Patent Publication Number: US-2021180526-A1

Title: Valve housing, exhaust-gas valve, exhaust system, vehicle, and method of manufacturing an exhaust-gas valve

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a U.S. non-provisional application claiming the benefit of German Application No. 10 2019 134 663.0, filed on Dec. 17, 2019, which is incorporated herein by reference in its entirety. 
     TECHNICAL FIELD 
     The disclosure relates to a valve housing for an exhaust-gas valve, comprising a first housing half-shell and a second housing half-shell, wherein the first housing half-shell and the second housing half-shell complement each other to form the valve housing. 
     The disclosure also relates to an exhaust-gas valve having such a valve housing. 
     Furthermore, the disclosure is directed to an exhaust system having such an exhaust-gas valve, and to a vehicle having such an exhaust system. 
     In addition, the disclosure relates to a method of manufacturing an exhaust-gas valve having a valve housing comprising a first housing half-shell and a second housing half-shell, and having a valve flap assembly. 
     BACKGROUND 
     Valve housings, exhaust-gas valves, exhaust gas systems, vehicles and methods of manufacturing exhaust-gas valves are known from the prior art. 
     The general aim is to design the aforementioned objects such that they can be manufactured in a cost-effective manner Accordingly, associated manufacturing methods should also be adapted to be realized in a cost-effective manner 
     At the same time, exhaust-gas valves, exhaust systems and vehicles must function reliably during operation. Valve housings, exhaust-gas valves and exhaust systems in particular can be exposed to high temperatures resulting from hot exhaust-gas flows. As exhaust systems often also include components which are only temperature-resistant up to a certain limit, exhaust-gas valves are also used to separate such components from hot exhaust-gas flows when necessary. It is of particular importance that the exhaust-gas valve closes tightly, i.e. that it allows no or only slight leakage in the closed state. Otherwise, there is a risk that the components with limited temperature resistance will be damaged. 
     It is clear that a small leakage, which requires a precise matching of the components of an exhaust-gas valve to each other, conflicts at least partially with a low-cost manufacturability. Therefore, when designing exhaust-gas valves, a compromise must always be found between a reliable function, in particular with regard to undesirable leakages, and low-cost manufacturability. The same applies to exhaust systems and vehicles equipped therewith. 
     SUMMARY 
     The subject disclosure provides an improved exhaust-gas valve that addresses the conflict of objectives between a low-cost manufacturability and a reliable function. The disclosed exhaust-gas valve can be manufactured in a cost-effective manner and at the same time works reliably, i.e. in particular avoids or at least reduces undesirable leakages. 
     For this purpose a valve housing is provided that includes a first housing half-shell and a second housing half-shell, wherein the first housing half-shell and the second housing half-shell complement each other to form the valve housing. A first valve seat for a valve flap of a valve flap assembly is formed exclusively on the first housing half-shell, and a swivel bearing mount to swivel mount the valve flap within the valve housing is formed on the first housing half-shell. 
     Such a configuration of the valve housing facilitates the manufacture thereof and the fitting of the valve flap assembly in the valve housing. In this context, the valve flap assembly is fitted only on the first housing half-shell. This is comparatively simple, as only two assemblies need to be fitted together. In addition, a good accessibility of the valve flap assembly is ensured during fitting. This allows the valve flap assembly to be fitted quickly and precisely on the first housing half-shell. This results in a reliable function of an exhaust-gas valve equipped with the valve housing. In particular, it has only little or no undesirable leakage. The second housing half-shell is therefore not required at all for fitting the valve flap assembly. It is placed onto the first housing half-shell in a subsequent fitting step. The fitting of an exhaust-gas valve having such a valve housing can thus generally be carried out quickly and with little effort. 
     In particular, the valve flap and/or swivel bearing mount is formed exclusively on the first housing half-shell. 
     The term “exclusively” means that the first valve seat or the swivel bearing mount is completely formed on the first housing half-shell, i.e. no part of the first valve seat or of the swivel bearing mount is formed on the second housing half-shell, and/or that no first valve seat or swivel bearing mount at all is formed on the second housing half-shell. 
     Preferably, the first housing half-shell and/or the second housing half-shell are formed sheet metal parts or is a formed sheet metal part. In particular, the first housing half-shell and/or the second housing half-shell are stamped-bent parts or is a stamped-bent part or deep-drawn parts or a deep-drawn part. Such housing half-shells can be produced at comparatively low cost. Formed sheet metal parts are in particular excellently suited for manufacture within the context of a mass production. Formed sheet metal parts can still be produced easily and cost-effectively even if they have a comparatively complex shape as functionally integrated components. The valve housing may thus be produced easily and cost-effectively in large quantities. 
     The valve housing may be a 3-way valve housing. The valve housing can therefore have three fluid connections, in particular exhaust-gas connections. The valve housing can thus be used in numerous cases of application in the field of exhaust-gas valves. 
     In one embodiment, a second valve seat for the valve flap is formed on the first housing half-shell, in particular it is formed exclusively on the first housing half-shell. Here, the term “exclusively” is to be understood again as already explained with regard to the first valve seat. The second valve seat is thus completely formed on the first housing half-shell, i.e. no part of the second valve seat is formed on the second housing half-shell and/or no second valve seat is formed at all on the second housing half-shell. The second valve seat is separate from the first valve seat. Preferably, the first valve seat is assigned to a first position of the valve flap, and the second valve seat is assigned to a second position of the valve flap which is separate therefrom. This means that the valve flap can only cooperate with valve seats that are provided on the same component, namely on the first housing half-shell. Therefore, the valve flap can be easily and reliably aligned with respect to the first valve seat and the second valve seat so that a high degree of tightness is ensured in the corresponding positions of the valve flap. In other words, unwanted leakage is avoided or at least significantly reduced. 
     According to a variant, the swivel bearing mount comprises two bearing openings for receiving a valve flap shaft of the valve flap assembly, the bearing openings being arranged opposite each other in the first housing half-shell. The valve flap shaft can be inserted into the two bearing openings. In particular, additional bearing elements and/or sealing elements are provided within the bearing openings for this purpose. This results in a simple and reliable mounting of the valve flap shaft. In addition, it can be fitted comparatively quickly on the first housing half-shell. 
     The first housing half-shell and the second housing half-shell can be connected to each other by a weld seam or a soldered seam. The first housing half-shell and the second housing half-shell are thus reliably connected to each other. At the same time, such a connection can be created using standard manufacturing methods and production equipment. In particular, a laser welding method, a metal active gas welding method or a soldering method may be used for this purpose. In addition, the two housing half-shells can be connected to each other in a gas-tight manner by the weld seam or the soldered seam. Alternatively, a seal may be provided between the first housing half-shell and the second housing half-shell so that only a mechanical connection between the housing half-shells has to be made by the weld seam or the soldered seam. 
     Furthermore, the first housing half-shell and the second housing half-shell may each have a connecting edge which is angled outwards, the housing half-shells being fastened to each other via the connecting edges. Preferably, the housing half-shells lie flat against each other via the connecting edges. The housing half-shells can thus be fastened to each other and sealed against each other relatively easily. 
     Alternatively, the first housing half-shell or the second housing half-shell may have a connecting edge. Here, the connecting edge extends from a housing wall of the first housing half-shell or a housing wall of the second housing half-shell and is offset outwards parallel to the housing wall. In addition, the housing half-shells are fastened to each other via the connecting edge. In this alternative, only one of the housing half-shells has a connecting edge. The housing half-shell having no connecting edge is inserted into a space within the connecting edge provided on the other housing half-shell. Such a connecting edge is colloquially referred to as a shoe box edge and such a connection as a shoebox connection. This is because the two housing half-shells are put together in the same way as a shoe box and the lid thereof. 
     For above purpose an exhaust-gas valve is provided, which has a valve housing according to the disclosure and is equipped with a valve flap assembly. The valve flap assembly comprises a valve flap and a valve flap shaft. The valve flap shaft is received in the swivel bearing mount such that the valve flap can be swiveled within the valve housing. Thus, the valve flap assembly is mounted exclusively on the first housing half-shell. The associated valve flap is therefore located within the valve housing. Due to the features and effects already mentioned for the valve housing, such an exhaust-gas valve can be installed comparatively quickly and easily. In addition, such an exhaust-gas valve has only a low level of undesirable leakage, as the valve flap assembly is precisely aligned with respect to the valve housing. This makes such an exhaust-gas valve particularly suitable for reliably protecting temperature-sensitive components against undesired heat and/or temperature effects. Furthermore, the features and advantages mentioned with regard to the valve housing apply equally to the exhaust-gas valve and vice versa. 
     In addition, for above purpose an exhaust system is provided having an exhaust-gas valve according to the disclosure. The features and advantages mentioned for the valve housing and the exhaust-gas valve apply equally to such an exhaust system. 
     The exhaust system may have a heat recovery system for recovering heat from exhaust gas and/or an exhaust gas recirculation system for introducing exhaust gas into an intake tract. The exhaust-gas valve may be a component of the heat recovery system and/or the exhaust gas recirculation system, in particular wherein an exhaust-gas supply to the heat recovery system and/or the exhaust gas recirculation system is adapted to be shut off by the exhaust-gas valve. Thus, the heat recovery system and/or the exhaust gas recirculation system can be reliably protected against the influence of high temperatures. These result in particular from hot exhaust-gas flows. 
     For above purpose, a vehicle having an exhaust system according to the disclosure is provided. The features and advantages mentioned for the valve housing, the exhaust-gas valve and the exhaust system apply equally to such a vehicle. 
     In addition, for above purpose a method of the type initially mentioned of manufacturing an exhaust-gas valve is provided, comprising the following steps: 
     a) mounting the valve flap assembly in the first housing half-shell so that a valve flap of the valve flap assembly is adapted for swiveling movement within the first housing half-shell, and 
     b) subsequently fastening the second housing half-shell to the first housing half-shell, the first housing half-shell and the second housing half-shell complementing each other to form the valve housing. 
     Thus, the valve flap assembly is initially fitted only on the first housing half-shell. The second housing half-shell thus only needs to be fastened to the first housing half-shell. The second housing half-shell is therefore only indirectly connected to the valve flap assembly. This generally results in a fast and cost-effective manufacture of the exhaust-gas valve. As the valve flap only has to be fitted directly in the first housing half-shell, the corresponding areas are easily accessible. This enables a precise fitting. Incidentally, the features and advantages mentioned for the valve housing, the exhaust-gas valve, the exhaust system and the vehicle apply equally to the method and vice versa. 
     The valve flap assembly can be aligned with at least one valve seat provided for cooperation with the valve flap. The alignment is carried out in particular during the fitting of the valve flap assembly and further in particular before the second housing half-shell is fastened to the first housing half-shell. The valve flap assembly is therefore easily accessible for alignment. Preferably, the at least one valve seat is provided on the first housing half-shell. The alignment of the valve flap assembly is thus no longer affected by the fitting of the second housing half-shell. Thus, an exhaust-gas valve may be manufactured which has no or only a small amount of unwanted leakage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be explained below using various example embodiments shown in the attached drawings in which: 
         FIG. 1  shows a motor vehicle according to the disclosure having an exhaust system according to the disclosure, which comprises an exhaust-gas valve according to the disclosure which has a valve housing according to the disclosure, the exhaust-gas valve being manufactured by a method according to the disclosure, 
         FIG. 2  shows a detail of the exhaust system according to the disclosure from  FIG. 1 , 
         FIG. 3  shows the valve housing according to the disclosure from  FIGS. 1 and 2  in a perspective detail view, 
         FIG. 4  shows a first housing half-shell of the valve housing from  FIG. 3 , 
         FIG. 5  shows a second housing half-shell of the valve housing from  FIG. 3 , 
         FIG. 6  shows a valve housing according to the disclosure in an alternative embodiment, 
         FIG. 7  shows a first housing half-shell of the valve housing from  FIG. 6 , and 
         FIG. 8  shows a second housing half-shell of the valve housing from  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION 
     Lists having a plurality of alternatives connected by “and/or”, for example “A, B and/or C” are to be understood to disclose an arbitrary combination of the alternatives, i.e. the lists are to be read as “A and/or B and/or C”. The same holds true for listings with more than two items. 
       FIG. 1  shows a vehicle  10  having an internal combustion engine  12  coupled to an exhaust system  14 . The purpose of the exhaust system  14  is to direct exhaust gas generated by the internal combustion engine  12  to an environment  16 . 
     As shown in  FIG. 2 , the exhaust system  14  comprises an engine-side exhaust-gas line  18  in the form of an engine-side exhaust-gas pipe. 
     The latter is adjoined by a branching point  22 , from which a first branch  24  of the exhaust system  14  and a second branch  36  originate. 
     The first branch  24  is fluidically coupled with an exhaust gas recirculation line  28  and an exhaust gas recirculation valve  30 . 
     The first branch  24  is also equipped with a heat exchanger  26 . 
     In addition, the first branch  24  is connected to an exhaust-gas valve  34  via an outflow line  32 . 
     The second branch  36  is configured without a heat exchanger and opens into the exhaust-gas valve  34 . 
     On the ambient side, an outlet line  38  is provided on the exhaust-gas valve  34 . 
     The exhaust-gas valve  34  comprises a valve housing  40  and a valve flap assembly  42 , wherein the valve flap assembly  42  in turn includes a valve flap shaft  44  and a valve flap  46 . 
     As in the representation of  FIG. 2  the valve flap assembly  42  is located within the valve housing  40 , the hidden components of the valve flap assembly  42  are shown as dashed lines. 
     The valve flap  46  is mounted for swiveling movement in the valve housing  40  via the valve flap shaft  44 . 
     The valve housing  40  is shown in detail in  FIGS. 3 to 5 . 
     It comprises a first housing half-shell  48  and a second housing half-shell  50 , which complement each other to form the valve housing  40 . 
     The valve housing  40  has a substantially cuboid shape. 
     Both the first housing half-shell  48  and the second housing half-shell  50  are formed sheet metal parts which were produced by deep drawing in the example embodiment shown. In other words, the first housing half-shell  48  and the second housing half-shell  50  are both deep-drawn parts. 
     In the illustration according to  FIG. 3 , the valve housing  40  in this context has a top side  52  and a bottom side  54  opposite the top side  52 . 
     The top side  52  and the bottom side  54  are connected by a front side  56  and a rear side  58 , and by a left side  60  and a right side  62 . 
     The front side  56  and the rear side  58  are located on opposite sides of the valve housing  40 . The same applies to the left side  60  and the right side  62 . 
     Respective adjoining sides are substantially at right angles to each other. Thus, the front side  56  is substantially perpendicular to the top side  52 , the left side  60 , the right side  62  and the bottom side  54 . The same applies to the other sides. 
     In addition, the first housing half-shell  48  and the second housing half-shell  50  complement each other such that the top side  52  and the left side  60  are completely formed by the first housing half-shell  48 . 
     The bottom side  54  and the right side  62  are completely formed by the second housing half-shell  50 . 
     The front side  56  and the rear side  58  are each partly formed by the first housing half-shell  48  and the second housing half-shell  50 . 
     More precisely, in the illustration according to  FIG. 3 , an upper left part of the front side  56  is formed by the first housing half-shell  48 , and a lower right part of the front side  56  is formed by the second housing half-shell  50 . The same applies to the rear side  58 . 
     In other words, the front side  56  and the rear side  58  are divided diagonally, the individual parts being formed by different housing half-shells  48 ,  50 . 
     In order to be able to connect the housing half-shells  48 ,  50  with each other, a first connecting edge  64  is provided on the first housing half-shell  48  and a second connecting edge  66  is provided on the second housing half-shell  50 . 
     The first connecting edge  64  is angled outwards with respect to the first housing half-shell  48 , i.e. it is angled outwards in sections with respect to the front side  56 , the left side  60 , the rear side  58  and the top side  52 . 
     The first connecting edge  64  is completely circumferential. 
     The second connecting edge  66  is angled outwards with respect to the second housing half-shell  50 . More precisely, it is angled outwards in sections with respect to the front side  56 , the bottom side  54 , the rear side  58  and the right side  62 . 
     The connecting edges  64 ,  66  are contiguous to each other and are connected by a weld seam  68 . Thus, the first housing half-shell  48  and the second housing half-shell  50  are also connected to each other the weld seam  68  or the soldered seam. 
     In addition, a first flow opening  70  is provided on the top side  52  which, when installed in the exhaust system  14 , is fluidically connected to the outflow line  32  (see  FIG. 2 ). 
     A second flow opening  72  which is fluidically connected to the second branch  36  when the exhaust-gas valve  34  is fitted in the exhaust system  14  is provided on the left side  60  (see  FIG. 2 ). 
     Furthermore, a third flow opening  74  is provided on the right side  62 . It is fluidically connected to the outlet line  38  inside the exhaust system  14  (see  FIG. 2 ). 
     In addition, a first bearing opening  76  is formed on the first housing half-shell  48  on the front side  56 . 
     A second bearing opening  78  is also formed on the first housing half-shell  48 , but on the rear side  58  thereof. 
     Thus, the first bearing opening  76  and the second bearing opening  78  are opposite each other on the first housing half-shell  48 . 
     The two bearing openings  76 ,  78  together form a swivel bearing mount  80 , which is formed exclusively on the first housing half-shell  48 . 
     In the fitted state of the exhaust-gas valve  34 , the valve flap shaft  44  is received in the swivel bearing mount  80 . More precisely, the valve flap shaft  44  is inserted at its opposite ends into the bearing openings  76 ,  78 . 
     Thus, the valve flap assembly  42  is mounted on the valve housing  40  as a whole. The valve flap  46  is adapted for swiveling movement with respect to the valve housing  40 . 
     Furthermore, a first valve seat  82  is formed in the area of the first flow opening  70  for cooperation with the valve flap  46 . 
     A second valve seat  84  which is separate from the first valve seat  82  is formed in the area of the second flow opening  72 . 
     Both the first valve seat  82  and the second valve seat  84  are formed exclusively on the first housing half-shell  48 . 
     The valve seats  82 ,  84  are formed integrally on the first housing half-shell  48 . 
     During operation of the exhaust system  14 , exhaust gas can flow through the exhaust-gas line  18  in a flow direction symbolized by an arrow  86  (see  FIG. 2 ). 
     The exhaust gas can get into the first branch  24  via the branching point  22 . 
     It then also flows through the heat exchanger. It is thus possible to recover heat from the exhaust-gas flow, more precisely from the partial flow in the first branch  24 . Thus, the heat exchanger  26  constitutes a part of a heat recovery system  88 . 
     Starting from the first branch  24 , the exhaust-gas flow can also selectively be fed back into an intake tract of the internal combustion engine  12  via the exhaust gas recirculation line  28  and the exhaust gas recirculation valve  30 . In this respect, the exhaust gas recirculation line  28  and the exhaust gas recirculation valve  30  are components of an exhaust gas recirculation system  90 . 
     Alternatively or additionally, the exhaust-gas flow from the first branch  24  can be directed via the first flow opening  70  into the outlet line  38 . This is of course only the case if the first flow opening  70  is not closed by the valve flap  46 . The valve flap  46  must therefore not rest against the first valve seat  82 . 
     From there, the exhaust-gas flow can reach the environment  16 . 
     That part of the exhaust gas which flows from the branching point  22  into the second branch  36  can, if the valve flap  46  is in the appropriate position, be directed via the second flow opening  72  into the exhaust-gas valve  34  and from there into the outlet line  38 . The valve flap  46  must therefore not rest against the second valve seat  84 . 
     The mentioned flow paths for the exhaust gas can be influenced by using the exhaust-gas valve  34 . In particular, the exhaust-gas valve  34 , more precisely the valve flap  46 , can assume a first valve position in which the valve flap  46  rests against the first valve seat  82  and thus closes the first flow opening  70 . 
     The valve flap  46  can also assume a second valve position, in which the valve flap  46  rests against the second valve seat  84  and closes the second flow opening  72 . 
     The exhaust-gas valve  34  is therefore a 3-2-way valve. 
     To manufacture the exhaust-gas valve  34 , the valve flap assembly  42  is first fitted in the first housing half-shell  48 . 
     On the one hand, the valve flap shaft  44  is inserted into the bearing openings  76 ,  78 . 
     On the other hand, the valve flap  46  is aligned with the first valve seat  82  and/or the second valve seat  84 . 
     The second housing half-shell  50  is fastened to the first housing half-shell  48  only when the valve flap assembly  42  has been completely fitted on the first housing half-shell  48  and finally aligned with the associated valve seats  82 ,  84 . The housing half-shells  48 ,  50  are then welded or soldered together. 
       FIGS. 6 to 8  show a valve housing  40  according to a further embodiment. The latter substantially corresponds to the first embodiment which has already been explained with reference to  FIGS. 3 to 5 . Therefore, only the differences will be discussed below. Identical and functionally identical parts are provided with the same reference numerals. 
     In the valve housing  40  according to  FIGS. 6 to 8 , only the first housing half-shell  48  is equipped with a connecting edge  64 . 
     The connecting edge  64  starts out from a housing wall section forming the front side  56 , a housing wall section forming the left side  60 , a housing wall section forming the rear side  58 , and a housing wall section forming the top side  52 , and is offset outwards parallel to these housing wall sections. 
     The connecting edge  64  is again designed to be completely circumferential. 
     The connecting edge  64  is further configured such that the second housing half-shell  50 , which is designed without a connecting edge, can be inserted into a space provided by the connecting edge  64 . 
     Then, the housing half-shells  48 ,  50  can again be fastened to each other via a weld seam  68  or a soldered seam. 
     Although various embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the true scope and content of this disclosure.