Abstract:
A mounting assembly which provides for a rigid connection between a valve assembly, such as a canister purge valve (CPV), and a component in an air flow system of a vehicle, such as an intake manifold, air box, or the like. The mounting assembly includes two brackets that are connected to the CPV, and the brackets are used to connect the CPV to an intake manifold. The first bracket includes an isolator having a slot, and a blade or flange extends into the slot, providing only one way of attachment between the CPV and the intake manifold. The second bracket includes a single bolt through a molded tab providing a second connection. The second bracket also has a second isolator; both isolators are made of rubber or other type of material suitable for isolating vibration. Each isolator provides vibration isolation between the intake manifold and the CPV.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/825,649 filed May 21, 2013, U.S. Provisional Application No. 61/825,681 filed May 21, 2013, and U.S. Provisional Application No. 61/825,616 filed May 21, 2013. The disclosures of the above applications are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates generally to a mounting configuration for a valve assembly which provides a secure connection and isolation from vibration. 
       BACKGROUND OF THE INVENTION 
       [0003]    Typical air flow systems for a vehicle include both a canister purge valve (CPV) and a turbo purge valve (TPV), each of which have vacuum ports connected to a hose. The CPV and TPV are in-line parts attached to the intake manifold of engines by the use of a rubber isolator mounted on a tab, and a rubber hose connecting the vacuum port to the manifold for fluid communication. 
         [0004]    There have been attempts to eliminate this hose and directly mount the valve to the intake manifold, similar to the CPV. Due to the port orientation and overall geometry of the CPV, mounting the TPV in the same mounting configuration (as is used with the isolator and the hose) is both impractical and also quite expensive, since two fasteners and isolators are required. Since the TPV is a turbo engine device, any direct mounting must be capable of withstanding cyclical pressures up to 40 psi. The valve must be completely rubber isolated from the manifold to minimize noise generation. Significant noise transmission occurs if any hard contact occurs between the TPV and the manifold. 
         [0005]    It is also important when mounting components to the engine that the center of mass of the part be well supported, as engine roll and vibration can induce significant g-forces on the component, generating unexpected failure modes. 
         [0006]    Accordingly, there exists a need for a connection between a TPV and a manifold, or other component, which provides a rigid connection, but also provides isolation from vibration, reducing noise. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is a mounting assembly which provides for a rigid connection between a valve assembly, such as a TPV or CPV, and a component in an air flow system of a vehicle, such as an intake manifold, air box, or the like. The mounting assembly is also suitable for providing commonality of parts between different types of CPVs that are used for different types of vehicles. 
         [0008]    The mounting assembly includes two brackets that are connected to the CPV, and the brackets are used to connect the CPV to an intake manifold, for example. The first bracket includes an isolator having a slot, and a blade or flange extends into the slot, providing only one way of attachment between the CPV and the intake manifold. This blade mount design of the CPV does not change significantly (other than minor mating feature changes), and the rubber isolator remains common to the inline part. The second bracket includes a single bolt through a molded tab providing a second connection capable of withstanding the pressure the CPV/TPV is exposed to. The second bracket also has a second isolator; both isolators are made of rubber or other type of material suitable for isolating the TPV or CPV from vibration. 
         [0009]    The CPV includes a port which extends into the intake manifold. Sealing as well as noise isolation between the port and the intake manifold are achieved through the use of a sealing device, such as two large O-rings in the sealing interface of the port, or an alternate sealing method. 
         [0010]    The mounting assembly of the present invention allows for proper mass support to the blade mount design, and the elimination of at least one hose, and only requires one fastener to rigidly connect the valve to the manifold. 
         [0011]    This mounting configuration of blade and bolt is not limited to engine mount components, or even rubber isolated components, and could be used for other system assemblies. 
         [0012]    In one embodiment, the present invention is a mounting assembly for a valve assembly, which includes a housing having at least one port, the housing being part of a valve assembly, a first bracket connected to the housing, and a first bracket aperture formed as part of the first bracket such that a first isolator is disposed in the first bracket aperture. A second bracket is connected to the housing, and an aperture is formed as part of the second bracket such that a second isolator is disposed in the aperture formed as part of the second bracket. A slot is formed as part of the first isolator, and a flange formed as part of a lower housing is disposed in the slot formed as part of the first isolator. 
         [0013]    A flow aperture is formed as part of the lower housing, and at least one port of the valve assembly is in alignment with the flow aperture when the flange is aligned with the slot formed as part of the first isolator, such that the port is inserted into the flow aperture as the flange is inserted into the slot formed as part of the first isolator. This configuration allows for the first isolator and second isolator to isolate the housing from vibration from the lower housing. 
         [0014]    A first groove is formed as part of the port, and a second groove is also formed as part of the port. A first O-ring is disposed in the first groove, and a second O-ring is disposed in the second groove, such that the first O-ring and the second O-ring are in contact with the inner surface of the flow aperture, providing a seal between the port and the flow aperture, and isolating the port from vibration from the lower housing. 
         [0015]    The mounting assembly also includes a washer having an aperture, where the second isolator substantially surrounds the washer, and an aperture is formed as part of the lower housing. The aperture of the washer is in alignment with the aperture of the lower housing when the flange is in alignment with the slot formed as part of the first isolator. A fastener is inserted through the aperture formed as part of the washer and into the aperture formed as part of the lower housing, securing the second isolator and the housing to the lower housing. 
         [0016]    As the fastener is inserted into the aperture formed as part of the lower housing, the washer absorbs the compressive stress from the fastener, preventing the second isolator from being exposed to stress from the fastener being inserted into the aperture formed as part of the lower housing. The fastener is substantially parallel to the at least one port disposed in the flow aperture, to ensure that the fastener absorbs tensile stress from the force of the air flow flowing into and out of the port of the lower housing. This configuration substantially eliminates potential from the fastener having to absorb shear stress from the force of the air flowing into or out of the port. 
         [0017]    The mounting configuration of the present invention allows for the valve assembly to be connected to different components of an air flow system of a vehicle. For example, the lower housing may be part of an air box, an intake manifold, a vapor canister, or another component in an air flow system. The mounting configuration provides for isolation of vibration from these components, while still providing a rigid connection and proper alignment between the housing and the lower housing during assembly. 
         [0018]    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 
         [0019]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0020]      FIG. 1  is a perspective view of a canister purge valve, according to embodiments of the present invention; 
           [0021]      FIG. 2  is a sectional front view of a canister purge valve, according to embodiments of the present invention; 
           [0022]      FIG. 3  is a perspective view of a first alternate embodiment of a canister purge valve, according to embodiments of the present invention; 
           [0023]      FIG. 4  is a perspective view of a second alternate embodiment of a canister purge valve, according to embodiments of the present invention; and 
           [0024]      FIG. 5  is a perspective view of a third alternate embodiment of a canister purge valve, according to embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    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. 
         [0026]    A canister purge valve (CPV) according to the present invention is shown in  FIGS. 1-2  generally at  10 . The CPV  10  includes a housing  12  which includes a first portion  14   a  and a second portion  14   b . Formed as part of the first portion  14   a  is a first port  16 , and a first bracket  18   a  which is part of a mounting assembly. Disposed in a first bracket aperture  19  of the first bracket  18   a  is a first isolator  20  having a slot  22 , and located in the slot  22  is a flange  24 , which is connected to a lower housing  26 . The lower housing  26  may be part of an air box, an intake manifold, a vapor canister, or the like, and the mounting assembly of the present invention may be used to attach the CPV  10  to any of these components. The slot  22  is substantially rectangular shaped, and the flange  24  is shaped to correspond to the shape of the slot  22 , such that the flange  24  fits within the slot  22 . 
         [0027]    The flange  24  protrudes away from a base portion  62  formed as part of the lower housing  26 . The first isolator  20  also includes a body portion  64 , and an upper isolator flange portion  66  and a lower isolator flange portion  68 , where in the first bracket  18   a  is disposed between the isolator flange portions  66 , 68  when the isolator  20  is connected to the bracket  18   a . As shown in  FIG. 2 , each of the isolator flange portions  66 , 68  protrude outwardly away from the body portion  64 , and the overall width  70  of the isolator flange portions  66 , 68  is wider than the width  72  of the aperture  19 , maintaining the position of the first isolator  20  in the aperture  19 . Part of the lower isolator flange portion  68  contacts the base portion  62  when the flange  24  is located in the slot  22 . 
         [0028]    Also part of the mounting assembly is a second bracket  18   b  which is connected to the second portion  14   b  of the housing  12 . The second bracket  18   b  includes an aperture  28 , and disposed in the aperture  28  is a second isolator  30  and a washer  32 . The aperture  28  is part of a flange portion  74 , and the flange portion  74  is partially disposed in a groove  30   a  formed as part of the second isolator  30 . The washer  32  includes an aperture  34 , and selectively disposed within the aperture  34  is a fastener, which in this embodiment is a bolt  36 . When assembled, the bolt  36  at least partially extends into an aperture  38  formed as part of the lower housing  26 . 
         [0029]    The second bracket  18   b  also includes a second port  40 , and the second port  40  is surrounded by a sealing device. In this embodiment, the sealing device is a first O-ring  42  disposed in a first groove  44 , and a second O-ring  46  disposed in a second groove  48 . The second port  40  extends into a flow aperture  50  formed as part of the lower housing  26 , and a seal between the second port  40  and the flow aperture  50  is provided by the O-rings  42 , 46 . More specifically, the first O-ring  42  is disposed in the first groove  44  and is in contact with the inner surface of the aperture  50 , and the second O-ring  46  is disposed in the second groove  48  and is also in contact with the inner surface of the aperture  50 . However, it is within the scope of the invention that other types of seals may be used, other than the O-rings  42 , 46 . The second portion  14   b  also includes an attachment  52  having a third port  54 . 
         [0030]    During the assembly of the CPV  10  to the lower housing  26 , the flange  24  is inserted into the slot  22 . The placement of the flange  24  into the slot  22  ensures that the aperture  34  of the washer  32  is properly aligned with the aperture  38  of the lower housing  26 , and provides alignment between the second port  40  and the flow aperture  50 . This prevents the CPV  10  from being twisted once the second port  40  is placed in the aperture  50 , and therefore prevents the O-rings  42 , 46  from being stretched or deformed when disposed in the flow aperture  50 . 
         [0031]    After the flange  24  is inserted into the slot  22  and the second port  40  is positioned in the flow aperture  50 , the bolt  36  is inserted through the aperture  34  of the washer  32  and into the aperture  38 . The aperture  38  an the bolt  36  are threaded such that the bolt  36  may be tightened. This provides a rigid connection between the CPV  10  and the lower housing  26 . As the bolt  36  is tightened, the compressive force generated by the bolt  36  is applied to the washer  32 , but the shape of the washer  32  prevents the compressive force from being transferred to the second isolator  30 , such that the second isolator  30  is not deformed by any of the compressive force in the washer  32 , the bolt  36 , or the housing  26 . The washer  32  includes an upper flange portion  56  which contacts the bolt  32  and a lower flange portion  58  which contacts the lower housing  26 . The second isolator  30  surrounds the washer  32  as shown in  FIG. 2 , and the second isolator  30  is disposed in the aperture  28  of the second bracket  18   b.    
         [0032]    The first bracket  18   a  does not contact the lower housing  26  because of the first isolator  20 , the second bracket  18   b  does not contact the lower housing  26  because of the second isolator  30  and the washer  32 , and the second port  40  does not contact the lower housing  26  because of the O-rings  42 , 46 . Therefore, the CPV  10  is not in contact with the lower housing  26 , but is still rigidly connected to the lower housing  26  because of the bolt  36  and the washer  32 . This prevents the CPV  10  from contacting the lower housing  26 , and therefore prevents any noise generation resulting from vibration in the lower housing  26 , and also provides noise isolation to the lower housing  26 . 
         [0033]    The direction of airflow into the second port  40  is shown is shown by an arrow  60  in  FIG. 2 . The air flow, and therefore the arrow  60 , is parallel to the bolt  36 . The bolt  36  therefore absorbs tensile stress from the force of the air flow flowing into the second port  40  from the lower housing  26 . This configuration substantially eliminates potential from the bolt  36  having to absorb shear stress from the force of the air flowing (i.e., air flow in the opposite direction) into the second port  40  from the lower housing  26 . The air flow through the second port  40  may be into or out of the port, depending on whether the CPV  10  is being exposed to pressurized air from a turbocharger, or vacuum pressure from an intake manifold of an engine. 
         [0034]    Partially formed as part of the second bracket  18   b  and the second portion  14   b  of the housing  12  is a check valve, shown generally at  78 . The check valve  78  includes a check valve aperture  80  in fluid communication with a cavity, shown generally at  82  in the second portion  14   b  of the housing  12 . The check valve  78  also includes a valve member  84  surrounded by a seal member  86 , where the seal member  86  is selectively in contact with a valve seat  88 . When the valve member  84  moves away from the valve seat  88 , the cavity  82  is in fluid communication with a check valve cavity, shown generally at  90 , through the check valve aperture  80 . The check valve  78  also includes a plurality of vents  92  which are in fluid communication with the check valve cavity  90 . The direction of the air flow in the flow aperture  50  and the second port  40  determines whether the seal member  86  is in contact with the valve seat  88 , and therefore whether the valve  78  is in an open position or a closed position. When the check valve  78  is in an open position, air (and purge vapor) is able to flow from the cavity  82  of the second portion  14   b  of the housing  12 , through the check valve aperture  80 , the check valve cavity  90 , through the vents  92 , and through the second port  40 . 
         [0035]      FIGS. 3-5  include alternate embodiments of the present invention, where like numbers refer to like elements. In these embodiments, the mounting assembly is shown in different configurations, allowing the mounting assembly to be used in different applications. In  FIG. 3 , the second bracket  18   b  and associated components have been removed, and the housing  12  is connectable to the lower housing  26  using the first bracket  18   a  and the flange  24 .  FIG. 4  includes an alternate embodiment of the second bracket  18   b , where the second bracket  18   b  includes an extended flange  76 , and the CPV  10  is oriented ninety degrees relative to the CPV  10  shown in  FIG. 1 . The embodiment shown in  FIG. 4  allows for the CPV  10  to be configured differently for different air flow system configurations. 
         [0036]    Yet another alternate embodiment of the present invention is shown in  FIG. 5 . In this embodiment, the first bracket  18   a  and the first isolator  20  have been eliminated, and there is a variation of the second bracket  18   b , washer  32 , and second isolator  30 . In this embodiment, however, the bolt  36  still extends through the washer  32  and the isolator  30 , however, the second port  40  has been removed, and bolt  36  is configured to be inserted through the washer  32  such that the bolt  36  is parallel to the third port  54 . 
         [0037]    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.