Check Valve With Internal Longitudinally Displaceable Sleeve Valve

The present invention relates to an active check valve for placement between an air pump and a manifold to prevent back flow of compressed gases from the manifold to the pump, and in particular, to an electrically driven flow control valve assembly for regulating the flow of a fluid, such as air, between an inlet and an outlet via a slide valve driven by an electromagnetically actuated motor, such as a solenoid.

Electromagnetic solenoid type flow control valves are generally known in the art. Conventional solenoid actuated valve devices have been proposed which use a linear motor of the movable coil type and a valve means. The linear motor includes a core, a bobbin slidably mounted on the core, a solenoid coil wound on the bobbin, permanent magnets with the magnetic flux of each magnet intersecting the winding of the solenoid coil at right angles and a yoke or body forming a magnetic circuit with the core. The valve means in general includes a sliding valve member which is slidable with the bobbin on the core in response to the electric current going through the solenoid coil to thereby proportionally control openings formed in the core between an inlet port and an outlet port.

In such conventional solenoid actuated valve devices, when the solenoid coil receives no electric current, the sliding valve member is always biased by means of a pair of springs in a direction so that the sliding valve member will completely open or completely close the openings to thereby interrupt or fully establish the fluid communication between the inlet and outlet ports. Therefore, in order to cause the sliding valve to move to the full extent in the opposite direction from which it is normally biased, a large magnetic or exciting force must be generated by the application of electric current to the solenoid coil.

In a known electromagnetic solenoid type flow control valve, the valve includes a valve member slidable along the outer surface of the core to cover the valve ports. When the solenoid coil is energized, the bobbin and the valve member are displaced against the influence of the springs to open the valve ports and to cover the valve ports.

In a known solenoid actuated valve device, a core is supported by a body and a cover member for axial movement relative thereto. While the solenoid coil receives no electric current, the bobbin, having a valve portion, is maintained in its original position, therefore the air at the inlet port is transmitted to the outlet port by means of the first opening. When the solenoid coil receives a positive electric current, the bobbin is moved to the right in proportion to the strength of the electric current whereby the valve portion proportionally opens the second opening means to thereby increase the fluid communication between the inlet and outlet ports. When the solenoid coil receives a negative electric current, the bobbin is moved to the left in proportion to the strength of the electric current whereby the valve portion proportionally closes the first opening to thereby restrict the fluid communication between the inlet and outlet ports, respectively.

A known slide valve is driven along a hollow core by a linear motor to control the degree of communication between an inlet and an outlet port through the hollow interior of the iron core. A bobbin-type slide valve is slidably disposed on the iron core and fixedly secured to a bobbin holder. The bobbin holder is biased by means of two springs. An electromagnetic coil is wound on the slide valve through the intermediary of the bobbin holder and a pair of permanent magnets are provided within the valve assembly and arranged in such a manner that the magnet flux produced thereby passes through the windings of the electromagnetic coil at a right angle.

An engine mixture control system is known for controlling primary and secondary air-fuel mixtures. Around the outer cylindrical surface of the support pipe there is fitted a slide sleeve of a generally hollow cylindrical form. The inner cylindrical surface of the slide sleeve closely conforms to the outer cylindrical surface of the support pipe, so that as the slide sleeve moves upwards and downwards with respect to the support pipe, the upper edge of the slide sleeve moves across the valve port and thus regulates the effective open area of the valve port.

In a known manually controllable automobile governor, a valve element is mounted on a body member with an opening extending through the body portion of the valve element. The body member closely fits within the passage in slidable relation therein to substantially prevent liquid flow between the passage wall and the body portion. An opening extends transversely through the valve element and is of a size sufficient to be able to carry a flow of liquid fuel equal to the flow capabilities of the opening in the valve element and the inlet passage of the body member. A compression spring engages the end of the valve element to normally close the transverse opening of the valve member. A coil or solenoid is wound circumferentially around and engaged with the body member. When the solenoid is energized, the valve element moves in opposition to the spring thereby opening the passage to allow greater fuel flow than is possible through the restricted opening.

While each of these previously known valve configurations appears to be capable of adequately performing its intended function, the configurations disclosed are overly complex and difficult to manufacture in a cost-effective manner. It is therefore desirable in the present invention to provide a simplified electromagnetically driven flow control valve assembly that is easier to manufacture in a cost-effective manner. It is further desirable to provide a simple construction valve to check flow when the valve assembly is in the closed condition.

The present invention relates to an active check valve for placement between an air pump and an exhaust manifold. The primary function of the valve is to prevent unacceptable amounts of back flow of exhaust gases from the exhaust manifold to the pump. The valve is normally closed and substantially prevents flow in the closed condition. The valve will open in response to an electric signal. An electric signal to the air pump for delivering positive air flow is only provided when the valve has opened. Preferably, once opened, the valve is switched to a lower energy consumption hold open state to reduce maximum current flow requirements when starting the air pump.

The valve includes an outer housing adapted to receive a solenoid adjacent one end thereof. An internal wall or tube extends longitudinally along the centerline of the housing. In the first embodiment, the internal tubing has radially opening longitudinally extending apertures through a sidewall thereof. In a second embodiment, radially opening longitudinally extending apertures are formed in an intermediate wall in the housing at an end opposite from the solenoid. A movable internal closure sleeve slidably engages within the wall or tube and is biased into a closed position blocking off the radially opening apertures by a spring. Energizing the solenoid causes the sleeve to move within the housing against the urgings of the spring to open the outlet apertures in the housing to allow fluid flow therethrough.

In the first embodiment of the present invention, a check valve preferably includes a housing with an inlet and an outlet. An elongated wall or tube extends longitudinally within the housing from the inlet and communicates with fluid flow from the inlet. The tube has an end cap opposite from the inlet closing the tube. The tube also includes at least one longitudinally extending radially opening aperture in a sidewall of the tube adjacent the end cap. An inner sleeve is slidably received within the tube for longitudinal movement therein between a first position closing the longitudinally extending, radially opening aperture, thereby blocking fluid flow between the inlet and outlet of the housing and a second position opening the longitudinally extending, radially opening aperture to fluid flow between the inlet and outlet of the housing. Biasing means normally urges the sleeve toward one of the first and second positions. Preferably, the sleeve is urged toward the first position to prevent fluid flow between the inlet and outlet of the housing. Actuating means drives the sleeve toward the other of the first and second positions against the urgings of the biasing means.

In a second or preferred embodiment of the present invention, a check valve is provided for selectively preventing and allowing flow of fluid from an inlet to an outlet. The check valve includes a housing having an inlet and an outlet, and at least one intermediate longitudinally extending aperture is disposed between the inlet and the outlet. An elongated longitudinally extending passage is defined by at least one wall extending parallel to a longitudinal axis within the housing. The elongated passage extends within the housing from the inlet and communicates with the inlet. An elongated inner sleeve is slidably received within the passage for longitudinal movement therein between a first position closing the at least one aperture to fluid flow between the inlet and the outlet, and a second position opening the aperture to fluid flow between the inlet and the outlet. Biasing means normally urges the sleeve toward one of the first and second positions. Actuating means drives the sleeve toward the other of the first and second positions against the urging of the biasing means. In this, the preferred embodiment, the intermediate aperture and valve seat is formed with a high angle of attack valve to reduce the effect of pressure and vacuum, thereby eliminating the need for bleed and passive valves commonly required in current systems. At least one outlet port is formed in a longitudinally extending wall connected to the housing disposed between the housing inlet and outlet. A valve seat connected to the longitudinally slidable sleeve engages the housing seat surrounding the outlet port to seal the outlet port eliminating any fluid flow therethrough when in the closed position. When the sleeve moves to draw the valve seat away from the housing seat, fluid flow is permitted through the outlet port between the housing inlet and outlet. Preferably, the sleeve moves in a direction toward the open position opposite from the direction of fluid flow between the inlet and outlet of the housing.

The present invention also addresses the concern of exhaust manifold cross talk on V6 and V8 engines that can cause excessive heating of current system components. In the preferred embodiment of the present invention, the fluid flow is split to separate outlets through two separate outlet ports in the housing. This effectively acts as two active check valves with one common inlet port, thereby reducing total system weight, amperage draw, added wiring and plumbing. This preferred configuration as disclosed in the second embodiment eliminates fluid blow by around the check valve that occurs in the first embodiment and which may be undesirable in certain applications.

Other objects, advantages and applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 is a cross-sectional view of a check valve according to the first embodiment of the present invention shown in the closed position;

FIG. 2 is a partial cross-sectional view of the check valve according to the first embodiment of the present invention shown with the valve in an open condition;

FIG. 3 is a cross-sectional view of a preferred second embodiment of a check valve according to the present invention shown in the closed position;

FIG. 4 is a cross-sectional view of the check valve according to the preferred second embodiment of the present invention shown with the valve in an open condition;

FIG. 5 is a side view of the check valve according to the second embodiment of the present invention as illustrated in FIGS. 3 and 4;

FIG. 6 is a side view of the check valve according to the second embodiment of the present invention with an alternative outlet connector configuration;

FIG. 7 is a side view of the check valve according to the second embodiment of the present invention with an alternative end effect for the outlet connectors;

FIG. 8 is a side view of the check valve according to the first embodiment of the present invention as illustrated in FIGS. 1 and 2 with a straight flow through configuration;

FIG. 9 is a side view of the check valve according to the first embodiment of the present invention with an alternative outlet connector configuration providing a 90.degree. flow path;

FIG. 10 is a side view of the check valve according to the first embodiment of the present invention with an alternative configuration for the outlet connector providing a 135.degree. flow path;

FIG. 11 is a side view of the check valve according to the first embodiment of the present invention with an alternative end effect for the outlet connector;

FIG. 12 is a side view of the check valve according to the first embodiment of the present invention with another alternative end effect configuration for the outlet connector;

FIG. 13 is a side view of the check valve according to the first embodiment of the present invention with an alternative end effect for the inlet connector and an alternative end effect for the outlet connector;

FIG. 14 is a side elevational view of the check valve according to the second embodiment of the present invention with an alternative end effect configuration for the inlet connector and an alternative end effect configuration for the outlet connector;

FIG. 15 is a cross-sectional view of the check valve according to the second embodiment of the present invention installed directly to a manifold; and

FIG. 16 is an end view of the check valve according to the second embodiment of the present invention taken as illustrated in FIG. 15 without illustrating the manifold.

A cross-sectional view of a check valve 10 according to the first embodiment of the present invention is shown in the closed position in FIG. 1. The check valve 10 preferably includes an elongated longitudinally extending wall or tube 12 having a first end 14 with an inlet connector 16 attached thereto or formed thereon. The elongated tube 12 preferably includes a second end 18 having an end cap 20 closing the elongated tube 12 opposite from the inlet connector 16. The elongated tube 12 also includes at least one longitudinally extending radially opening aperture 22 in a sidewall 24 of the elongated tube adjacent the end cap 20. The inner sidewall 24 of the elongated tube 12 defining a sleeve seat for the check valve 10.

An inner sleeve 26 is slidably received within the elongated tube for longitudinal movement therein from a first position closing the at least one aperture 22, as illustrated in FIG. 1, to prevent fluid flow between the inlet and the apertures 22, and a second position opening the at least one aperture 22 to fluid flow between the inlet and the apertures 22, as illustrated in FIG. 2. The inner sleeve 26 defining a sleeve valve. The first position of the inner sleeve 26, as illustrated in FIG. 1, is defined by the inner sleeve 26 abutting against the end cap 20 as shown at 28, also defining a first end limit of movement of the inner sleeve 26. The inner sleeve 26 is movable to a second end limit of movement within the elongated tube 12, as shown in FIG. 2, to abut against the inlet connector 16 as shown at 30. When in the first position, the inner sleeve or sleeve valve covers and closes fluid communication between the inlet 16 and the at least one longitudinally extending, radially opening aperture 22. When in the second position, the inner sleeve allows fluid communication from the inlet 16 through the inner sleeve 26 and out of the at least one longitudinally extending, radially opening aperture 22, as shown in FIG. 2.

Biasing means 32 normally urges the inner sleeve 26 toward one of the first and second positions. The biasing means 32 may include a spring 34 having a first end supported by a first spring seat 36 formed on or connected to the inlet connector 16. A second spring seat 38 is formed on or connected to the inner sleeve 26. The spring 34 is disposed between the first and second spring seats, 36 and 38 respectively, to bias the inner sleeve 26 toward one of the first and second end limits of movement or positions, 28 and 30 respectively. As illustrated in FIG. 1, the inner sleeve 26 is biased toward the first end limit of movement 28 so that the valve 10 is in a closed position normally.

A housing 40 is connected to an external surface of the elongated tube 12 to enclose the at least one longitudinally extending, radially opening aperture 22 and to define a buffer chamber 42 disposed about the aperture 22. An outlet connector 44 is formed on or connected to the housing 40. The inlet connector 16 is particularly adapted to receive flow from an air pump for passage of compressed air through the elongated tube 12, inner sleeve 26 and passage out of aperture 22 when said inner sleeve is in the second end limit of movement 30, as illustrated in FIG. 2, for passage into the buffer chamber 42 defined by housing 40 for subsequent passage out of the outlet connector 44 to a manifold assembly. The housing 40 may include a radially extending base wall 46. The base wall 46 defining a stop or collar for limiting longitudinal movement of coil 48 in one direction. The coil 48 being disposed around the external surface of the elongated tube 12. A collar 50 being disposed on an opposite end of the coil 48 to prevent longitudinal movement of the coil along the elongated tube in the direction opposite from the base wall 46. The collar 50 acting as a coil retainer clip.

Preferably, the elongated tube 12 or sleeve seat, end cap 20, including the first end limit of movement seat 28, and housing 40, including the radially extending base wall 46 are constructed of 304 stainless steel. The sleeve valve or inner sleeve 26 slidably received within the elongated tube 12 is preferably constructed of coated 1015 steel. The coil 48 is preferably 12.9 ohms, 1.3 amps at 17.2 volts direct current.

Referring now to FIGS. 3 and 4, a preferred embodiment of the present invention is illustrated. The preferred second embodiment includes a check valve 10 for selectively preventing and allowing fluid flow between an inlet connector 16 and an outlet connector 44. The check valve 10 includes a passage, such as elongated tube 12, defined in part by at least one sidewall 24 extending parallel to a longitudinal axis of the elongated housing 40. At least one stationary intermediate, longitudinally extending, radially opening aperture 22 is disposed between the inlet connector 16 and the outlet connector 44. Reciprocal means, such as inner sleeve 26, is slidably received within the portion of the passage defined by the sidewall 24. The reciprocal means carries a valve seat 52 engageable with the housing 40 to substantially close the intermediate aperture 22 when in a first position or first end limit of movement 28, and to substantially open the intermediate aperture 22 when in a second position or second end limit of movement 30. The fluid flow passes straight through the reciprocal means along a linear path when the valve seat 52 is moved away from the intermediate aperture 22 toward the second end limit of movement 30.

The check valve 10 also includes a first spring seat 36 connected to the sidewall 24 of the passage. A second spring seat 38 is connected to the reciprocal means. Biasing means 32, such as a valve return spring 34, is disposed within the passage having a first end abutting against the first spring seat 36 and a second end abutting against the second spring seat 38 for normally urging the reciprocal means toward one of the first and second positions, 28 and 30 respectively. Actuating means, such as a solenoid coil 48, is disposed with windings around the passage for urging the reciprocal means toward the other of the first and second positions, 28 and 30 respectively, against the urgings of the biasing means 32, such as valve return spring 34, in response to current flow through the actuating means, such as solenoid coil 48. The solenoid coil 48 acts on the reciprocating means, such as a metallic inner sleeve 26, by creating a magnetic field in response to application of power to the coil 48 to cause the metallic inner sleeve 26 to move in opposition to the urgings of the valve return spring 34 to open the fluid flow passage. In the preferred embodiment of the present invention as illustrated in FIGS. 3 and 4, the valve seat 52 has a high angle of attack to reduce pressure and vacuum effects on operation of the reciprocal means.

Control means 54 prevents application of power to a fluid pump means 56 until the reciprocal means is in the second position. When the reciprocal means is in the second position, the control means 54 reduces the current flowing to the reciprocal means prior to applying power to the fluid pump means 56. The starting of an air pump can reduce available power to 9 volts direct current. Therefore, the minimum functional voltage for the check valve 10 has been set at 9 volts direct current. The check valve 10 according to the present invention will continue to open at less than 8.5 volts direct current at 21.degree. C., but will not have the same performance as at 11 volts direct current. To increase the performance, the coil has been selected for more pull at lower voltages. The control means 54, or system control module, has been added to remove the reduced voltage effect of the air pump. When power is applied to the control means 54, the active check valve 10 according to the present invention is opened. This removes the reduced voltage effect of the air pump. Within a few milliseconds, the check valve 10 is fully opened and it magnetically triggers the control means 54. At this point, the control means 54 performs two functions; first setting the check valve 10 in a reduced current mode, and second starting the air pump in that order. When power is removed from the control means 54, the active check valve 10 closes and the air pump spins down. The reduced current mode of the check valve 10 cuts the total system power requirements by more than 1.5 amps. As with most electrical devices, self-heating can be a problem. Even with a low amperage coil, the high watt to surface area ratio can cause self-heating above the maximum desired operating temperature. This is typically tested at 17.2 volts direct current for 45 minutes. When in the reduced current mode, the check valve 10 according to the present invention has a watt to surface area ratio that is reduced to less than 1/4 of that ratio for the full current mode. The control means 54 prevents starting the fluid pump means 56 if the check valve 10 does not open, eliminating the possibility of the fluid pump means 56 burning out from a dead head condition. With the control means 54, the pump is protected, since the control means 54 will not power the fluid pump means 56 until the check valve 10 is open.

By way of example, and not limitation, experimental testing with check valves 10 without control modules require a minimum of 0.9 amps to open the check valve 10, but only 0.15 amps to keep the check valve 10 open. When power is removed from the fluid pump means 56, the fluid pump means 56 becomes a generator, and the check valve 10 stays open until the fluid pump means 56 is almost spun down. Low line pressure between the fluid pump means 56 and the check valve 10 can allow exhaust contaminants to enter the pump which is undesirable.

After adding the control means 54, when the power is removed, the control means 54 has the check valve 10 in a reduced current mode requiring approximately 0.34 amps. In this reduced current mode, the check valve 10 will close much sooner than it would if held open by the full 0.9 amps typically previously applied. The present invention also reduces costs in material and labor. By providing the control means 54 with connections for both the check valve 10 and the fluid pump means 56, only one cable with two wires, one positive and one negative, is required for power.

FIG. 5 is a side view of the check valve according to the second embodiment of the present invention having barbed tube end effects for the inlet 16 and outlets 44. The barbed tube end effects for the inlets and the outlets are suitable for receiving rubber hose clamp connectors (not shown). FIG. 6 is a side view of the check valve according to the second embodiment of the present invention with barbed tube end effects for the inlet 16 and the outlets 44. In addition, FIG. 6 illustrates an alternative configuration for the outlets 44 from the outlets 44 in FIG. 5 which are generally disposed at a 90.degree. angle with respect to one another, where the outlets 44 in FIG. 6 are disposed generally 180.degree. with respect to one another. FIG. 7 is a side view of the check valve according to the second embodiment of the present invention with a barbed tube end effect for the inlet 16 and with inverted flare end effects for the outlets 44. The inverted flare end effect is suitable for welded connections and may also be used on the inlet 16 if desired as illustrated in FIGS. 1 and 2. The inverted flare end effects for the outlets 44 may also be provided in the configuration of the outlets 44 as illustrated in FIG. 5 if desired.

FIG. 8 is a side view of the check valve according to the first embodiment of the present invention having barbed tube end effects for the inlet 16 and the outlet 44. The barbed tube end effect is suitable for rubber hose clamp connector type applications. FIG. 8 illustrates a straight flow through configuration for the check valve as also illustrated in FIGS. 1 and 2. FIG. 9 is a side view of the check valve according to the first embodiment of the present invention with an alternative outlet 44 configuration. The outlet configuration illustrated in FIG. 9 provides for a 90.degree. flow path through the check valve of the present invention. FIG. 10 is a side view of the check valve according to the first embodiment of the present invention with a third configuration for the outlet connector 44. In this configuration, a 135.degree. flow path is provided through the check valve according to the present invention. The barbed tube end effect on the inlet 16 or the outlet 44 for the first embodiment of the invention as illustrated in FIGS. 8-10 can be replaced as desired with an inverted flare end effect for the inlet 16 and/or the outlet 44. FIG. 11 is a side view of the check valve according to the first embodiment of the present invention having a barbed tube end effect on the inlet 16 and a threaded male end effect for the outlet 44. The threaded male and female end effects preferably are formed with standard national pipe thread (NPT) male and/or female configurations as desired for the inlet 16 and/or outlet 44. An electrical connector 64 is also illustrated in FIG. 11 suitable for attachment to the control means 54 (shown in FIGS. 3 and 4). FIG. 12 is a side view of the check valve according to the first embodiment of the present invention having a barbed tube end effect for the inlet 16 and a threaded female end effect for the outlet 44. FIG. 13 is a side view of the check valve according to the first embodiment of the present invention having a threaded end effect for the inlet 16 and a threaded male end effect for the outlet 44. FIG. 14 is a side view of the check valve according to the first embodiment of the present invention with a threaded male end effect for the inlet 16 and a threaded female end effect for the outlet 44. The inlet 16 and outlet 44 for any of the embodiments disclosed herein can be of the same end effect configuration or can have different end effect configurations. The inlet 16 and outlets 44 can be selected as desired from any connector fitting known to those skilled in the art and in any orientation required for the particular application. The inlet 16 and outlet 44 may include a barbed tube end effect, an inverted flare end effect, a threaded male end effect and/or a threaded female end effect.

FIG. 15 is a side view of the check valve according to the second embodiment of the present invention connected directly to a manifold 58 with the manifold 58 shown in cross-section. A gasket 60 is disposed between the manifold 58 and an outwardly extending flange of the body 40 of the check valve 10. The outwardly extending flange of the housing 40 of the check valve 10 is connected to the manifold 58 by threaded fasteners 62. The outlet 44 in this configuration corresponds to the aperture 22 formed in the housing 40 since no additional end effect or redirection of the outlet 44 is required. FIG. 16 is an end view of the check valve according to the second embodiment of the present invention taken as shown in FIG. 15. FIG. 16 also illustrates an electrical connector 64 suitable for attachment to the control means 54 (shown in FIGS. 3 and 4). The inlet connector 16 for the embodiment illustrated in FIGS. 15 and 16 can be of any suitable configuration or end effect. By way of example, and not limitation, the outlet 16 may have a barbed tube end effect, an inverted flare end effect, a threaded male end effect or a threaded female end effect.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.