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 a soft seal and non-detachable poppet for ultra-low leakage and improved performance.

BACKGROUND OF THE INVENTION

A compressor bypass valve is an electromechanical device that makes use of electromagnetic action to release pressure from the intake system on various types of motors. The 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.

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.

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. Leakage in compressor by pass valves leads to lack of power in the turbo charging system. Leakage in valve leads to slow build of the boost in the turbocharger and declining performance. Hence, there is a need of compressor by pass valve with improved leakage.

US8322681B2 discloses a relief valve comprising a first valve body for opening and closing a fluid passageway between a first valve connection and a second valve connection, a second valve body which is disposed on the first valve body and is used for opening and closing a valve passageway located between the first valve connection and a valve interior, a one throttle duct between the valve interior and a face of the first valve body, a spring for opening the second valve body, and an actuator for closing the second valve body. This relief valve further comprising a movable member that can be moved further in the same direction once the second valve body has been closed, thus allowing the first valve body to be opened by having the second valve body engage a valve seat located on the first valve body, and a stop element connected to the second valve body and/or the movable member engages the first valve body via the spring to close the first valve body. The main drawback of the invention is that with usage, the leakage increases resulting in the decrease in performance.

US7588047B2 discloses a compressor bypass valve for multistage supercharging an internal combustion engine equipped with a supercharging system. The valve includes a displacement body accommodated in a valve housing. The displacement body is divided into a first displacement part and a second displacement part. The first displacement part, facing the upstream side, moves to close or open the bypass in response to a pressure differential. But no provision is present of eliminating the leakage that results in the decrease in performance.

Therefore, there is a need of an electrical compressor by pass valve that reduces leakage efficiently and ensures safety of valve against detachment while its storage and transportation.

OBJECT OF THE INVENTION

The main object of the present invention is to provide an improved electrical compressor by-pass valve with a soft seal and non-detachable poppet for ultra-low leakage and improved performance.

Another object of the present invention is to provide a rubber/soft material over moulded poppet sub assembly that provides an effective sealing of the valve duct against leakage.

Yet another object of the present invention is to provide a radial sealing element with two legs wherein outer leg is longer than the inner leg and the outer leg is 1.1-1.9 times greater than inner leg and avoids leakage from inside of valve. Still another object of the present invention is to provide a circular lip, also known as a C-clip, Seeger ring, snap ring or Jesus clip, is a type of fastener or retaining ring consisting of a semi-flexible metal ring with open ends which is snapped into place, into a machined groove on a dowel pin or other part to permit rotation but to prevent detachment of the poppet subassembly during storage and transportation.

SUMMARY OF THE INVENTION

The present invention provides an improved electrical compressor by-pass valve with a soft seal and a non-detachable poppet over moulded with rubber for ultra-low leakage and improved performance.

In a main embodiment, the present invention provides an improved electrical compressor by-pass valve comprising of a first valve body, a second valve body, a bobbin, a coil winding, an electrical terminal, a guiding pin, a compression spring, a circular lip element, a radial sealing element or sealing ring, a soft seal and a poppet sub assembly. The poppet sub assembly is made by rubber/ soft material over moulding and has an effective diameter which is greater than the inner diameter of the radial sealing element or sealing ring. The radial sealing element or sealing ring is two leg sealing ring wherein one of the leg is longer than the other leg (i.e. the outer leg is 1.1 -1.9 times greater than inner leg) of the sealing ring to avoid leakage through inside of valve by sealing the poppet sealing sub assembly radially.

Here, the guiding pin is cylindrical with a circular groove at the bottom portion of the guiding pin. In the circular groove provided at the bottom of the guiding pin, the circular lip element is fitted such that it acts as a stopping element used for safety of valve against detachment while its storage and transportation.

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 electrical compressor by pass valve in accordance to the present invention. Fig. 2 shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve in accordance to the present invention.

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

Fig. 4 shows a comparison graph for leakage in accordance to 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 with a soft seal, a circular lip element, a radial sealing element and a non-detachable poppet over moulded with rubber for ultra-low leakage and improved performance.

In a main embodiment, the present invention provides an improved electrical compressor by-pass valve comprising of a first valve body, a second valve body, a bobbin, a coil winding, an electrical terminal, a guiding pin, a compression spring, a circular lip element, a radial sealing element or sealing ring, a soft seal and a poppet sub assembly. The poppet sub assembly is made by rubber over moulding and has an effective diameter which is greater than the inner diameter of the radial sealing element or sealing ring. The radial sealing element or sealing ring is two leg sealing ring wherein one of the leg is longer than the other leg of the sealing ring to avoid leakage through inside of valve by sealing the poppet sealing sub assembly radially. Here, the guiding pin is cylindrical with a circular groove at the bottom portion of the guiding pin. In the circular groove provided at the bottom of the guiding pin, the circular lip element is fitted such that it acts as a stopping element used for safety of valve against detachment while its storage and transportation.

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 first valve body 2 that acts as an upper housing of the valve 1 and a second valve body 3 that acts as a lower housing of the valve 1. In the first valve body 2, an electrical terminal 6 is provided which is in connection with the bobbin 4. On the bobbin 4, a coil winding 5 is provided which gets energized when current is passed through the electrical terminal 6. In the second valve body 3, a poppet sub assembly 12 is provided. A radial sealing element or sealing ring 10 is provided between the inner surface of the second valve body 3 and the outer surface of the poppet sub assembly 12. On the bottom end of the poppet sub assembly 12, a soft seal 11 is provided. A guiding pin 7 is provided in the valve 1 such that the top portion of the guiding pin 7 is in the first valve body 2 with a spring 8 around it and the bottom portion of the guiding pin 7 protrudes out of the second valve body 3. On the bottom portion of the guiding pin 7, a circular groove is provided in which the circular lip element 9 fits. The circular lip is also referred as circlip. The circular lip element is also known as C-clip, Seeger ring, snap ring or Jesus clip, which is a type of fastener or retaining ring consisting of a semi-flexible metal ring with open ends which is snapped into place, into a machined groove on a dowel pin or other part to permit rotation but to prevent detachment of the poppet subassembly during storage and transportation.

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 electrical compressor by pass valve, the second valve body 3 is having a poppet sub assembly 12, a radial sealing element 10 and the circular lip element 9 fitted in the circular groove 13 of the guiding pin. The inner diameter (Y) of the radial sealing element 10 is greater than effective diameter (X) of the poppet sub assembly 12. The radial sealing element 10 is a two leg sealing ring wherein the outer leg 14 is 1.1-1.9 times longer than the inner leg 15. Fig. 3 shows an enlarged sectional view of the bottom portion of the electrical compressor by pass valve with soft seal in accordance to the present invention. The inner diameter (Y) of the radial sealing element 10 is greater than effective diameter (X) of the poppet sub assembly 12 fitted with the soft seal 11 at the bottom. Fig. 4 shows a comparison graph for leakage in accordance to the present invention. As compared to an electrical compressor bypass valve known in the art where the inner diameter of the radial sealing ring is equal to the effective diameter of the circular sealing element, the valve 1 in accordance with the present invention having a rubber over moulded poppet sub assembly an effective sealing of the valve duct is achieved up to 2 LPM of leakage. The poppet sub assembly is more efficient than the prior art in respect of sealing.

Therefore, the improved electrical compressor bypass valve provides ultra-low leakage having poppet sub assembly over moulded with rubber that reduces the leakage from turbo valve seat. 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.