Abstract:
A valve assembly, such as a canister purge solenoid (CPS) having one or more interchangeable components which may be used to reconfigure the valve assembly to have one or more additional vacuum ports. The design of the valve assembly eliminates the need to mold these ports into the intake manifold, simplifying the design of the manifold, and the tooling needed to make the manifold. The direct mount design of the CPS of the present invention includes at least one additional port to serve as an additional vacuum port to be used for any other purpose, such as a PCV valve, brake booster, or the like.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/825,649 filed May 21, 2013, U.S. Provisional Application No. 61/825,681 filed May 21, 2013, and U.S. Provisional Application No. 61/825,616 filed May 21, 2013. The disclosures of the above applications are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to a valve assembly mounted to an intake manifold which provides for additional vacuum sources to accommodate different vacuum needs for an airflow system of an engine. 
     BACKGROUND OF THE INVENTION 
     Engine vacuum is used to drive multiple devices on modern engines (such as the positive crankcase ventilation (PCV) valve, brake boosters, etc.), and additional ports may be needed to provide the necessary vacuum to operate these devices. These ports may be added to a component such as the intake manifold, or the like. Current designs commonly incorporate vacuum ports into the intake manifold or throttle body. However, this requires different tooling and equipment to manufacture the different intake manifolds having numerous possible vacuum port configurations. 
     Incorporating multiple types of tooling and equipment in the manufacturing process is both costly and inefficient. Accordingly, there exists a need for a configuration which accommodates different uses for the vacuum generated by an intake manifold. 
     SUMMARY OF THE INVENTION 
     The present invention is a valve assembly having one or more interchangeable components which may be used to reconfigure the valve assembly to have one or more additional vacuum ports. The design of the present invention eliminates the need to mold these ports into the intake manifold, simplifying the design of the manifold, and the tooling needed to make the manifold. 
     In one embodiment, the valve assembly is a canister purge solenoid (CPS). The direct mount design of the CPS of the present invention includes at least one additional port to serve as an additional vacuum port to be used for any other purpose, such as a PCV valve, brake booster, or the like. 
     One of the advantages of the design of the present invention is reduced cost, less tool complexity, and a reduced amount of connections. The additional vacuum port(s) is easier to incorporate into the valve assembly, than an intake manifold or air box. 
     In alternate embodiment, two or more vacuum ports could be incorporated into the design, allowing the vacuum generated by the intake manifold or air box to be used for more than one application. 
     In one embodiment, the present invention is a valve assembly in the form of a canister purge solenoid having a plurality of attachments, where the valve assembly includes a housing, such as a reservoir, at least one cavity formed as part of the reservoir, a first flange portion integrally formed as part of the reservoir, and a second flange portion integrally formed as part of the reservoir. A first vent port is attached to the first flange portion and is in fluid communication with an intake manifold and the at least one cavity. One of a plurality of attachments is selectively connected to the second flange portion formed as part of the reservoir, such that the connection of a first of the plurality of attachments to the second flange portion places the valve assembly in a first configuration, and the connection of a second of the plurality of attachments to the second flange portion places the valve assembly in a second configuration. 
     Vacuum pressure from the intake manifold is used to actuate a device connected to the first of the plurality of attachments when the first of the plurality of attachments is connected to the second flange portion, and air flow is prevented from entering or exiting the reservoir when the second of the plurality of attachments is connected to the second flange portion. 
     The first vent port also includes a first cap portion, a first base portion integrally formed with the first cap portion, and a first outer flange portion integrally formed with the first base portion. The first outer flange portion is connected to the first flange portion when the first vent port is attached to the reservoir. 
     One of the plurality of attachments may be a second vent port in fluid communication with the cavity, where the second vent port is connected to the second flange portion. The second vent port includes a second cap portion, a second base portion integrally formed with the second cap portion, and a second outer flange portion integrally formed with the second base portion. The second outer flange portion is connected to the second flange portion when the second vent port is attached to the reservoir. 
     One of the plurality of attachments may also be a cap member. The cap member may also include an outer flange portion and a wall member integrally formed with the outer flange portion. The outer flange portion of the cap member is connected to the second flange portion formed as part of the reservoir. The wall member is solid, and prevents air from entering and exiting the reservoir. 
     The device which uses vacuum pressure for actuation may be one of several components. Examples include, but are not limited to, a positive crankcase ventilation valve, a brake booster, and an air injection unit, or any other component suitable for connection with the canister purge solenoid, and requires vacuum for actuation. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a canister purge valve having one or more of a plurality of attachments in a first configuration, according to embodiments of the present invention; and 
         FIG. 2  is a sectional side view of a canister purge valve having one or more of a plurality of attachments in a first configuration, according to embodiments of the present invention; 
         FIG. 3  is a perspective view of a canister purge valve having one or more of a plurality of attachments in a second configuration, according to embodiments of the present invention; and 
         FIG. 4  is a sectional side view of a canister purge valve having one or more of a plurality of attachments in a second configuration, according to embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     A canister purge solenoid (CPS) according to the present invention is shown in the Figures generally at  10 . The CPS  10  has multiple configurations and is suitable for connection with different attachments to provide one or more ports, allowing for the vacuum from an intake manifold to be used to actuate different components, depending on the applications desired. The CPS  10  includes an inlet port  12  in fluid communication with a carbon canister. 
     Referring to  FIGS. 1-4 , the CPS  10  includes an overmold assembly  14 , and disposed within the overmold assembly  14  is a solenoid assembly, shown generally at  16 , and the solenoid assembly  16  is disposed within a cavity, shown generally at  18 , formed as part of the overmold assembly  14 , and the cavity  18  includes an inner wall portion  20 , and also forming part of the cavity  18  is an outer wall portion  22  of the overmold assembly  14 . 
     The solenoid assembly  16  includes a stator insert  24  which surrounds a support  26  formed as part of the overmold assembly  14 . A first washer  28  is disposed between an upper wall  30  of the overmold assembly  14  and a bobbin  32 . The bobbin  32  is surrounded by a coil  34 , and two straps (not shown) surround the coil  34 . There is a sleeve  36  which is surrounded by the bobbin  32 , and the sleeve  36  partially surrounds a moveable armature  38 . The armature  38  includes a cavity, shown generally at  40 , and located in the cavity  40  is a spring  42 , which is in contact with an inner surface  48  of the cavity  40 . The spring  42  is also mounted on a narrow diameter portion  44  of the support  26 . Disposed between part of the armature  38  and the bobbin  32  is a second washer  46 . Connected to the overmold assembly  14  is a cap  50 , and formed as part of the cap  50  is a valve seat  52  and a cap aperture  54 , where purge vapor is able to flow from an overmold assembly cavity, shown generally at  56 , formed as part of the overmold assembly  14  and through the cap aperture  54 . 
     The armature  38  includes a stopper portion  58  which is made of a rubber or other flexible material. The stopper portion  58  includes a contact surface  60  which contacts the valve seat  52  when the armature  38  is in the closed position. The stopper portion  58  includes a plurality of post members  62 , which are of the same durometer, but are of different sizes, and therefore have different levels of stiffness. The largest post members  62  are in contact with the bottom surface of the washer  46  when the armature  38  is in the closed position, as shown in  FIG. 3 . The smaller post members  62  contact the bottom surface of the washer  46  when the armature  38  moves to the open position. The coil  34  is energized to move the armature  38  away from the valve seat  52 , placing the solenoid assembly  16  in an open position. The more the coil  34  is energized, the further the armature  38  moves away from the valve seat  52 , and the greater number of post members  62  contact the bottom surface of the washer  46 . The movement of the armature  38  to open and close the solenoid assembly  16  controls the amount of purge vapor allowed to pass through the CPS  10 , and into the intake manifold. 
     Because the post members  62  are made of rubber, the post members  62  are able to deform as the armature  38  is moved further away from the valve seat  52 . The largest post members  62  in contact with the bottom surface of the washer  46  deform first when the armature  38  moves away from the valve seat  52 . As the armature  38  moves further away from the valve seat  52 , more of the post members  62  contact the bottom surface of the washer  46 , and then begin to deform as the armature  38  moves even further away from the valve seat  52 . The deformation of the post members  62  (when the armature  38  is moved to the open position away from the valve seat  52 ) functions to dampen the movement of the armature  38 , eliminating noise, and preventing metal-to-metal contact between the armature  38  and the stator insert  24 . 
     Disposed between the bottom surface of the washer  46  and an inside surface  64  of the cap  50  is a filter  66 . The filter  66  is made of several blades of plastic which are adjacent to one another. The filter  66  is designed to limit the size of debris and particles passing through the blades of plastic to less than 0.7 millimeters. The distance between the armature  38  and the stator insert  24  is about 1.0 millimeters, and is the maximum allowable distance between the contact surface  60  of the stopper portion  58  and the valve seat  52 . The filter  66  ensures that no particles may pass through the filter  66  that are too large to affect the functionality of the solenoid assembly  16  (the particles being too large to fit between the valve seat  52  and the stopper portion  58 ) when the armature  38  is in the open position. 
     The aperture  54  is also in fluid communication with a reservoir cavity, shown generally at  68 , formed as part of housing, which in this embodiment is a reservoir  70 . As mentioned above, the more the coil  34  is energized, the further the armature  38  moves away from the valve seat  52 , placing the solenoid assembly  16  in an open position, allowing air and purge vapor to pass from the overmold assembly cavity  56 , through the cap aperture  54  and into the reservoir cavity  68 . The reservoir  70  essentially functions as a modular housing, having multiple configurations, making the CPS  10  suitable for multiple applications, and therefore suitable for use in different types of vehicles having additional components requiring vacuum actuation. 
     In one configuration shown in  FIGS. 1-2 , there are two attachments connected to the reservoir  70 , the first attachment is a first vent port  72 , and the second attachment is a second vent port  74 . Each of the attachments are connected to the reservoir  70  using one of a plurality of connection structures. The cavity  68  is in fluid communication with both of the first vent port  72 , and the second vent port  74 , which are substantially similar in construction. 
     The first vent port  72  is connected to a first hose or conduit  76 , and the first hose  76  provides fluid communication between the first vent port  72  and the intake manifold, placing the CPS  10  in fluid communication with the intake manifold. The first vent port  72  includes a first cap portion  78 , and the first cap portion  78  includes a first outer flange portion  80  which is connected to a first connection structure, which in this embodiment is a first flange portion  82  formed as part of the reservoir  70 . The connection between the outer flange portion  80  and the flange portion  82  may be any suitable connection, such as snap-fitting, welding, an adhesive, or the like. The connection between the cap portion  78  and the flange portion  82  forms a first port cavity, shown generally at  84 , and formed as part of a first side wall  86  of the reservoir  70  is a first port aperture  88 , which allows for fluid communication between the cavity  84  and the cavity  68 . 
     The first vent port  72  also includes a first inner wall  90  integrally formed with the cap portion  78 . The inner wall  90  is part of a first base portion  92 , and formed as part of the base portion  92  is a first plurality of vents  94  which are in fluid communication with the cavity  84 , such that purge vapor is able to flow from the cavity  68  through the aperture  88  into the cavity  84 , and through the vents  94  and into the first vent port  72 . 
     There is also an aperture  96  formed as part of the side wall  86 , and aperture  98  formed as part of the base portion  92 . The apertures  96 , 98  allow additional purge vapor to flow from the reservoir cavity  68 , through the first port cavity  84 , and through the vents  94 . However, the first vent port  72  is constructed such that a check valve is able to be placed in the cavity  84 , allowing the CPS  10  to be adaptable for applications requiring a check valve. In one of these applications, the check valve may include a guide member which extends into the apertures  96 , 98 , to guide the movement of the check valve. 
     As mentioned above, the configuration of the CPS  10  is adaptable for different applications, and for use with additional components requiring vacuum to function. The configuration of the CPS  10  shown in  FIGS. 1-2  includes the second attachment, which in this embodiment is the second vent port  74 , which has similar components to the first vent port  72 , and functions in a similar manner. The second vent port  74  includes a second cap portion  78   a  having a second outer flange portion  80   a  connected to a second connection structure, which in this embodiment is a second flange portion  82   a  of the reservoir  70 , and a second port cavity, shown generally at  84   a , formed by the connection of the cap portion  78   a  to the second flange portion  82   a . A second side wall  86   a  is also formed as part of the reservoir  70 , and a second port aperture  88   a  is formed as part of the second side wall  86   a  to provide fluid communication between the cavity  68  and the second port cavity  84   a . There is also an inner wall  90   a  formed as part of the base portion  92   a . The base portion  92   a  and the second cap portion  78   a  are part of the second vent port  74 . Similarly to the first base portion  92 , there is a second plurality of vents  94   a  formed as part of the second base portion  92   a . There is also an aperture  96   a  formed as part of the second side wall  86   a  and, and aperture  98   a  formed as part of the second base portion  92   a.    
     A second conduit, or second hose  100  may be connected to the second vent port  74 , and the second hose may be connected to another device requiring vacuum pressure for actuation, such as a PCV, a brake booster, or the like. The vacuum pressure from the intake manifold draws air from the reservoir cavity  68  into the first hose  76 , and therefore into the intake manifold. When the solenoid assembly  16  is in an open position, the purge vapor is allowed to pass from the overmold assembly cavity  56 , through the cap aperture  54 , the reservoir cavity  68 , and into the first conduit  76 . Additionally, the second vent port  74  is also exposed to this vacuum pressure, and therefore the second conduit  100  is also exposed to this vacuum pressure as well. This allows for the component connected to the second conduit  100  to be actuated using the vacuum pressure from the intake manifold. Therefore, the component connected to the second conduit  100  may be actuated using vacuum pressure from the intake manifold, regardless of whether the solenoid assembly  16  is in an open or closed position. 
     Another configuration of the CPS  10  is shown in  FIGS. 3-4 . In this configuration, the second vent port  74  is not used. Instead, another type of attachment, which in this embodiment is a cap member  78   b , is attached to the reservoir  70 . More specifically, the cap member  78   b  includes a second outer flange portion  80   b  which is attached to the second flange portion  82   a  of the reservoir  70 . The reservoir  70  is of the same construction in  FIGS. 1-4 , and the second flange portion  82   a  is connectable with either the second outer flange portion  80   b  of the cap member  78   b , or the second outer flange portion  80   a  of the second cap portion  78   a . The second outer flange portion  80   b  of the cap member  78   b  is connected to the second flange portion  82   a  in the same manner as the second outer flange portion  80   a  of the second cap portion  78   a , through a laser weld, a snap-fit connection, an adhesive, or the like. The connection of either the cap portion  78   a  or the cap member  78   b  to the second flange portion  82   a  of the reservoir  70  allows for the construction of the reservoir  70  to remain the same, while allowing for the CPS  10  to be adaptable for different applications, where an additional vacuum source is necessary. Where an additional vacuum source is not necessary, the BSV assembly  34  may be configured to have the cap member  78   b  as shown in  FIGS. 3-4 . Where additional vacuum source is necessary, the BSV assembly  34  may be configured to include the cap portion  78   a  having the second vent port  74 , as shown in  FIGS. 1-2 . 
     The present invention is not limited to the configurations described above. It is also within the scope of the invention that the second vent port  74  may be attached to the second flange portion  82   a , and the cap member  78   b  may be attached to the first flange portion  82 , if the packaging requirements require such a configuration. 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.