INTERNAL FLOW LIMITER” FIELD OF THE INVENTION

The present invention relates to an improved electrical compressor by-pass valve. More particularly, the present invention relates to an improved electrical compressor by-pass valve with floating internal flow limiter to provide sealing of turbocharger duct in no current condition and allowing passage to over pressurized air upon energization with quick opening and closing time.

BACKGROUND OF THE INVENTION

A compressor bypass valve helps to route the pressure generated within a turbo or supercharged engine back into the non-pressurized end of the intake system. An electrical compressor by pass valve is more compact, efficient, cost effective and reduces the switching times significantly to cater the needs of turbo engines that require fast load alteration.

The main function of the compressor bypass valve is to allow the escape of pressure during the segment of operation when the throttle plate is closed. Without the presence of the valve to allow the pressure to be rerouted, the pressurized air would simply crash into the throttle plate thus building up the pressurized air and eventually be repelled back into the turbo. This strong wave of pressurized air would not only create additional wear on the turbo, but also slow down and possibly stop the action of the turbo altogether.

In state of the art, the electrical compressor by pass valve has a two sealing arrangement wherein to maintain the pressure inside the valve there is a requirement of duct for air by pass. To maintain adequate pressure, the ducts are placed on bottom or wall of the plunger or valve body. Further, based on the design requirements, the ducts are positioned. With the two sealing arrangement and other design specifications, the duct has to be specifically made at a point else the valve does not work properly. US8322681B2 discloses a comprises a first valve body for opening and closing a fluid passageway between at least a first valve connection and at least a second valve connection, a second valve body, disposed on the first valve body, for opening and closing a valve passageway, disposed in the first valve body, between the first valve connection and an interior of the valve, and a throttle duct, preferably a plurality of throttle ducts, establishing a connection between the interior of the valve and a face of the first valve body. The first valve body is formed substantially cylindrically and wherein the at least one throttle duct includes a plurality of throttle ducts distributed across the circumference of the face and positioned opposite a valve seat and in a flow direction upstream of a seal of the first valve body. The cited invention is two sealing arrangement and has a plurality of ducts distributed across the circumference of the face and positioned opposite a valve seat. Here the valve is able to work efficiently only with the specific placement of the ducts.

Therefore, there is a need to develop an electrical compressor by pass valve that enables intentional flow of air for maintaining the pressure inside the valve. OBJECT OF THE INVENTION

The main object of the present invention is to provide an improved electrical compressor by-pass valve (eCBV) with floating internal flow limiter.

Another object of the present invention is to provide a turbocharger bypass valve to seal off the pressurized air in the turbocharger duct in no current condition and allow a passage to the over pressurized air when it is energized.

Yet another object of the present invention is to provide a movable plunger assembly having a plunger sub assembly and single part moving core to pull plunger sub assembly with the help of an adjusting pin.

Still another object of the present invention is to provide a solenoid over moulded housing with a movable plunger sub assembly and a valve housing assembled with a spring to keep plunger sub assembly in place in non-energized condition.

SUMMARY OF THE INVENTION The present invention provides an improved electrical compressor by-pass valve (eCBV) with a floating internal flow limiter and which is enabled to seal off the pressurized air in the turbocharger duct in no current or off condition and allow a passage to the over pressurized air when it energized.

In a main embodiment, the present invention provides an improved electrical compressor by-pass valve comprising of a solenoid over moulded housing, a fix core insert, a fix core, a spring, a valve housing, a bobbin, a coil winding, an electrical terminal, a guiding pin, a flow limiter, a single part moving core, and a plunger sub assembly. The flow limiter is a bleed flow control rubber disc that allows controlled amount of leakage. Further, in the plunger sub assembly optionally a partial soft seal is provided. The single part moving core is designed such that it eliminates need of a separate spring retainer. The bottom end of the moving core has a flange that enables it to act as a spring retainer and further it is provided with a plurality of air flow area. In the solenoid over moulded housing, the fix core is provided with an incision for fix core insert. The addition of fix core insert in solenoid increases the performance of release voltage in range from 40% to 50%.

Here, the plunger sub assembly is such that it eliminates any need of a secondary valve body along with the guiding pin. The guiding pin is cylindrical rod with a round head and a uniform added thickness in its middle portion. A clearance is provided between the plunger sub assembly and the valve housing. Also, a clearance is provided between the guiding pin and the inner surface of the neck of the plunger body.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the device and method of the present invention may be obtained by reference to the following drawing:

Fig. 1 is a cross sectional view of the improved electrical compressor by pass valve in accordance with the present invention.

Fig. 2 shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance with the present invention. Fig. 3(a) shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve with a partial soft seal in accordance with the present invention.

Fig. 3(b) shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve without soft seal in accordance with the present invention.

Fig. 4 shows various views of the valve housing in accordance with the present invention.

Fig. 5 shows various views of the flow limiter in accordance with the present invention.

Fig. 6 shows another enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance with the present invention.

Fig. 7 shows a perspective view of the single part moving core of the electrical compressor by pass valve in accordance with the present invention.

Fig. 8 shows a perspective view of the guiding pin in accordance with the present invention. Fig. 9 shows an enlarged sectional view of the fix core and fix core insert in accordance with the present invention.

Fig. 10 shows another enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance with the present invention.

Fig. 11 shows a comparison graph for release voltage in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The present invention provides an improved electrical compressor by-pass valve (eCBV) with a floating internal flow limiter and which is enabled to seal off the pressurized air in the turbocharger duct in no current or off condition and allow a passage to the over pressurized air when it is energized.

In a main embodiment, the present invention provides an improved electrical compressor by-pass valve comprising of a solenoid over moulded housing, a fix core, a fix core insert, a spring, a valve housing, a bobbin, a coil winding, an electrical terminal, a guiding pin, a flow limiter, a single part moving core, and a plunger sub assembly. The flow limiter is a bleed flow control rubber disc that allows controlled amount of leakage. The allowable flow amount is in the range of 0.5 1/m to 5 1/m. Further, in the plunger sub assembly optionally a partial soft seal is provided. The single part moving core is designed such that it eliminates need of a separate spring retainer. The bottom end of the moving core has a flange that enables it to act as a spring retainer and further it is provided with a plurality of air flow area. In the solenoid over moulded housing, the fix core is provided with an incision for fix core insert. The addition of fix core insert in solenoid increase the performance of release voltage in range from 40% to 50%.

Here, the plunger sub assembly is such that it eliminates any need of a secondary valve body along with the guiding pin. The guiding pin is cylindrical rod with a round head and a uniform added thickness in its middle portion. A clearance is provided between the plunger sub assembly and the valve housing. Also, a clearance is provided between the guiding pin and the inner surface of the neck of the plunger body.

Now referring to Fig. 1 is a cross sectional view of the electrical compressor by pass valve in accordance to the present invention. Said electrical compressor by pass valve 1 comprises of a solenoid over moulded housing 2, a fix core insert 3, a spring 4, a valve housing 5, a bobbin 6, a coil winding 7, an electrical terminal 8, a guiding pin 9, a flow limiter 10, a single part moving core 11, a fix core 15 and a plunger sub assembly 12. Said electrical compressor by pass valve 1 is a solenoid valve. In the solenoid over moulded housing 2, the fix core 15 is provided with an incision for the fix core insert 3 that helps in increasing the release voltage of the valve. Inside the solenoid over moulded housing 2 below the fix core insert 3, the single part moving core 11 is provided with the spring 4 around it. The valve housing 5 is fitted with solenoid over moulded housing 2 with an O ring in between. On the bottom end of the valve housing 5, the plunger sub assembly 12 is fitted. The plunger sub assembly 12 has a plunger body at its outer surface which is in contact with the valve housing 5. Between the plunger sub assembly 12 and plunger body 14, the flow limiter 10 is provided. The flow limiter 10 allows a controlled amount of leakage. The allowable flow amount is in the range of 0.5 1/m to 5 1/m. A soft seal 13 is optionally provided in the valve 1.

Said valve 1 in no current or OFF condition seals off the pressurized air in the turbocharger duct and allow a passage to the over pressurized air when it is energized through current passed through terminal 8 to the coil winding 7.

Fig. 2 shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance to the present invention. In the bottom portion of the valve, the single part moving core 11 with two to eight axial holes and spring resting outer flange is fitted in the plunger sub assembly 12 which is fitted in the valve housing 5. The plunger sub assembly 12 is then fitted in the plunger body 14 with a flow limiter 10 in between.

Fig. 3(a) shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve with a partial soft seal in accordance to the present invention. In the bottom portion of the valve 1, the plunger body 14 is designed such that only a partial soft seal 13 is required between the plunger body 14 and plunger disk 15.

Fig. 3(b) shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve without soft seal in accordance to the present invention. In the bottom portion of the valve 1, the plunger body 14 is designed as a single element without any soft seal. Fig. 4 shows various views of the valve housing in accordance to the present invention. The valve housing 5 is such that at the bottom end, a flange extending inward has a protruding radial ring with at least one to four cut outs 16 that provides limited air flow.

Fig. 5 shows various views of the flow limiter in accordance to the present invention. The internal floating flow limiter 10 is a polygonal shaped diaphragm with at least one to four cut outs 17 that help in maintaining limited air flow.

Fig. 6 shows another enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance to the present invention. The moving core 11 is designed such that at the bottom end it has an outer flange 19 which helps in retaining the spring 4 and no separate spring retainer is required. Further, the guiding pin 9 is fitted in the valve such that there is no need of a secondary valve body in area 18 between the plunger disk 15 and guiding/ adjusting pin 9.

Fig. 7 shows a perspective view of the single part moving core of the electrical compressor by pass valve in accordance to the present invention. The moving core 11 has a plurality of air flow area 20 in the middle portion of the moving plunger 11. Further, the bottom end of the moving plunger 11 has outer flange 19 that acts as a spring retainer.

Fig. 8 shows a perspective view of the guiding pin in accordance to the present invention. The guiding pin 9 is a cylindrical rod with a round head 21 and a uniform added thickness 22 in the middle portion.

Fig. 9 shows an enlarged sectional view of the fix core and fix core insert in accordance to the present invention. The fix core 15 is provided with an incision 26 for the fix core insert 3 that helps in increasing the release voltage of the valve.

Fig. 10 shows another enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance to the present invention. A clearance 23 of approximately 0.5-4 mm is provided between the plunger sub assembly 12 and the valve housing 5. Also, a clearance 24 of approximately 1-3 mm is provided between the guiding pin 9 and the inner surface of the neck 25 of the plunger body 14. Fig. 11 shows a comparison graph for release voltage in accordance to the present invention. The present invention is compared with an old design of solenoid compressor by pass valve without fix core insert in the middle of the solenoid. Form the comparison graph it is clearly seen that the release voltage at 180 kPa of the present invention has increased by 50% due to the addition of fix core insert in the middle of the solenoid.

Therefore, the improved electrical compressor bypass valve having an internal flow limiter with increased performance of release voltage that allows sealing of the pressurized air in the turbocharger duct in no current or off condition and allow a passage to the over pressurized air when it energized. The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.