Abstract:
A rotary valve plate adapted for housing within a conduit employs a vibration absorbing bumper pad coupled to the valve plate at a surface thereof adapted to contact an inner surface of the conduit whenever the valve plate is rotated to a closed position. The bumper pad minimizes vibratory noise and improves the durability of the valve plate over extended periods of operation.

Description:
FIELD 
       [0001]    The present disclosure relates to valve flaps or plates equipped with a vibration absorbing bumper pad. 
       BACKGROUND 
       [0002]    This section provides background information related to the present disclosure which is not necessarily prior art. 
         [0003]    Many exhaust systems in the automotive field have attempted to use both active and passive valve assemblies to alter the characteristics of exhaust flow through a conduit as the exhaust pressure increases due to increasing engine speed. Active valves carry the increased expense of requiring a specific actuating element, such as a solenoid. Passive valves utilize the pressure of the exhaust stream in the conduit with which the valve is associated. 
         [0004]    Traditionally, passive valves, even at their lower expense, give rise to problems of accelerated wear and vibratory noise or chatter when the valve switches from an open position to a fully closed position wherein a portion of the valve plate contacts an inner surface of the conduit housing the valve. 
       SUMMARY 
       [0005]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0006]    Accordingly, in a rotary valve plate adapted for housing within a conduit, a vibration absorbing bumper pad is coupled to the valve plate at a surface thereof adapted to contact an inner surface of the conduit whenever the valve plate is rotated to a closed position. 
         [0007]    In a further aspect of the disclosed teachings, an exhaust pressure actuated valve assembly for placement inside a tubular exhaust conduit includes a valve flap having first and second arcuate edges substantially conforming to and in contact with curved portions of the exhaust conduit when the valve flap is in a closed position. First and second linear edges of the valve flap extend between the first and second arcuate edges and provide clearance between the valve flap and an inner surface of the conduit when the valve flap is in a closed position. An axle is adapted to pivotally couple the valve flap to the exhaust conduit about a longitudinal axis of the axle. The axle includes first and second legs protruding outwardly of the first and second linear edges of the valve flap and adapted to be received in openings of the exhaust conduit. A vibration absorbing bumper pad is coupled to the valve flap at one of the first and second arcuate edges. 
         [0008]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0009]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0010]    The objects and features of the present teachings will become apparent upon a reading of a detailed description, taken in conjunction with the drawing, in which: 
           [0011]      FIGS. 1A and 1B  are a front plan view and a side plan view, respectively, of a snap action valve plate assembly arranged in accordance with the present teachings; 
           [0012]      FIG. 2  is an exploded view of a bumper pad and valve plate taken from the rear side of the plate; 
           [0013]      FIG. 3  is a rear view of the valve plate in the assembled bumper pad/valve plate condition; 
           [0014]      FIG. 4  is a perspective view of a front face of a valve plate assembly arranged in accordance with the present teachings; and 
           [0015]      FIGS. 5A ,  5 B present respective end and side cross-sectional views of a conduit housing a snap action valve plate arranged in accordance with the present teachings. 
       
    
    
       [0016]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0017]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0018]    Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
         [0019]    The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
         [0020]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
         [0021]    Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
         [0022]    With reference to  FIGS. 1A ,  1 B,  2 ,  3  and  4 , snap action valve plate  100  has a front surface  110 , a rear surface  112  and an indentation  114  in the valve plate for receipt of axle  116 . 
         [0023]    Valve plate  100  and axle  116  are substantially similar to the snap action valve assembly disclosed in commonly assigned U.S. Pat. No. 7,434,570. An improvement to snap action plate  100  is the addition of a vibration absorbing bumper pad  102  having a rear surface  106  and a front surface  108 . Compressed dent regions  104   a  and  104   b  of bumper pad  102  have an increased density and promote stronger spot welding of bumper pad  102  to valve plate  110  in the area of dents  104   a  and  104   b . Preferably, dent regions  104   a  and  104   b  are substantially circular as shown. 
         [0024]    Bumper pad  102  is preferably comprised of a vibration absorbing knitted metal mesh material, preferably stainless steel. 
         [0025]    As seen from  FIG. 1A , axle  116  has first and second legs extending from opposite edges of valve plate  110  and these legs are each surrounded by bushings  118   a  and  118   b  which preferably also are comprised of knitted stainless steel mesh. 
         [0026]    Bumper pad  102  is welded to valve plate  110  such that it covers one of the arcuate edges of valve plate  110  which comes into contact with an inner surface of a conduit in which it is mounted when the valve swings to its fully closed position as shown in solid lines in  FIGS. 5A and 5B . Valve plate  120  is shown in phantom outline in  FIG. 5B  when the valve has rotated to a fully opened position wherein linear edges  120  and  122  of valve plate  100  contact the inner surface of conduit  500 , and in this fully opened position edges  120  and  122  are substantially parallel to a longitudinal axis  503  of conduit  500 . In the closed position of valve  100  shown in  FIG. 5A , it is seen that the arcuate edges  124  and  126  of valve plate  100  are in contact with a matching arcuate internal surface of conduit  500 . A front surface  108  of bumper pad  102  cushions the impact between plate  120  and conduit  500  as the valve plate is rotated to the fully closed position. The mesh bumper pad thus absorbs vibrations and minimizes vibratory noise and excessive wear of the valve plate  120 . 
         [0027]    The foregoing description has been provided for purposes of illustration and example. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.