Coolant control valve

Abstract

A fluid actuated normally closed coolant control valve. The valve comprises a valve housing, an inlet port, the inlet port configured for fluid communication with either a coolant source or a heat exchanger of a DEF tank; an outlet port configured for fluid communication with the other of the heat exchanger of a DEF tank or the coolant source; a valve chamber, a valve and an actuator configured to actuate the valve. The actuator is a fluid actuated piston. The valve is biased to a closed condition in which the flow of coolant from the inlet port to the outlet port is prevented by the valve. The valve is actuatable to an open condition in which the flow of coolant from the inlet port to the outlet port is permitted, and the valve is withdrawn from the valve chamber, wherein the flow factor for the valve is greater than 1.5.

Claims

1. A fluid actuated coolant control valve comprising: a valve housing; an inlet port defined within the valve housing, the inlet port configured for fluid communication with one of a coolant source or a heat exchanger of a Diesel Emission Fluid (DEF) tank; an outlet port defined within the valve housing, the outlet port configured for fluid communication with the other one of the heat exchanger of the DEF tank or the coolant source; a valve chamber fluidly connecting the inlet port and the outlet port; a movable valve member; an actuator configured to actuate the movable valve member, wherein the actuator comprises a fluid actuated piston coupled to the movable valve member and disposed in a piston chamber within the actuator; a pilot port configured to receive actuation pneumatic fluid to move the fluid actuated piston and the movable valve member coupled thereto; a vent tube, separate from the pilot port, and configured to vent coolant weeping to the piston chamber from the valve chamber to an external environment of the fluid actuated coolant control valve; and a lid configured to close an open end of the valve housing to define the piston chamber, wherein the lid is disposed at least partially external to the valve housing, and wherein the lid comprises the vent tube such that the vent tube is disposed external to the valve housing and an orientation of the vent tube is independent of the valve housing, wherein the movable valve member is biased by a biasing element to a valve closed condition in which a flow of coolant from the inlet port to the outlet port is prevented by the movable valve member in the valve chamber, and wherein the movable valve member is actuatable, when the actuation pneumatic fluid moves the fluid actuated piston coupled to the movable valve member, to a valve open condition in which the flow of coolant from the inlet port to the outlet port is permitted and the movable valve member is withdrawn from the valve chamber.

2. The fluid actuated coolant control valve according to claim 1, wherein the movable valve member has a sealing bead on a lower surface thereof to facilitate sealing the valve chamber in the valve closed condition.

3. The fluid actuated coolant control valve according to claim 1, wherein the vent tube is provided in an upper portion of the lid.

4. The fluid actuated coolant control valve according to claim 1, wherein the biasing element is a coil spring.

5. The fluid actuated coolant control valve according to claim 1, wherein the valve housing is formed from a single piece.

6. The fluid actuated coolant control valve according to claim 1, wherein the lid is disposed partially within the valve housing and partially external to the valve housing.

7. The fluid actuated coolant control valve according to claim 1, wherein the vent tube is connectable to a hose.

8. The fluid actuated coolant control valve according to claim 7, wherein the hose, when connected to the vent tube, is configured to direct weeping coolant away from the fluid actuated coolant control valve.

9. The fluid actuated coolant control valve according to claim 1, wherein the inlet port has a bore size that is different than a bore size of the outlet port.

10. The fluid actuated coolant control valve according to claim 1, wherein the inlet port has a bore size that is larger than a bore size of the outlet port.

11. The fluid actuated coolant control valve according to claim 1, wherein the valve housing is plastic.

12. The fluid actuated coolant control valve according to claim 1, wherein the lid is plastic.

13. The fluid actuated coolant control valve according to claim 1, wherein the fluid actuated piston is plastic.

14. A coolant control system for a vehicle, the coolant control system comprising a fluid actuated coolant control valve, a coolant source, and a heat exchanger of a Diesel Emission Fluid (DEF) tank, wherein the fluid actuated coolant control valve comprises: a valve housing; an inlet port defined within the valve housing, the inlet port configured for fluid communication with one of the coolant source or the heat exchanger of the DEF an outlet port defined within the valve housing, the outlet port configured for fluid communication with the other one of the heat exchanger of the DEF tank or the coolant source; a valve chamber fluidly connecting the inlet port and the outlet port; a movable valve member; an actuator configured to actuate the movable valve member, wherein the actuator comprises a fluid actuated piston coupled to the movable valve member and disposed in a piston chamber within the actuator; a pilot port configured to receive actuation pneumatic fluid to move the fluid actuated piston and the movable valve member coupled thereto; a vent tube, separate from the pilot port, and configured to vent coolant weeping to the piston chamber from the valve chamber to an external environment of the fluid actuated coolant control valve; and a lid configured to close an open end of the valve housing to define the piston chamber, wherein the lid is disposed at least partially external to the valve housing, and wherein the lid comprises the vent tube such that the vent tube is disposed external to the valve housing and an orientation of the vent tube is independent of the valve housing, wherein the movable valve member is biased by a biasing element to a valve closed condition in which a flow of coolant from the inlet port to the outlet port is prevented by the movable valve member in the valve chamber, and wherein the movable valve member is actuatable, when the actuation pneumatic fluid moves the fluid actuated piston coupled to the movable valve member, to a valve open condition in which the flow of coolant from the inlet port to the outlet port is permitted and the movable valve member is withdrawn from the valve chamber.

15. A Diesel Emission Fluid (DEF) system for a diesel-powered vehicle having a coolant control valve, the coolant control valve comprising: a valve housing; an inlet port defined within the valve housing, the inlet port configured for fluid communication with one of a coolant source or a heat exchanger of a DEF tank; an outlet port defined within the valve housing, the outlet port configured for fluid communication with the other one of the heat exchanger of the DEF tank or the coolant source; a valve chamber fluidly connecting the inlet port and the outlet port; a movable valve member; an actuator configured to actuate the movable valve member, wherein the actuator comprises a fluid actuated piston coupled to the movable valve member and disposed in a piston chamber within the actuator; a pilot port configured to receive actuation pneumatic fluid to move the fluid actuated piston and the movable valve member coupled thereto; a vent tube, separate from the pilot port, and configured to vent coolant weeping to the piston chamber from the valve chamber to an external environment of the coolant control valve; and a lid configured to close an open end of the valve housing to define the piston chamber, wherein the lid is disposed at least partially external to the valve housing, and wherein the lid comprises the vent tube such that the vent tube is disposed external to the valve housing and an orientation of the vent tube is independent of the valve housing, wherein the movable valve member is biased by a biasing element to a valve closed condition in which a flow of coolant from the inlet port to the outlet port is prevented by the movable valve member in the valve chamber, and wherein the movable valve member is actuatable, when the actuation pneumatic fluid moves the fluid actuated piston coupled to the movable valve member, to a valve open condition in which the flow of coolant from the inlet port to the outlet port is permitted and the movable valve member is withdrawn from the valve chamber.

16. A vehicle having a Diesel Emission Fluid (DEF) system, the DEF system having a coolant control valve comprising: a valve housing; an inlet port defined within the valve housing, the inlet port configured for fluid communication with one of a coolant source or a heat exchanger of a DEF tank; an outlet port defined within the valve housing, the outlet port configured for fluid communication with the other one of the heat exchanger of the DEF tank or the coolant source; a valve chamber fluidly connecting the inlet port and the outlet port; a movable valve member; an actuator configured to actuate the movable valve member, wherein the actuator comprises a fluid actuated piston coupled to the movable valve member and disposed in a piston chamber within the actuator; a pilot port configured to receive actuation pneumatic fluid to move the fluid actuated piston and the movable valve member coupled thereto; a vent tube, separate from the pilot port, and configured to vent coolant weeping to the piston chamber from the valve chamber to an external environment of the coolant control valve; and a lid configured to close an open end of the valve housing to define the piston chamber, wherein the lid is disposed at least partially external to the valve housing, and wherein the lid comprises the vent tube such that the vent tube is disposed external to the valve housing, and an orientation of the vent tube is independent of the valve housing, wherein the movable valve member is biased by a biasing element to a valve closed condition in which a flow of coolant from the inlet port to the outlet port is prevented by the movable valve member in the valve chamber, and wherein the movable valve member is actuatable, when the actuation pneumatic fluid moves the fluid actuated piston coupled to the movable valve member, to a valve open condition in which the flow of coolant from the inlet port to the outlet port is permitted and the movable valve member is withdrawn from the valve chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is schematic vehicle DEF system including the valve of the present invention;

(3) FIG. 2 is a perspective view of the valve of the present invention;

(4) FIG. 3 is a front elevation of the valve of FIG. 2;

(5) FIG. 4 is an exploded view of the valve of FIG. 2;

(6) FIG. 5 is a cross-sectional view of the valve of FIG. 1 in an open condition;

(7) FIG. 6 is an alternate cross-sectional view of the valve of FIG. 1 in an open condition;

(8) FIG. 7 is a cross-sectional view of an alternate valve in a closed condition; and

(9) FIG. 8 is a cross-sectional view of an alternate valve in a closed condition.

DETAILED DESCRIPTION

(10) A. Diesel Emission Fluid (DEF) System

(11) A Diesel Emission Fluid (DEF) system for a diesel-powered vehicle is shown in FIG. 1. The DEF system 100 is arranged to provide DEF upstream of a SCR catalytic converter 110 using a dosing module 120. The dosing module 120 injects DEF into the exhaust stream to reduce the presence of nitrous oxide. The dosing module 120 is controlled by a dosing control unit 122. A DEF supply module 130 is fluidly connected to a DEF tank 132. The DEF tank includes a level sensor 134 and a temperature sensor 136. DEF will freeze at temperatures below 12 degrees Fahrenheit (−11 degrees Centigrade). To thermally manage the temperature of the DEF, a heat exchanger 138 is provided in the DEF tank 132. The heat exchanger 138 may comprise at least one fluid conduit immersed in the DEF held within the DEF tank 132. Thermal management fluid, or coolant is supplied from a coolant source 140 to the heat exchanger 138 via a fluid pathway 142. Fluid pathway 142 may comprise hoses or associated plumbing and is part of the closed-circuit coolant system. Flow of coolant along fluid pathway 142 and hence to the heat exchanger 138 is regulated by the valve 10. The valve is actuated using pilot pressure from the fluid source (not shown). The valve may be controlled by the dosing control unit 122. In an alternate arrangement, the valve 10 may be positioned downstream of the DEF tank 132, rather than upstream as shown in FIG. 1.

(12) B. Coolant Control Valve

(13) Referring to FIGS. 2 to 6, a valve 10 is shown.

(14) The valve 10 comprises a substantially cylindrical valve housing 20. The valve housing 20 is hollow, having inside wall 27. The valve housing 20 has an actuator portion 22 and a coolant flow portion 24.

(15) The coolant flow portion 24 has an inlet port 30 and an outlet port 32. The inlet port 30 and outlet port 32 are fluidly connected by a valve chamber 36 provided in the coolant flow portion 24 of the valve housing 20.

(16) In an exemplary valve of the present invention, the inlet port 30 has a bore size of approximately 8 mm. The outlet port 32 has a bore size of approximately 7 mm. The valve chamber 36 has a minimum orifice size of approximately 10.5 mm. The limiting flow area is therefore the bore diameter of the outlet port 32. The flow factor, K.sub.v through the valve chamber is 1.62 m.sup.3.h.sup.−1.bar.sup.−0.5. The debris tolerance is also a factor of the limiting flow area, such that the debris tolerance of the exemplary valve is approximately 7 mm.

(17) The skilled person will appreciate that other sized outlet ports may be used. An increase in the limiting flow area will result therefore in increases in the flow factor, K.sub.v through the valve chamber, and likewise an increase in the debris tolerance.

(18) The actuator portion 22 has a pilot port or pilot connector 40. A pilot fitting assembly 42 is housed within the pilot connector 40. The pilot fitting assembly 42 may be a push to fit connector.

(19) The actuator portion 22 of the valve includes a lid 50, a piston 60, a spring 70, a stem 80, a poppet 82 and a stem guide 90.

(20) The lid 50 closes the open end of the valve housing 20 to define a piston chamber 61 therein. An O-ring seal 52 seals the lid 50 to the inside wall 27 of the valve housing 20. The seal 52 is retained within a groove 54 provided on an outer surface of the lid 50. A vent tube 56 is provided in an upper portion of the lid 50. During installation of the valve 10, a rubber hose or similar is connected to the vent tube 56 so as to direct any weep away from the valve 10, and to prevent ingress of water or debris external to the coolant system. A pair of lid pins 26 bear against an upper surface of the lid 50. The lid pins 26 are sized to pass through a pair of apertures 28 provided in the actuator portion 22 of the valve housing 20. The lid 50 is hollow, with an annular shoulder 58 defined on an inside surface in a lower portion of the lid 50.

(21) The piston 60 is mounted for linear reciprocation within actuator portion 22 of the valve housing 20. A large O-ring seal 62 seals an upper portion of the piston 60 to the inside wall 27 of the valve housing 20. A small O-ring seal 64 seals a lower portion of the piston 60 to the inside wall 27 of the valve housing 20. Both seals 62, 64, are retained within respective grooves 66, 68 provided on an outer surface of the piston 60.

(22) The piston 60 is hollow with a spring 70 arranged therein. The spring 70 bears upon an annular shoulder provided on an inner surface of the piston 60. The spring 70 also bears upon the annular shoulder 58 of lid 50.

(23) The stem 80 is coupled at its upper end to the piston 60 by a poppet retainer 72. The stem 80 passes through an aperture at the lower end of the piston 60 and interlocks with the poppet retainer 72. The stem 80 is coupled at its lower end to a poppet 82. The poppet 82 is the valve member. The poppet 82 is sized to move linearly within the valve chamber 36. The poppet 82 is provided with a sealing bead 86 on a lower surface of the poppet 82.

(24) The stem 80 is slidably coupled to a bushing or stem guide 90. The stem guide 90 is coupled to the inside wall 27 of the valve housing 20. An O-ring seal 92 seals the stem guide 90 to the inside wall 27 of the valve housing 20. The seal 92 is retained within a groove 94 provided on an outer surface of the stem guide 90. An O-ring seal 84 seals the stem 80 to stem guide 90. The seal 84 is retained within a stepped bore 96 provided on an inner surface of the stem guide 90, and by a stem O-ring retainer 98.

(25) The valve inlet port 30 is in fluid communication with the coolant source 140. The valve outlet port 32 is in fluid communication with the DEF tank 132. In an alternate arrangement, the valve inlet port 30 may be in fluid communication with the DEF tank 132, downstream and the valve outlet port 32 may be in fluid communication with the coolant source. The stem 80 is configured to displace the poppet 82. The stem guide 90 is configured to guide the valve stem 80 in a substantially linear direction. The poppet 82 is configured to prevent the flow of coolant from the coolant source 140 to the DEF tank 132. For example, the poppet 82 is configured to prevent the flow of coolant when pressed against the valve chamber seat 38 by action of the spring 70. The piston 60 is configured to draw poppet 82 away from the valve chamber seat 38, against the action of the spring 70, so as to allow coolant flow.

(26) An actuation chamber 44 is formed in the valve housing 20 between the large O-ring seal 62 of the piston 60 and the small O-ring seal 64 of the piston 60. The actuation chamber 44 is in fluid communication to a source of fluid pressure via the pilot fitting assembly 42 housed within the pilot connector 40. The pilot fitting assembly 42 is a push to fit connection arrangement.

(27) The valve housing 20, lid 50 and piston 60 may be made from plastic. The valve housing 20 may be injection molded. The poppet 82 may be made of rubber, over-molded to the stem 80. The stem guide 90 may be made of brass. The stem guide 90 may be machined.

(28) C. Valve Conditions

(29) The valve 10 is a 2/2-way valve, having two ports and two valve conditions—open and closed.

(30) The valve 10 is a normally closed valve. The spring 70 bears upon an annular shoulder provided on an inner surface of the piston 60 and the annular shoulder 58 of lid 50. Because the lid 50 is restricted from moving by the lid pins 26, the piston 60 is forced downwards in the piston chamber 61, which in turn forces stem 80 and poppet 82 downwards until the sealing bead 86 of poppet 82 engages with valve chamber seat 38 to provide a fluid tight seal in the valve 10 closed condition.

(31) The spring 70 maintains the valve 10 in the closed condition until the piston force overcomes the spring force. Without pressure applied, the valve 10 does not allow the flow of coolant, with pressure applied the valve 10 will open and allow the flow of coolant.

(32) The valve 10 is actuated to an open condition by pneumatic actuation. The source of fluid pressure creates a pilot pressure within actuation chamber 44 which drives piston 60 upwards in the piston chamber 61 against the spring 70 force. This draws poppet 82 away from the valve chamber seat 38 as best shown in FIGS. 5 and 6. When the valve 10 is fully open, the poppet 82 is clear of the inlet port 30 and valve chamber 36 and does not interfere with the flow of coolant. This also ensures that the debris tolerance of the valve is a factor of the smallest bore size of the inlet port 30, outlet port 32 or valve chamber 36 and not limited by the poppet 82.

(33) The source of fluid pressure may alternatively be turbo boost air pressure, engine lubricating oil pressure or the pressurized fluid of the coolant system.

(34) The pilot pressure necessary to actuate the piston 60 may be approximately 40 psi.

(35) In use, the O-ring seal 84 may permit a very small quantity of coolant to pass between the stem 80 and the stem guide 90. This is known as weep. By locating the vent tube 56 in the lid 50, at the top of the valve housing 20, the valve 10 benefits from the piston chamber 61 acting as a weep reservoir. Over the lifetime of the valve 10, the valve 10 will not exhibit any coolant leakage due to weep.

(36) According to another embodiment of the present invention there is a valve 210 as depicted in FIG. 7.

(37) FIG. 7 shows a valve 210 according to another embodiment. Similar reference numerals have been used for features similar to those described in relation to valve 10, pre-fixed with a “2” to indicate those features as being in relation to valve 210. Only the main differences to valve 10 shall be described in detail.

(38) Valve 210 has a coolant flow portion 224 with an inlet port 230 and an outlet port 232. The inlet port 230 is provided with an inlet port fitting 231. The outlet port 232 is provided with an outlet port fitting 233.

(39) The valve 210 is shown in a closed condition, with the sealing bead 286 of poppet 282 engaged with valve chamber seat 238 to provide a fluid tight seal and prevent flow of coolant from the inlet port 230 to the outlet port 232.

(40) Further embodiments of the coolant control valve are also envisaged.

(41) FIG. 8 shows a valve 310 according to another embodiment. Similar reference numerals have been used for features similar to those described in relation to valve 10, pre-fixed with a “3” to indicate those features as being in relation to valve 310. Only the main differences to valve 10 shall be described in detail.

(42) Valve 310 has a coolant flow portion 324 with an inlet port 330 and an outlet port 332. The inlet port 330 is provided with an inlet port fitting 331. The outlet port 332 is provided with an outlet port fitting 333.

(43) The valve 310 is shown in a closed condition, with the sealing bead 386 of poppet 382 engaged with valve chamber seat 338 to provide a fluid tight seal and prevent flow of coolant from the inlet port 330 to the outlet port 332.

(44) The vent tube 356 is provided in the valve housing 320, between the actuator portion 322 and the coolant flow portion 324. The vent tube 356 is in fluid communication with the piston chamber 361. During installation of the valve 310, a rubber hose 357 or similar is connected to the vent tube 356 so as to direct any weep away from the valve 310, and to prevent ingress of water or debris external to the coolant system.

(45) In the valve 310 closed condition, the piston 360 does not reach the end of the piston chamber 361, such that an inlet to the vent tube 356 is continually exposed.