Patent Description:
Multi-port valves are used in a variety of industries and applications. Such valves include one or more inlet ports and one or more outlet ports. A valve member disposed within a housing of the valve is responsible for governing the flow between the various ports. A portion of the valve member, e.g. a valve stem, protrudes from the housing and is acted upon by an actuator attached to the multi-port valve. As result, the actuator governs the position of the valve member within the housing, which in turn governs the flow between the various ports.

Such multi-port valves advantageously provide a single flow device which can effectively replace multiple flow devices which only employ a single inlet and a single outlet. However, such multi-port valves are not without their own drawbacks. For example, the overall complexity of the valve increases as the number of ports increases. This can lead to relatively high part count assemblies. Further, this complexity in construction also results in a more complex manufacturing process for making the valve. Indeed, the multiple ports are associated with multiple inlets and outlets of the valve which must be welded onto a housing. Further the desired fitting for each inlet and outlet must also be welded on to its respective inlet or outlet.

Such welded up assemblies increase the number of potential leak paths of the valve. Further, to achieve such welds, special machining steps are often needed at the inlets and outlets as well as the housing to ensure there is a tight fit between these components for subsequent welding.

Furthermore, a number of individual seals are required to effectively seal the various ports of the multi-port valve off from one another. These multiple seals also lead to an increase in overall cost and complexity of the multi-port valve.

Multi-port valves that overcome these issues are available from the assignee of the instant application, and are described in <CIT>, and co-pending <CIT> (Publication No. <CIT>, and claiming priority to <CIT>. Documents <CIT>,
<CIT> and <CIT>) relate to multi-port, multi-plane valves.

In many applications that utilize such multi-port valves, fluid flow in multiple planes is required and typically provided via the external plumbing in the fluid control system. Unfortunately, the use of such external plumbing greatly increases the required volume or footprint of the overall fluid control system, and can create problems necessitating re-routing and re-locating of other components in its or other systems that need to occupy that volume.

Accordingly, there is a need in the art for a multi-port valve that provides multi-planar fluid flow and control within the volume of the valve itself. Embodiments of the present invention provide such a multi-port multi-plane valve. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.

In one aspect, embodiments of the present invention provide a multi-port multi-plane valve having a reduced part count and a reduced cost relative to prior designs, and that provides multi-planar fluid flow and control. An embodiment of such a multi-port multi-plane valve is claimed in claim <NUM>. An embodiment of a method of operating a multi-port, multi-plane valve is claimed in claim <NUM>. Preferred embodiments are claimed in the dependent claims.

On the contrary, the intent is to cover all alternatives and modifications, insofar as they fall within the scope of the invention as defined by the appended claims.

Turning now to the figures, as will be understood from the following, embodiments of a multi-port multi-plane valve assembly and its associated multi-port multi-plane valve are described herein. The multi-port multi-plane valve advantageously overcomes existing problems in the art by presenting an overall construction with a reduced part count, a reduced number of potential leak paths, a reduction in overall assembly time and cost, and reduced external plumbing to provide fluid flow and control in multiple planes.

As discussed in the above identified co-pending <CIT> (Publication No. <CIT>, multi-port valve assemblies typically, as here, include an actuator (not shown herein) mounted to the multi-port valve. The actuator is responsible for actuating a valve member (i.e., a shell body as described below) which in turn governs the flow characteristics through the valve. The actuator may be any style of actuator typically used in valve actuation, e.g., rotary, linear, etc., and may rely on any type of power source typically used in valve actuation, e.g., electric, hydraulic, and pneumatic, etc. Monitoring of the rotational position of the valving member may also utilize any type of position sensing, e.g., via a Hall-effect sensor, potentiometer, stepper motor control, etc. As such, the actuator and position sensing are non-limiting on the invention herein.

Turning now to <FIG>, an embodiment of the multi-port multi-plane valve <NUM>. Valve <NUM> includes a housing <NUM>. In one advantageous implementation of the invention, housing <NUM> is formed as a single piece. By "formed as a single piece" it is meant that the main body of housing <NUM> and its associated ports are not an assembly of separate components which are subsequently joined together by a joining process, e.g., welding, as is done in conventional valve housings. Rather, housing <NUM> is formed as a single unitary piece by any process capable of achieving such a configuration, e.g. inj ection molding, 3D printing, etc. However, it is contemplated by the teachings herein that housing <NUM> may be embodied as an assembly of separate components which are subsequently joined together by a j oining process.

As illustrated, housing <NUM> includes a plurality of ports, in particular, a first port <NUM>, a second port <NUM>, a third port <NUM>, a fourth port <NUM>, and a fifth port <NUM> (see <FIG>) that lies in a plane or along an axis that is normal to the plane of the other four ports <NUM>, <NUM>, <NUM>, <NUM> in the illustrated embodiment. Of course those skilled in the art will recognize that other angles may be provided. Each of the ports <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are in fluid communication with an internal cavity <NUM> of housing <NUM>. Further, each of ports <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may function as an inlet or an outlet, or both, of valve <NUM>.

Still referring to <FIG>, internal cavity <NUM> receives a generally cylindrical shell body <NUM> which operates as a valve member for controlling the flows between the plurality of ports <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. A seal member <NUM> is also received in cavity <NUM> and surrounds the outer periphery of shell body <NUM>. This seal member <NUM> is a continuous cylindrical element, except for the openings formed therein. As will be discussed below, seal member <NUM> is a single piece seal which advantageously creates a seal for each of the plurality of ports <NUM>, <NUM>, <NUM>, <NUM> to prevent unintended cross flow or short circuiting.

Seal member <NUM> also advantageously entirely seals internal cavity <NUM>, such that no additional seals need be associated with port <NUM> or a cover <NUM> (see <FIG>) of valve <NUM>. It is possible, however, that seal member <NUM> may also be formed as separate seal segments which immediately next to one another in the circumferential direction, which together define a seal member which surrounds the shell body <NUM>. The term "seal member" as used herein includes both configurations, i.e. a single unitary seal member, or a seal member formed of a plurality seal segments.

Shell body <NUM> includes a plurality of openings. The openings of seal member <NUM> remain statically aligned with ports <NUM>, <NUM>, <NUM>, <NUM>, <NUM> so that each opening is associated with one port, and seals against an interior surface of housing <NUM> that defines cavity <NUM>, around the opening of the port into cavity <NUM>. Opening <NUM> and <NUM> in shell body <NUM>, however, are selectively alignable with ports <NUM>, <NUM>, <NUM>, <NUM>, and opening <NUM> is aligned with port <NUM> to govern the flows between the ports. The shell body <NUM> includes a valve stem <NUM> (see <FIG>) which extends through an opening in housing <NUM>. This valve stem, and in turn the remainder of shell body <NUM>, is rotatable about axis by an actuator as discussed above.

A plurality of port bodies, namely, a first port body <NUM>, a second port body <NUM>, a third port body <NUM>, a fourth port body <NUM>, and a fifth port body <NUM> (see <FIG>) are respectively received in the first through fifth ports <NUM>, <NUM>, <NUM>, <NUM>, <NUM> as illustrated. The port bodies <NUM>, <NUM>, <NUM>, <NUM> are substantially identical to one another, but port body <NUM> differs in the illustrated embodiment. Port body <NUM>, <NUM>, <NUM>, <NUM> includes a through bore <NUM>, <NUM>, <NUM>, <NUM> which communicates with an internal cavity <NUM> containing shell body <NUM> rotatably disposed therein through port <NUM>, <NUM>, <NUM>, <NUM>, respectively, of housing <NUM>. Port body <NUM> provides passage through port <NUM> of housing <NUM> as shown in <FIG>.

Having now described the structure of an embodiment of the present invention, attention will now be directed to the orientation of the shell body <NUM> in each of <FIG> to discuss the fluid control provided by rotation thereof.

As shown in <FIG>, the shell body <NUM> is located in a first position referred to herein as <NUM>°. In such position the openings <NUM> and <NUM> provide fluid communication between ports <NUM> and <NUM> (see <FIG>) and provide a change in the axis of flow between the two different planes in which the ports <NUM> and <NUM> lie. In this position the opening <NUM> provides fluid communication between ports <NUM>, <NUM>, and <NUM>. This communication is equal between ports <NUM> and <NUM>, and may provide a <NUM>% - <NUM>% mix of fluid flow from ports <NUM>, <NUM> into port <NUM>, or vice versa, in certain implementations. Indeed, the percentage mix or flow can be varied between the ports <NUM>, <NUM> by rotating the shell body <NUM> to provide a greater or lesser communication with opening <NUM>.

Once the shell body <NUM> has rotated about <NUM>° in the illustrated embodiment as shown in <FIG>, port <NUM> is isolated such that it has no fluid communication to any of the other ports. However, fluid communication is still provided between ports <NUM> and <NUM> (and between <NUM> and <NUM>). A rotation of the shell body <NUM> about <NUM>° from the orientation of <FIG> in the other direction as shown in <FIG> isolates port <NUM> such that it has no fluid communication to any of the other ports. However, fluid communication is still provided between ports <NUM> and <NUM> (and between <NUM> and <NUM>). As the angle of rotation is varied, the area of the openings <NUM> and <NUM> that is exposed to the particular port also varies once an edge of the opening moves past the seal <NUM> edge.

<FIG> illustrate similar rotational alignments as shown in <FIG>, but starting with an orientation of the shell body <NUM> that is <NUM>° from that shown in <FIG>. Such orientations provide fluid communication between ports <NUM> and <NUM>, and variable mixing (or division) of flow between ports <NUM>, <NUM>, and <NUM>, as well as isolation of ports <NUM> and <NUM> as discussed with regard to <FIG> and <FIG>.

With the symmetrical layout of the four ports <NUM>, <NUM>, <NUM>, <NUM> and the openings <NUM>, <NUM>, similar operation will become apparent to those skilled in the art from the foregoing when the shell body <NUM> is initially oriented at <NUM>° and <NUM>° from the orientation shown in <FIG>, and a discussion thereof will be forgone in the interest of brevity.

<FIG> provide isometric side views of the embodiment of the multi-port multi-plane valve <NUM> shown with the shell body <NUM> positioned as shown in <FIG> when viewed into port body <NUM> and <NUM>, respectively. <FIG> provides isometric side views of the embodiment of the multi-port multi-plane valve <NUM> shown with the shell body <NUM> positioned as shown in <FIG> when viewed into port body <NUM>.

Turning now to <FIG>, there are illustrated isometric views of an embodiment of a multi-port multi-plane valve similar to that discussed hereinabove. However, the reference numerals have been removed and replaced with five port designations <NUM> - <NUM> to simplify the understanding of the operation thereof for the following description. In order to aid in this description, the isometric cross-sectional view of <FIG> is also instructive as it illustrates the internal passages and the shell body with the same five port designations <NUM> - <NUM>. Further, <FIG> and the figures included thereafter introduce flow arrows and blocked flow symbols to aid in the understanding of the operation of the valve. However, it should be noted that the directional heads of the flow arrows shown in <FIG> are not limiting on the flow direction through the valve, but instead only illustrate possible flows through the valve based on the communication enabled by the positioning of the shell body. Indeed, flow in other directions is also possible based on the external plumbing and flow system, and flow in both directions at different times through the same ports based on these external factors is also possible.

Turning now to <FIG>, the shell body is located in a first position referred to herein as <NUM>°. In such position the shell body provides fluid communication between ports <NUM> and <NUM>, and fluid communication between ports <NUM>, <NUM>, and <NUM>. As the shell body is rotated, the percentage flow can be varied between the ports <NUM> and <NUM> to provide a greater or lesser flow from port <NUM>.

Once the shell body has rotated about <NUM>° in the illustrated embodiment as shown in <FIG>, port <NUM> is isolated as shown by the blocked flow symbol such that it has no fluid communication to any of the other ports. However, fluid communication is still provided between ports <NUM> and <NUM> (and between <NUM> and <NUM>). A rotation of the shell body about <NUM>° from the orientation of <FIG> in the other direction as shown in <FIG> isolates port <NUM> as shown by the blocked flow symbol such that it has no fluid communication to any of the other ports. However, fluid communication is still provided between ports <NUM> and <NUM> (and between <NUM> and <NUM>).

<FIG> illustrate similar rotational alignments as shown in <FIG>, but starting with an orientation of the shell body that is <NUM>° from that shown in <FIG>. Such orientations provide fluid communication between ports <NUM> and <NUM>, and variable flow between ports <NUM>, <NUM>, and <NUM>, as well as isolation of ports <NUM> and <NUM> as discussed with regard to <FIG> and <FIG>.

With the symmetrical layout of the four ports <NUM>-<NUM> and the openings in the shell body, similar operation will become apparent to those skilled in the art from the foregoing when the shell body is initially oriented at <NUM>° and <NUM>° from the orientation shown in <FIG>, and a discussion thereof will be forgone in the interest of brevity.

With reference now to <FIG>, there is illustrated an embodiment of the multi-port, multi-plane valve that includes a shell body having a first and a second flow enhancer channel 20A, 20B provided on either side of the opening <NUM>. These flow enhancer channels 20A, 20B also provide fluid communication to opening <NUM> leading to port <NUM>, and operate to increase the flow thru the right angle opening when the shell body has been rotated to a position that is blocking the flow though one of the ports (<NUM> in <FIG> and <FIG> in <FIG>) on the other side of the valve. Such enhanced flow reduces the pressure drop occurring on one side of the valve when controlling flow paths on the other side of the valve. In embodiments, opening <NUM> is wider than the first flow enhancer channel 20A and wider than the second flow enhancer channel 20B. Further, in embodiments, the first flow enhancer channel 20A has the same width as the second flow enhancer channel 20B.

As described herein, embodiments of the present invention The multi-port multi-plane valve advantageously overcomes existing problems in the art by presenting an overall construction with a reduced part count, a reduced number of potential leak paths, and a reduction in overall assembly time and cost. In embodiments, the multi-port multi-plane valve has particular suitability for routing coolant in a thermal system, e.g., an engine or motor of a vehicle. For example, the multi-port multi-plane valve can be used to route coolant in a first thermal loop and at least one other thermal loop. In embodiments, a first thermal loop may be to route the coolant to engine/motor components or a battery in need of cooling or warming, and a second thermal loop may be provided to cool or warm the coolant (e.g., to a radiator, chiller, or heater). Depending on the particular needs of the coolant and the components to which it is being routed, the shell body <NUM> is able to be rotated to direct the flow of coolant through the desired thermal loops.

Claim 1:
A multi-port, multi-plane valve (<NUM>), comprising:
a housing (<NUM>) defining an internal cavity (<NUM>) and comprising a plurality of ports (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein each of the plurality of ports is in communication with the internal cavity and wherein at least one port of the plurality of ports lies in a first plane normal to a second plane of the other ports of the plurality of ports; and
a shell body (<NUM>) rotatably disposed within the internal cavity (<NUM>) to selectively provide planar fluid communication between a first subset of the plurality of ports and multi-plane fluid communication between a second subset of the plurality of ports;
characterised in that the shell body includes an opening and at least one flow enhancer channel (20A, 20B) arranged in the second plane, the at least one flow enhancer channel configured to reduce a pressure drop occurring in the multi-plane fluid communication when varying the multi-plane fluid communication between the second subset of the plurality of ports.