Combined check valve and pressure sensor

A check valve, for use in a vacuum accumulator. The check valve includes a movable gate, which blocks fluid flow. The gate carries a first electrical contact, which mates with a second electrical contact, when the gate closes, thereby issuing a signal which indicates closure. The invention eliminates the need for a separate pressure sensor, for sensing pressure within the accumulator.

The invention concerns a check valve for use in a vacuum accumulator, such 
as in a power braking system in a motor vehicle. The check valve contains 
an integral sensor which senses state of the valve (i.e., open or closed). 
BACKGROUND OF THE INVENTION 
Internal combustion engines which run on the Otto cycle generate a low 
pressure, commonly called vacuum, in the intake manifolds. This vacuum is 
often used as an energy source, as for operating power brakes, and valves 
in the cabin heating and cooling system. 
However, engines which run on the Diesel cycle do not, in general, produce 
a sufficient vacuum for these purposes. In these engines, an auxiliary 
vacuum pump is used. FIG. 1 is a simplified schematic of a vacuum system 
used in such a vehicle. 
The vacuum pump P draws vacuum on an accumulator AC, through a check valve 
CV. A sensor SN measures the pressure within the accumulator. When the 
pressure falls below a threshold, the sensor issues a signal to a control 
system CS, which orders the pump to terminate operation, because 
sufficient vacuum exists within the accumulator. After termination, the 
check valve closes. 
When the pressure rises sufficiently, due to leakage and draw-down by usage 
of energy stored in the accumulator, the sensor detects the rise,.and the 
control system orders the pump to resume operation. 
The inventors have developed an apparatus which consolidates the sensor and 
the check valve into a single device. 
OBJECTS OF THE INVENTION 
An object of the invention is to provide an improved check valve for a 
vacuum system. 
A further object of the invention is to provide a vacuum sensor which is 
integrated into a check valve. 
SUMMARY OF THE INVENTION 
In one form of the invention, a proximity sensor is associated with a gate 
in a check valve. The proximity sensor issues a signal when the gate 
reaches a predetermined position.

DETAILED DESCRIPTION OF THE INVENTION SIMPLIFIED VIEW OF INVENTION FIG. 2 
FIGS. 2 and 3 provide simplified views of principles used by the invention. 
In FIG. 2, springs S are supported by a body B, which is fixed in 
position, as indicated by the ground symbol GR. The springs, in turn, 
support a gate G. 
The gate is in an open position, because of high pressure air, HP, on the 
left side of the Figure, compared with the low pressure air, LP, on the 
right side. The high pressure air applies a force which overcomes the 
spring force, which is indicated by arrow SF. 
Under these conditions, air flows past the gate, as indicated by the dashed 
arrows. 
When the air pressure on the left falls below that on the right by a 
sufficient amount, as indicated by low pressure, LP, on the left of FIG. 
2B, and high pressure, HP, on the right, the force of springs S is no 
longer overcome. The combined force of the springs S and the high pressure 
air HP close the gate G, as indicated. The gate now engages an O-ring, OR, 
and seals off airflow. In addition, electrical contacts C1 and C2 make 
connection, allowing instrumentation (not shown) to detect closure of the 
gate. 
FIG. 3 
FIG. 3 illustrates another simplified form of the invention. The gate takes 
the form of a diaphragm D which is supported by bellows BE. In FIG. 3A, 
the high pressure HP exceeds the combination of the low pressure LP and 
the spring force of the bellows, thereby allowing airflow, as indicated by 
the dashed arrows. 
When the high pressure HP falls, and becomes the low pressure LP indicated 
in FIG. 3B, the drop allows the diaphragm to mate with the O-ring OR, the 
diaphragm D blocks airflow. However, the contacts C1 and C2 do not connect 
at this time, because stationary contact C1 is mounted on a threaded stud 
TS. The threaded stud has been withdrawn to the left. 
As the pressure on the left falls further, the situation becomes as shown 
in FIG. 3C. Low pressure, LP, exists on the left, and very high pressure, 
VHP, exists on the right. The larger pressure differential, compared with 
that of FIG. 3B, causes the diaphragm D to become bowed, as indicated. Now 
the contacts C1 and C2 connect. 
In the sequence shown in FIG. 3, the diaphragm first seals off airflow 
(FIG. 3B), and then the contacts C1 and C2 connect (FIG. 3C). However, the 
reverse sequence can be achieved, which is shown in FIG. 4. 
FIG. 4 
In FIG. 4A, the threaded stud TS is first advanced to the right. Further, 
the threaded stud is supported by a support S which is resilient. As 
pressure on the left drops from HP in FIG. 4A to LP in FIG. 44B, the 
diaphragm D moves to the left, as in FIG. 4B, and the contacts C1 and C2 
connect. Then, further pressure drop causes the diaphragm to move further 
leftward. This motion bends the resilient support, as indicated in FIG. 
4C. Yet further motion of the diaphragm makes contact with the O-ring OR, 
thereby blocking airflow. 
In the sequence of FIG. 4, the contacts C1 and C2 first meet, and then the 
diaphragm mates with the O-ring OR, to block airflow. 
MORE DETAILED FORM OF THE INVENTION 
Numerous approaches exist to implementing the invention discussed above. 
FIG. 5 illustrates one approach. A vacuum pump VP draws a vacuum on an 
accumulator AC, as indicated by arrows 3. The air exhausts through ports 
PO in a muffler MU, as indicated. 
Diaphragm D cooperates with O-ring OR to block the airflow 3, when in 
contact with the O-ring. The diaphragm is corrugated in cross section, as 
shown. FIG. 6 illustrates a top view of the diaphragm (corrugations are 
not shown). 
FIG. 7 illustrates the diaphragm in the open position. The dashed arrows 3 
indicate airflow. The diaphragm is supported by legs L, which act as leaf 
springs. The legs L, together with the body of the diaphragm D, define 
channel C through which the airflow passes. 
When in the closed position (not shown), the diaphragm contacts the O-ring 
of FIG. 5 along the phantom line PL shown in FIG. 7. 
In FIG. 5, contacts C1 and C2 are shown as open. When the diaphragm moves 
sufficiently leftward, the contacts close. Contact C1 is supported by a 
flexible support S, which can take the form of a leaf spring. Threaded 
stud TS adjusts the position of contact C1. 
FIG. 8 illustrates one possible configuration of legs L. A Tinnermann nut 
TI is integrally formed into each leg, and mates with a boss 3, also 
indicated in FIG. 5. A Tinnermann nut acts somewhat like a ratchet. Each 
pawl P makes a slight indentation D (shown in exaggerated form) in the 
boss 6, to secure the pawls to the boss. 
ADDITIONAL CONSIDERATIONS 
1. The form of the invention shown in FIG. 2 (and those shown in FIGS. 3 
and 4, if the threaded stud TS is properly adjusted) produces a signal 
which indicates when the diaphragm-check valve closes. The spring 
constants involved (e.g., springs S in FIG. 2 or bellows B in FIG. 3) are 
designed so that a known pressure differential causes the closure of the 
diaphragm. 
Thus, under the invention, the check valve is designed to close when a 
predetermined pressure differential across the diaphragm is attained, and 
contacts C1 and C2 produce a signal indicating closure. A control system 
(not shown) detects the signal, and issues the appropriate signal to a 
vacuum pump. 
2. Manufacturing irregularities may cause different diaphragms to close at 
different pressure differentials. (Pressures LP and HP in FIG. 2 
illustrate the differential.) Also, even if a given diaphragm closes at 
the proper pressure differential, usage of the diaphragm can cause various 
spring constants to change, causing closure to occur at different pressure 
differentials. 
To accommodate these factors, the spring constant of the diaphragm, 
indicated by springs S and bellows B in FIGS. 2 and 3, can be changed. One 
approach is shown in FIG. 9. The support body B is made movable, by a 
second threaded stud TS2. 
Movement of the support body changes the preloading of the springs 
involved. 
3. The contacts C1 and C2 produce a signal when they connect: wires 
connecting them become shorted together. The contacts produce another 
signal when they become disconnected: they become open circuited. 
Another approach to producing signals is in FIG. 10. When the contacts are 
open, resistor R produces a high voltage on wire W1. When the contacts 
close, wire W1 becomes shorted to ground, producing a low (or zero) 
voltage. 
4. As discussed above, the threaded stud TS in FIG. 3 can move contact C1 
both left- and rightward. When C1 is generally on the left, the diaphragm 
D first closes, and then the contacts meet. The meeting occurs when 
pressure increases on the right side of FIG. 3 to bow the diaphragm 
sufficiently. Thus, in FIG. 3, closure of the contact can indicate when a 
given pressure has been attained. A similar indication can occur in the 
apparatus of FIG. 4. 
In FIG. 4, the contacts first meet, and then the diaphragm closes, when 
pressure becomes sufficient. There is a region wherein C1 can be located, 
such that closure of C1 with C2 can indicate the value of pressure on the 
right side of the diaphragm. 
When C1 is within this region, the diaphragm is almost closed when the 
contacts close, and imposes a restriction in the airflow indicated by the 
dashed arrows in FIG. 4. This restriction causes an increase in pressure 
on the right of the Figure. 
Calibration of the system will show the pressure existing on the right side 
of Figure, at closure of the contacts, for various positions of C1. Thus, 
after calibration, closure of the contacts indicates that accumulator 
pressure has reached the calibrated pressure. 
It should be noted that the pressure indicated in the case of FIG. 3 will 
be a static pressure. But in FIG. 4, there is airflow through the 
diaphragm at the time of contact closure, so that the pressure indicated 
will be a combination of static and dynamic pressures. Either, or both, 
can be taken as indicators. 
5. The closing of the contacts need not be used to indicate attainment of a 
predetermined pressure. Instead, contact closure can indicate attainment 
of a predetermined position by the diaphragm. 
6. A control system used by the invention will be explained, with reference 
to FIG. 13. In that Figure, vacuum is drawn in a brake booster BB by a 
vacuum pump VP, through a check valve CV. In FIG. 13A, diaphragm D in its 
closed position. In FIG. 13B, it is open. 
The invention is configured such that, in FIG. 13A, the diaphragm switch 
(not shown, but of the type shown in FIGS. 2-4) is closed. Conversely, in 
FIG. 13B, when the diaphragm D is open, the diaphragm switch is open. 
Therefore, as a general proposition, in this embodiment, an open diaphragm 
switch indicates that insufficient vacuum exists in the brake booster BB. 
However, while the vacuum pump VP is running, and irrespective of the 
pressure within the brake booster BB, the diaphragm D is held in the open 
position, as shown in FIG. 13B. Thus, the vacuum pump would tend to run 
indefinitely, because the diaphragm switch will never change state. 
In order to prevent this situation, the logic of FIG. 12 is implemented, 
preferably in the on-board computer of the vehicle. Initially, the logic 
checks the ignition switch, in block 50. If the switch is off, indicating 
that the vehicle is not running, the logic idles in loop 53. If the switch 
is on, the logic takes branch 55. 
In blocks 57 and 59, the logic inquires whether the diaphragm switch is 
open. (The diaphragm switch is indicated by contacts C1 and C2 in FIGS. 
2-5.) If not, indicating that sufficient vacuum is held in the brake 
booster BB in FIG. 13, the logic idles in loop 61. 
If the diaphragm switch is open, the logic takes branch 64. Block 66 starts 
the vacuum pump. Block 68 causes the pump to run for T seconds. The 
variable T is significant because, at different altitudes, different 
amounts of air must be exhausted from the brake booster BB to reach a 
given absolute vacuum. For example, at high altitudes, a lesser mass of 
air must be withdrawn. At lower altitudes, a greater mass must be 
withdrawn. 
The variable T is set to accommodate the worst-case situation, namely, at 
the lowest altitude expected. Therefore, block 68 causes the pump to run 
long enough to exhaust the brake booster sufficiently, at the lowest 
altitude expected. 
As stated above, the pump will now tend to continue running. Blocks 70 and 
72 prevent this. Block 70 stops the pump. This stoppage allows air to leak 
into chamber B in FIG. 13, causing the pressure in chamber B to eventually 
exceed that in chamber A, thereby closing the diaphragm D. The closed 
situation is shown in FIG. 13A, and the diaphragm switch (not shown) now 
closes. 
After a delay D in block 72, which is long enough to allow leakage to close 
the diaphragm, block 57 examines the diaphragm switch. If it is closed, 
indicating that sufficient vacuum exists in the brake booster BB, the 
logic idles in loop 61. 
If the diaphragm switch is open, indicating that insufficient vacuum 
exists, branch 64 is taken. 
If, for some reason, such as malfunction, the diaphragm switch does not 
close, the logic continually runs in loop 75, wherein the pump continually 
cycles for time T, and then waits for delay D. 
The combination of time T and delay D, which define the duty cycle of the 
pump, should be arranged so that sufficient vacuum exists in the presence 
of selected malfunctions which tend to lose vacuum. For example, the duty 
cycle will probably be arranged to maintain vacuum in the presence of a 
pinhole in the check valve CV in FIG. 13. However, the duty cycle will 
probably not be designed to maintain vacuum if a giant hole penetrates the 
brake booster BB. 
7. Some of the events discussed above can be explained with reference to 
TABLE 1, below. 
TABLE 1 
______________________________________ 
Booster Chamber Chamber Pump Muffler 
Event Pressure 
A Press. B Press. 
SW Flow Flow 
______________________________________ 
No Brakes 
Low Low HI CL No No 
Brakes HI Low HI CL No No 
After Brakes 
HI HI HI OP RT RT 
After T Low Low Low OP No No 
During D 
Low Low HI CL* LF LF 
After D Low Low HI CL No No 
______________________________________ 
*approaching 
The first line refers to driving without application of brakes. "Booster 
Pressure" (BB, FIG. 13) is Low (i.e., vacuum is maintained), as indicated. 
"Chamber A Pressure" is also Low, because connected to booster BB. 
"Chamber B pressure" is HI, because the pump is off, and the diaphragm D 
is closed. The diaphragm switch "SW" is closed. There is no "Pump Flow," 
as indicated by the entry "No." There is no "Muffler Flow," again, 
indicated by "No." 
The second line refers to ordinary application of brakes. Booster Pressure 
now goes HI, because atmospheric pressure is used to power assist the 
brakes. Booster porting maintains Chamber A at its original pressure until 
the brake is released, at which time the atmospheric side of the booster 
is ported to Chamber A, thereby requiring the pump to remove the air from 
the rear or high pressure side of the booster. However, Chamber A pressure 
stays LO, Chamber B Pressure stays HI, keeping the diaphragm D closed. 
There is no flow through the Pump or Muffler. 
A valve, not shown, is interconnected between Chamber A and the booster. 
When a driver applies brake, this valve maintains Chamber A separate from 
the booster, thereby explaining why the second line states that Chamber A 
Pressure is different from Booster Pressure. However, when the driver 
releases the brakes, this valve connects Chamber A with the booster, 
thereby allowing Chamber A Pressure to equalize with Booster Pressure, 
consistent with the third line, explained immediately below. 
The third line refers to the time interval after release of brakes. Booster 
Pressure remains HI, because nothing has replenished the booster. Chamber 
A Pressure is HI, because connected to Booster BB. The diaphragm D opens, 
causing switch SW to open. The logic of FIG. 14 starts the pump, causing 
Pump Flow and Muffler Flow in Table 1 to move to the right, RT. 
The fourth line refers to the time interval IMMEDIATELY after time T. 
Immediately after T, Booster Pressure is Low, as are both Chamber A and B 
Pressures. The diaphragm D is open, keeping the switch SW in an open 
state, OP. There is no flow in the Pump or Muffler. 
The fifth line refers to the time delay D. Booster Pressure is Low, as is 
Chamber A Pressure. Chamber B Pressure is HI, because diaphragm D is 
closed, causing the switch SW to be closed, CL. Flow through the Pump and 
Muffler is now to the left, LF, because of leakage. 
The last line refers to the time interval after the time delay D. The three 
pressures are the same as in the fifth line. The diaphragm D closes the 
switch SW. Airflow through the Pump and the Muffler have terminated. 
8. The logic described above is based on the concept that an open diaphragm 
switch corresponds to an open diaphragm, and appropriate steps are taken. 
However, the switch can be arranged, so that an open diaphragm corresponds 
to a closed switch. Modification of the logic shown in FIG. 12, to 
accommodate such an arrangement, is considered straightforward. 
9. FIG. 5 shows a "J" shaped support for contact C1. This support can be 
constructed of a bimetallic material which moves C1 left- or rightward, as 
temperature changes. This bending can offset opposite changes in the 
position of C2, also caused by temperature changes, but by expanding and 
contracting the components which support C2. Thus, the bi-metallic support 
introduces added temperature stability. 
Numerous substitutions and modifications can be undertaken without 
departing from the true spirit and scope of the invention. For example: 
1. Other gates beside a diaphragm can be used. A flapper valve can be used. 
A ball-type valve can be used. 
2. Mechanical electrical contacts were discussed above. However, these 
contacts provide one example of the more generic concept of proximity 
detection. FIG. 11 shows a PROXIMITY SENSOR, used to detect position of 
the diaphragm. 
The PROXIMITY SENSOR can take the form of a Hall Effect probe, an optical 
sensor, an inductive sensor, or other type. The invention is not 
restricted to the particular type of proximity detection discussed. 
3. A vacuum system was discussed above. However, the invention is also 
applicable to check valves used in positive-pressure systems. 
What is desired to be secured by Letters Patent is the invention as defined 
in the following claims.