Patent Publication Number: US-11644116-B1

Title: Unitized valve body having flow passages

Description:
FIELD 
     The present disclosure relates to a valve body having flow passages and a vehicle including a valve body having flow passage. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     Transmission valve bodies typically consist of aluminum castings with worm trail routing of multiple connections between various working elements. These worm trail fluid paths typically must be two-dimensional, and cannot cross over a path of another trail. Due to this two-dimensional limitation of typical transmission valve bodies, providing a flow path from one element to another can often require a lengthy and convoluted path that adds to the complexity, cost, and size of the casting. 
     One method of overcoming this two-dimensional limitation includes manufacturing multiple valve bodies, each having its own two-dimensional worm trails, and connecting the valve bodies with one or more separator plates configured to permit fluid communication between the worm trails of the valve bodies in a third dimension at predetermined locations. Such separator plates require gasket seals and precise machining of the gasket surfaces. These separator plates also only allow binary cross-over of the hydraulic circuitry from one two-dimensional worm trail casting to another two-dimensional worm trail casting. Furthermore, the use of separator plates typically requires the use of additional fasteners to connect the assembly together, which can increase cost and assembly time. Additionally, the two-dimensional worm trails of each valve body must be routed around these fasteners, adding further size and complexity. 
     These sizing and complexity issues related to transmission valve bodies, among other issues related transmission valve bodies, are addressed by the present disclosure. 
     SUMMARY 
     This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features. 
     In one form, the present disclosure provides a unitized valve body for use in an automatic transmission. The unitized valve body comprises a plurality of valve bores and a plurality of hydraulic passages. Each valve bore is configured to receive a valve. The plurality of hydraulic passages are in fluid communication with the valve bores and arranged parallel to each other. The plurality of valve bores extend normal to the hydraulic passages and are arranged above and below the hydraulic passages. 
     In variations of the unitized valve body of the above paragraph, which may be implemented individually or in any combination: the valve bores are arranged above and below the hydraulic passages in a staggered arrangement; a plurality of annuluses in fluid communication with a respective valve bore, the hydraulic passages being in fluid communication with the valve bores via the annuluses; a first set of hydraulic passages of the plurality of hydraulic passages are arranged in a row; a second set of hydraulic passages of the plurality of hydraulic passages are arranged in a row and a linking passage fluidly connects one hydraulic passage of the first set of hydraulic passages with one hydraulic passage of the second set of hydraulic passages; the linking passage extends normal to the hydraulic passages and the valve bores; the hydraulic passages are substantially linear; the valve body does not include mechanical fasteners; the valve body is formed by additive manufacturing; and the hydraulic passages have a circular cross-section. 
     In another form, the present disclosure provides a unitized valve body for use in an automatic transmission. The unitized valve body comprises a plurality of valve bores and a plurality of hydraulic passages. The plurality of hydraulic passages are in fluid communication with the valve bores and are arranged parallel to each other. The hydraulic passages being substantially linear. The plurality of valve bores extend normal to the hydraulic passages and are arranged above and below the hydraulic passages. 
     In yet another form, the present disclosure provides a unitized valve body manufactured by an additive manufacturing process. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which: 
         FIG.  1    is a schematic view of a vehicle including a transmission having a valve body assembly according to the principles of the present disclosure; 
         FIG.  2    is a perspective view of the valve body assembly of  FIG.  1   ; 
         FIG.  3    is another perspective view of the valve body assembly of  FIG.  1   ; 
         FIG.  4    is a perspective view of a valve body of the valve body assembly of  FIG.  1   ; 
         FIG.  5    is a cross-sectional perspective view of the valve body of the valve body assembly of  FIG.  1   ; 
         FIG.  6    is another cross-sectional perspective view of the valve body of the valve body assembly of  FIG.  1   ; 
         FIG.  7    is yet another cross-sectional perspective view of the valve body of the valve body assembly of  FIG.  1   ; and 
         FIG.  8    is a schematic view of a portion of a hydraulic circuit of the transmission of  FIG.  1   . 
     
    
    
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     With reference to  FIG.  1   , a vehicle  10  is provided that includes a drivetrain system  12  and a powertrain system  14 . In the particular configuration shown in  FIG.  1   , the drivetrain system  12  includes, inter alia, a propeller shaft  16 , a primary axle  18 , a secondary axle  20 , and a rear differential  24 . Rotary power (vehicle torque) generated by the powertrain system  14  is transmitted to the drivetrain system  12 . That is, rotatory power generated by the powertrain system  14  is transmitted to the primary axle  18  via the propeller shaft  16  to drive a set of rear wheels  26 . The primary axle  18  includes a first shaft  18   a  and a second shaft  18   b . The first shaft  18   a  drives a first wheel  26   a  of the set of rear wheels  26  and the second shaft  18   b  drives a second wheel  26   b  of the set of rear wheels  26 . The secondary axle  20  includes a first shaft  20   a  and a second shaft  20   b . The first shaft  20   a  is connected to a first wheel  32   a  of a set of front wheels  32  and the second shaft  20   b  is connected to a second wheel  32   b  of the set of front wheels  32 . The powertrain system  14  includes an engine  34  and a transmission  36  such as an automatic transmission, for example. The engine  34  generates rotary power and may be an internal combustion engine, for example. 
     The transmission  36  transmits rotary power from the engine  34  to the drivetrain system  12 . The transmission  36  is generally controlled using hydraulic fluid. That is, the transmission  36  is cooled, lubricated, actuated, and modulates torque, for example, using hydraulic fluid. To these ends, the transmission  36  is in electrical communication with an electronic controller  40  used to direct, control, or otherwise regulate flow of fluid throughout the transmission  36 . In order to facilitate the flow of hydraulic fluid throughout the transmission  36 , the vehicle  10  includes at least one or more pumps to supply pressurized fluid to the transmission  36 . It should be appreciated that the pumps provide high flow high pressure hydraulic fluid to the transmission  36 . 
     The transmission  36  includes, inter alia, a casing (not shown) and a valve body assembly  38 . With reference to  FIGS.  2 - 7   , the valve body assembly  38  is secured to the casing and includes a plurality of solenoid actuators  48  and a valve body  50 . Each solenoid actuator  48  includes a spool valve (not shown; i.e., hydraulic control valve). The spool valve is slidably disposed within a corresponding valve bore  53  of the valve body  50  and is configured to be axially positioned by an armature (not shown) of the solenoid actuator  48  depending on an activation state of the solenoid actuator  48 . The spool valve includes a plurality of cylindrical sealing segments (not shown) axially spaced apart from each other and having an outer diameter greater than adjacent lengths of the spool valve. A cylindrical surface (not shown) of the sealing segments is allowed to engage an inner cylindrical surface of the valve bore  53 , while fluid communication is permitted in the areas between adjacent ones of the sealing segments. A spring (not shown) may bias the spool valve in an axial direction within the valve bore  53 . The solenoid actuators  48  can be on/off actuators, variable pressure actuators, or variable flow actuators and can receive electrical power from an electrical source and can receive control signals from a control module. 
     The valve body  50  is in the form of a single unitized, monolithic body that can be manufactured by an additive manufacturing process. In this way, the valve body  50  does not include fasteners such as bolts, for example, securing two or more shells or housings to each other and/or to one or more separator plates. In one example, the manufacturing process can include aluminum binder jetting. In another example, the manufacturing process can include laser sintering, for example, that can generally include a laser, a means for applying subsequent layers of powdered sintering material (e.g., metal powder), and a controller that controls operation of the laser and the amount and timing of the deposition of the metal powder. It should be understood that other 3D printing/additive manufacturing methods may be employed to achieve the unitized, monolithic body, along with a variety of different materials, while remaining within the scope of the present disclosure. 
     The valve body  50  includes a plurality of sides  62 . In the example illustrated, side  62   a  ( FIGS.  2 ,  4 , and  7   ) of the valve body  50  defines the plurality of valve bores  53  formed therein. The valve body  50  also defines a plurality of annuluses or rings  63  ( FIGS.  5  and  7   ) and a plurality of trunk hydraulic passages  64  ( FIGS.  4 - 7   ). The plurality of annuluses  63  are axially spaced apart from each other along a corresponding valve bore  53 . The annuluses  63  are also in fluid communication with the corresponding valve bore  53 . Each annulus  63  is also in fluid communication with a corresponding passage  64  via an inlet/outlet port. One example of such annulus  63  is disclosed in Applicant&#39;s co-pending application titled “UNITIZED VALVE BODY HAVING ANNULUS” which is commonly owned with the present application and the contents of which are incorporated herein by reference in its entirety. 
     A plurality of connecting passages  66  are in fluid communication with different devices through the transmission  36 . For example, the connecting passages  66  can be coupled to a corresponding one of a return line of a pump (not shown), an outlet of a cooling fluid circuit (not shown), a supply line of the pump (not shown), a clutch lubrication circuit (not shown), a clutch actuator (not shown) corresponding to the odd numbered gears (not shown) of the transmission  36 , a filtered fluid inlet (not shown), or a clutch actuator (not shown) corresponding to the even numbered gears (not shown) of the transmission  36 , though other devices can be used. 
     The plurality of connecting passages  66  are also in fluid communication with respective valve bores  53  and/or one or more hydraulic passages  64 . As shown in  FIG.  8   , in one example, passage  66   a  fluidly connects one annulus  63  associated with a respective valve bore  53  to another annulus  63  associated with the respective valve bore  53 . In another example, connecting passages  66   b ,  66   c  fluidly connect a respective annulus  63  associated with one valve bore  53  to a respective annulus  63  associated with another valve bore  53 . The first and second connecting passages  66   b ,  66   c  may be fluidly connected via a respective hydraulic passage  64 . 
     With reference to  FIGS.  4 - 8   , the hydraulic passages  64  may be connected to a pressurized fluid source such as a pump located external to the valve body  50 . The hydraulic passages  64  are also in fluid communication with the valve bores  53  and are arranged parallel to each other. The valve bores  53  extend normal to the hydraulic passages  64  and are arranged above and below the hydraulic passages  64  in a staggered arrangement ( FIG.  5   ). In the example illustrated, each hydraulic passage  64  is substantially linear and has a generally circular cross-section. In some forms, the hydraulic passages  64  may have a semi-circular or other suitable cross-section, for example, allowing hydraulic fluid to easily flow through. One or more of the hydraulic passages  64  extend substantially a length of the valve body  50 . A set of hydraulic passages  64  are arranged in a row and are fluidly isolated from each other ( FIGS.  4  and  6   ). One hydraulic passage  64  of the set of hydraulic passages  64  arranged in one row is in fluid communication with a corresponding hydraulic passage  64  of another set of hydraulic passages  64  arranged in another row via a linking passage  70 . The linking passage  70  extends normal to the hydraulic passages  64  and the valve bores  53 . The annuluses  63  are 2.1 times greater than the diameter of the hydraulic passages  64 . The valve bores  53  are 2 times greater than the diameter of the hydraulic passages  64 . The linking passages  70  are 1.5 times greater than the diameter of the hydraulic passages  64 . 
     The valve body  50  of the present disclosure being additively manufactured provides the benefit of allowing multiple hydraulic passages  64  of the plurality of hydraulic passages  64  to be connected to the valve bores  53 . In this way, the hydraulic passages  64  are positioned parallel to each other and the valve bores  53  may be arranged above and below the hydraulic passages  64  in a staggered arrangement, which reduces the overall footprint of the valve body  50 . The valve body  50  of the present disclosure being additively manufactured also provides the benefit of reduced passage lengths allowed by connecting passages in multiple dimensions. 
     Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability. 
     As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” 
     In this application, the term “controller” and/or “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components (e.g., op amp circuit integrator as part of the heat flux data module) that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip. 
     The term memory is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc). 
     The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer. 
     The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.