each other. The inner openings and the outer openings may be configured to be fluidly coupled to the first and second openings of the retainer. The plurality of reed petals may be configured to extend over the two or more inner openings and the two or more outer openings. The center retainer and the one or more reed cages may include one or more reed cage grooves and reed cage flanges configured secure the one or more reed cages to the retainer. The improved reed cage may eliminate the need for separate inserts to secure the reed cage and reed petals to the retainer. The improved reed cage may also be independently interlockable, e.g., without the use of tools.

[0030] FIGS. 2-5 show one example of an improved reed valve assembly 20 consistent with the present disclosure. In particular, FIG. 2 shows an assembled reed valve assembly 20 with the reed valves, FIG. 3 shows the reed valve assembly 20 without the reed petals, FIG. 4 shows an exploded view of the reed valve assembly 20 without the reed petals, and FIG. 5 is a cross-sectional view of the reed valve assembly 20 without the reed petals.

[0031] With reference to FIG. 2, the reed valve assembly 20 includes a retainer 22 (also known as a manifold), one or more reed cages 24, and a plurality of resiliently deformable reed petals 26a, 26b (collectively referred to as reed petals 26). In the illustrated example, two reed cages 24 are shown which collectively form a generally W-shaped cross-section having two or more outer openings 28a (e.g., as shown in FIG. 3) on the outside 27 of the W (selectively covered/sealed by one or more outer reed valves 26a) and two or more inner openings 28b on the inside 29 of the W (selectively covered/sealed by one or more inner reed petals 26b). The inner and outer openings 28a, 28b may be collectively referred to as openings 28. As may be appreciated, air may flow through the bottom 30 of the retainer 22 and through the openings 28 in the reed cage 24 when the reed petals 26 are in the unseated (e.g., open) position. When the reed petals 26 are in the seated (e.g., closed) position, the reed valves 26 may seal against the reed cage 24 such that air generally cannot pass through the openings 28 of the reed valve assembly 10. Of course, the reed valve assembly 10 can be designed to allow air to still pass through the reed valve assembly 10 when the reed petals 26 are in the seated position.

[0032] In the illustrated example, the reed cage 24 includes two outer openings 28a on the opposing sides of the outside 27 of the W and two inner openings 28b on opposing sides of the inside of the W. Of course, it should be appreciated that the inner and/or outer sides 27, 29 of the reed cage 24 may have less than and/or two or greater than two openings 28a, 28b. In addition (or alternatively), the reed cage 24 may include a single reed cage 24 (as described herein) which may form a generally W-shaped cross-section. Moreover, any of the reed cages 24 described herein may have other cross-sectional shapes (either singularly or in combination).

[0033] Turning now to FIG. 6, one example of a reed petal 26 is generally illustrated. The illustrated reed petal 26 is configured to cover/seal two openings 28; however, it should be appreciated that the reed petal 26 may take any other form known to those skilled in the art. The use of a single inner and/or outer reed petal 26a, 26b to cover/seal multiple openings 28 reduces the number of parts that need to be assembled. Alternatively, one or more of the openings 28 may be covered/sealed by individual reed petals 26 (e.g., each opening 28 may be covered/sealed by a different reed petal 26). In any event, the reed petal 26 includes a flexible body 32 configured to extend across and cover/seal the opening 28. The flexible body 32 may be made from carbon fiber, plastic, metal, and/or the like. The reed petal 26 (e.g., the body 32) may include one more holes 34 configured to receive outer petal tabs 1002 formed in the reed cage 24 and/or retainer 22 as described herein. The holes 34 may be disposed proximate the bottom (base) 36 of the reed valve 26.

[0034] Turning now to FIGS. 7-9, one example of a retainer 22 consistent with the present disclosure is generally illustrated. In particular, FIG. 7 is a perspective view of the retainer 22 and FIGS. 8-9 are cross-sectional views of the retainer 22.

[0035] The retainer 22 includes a flange 70, two or more openings 72, and optionally one or more reed stops 74. The flange 70 may define a perimeter of the retainer and may include one or more bolt/screw holes 76 for securing the retainer 22 (and the reed valve assembly 20) to an intake system or other engine component. The reed stops 74 may be configured to limit the opening movement of the reed petals 26 (e.g., the outer reed petals 26a) and keep the reed petals 26 from pivoting too far. The reed stops 74 may extend at least partially perpendicularly from the flange 70 and may be slightly arced to conform to the natural bending of the reed petals 26 as they open.

[0036] The retainer 22 may include one or more petal slots 78 configured to receive one or more outer petal tabs 1002 (see FIGS. 10-11) associated with the reed cage 24 as the reed cage 24 is advanced into the openings 72 through the bottom 30 of the retainer 22. The petal slots 78 may extend through the retainer 22 (e.g., through the reed stop 74) and/or partially into the retainer 22 (e.g., partially through the reed stop 74). The outer petal tabs 1002 may be configured to deflect and/or resilient deform as reed cage 24 is advanced into the retainer 22 and lock into the petal slots 78 to secure the reed cage 24 to the retainer 22. Similar to U.S. Pat. No. 6,880,577, the holes 34 of the outer reed petals 26a may also receive the outer petal tabs 1002 to secure the outer reed petals 26a between the retainer 22 and the reed cage 24 as the reed cage 24 and outer reed petals 26a are advanced into the retainer 22. It should be appreciated; however, that the arrangement of the petal slots 78 and outer petal tabs 1002 may be reversed, i.e., the reed cage 24 may include the petal slots 78 and the retainer 22 may include the outer petal tabs 1002.

[0037] As noted above, the openings 72 may be configured to receive the reed cage 24 and reed petals 26. As explained herein, the reed cage 24 may be a single reed cage (e.g., having a W cross-section) or two or more reed cages (e.g., forming a W cross-section). In any event, the reed cage 24 is inserted through the bottom 30 of the retainer 22 and at least partially through the openings 72. The two or more openings 72 may be at least partially separated by one or more center retainers 80. The center retainer 80 may be formed integrally with the retainer 22. For example, the center retainer 80 may be formed along with the rest of the retainer 22 during a single molding process. Alternatively, the center retainer 80 may be formed separately from the rest of the retainer 22. In at least one example, the center retainer 80 may be secured (e.g., using an adhesive and/or welding (such as ultrasonic welding or the like)) and/or secured using one or more fasteners (e.g., but not limited to, tabs, detents, snaps, interference/frictional connections, mechanical interference connection, and/or the like).

[0038] In the illustrated example, the center retainer 80 extends from one side 82a of the flange 70 to an opposite side 82b of the flange 70. The center retainer 80 may be configured to form two openings 72 having approximately the same size and/or dimensions. In at least one example, a portion of the center retainer 80 extends above the top surface 84 of the flange 70. Alternatively (or in addition), a portion of the center retainer 80 may be disposed above the bottom 30 of the retainer 22 (e.g., above the bottom of the flange 70). As can be seen, e.g., in FIG. 5, having the bottom of the center retainer 80 above the bottom 30 of the retainer 22 allows a single reed cage 24 (see, e.g., FIGS. 12-13) to be advanced through the bottom 30 and extend through the openings 72 of the retainer 22 while being flush or recesses relative to the bottom 30 of the retainer 22. With reference to FIGS. 12-13, the single piece reed cage 24 may include one or more interconnects 1200 that connect two or more portions of the reed cage 24 (e.g., two reed cages 24 generally illustrated in FIGS. 10-11) into a single piece reed cage 24 as shown in FIGS. 12-13. If the center retainer 80 extended below the bottom 30 of the retainer 22, then a single piece reed cage 24 would also have be disposed below the bottom 30 of the retainer 22. For example, the interconnects 1200 would have to be disposed below the bottom 30 of the retainer 22.

[0039] With reference to FIGS. 5 and 8-12, the center retainer 80 includes one or more reed cage grooves, channels, slots, and/or recesses 86 and/or one or more petal grooves, channels, slots, and/or recesses 88 configured to receive one or more reed cage flange, tabs, protrusions, and/or detents 1004 and inner petal tabs 1102 of the reed cage 24, respectively. In the illustrated example, the center retainer 80 includes a single reed cage groove 86 and a single petal groove 88 extending substantially along the entire length of the center retainer 80; however, it should be appreciated that the center retainer 80 may include one or more reed cage grooves 86 and/or and one or more petal grooves 88 extending along only a portion of the center retainer 80. The petal groove 88 may be disposed above the reed cage groove 86. In at least one example, at least a portion of the petal groove 88 may be disposed flush and/or above the upper surface 87 of the retainer 22 (e.g., flush and/or above the upper surface of the flange 70) and at least a portion of the reed cage groove 86 may be disposed flush and/or below the upper surface 87 of the retainer 22 and/or flush or above the bottom surface 30 of the retainer 22 (e.g., flush and/or below the upper surface of the flange 70 and flush or above the bottom surface of the flange 70). The reed cage 24 may optionally include a lip 1006 extending outwardly beyond the body 1008 of the reed cage 24 that is configured to be received at least partially through the openings 72 of the retainer 22. The lip 1008 may be configured to engage a portion of the opening 72 (e.g., a shoulder or the like 75) and generally prevent over insertion of the reed cage 24 relative to the retainer 22.

[0040] The reed cage groove 86 may be configured to receive the reed cage flange 1004 of the reed cage 24 (e.g., while being advanced from the bottom 30 of the retainer 22) and generally lock (e.g., fix) the position of the reed cage 24 relative to the retainer 22. The inner petal tabs 1102 of the reed cage 24 may extend through the holes 34 of the inner reed petals 26b and extend into the petal groove 88 (e.g., while being advanced from the bottom 30 of the retainer 22) to secure the inner petals 26b. In some examples, the reed cage groove 86 and the petal groove 88 (along with the reed cage flange 1004 and the inner petal tabs 1102) may work in combination to generally lock (e.g., fix) the position of the reed cage 24 relative to the retainer 22. In any event, the reed cage 24 (along with petals 26) may be secured to the retainer 22 in a bottom to top arrangement without the use of additional tools and/or means. It should be appreciated that the arrangement of the reed cage groove 86 and the reed cage flange 1004 and/or the arrangement of the petal groove 88 and the reed cage flange 1004 may be reversed. Put another way, the reed cage groove 86 may be formed in the reed cage 24 and the reed cage flange 1004 may be formed in the center retainer 80. Similarly, the petal groove 88 may be formed in the reed cage 24 and the reed cage flange 1004 may be formed in the center retainer 80. In some examples, the reed cage flange 1004 may extend outwardly and downwardly and may be configured to be resiliently bent and/or deformed while the reed cage 24 is being advanced through the openings 72 of the retainer 22, thereby allowing the reed cage flange 1004 to snap back into the reed cage groove 86. Once the reed cage flange 1004 is generally received in the reed cage groove 86, the reed cage 24 cannot be removed without bending/deforming the reed cage flange 1004 generally inwardly and away from the reed cage groove 86.

[0041] Turning now to FIGS. 14-19, the reed valve assembly 20 may optionally include one or more air guides 1400. In particular, FIG. 14 is an exploded view of the reed valve assembly 20 with the air guide 1400, FIG. 15 is an assembled top view of the reed valve assembly 20 with the air guide 1400, FIGS. 16 and 17 are an assembled bottom view of the reed valve assembly 20 with the air guide 1400, FIG. 18 is a top view of the air guide 1400, and FIG. 19 is a bottom view of the air guide 1400. The air guide 1400 may be advance at least partially through the bottom 30 of the retainer 22 to aid in securing the reed cage 24 (and also the reed petals 26) to the retainer 22. The air guide 1400 may include a body portion 1402 configured to extend at least partially within the passageway of the reed cage 24. The body portion 1402 may be configured to aid in air flow through the reed valve assemble 20. The air guide 1400 may also include one or more locking projections 1406. The locking projections 1406 may be configured to aid in securing the reed cage 24 to the retainer 22. For example, the locking projections 1406 may include a V-shaped snap groove 1408 that may engage with the reed cage 24 and/or the retainer 22 (e.g., the center retainer 70). In the illustrated example, the air guide 1400 includes a first and a second locking projection 1406 ending outwardly from opposites sides 1410a, 1410b of the air guide 1400.

[0042] As may be appreciated, one or more of the center retainers 80 consistent with the present disclosure allows for the elimination of the separate inserts 7 (e.g., FIG. 1) used to hold the inner reed petals and/or reed cages in prior designs. Elimination of the separate inserts 7 may reduce the number of components that are necessary to assemble a reed valve assembly 20. In addition, elimination of the separate inserts 7 may allow for all the components to assembled in a front-back direction (e.g., stack) and eliminates the need to install parts from the side. The center retainer 80 provides for retention of the reed cages 24 using a tool-less assembly, for example, in only a front-back direction, not a combination of front-back and left-right. The reed cage design of the present disclosure allows for the parting line to be split left/right vs top/bottom, thereby facilitating overmolding and allowing for detailed tip geometry not previously possible. An optional air guide blocks the cage-manifold snap from releasing.

[0043] While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the claims.