Patent Publication Number: US-2023139552-A1

Title: Coolant flow control valve

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of provisional application 63/263,422, filed Nov. 2, 2021. The disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to a multi-port coolant flow control valve assembly which includes a rotor having various channels which are used to configure the multi-port valve assembly to have various flow paths between multiple ports. 
     BACKGROUND OF THE INVENTION 
     Multi-port valves for directing fluid through various conduits are generally known. Some of the more common types of valve are a three-port valve and a four-port valve, where a single valve member is used to direct fluid from an inlet port to one of several outlet ports. Some multi-port valves include a five-port configuration, where multiple actuators are used to change the configuration of the valve to direct the flow of fluid as desired. There are also manifold style valves up to eight ports are available but offer very little flexibility to accommodate different flow modes and different flow paths. 
     These current designs have a limited amount of ports and flow channels, and may include the use of a proportioning valve, where the maximum number of three flow configurations is achieved using a five-port valve. For a non-proportioning valve, maximum number of inlets/outlets is eight. Current thermal management systems require the use of multiple valves to provide thermal management to desired components. Using multiple valves also requires multiple actuators driven separately by a control unit, and each of the actuators and valves may have different mounting requirements. This results in increased cost due to multiples of the same components used for each valve (i.e., holding bracket, actuator, electrical harness, etc.). Extra connections for fluid flow between different valves are also required, which also influences cost, and can be complex to manufacture. Some of these existing designs offer little to no flexibility to accommodate multiple flow modes and multiple flow paths. 
     Accordingly, there exists a need for a multi-port valve assembly which is able to direct flow from an inlet port to multiple outlet ports, which enables a simpler thermal management system and is less costly to manufacture. 
     SUMMARY OF THE INVENTION 
     In an embodiment, the present invention is a coolant flow control valve (CFCV) which includes an actuator which is used to rotate a rotor to one or more positions, and thus direct coolant (passing through the rotor) between ports. The rotor is rotated to different positions to create various flow paths, such that coolant is directed between the different openings linking various components of a thermal management system. 
     In an embodiment, the present invention is a multi-level rotor which accommodates an increased number of inlet ports, outlet ports, and flow channels using a single rotor located in a housing, enabling a larger number of flow configurations. 
     In an embodiment, the housing includes nine ports which may function as an inlet or an outlet, which achieve different flow configurations. 
     For a thermal management system, reduced cost and less space utilization is achieved by a reduced number of valves in a system, where a single rotor is able to fluidically connect nine inlets/outlets, and a reduced number of supporting components (i.e., holding brackets, hoses, harnesses etc.). 
     In an embodiment, the present invention includes a multi-level flow routing rotor which enables different flow configurations at each level, depending on the degree of rotation. The channels at different levels are sealed from each other within the housing allowing multiple flow configurations. The flow channels are manufactured into a single entity and thus always have same positional accuracy relative to each other when the rotor is moving. At different rotational angles of the rotor, flow channels at each level flow into/out of different mating ports. 
     In an embodiment, the present invention is a coolant flow control valve assembly, which includes a housing, a plurality of ports, each of the plurality of ports formed as part of the housing, a rotor disposed in the housing, and a plurality of channels integrally formed as part of the rotor, each of the channels selectively in fluid communication with one or more of the ports. The coolant flow control valve assembly also includes a first plane extending through the rotor, a second plane extending through the rotor, a first level on one side of the first plane, where a portion of the channels is integrally formed as a part of the rotor which is located on the first level, a second level on the opposite side of the first plane in relation to the first level, and located between the first plane and the second plane, where a portion of the channels is integrally formed as a part of the rotor which is located on the second level, and a third level located on the opposite side of the second plane in relation to the second level, where a portion of the channels is integrally formed as part of the rotor which is located on the third level. In an embodiment, the coolant flow control valve assembly also includes a plurality of flow paths formed by the orientation of the rotor relative to the housing and the ports, where the rotor is placed in one of a plurality of configurations to achieve the flow paths. 
     In an embodiment, the channels includes at least one recess channel integrally formed as part of the rotor, where the recess channel is located on the third level, at least one through-channel integrally formed as part of the rotor, where the through-channel is located on the second level, at least one side channel integrally formed as part of the rotor, and a central channel integrally formed as part of the rotor, where the central channel is in fluid communication with the side channel. In an embodiment, the rotor is rotated relative to the housing such that one of the flow paths includes one of the recess channel, the through-channel, or the side channel. 
     In an embodiment, the recess channel is fluidically isolated from the second recess channel, the through-channel, and the side channel. In an embodiment, the through-channel is fluidically isolated from the side channel. 
     In an embodiment, the at least one side channel includes a shallow recess portion, and an elongated channel integrally formed with and in fluid communication with the shallow recess portion. The elongated channel is in fluid communication with the central channel. In an embodiment, the shallow recess portion is located on the second level, and the elongated channel is located on the first level. 
     In an embodiment, the shallow recess portion further comprising at least one bulge portion, and the rotor is rotated an angular distance between two or more of a plurality of configurations, such that the side channel maintains fluid communication with one of the ports as the rotor is rotated between two or more of the configurations. 
     In an embodiment, the central channel is located on the first level. 
     In an embodiment, the recess channel includes a first recess channel integrally formed as part of the rotor, where the first recess channel is located on the third level, and a second recess channel integrally formed as part of the rotor, where the second recess channel is located on the third level. In an embodiment, the rotor is rotated relative to the housing such that one of the flow paths includes one of the first recess channel, the second recess channel, or the side channel. 
     In an embodiment, at least one of the flow paths facilitates flow between the first level and the second level. 
     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 A  is side view of a coolant flow control valve, according to embodiments of the present invention; 
         FIG.  1 B  is a sectional view taken along line  1 B- 1 B of  FIG.  1 A ; 
         FIG.  1 C  is first side view of a rotor used as part of a first embodiment of a coolant flow control valve assembly, according to embodiments of the present invention; 
         FIG.  1 D  is a perspective view of a rotor used as part of a first embodiment of a coolant flow control valve assembly, according to embodiments of the present invention; 
         FIG.  1 E  is a second side view of a rotor used as part of a first embodiment of a coolant flow control valve assembly, according to embodiments of the present invention; 
         FIG.  1 F  is a third side view of a first embodiment of a coolant flow control valve assembly, according to embodiments of the present invention; 
         FIG.  1 G  is a sectional view taken along lines  1 G- 1 G of  FIG.  1 E ; 
         FIG.  1 H  is a sectional view taken along lines  1 H- 1 H of  FIG.  1 F ; 
         FIG.  2 A  is a first sectional view of a coolant flow control valve assembly taken along lines  2 A- 2 A in  FIG.  1 A , with the rotor in a first configuration, according to embodiments of the present invention; 
         FIG.  2 B  is a second sectional view of a coolant flow control valve assembly taken along lines  2 B- 2 B in  FIG.  1 A , with the rotor in a first configuration, according to embodiments of the present invention; 
         FIG.  2 C  is a third sectional view of a coolant flow control valve assembly taken along lines  2 C- 2 C in  FIG.  1 A , with the rotor in a first configuration, according to embodiments of the present invention; 
         FIG.  3 A  is a first sectional view of a coolant flow control valve assembly, with the rotor in a second configuration, according to embodiments of the present invention; 
         FIG.  3 B  is a second sectional view of a coolant flow control valve assembly, with the rotor in a second configuration, according to embodiments of the present invention; 
         FIG.  3 C  is a third sectional view of a coolant flow control valve assembly, with the rotor in a second configuration, according to embodiments of the present invention; 
         FIG.  4 A  is a first sectional view of a coolant flow control valve assembly, with the rotor in a third configuration, according to embodiments of the present invention; 
         FIG.  4 B  is a second sectional view of a coolant flow control valve assembly, with the rotor in a third configuration, according to embodiments of the present invention; 
         FIG.  4 C  is a third sectional view of a coolant flow control valve assembly, with the rotor in a third configuration, according to embodiments of the present invention; 
         FIG.  5 A  is a first sectional view of a coolant flow control valve assembly, with the rotor in a fourth configuration, according to embodiments of the present invention; 
         FIG.  5 B  is a second sectional view of a coolant flow control valve assembly, with the rotor in a fourth configuration, according to embodiments of the present invention; 
         FIG.  5 C  is a third sectional view of a coolant flow control valve assembly, with the rotor in a fourth configuration, according to embodiments of the present invention; 
         FIG.  6 A  is a first sectional view of a coolant flow control valve assembly, with the rotor in a fifth configuration, according to embodiments of the present invention; 
         FIG.  6 B  is a second sectional view of a coolant flow control valve assembly, with the rotor in a fifth configuration, according to embodiments of the present invention; and 
         FIG.  6 C  is a third sectional view of a coolant flow control valve assembly, with the rotor in a fifth 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 first embodiment of a coolant flow control valve assembly according to the present invention in shown in  FIGS.  1 A- 6 C  generally at  10 . Referring to  FIGS.  1 A- 1 H , the valve assembly  10  includes a housing  12 , and inside the housing  12  is a cavity, shown generally at  14 . Located in the cavity  14  is a valve member, which in this embodiment is a rotor, shown generally at  16 . The rotor  16  is generally cylindrical in shape. The rotor  16  is able to rotate about an axis  18 . In an embodiment, the rotor  16  is connected to a gear train, which is driven by an electric motor to rotate the rotor in the housing  12 , but it is within the scope of the invention that the rotor  16  may be rotated using other devices. 
     The housing  12  includes several ports  20   a , 20   b , 20   c , 20   d , 20   e ,  20   f , 20   g , 20   h , 20   i . The ports  20   a , 20   b , 20   c , 20   d , 20   e , 20   f , 20   g , 20   h , 20   i  are in selective fluid communication with various channels integrally formed as part of the rotor  16 . The rotor  16  has channels which distribute fluid between two levels, a first level, shown generally at  22 , a second level, shown generally at  24 , and a third level, shown generally at  26 . The first level  22  and the second level  24  are separate by a first plane  28 , where the first level  22  is on one side of the first plane  28 , and the second level  24  is on the opposite side of the first plane  28  as the first level  22 . The second level  24  and the third level  26  are separated by a second plane  30 , where the second level  24  is on the opposite side of the second plane  30  as the third level  26 . 
     One of the ports  20   e  is on one side of the first plane  28  on the first level  22 , and another portion of the ports  20   a , 20   b , 20   c , 20   d  is located on the opposite side of the first plane  28  on the second level  24 . The portion of the ports  20   a , 20   b , 20   c , 20   d  located on the second level  24  are also on one side of the second plane  30 , and another portion of the ports  20   f , 20   g , 20   h , 20   i  are on the opposite side of the second plane  30  on the third level  26 . 
     Integrally formed as part of the rotor  16  is a first side channel, shown generally at  32 , a second side channel, shown generally at  34 , and a third side channel, shown generally at  36 . The first side channel  32  includes a first shallow recess portion  32   a  and a first elongated channel  32   b , which are in fluid communication with each other. The first elongated channel  32   b  is in fluid communication with a central channel  38 . The first shallow recess portion  32   a  is located on the second level  24  and the first elongated channel  32   b  is located on the first level  22 , such that when the rotor  16  is placed in one of a plurality of configurations, the fluid is able to flow between the first level  22  and the second level  24 . 
     The second side channel  34  includes a second shallow recess portion  34   a  and a second elongated channel  34   b , which are in fluid communication with each other. The second elongated channel  34   b  is in fluid communication with the central channel  38 . The second shallow recess portion  34   a  is located on the second level  24 , and the second elongated channel  34   b  is located on the first level  22 , such that when the rotor  16  is placed in one of a plurality of configurations, the fluid is able to flow between the first level  22  and the second level  24 . 
     The third side channel  36  includes a third shallow recess portion  36   a  and a third elongated channel  36   b , which are in fluid communication with each other. The third elongated channel  36   b  is in fluid communication with the central channel  38 . The third shallow recess portion  36   a  is located on the second level  24 , and the third elongated channel  36   b  is located on the first level  22 , such that when the rotor  16  is placed in one of a plurality of configurations, the fluid is able to flow between the first level  22  and the second level  24 . Because the first side channel  32 , the second side channel  34 , and the third side channel  36  are all in fluid communication with the central channel  38 , the first side channel  32 , the second side channel  34 , and the third side channel  36  are all in fluid communication with each other. Furthermore, the central channel  38  is in fluid communication with the fifth port  20   e . The third shallow recess portion  36   a  also incudes a bulge portion  36   c , such that the third shallow recess portion  36   a  is also wider than the first shallow recess portion  32   a  and the second shallow recess portion  34   a.    
     Also integrally formed as part of the rotor  16  is a through-channel, shown generally at  40 , which is located on the second level  24 . The through channel  40  includes an elongated through-channel portion, shown generally at  40   a , and a wide portion, shown generally at  40   b , which are in fluid communication with one another. The elongated through-channel portion  40   a  extends through the rotor  16  such that the elongated through-channel portion  40   a  intersects with the axis  18 . 
     Also formed as part of the rotor  16  is a first recess channel, shown generally at  42 , and a second recess channel, shown generally at  44 , where both of the recess channels  42 , 44  are located on the third level  26 . The first recess channel  42  includes a first side wall  42   a , an outer wall  42   b , and an inner wall  42   c.  The second recess channel  44  includes a second side wall  44   a , an outer wall  44   b , and an inner wall  44   c.    
     The through channel  40  is fluidically isolated from the first side channel  32 , the second side channel  34 , and the third side channel  36 , and the through channel  40  is also fluidically isolated from the first recess channel  42  and the second recess channel  44 . The first recess channel  42  and the second recess channel  44  are also fluidically isolated from the first side channel  32 , the second side channel  34 , and the third side channel  36 . 
     Various configurations of the rotor  16  relative to the housing  12  are shown in  FIGS.  2 A- 6 C , which achieve various flow configurations.  FIG.  2 A  is a sectional view taken along lines  2 A- 2 A in  FIG.  1 A ,  FIG.  2 B  is a sectional view taken along lines  2 B- 2 B in  FIG.  1 A , and  FIG.  2 C  is a sectional view taken along lines  2 C- 2 C in  FIG.  1 A .  FIGS.  3 A- 6 C  are similar sectional views, with the rotor  16  in different configurations. 
     Referring to  FIGS.  2 A,  2 B, and  2 C , the rotor  16  is placed in a first configuration, where port  20   e  is in fluid communication with port  20   b  through the first side channel  32  to create a first flow path  100 , where the first flow path  100  includes flow between the first level  22  and the second level  24  through the first shallow recess portion  32   a  and the first elongated channel  32   b . When the rotor  16  is in the first configuration, the port  20   a  is in fluid communication with the port  20   d  through the wide portion  40   b  of the through channel  40  to create a second flow path  102 , the port  20   f  in in fluid communication with the port  20   g  through the first recess channel  42  to create a third flow path  104 , and the port  20   h  is in fluid communication with the port  20   i  through the second recess channel  44  to create a fourth flow path  106 . There is no fluid that passes through the side channels  34 , 36 , the elongated through-channel portion  40   a , or the port  20   c.    
     Referring to  FIGS.  3 A,  3 B, and  3 C , the rotor  16  is placed in a second configuration, where the port  20   d  is in fluid communication with the port  20   e  through the third side channel  36  to form a fifth flow path  108 , where the fifth flow path  108  includes flow between the first level  22  and the second level  24  through the third shallow recess portion  36   a  and the third elongated channel  36   b . When the rotor  16  is in the second configuration, the port  20   a  is in fluid communication with the port  20   b  through the wide portion  40   b  of the through channel  40  to create a sixth flow path  110 , the port  20   g  is in fluid communication with the port  20   h  through the first recess channel  42  to create a seventh flow path  112 , and the port  20   f  is in fluid communication with the port  20   i  through the second recess channel  44  to create an eighth flow path  114 . There is no fluid that passes through the side channels  32 , 34  or the port  20   c.    
     Referring to  FIGS.  4 A,  4 B, and  4 C , the rotor  16  is placed in a third configuration, and the third configuration includes, the second flow path  102 , the third flow path  104 , and the third flow path  106 . When the rotor  16  is in the third configuration, the port  20   e  is in fluid communication with the port  20   c  through the second side channel  34 , creating a ninth flow path  116 , where the ninth flow path  116  includes flow between the first level  22  and the second level  24  through the second shallow recess portion  34   a  and the second elongated channel  34   b . There is no fluid that passes through the first side channel  32 , the third side channel  36 , or the port  20   b  when the rotor  16  is in the third configuration. 
     The rotor  16  is in a fourth configuration in  FIGS.  5 A,  5 B , and  5 C. The fourth configuration also includes the third flow path  104 , the fourth flow path  106 , and the fifth flow path  108 . However, when the rotor  16  is in the fourth configuration, the port  20   a  is in fluid communication with the port  20   c  through the elongated through-channel portion  40   a  and the wide portion  40   b  of the through channel  40 , creating a tenth flow path  118 . There is no fluid that flows through the side channels  32   b , 34   b  or the port  20   b.    
     Referring to  FIGS.  6 A,  6 B, and  6 C , the rotor  16  is placed in a fifth configuration, and the fifth configuration includes, the fifth flow path  108 , the seventh flow path  112 , the eighth flow path  114 , and the tenth flow path  118 . 
     As mentioned above, bulge portion  36   c  is part of the third shallow recess portion  36   a , such that the third shallow recess portion  36   c  is wider compared to the first shallow recess portion  32   a  and the second shallow recess portion  34   a . The bulge portion  36   c  allows for the rotor  16  to be rotated an angular distance, such that the third side channel  36  remains in fluid communication with the port  20   d  when the rotor  16  is rotated between the second configuration, fourth configuration, and the fifth configuration. This allows for the fifth flow path  108  to be maintained when the rotor  16  is rotated between the second configuration, fourth configuration, and the fifth configuration. The bulge portion  36   c  provides for similar fluid communication is able to be maintained between the third side channel  36  and the port  20   a , between the third side channel  36  and the port  20   b , or between the third side channel  36  and the port  20   c , as the rotor  16  is rotated to other possible configurations. 
     It is within the scope of the invention that the rotor  16  in either embodiment may be placed in additional configurations to achieve other flows paths in addition to the ones already described. 
     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.