MOUNTING CONFIGURATION FOR VALVE ASSEMBLY

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

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

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

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.

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.

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.

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

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 is a perspective view of a canister purge valve, according to embodiments of the present invention;

FIG. 2 is a sectional front view of a canister purge valve, according to embodiments of the present invention;

FIG. 3 is a perspective view of a first alternate embodiment of a canister purge valve, according to embodiments of the present invention;

FIG. 4 is a perspective view of a second alternate embodiment of a canister purge valve, according to embodiments of the present invention; and

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

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 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 14a and a second portion 14b. Formed as part of the first portion 14a is a first port 16, and a first bracket 18a which is part of a mounting assembly. Disposed in a first bracket aperture 19 of the first bracket 18a 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.

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 18a is disposed between the isolator flange portions 66,68 when the isolator 20 is connected to the bracket 18a. 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.

Also part of the mounting assembly is a second bracket 18b which is connected to the second portion 14b of the housing 12. The second bracket 18b 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 30a 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.

The second bracket 18b 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 14b also includes an attachment 52 having a third port 54.

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.

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 18b.

The first bracket 18a does not contact the lower housing 26 because of the first isolator 20, the second bracket 18b 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.

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.

Partially formed as part of the second bracket 18b and the second portion 14b 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 14b 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 14b 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.

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 18b and associated components have been removed, and the housing 12 is connectable to the lower housing 26 using the first bracket 18a and the flange 24. FIG. 4 includes an alternate embodiment of the second bracket 18b, where the second bracket 18b 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.

Yet another alternate embodiment of the present invention is shown in FIG. 5. In this embodiment, the first bracket 18a and the first isolator 20 have been eliminated, and there is a variation of the second bracket 18b, 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.

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.

Claims

1. An apparatus, comprising:

a mounting assembly, including: a first bracket; a second bracket; a first isolator connected to the first bracket; a second isolator connected to the second bracket; and a lower housing; wherein the first bracket and the second bracket are connected to the lower housing such that during assembly of the mounting assembly to the lower housing, when the first bracket is connected to the lower housing, the second bracket is properly located relative to the lower housing, facilitating the connection of the second bracket to the lower housing, and the first isolator and the second isolator isolate vibration between the lower housing and the first bracket and the second bracket.

2. The apparatus of claim 1, further comprising:

a slot formed as part of the first isolator; and

a flange formed as part of the lower housing, the flange at least partially extending into the slot formed as part of the first isolator;

wherein the second bracket is in alignment with the lower housing when the flange formed as part of the lower housing is in alignment with the slot formed as part of the first isolator.

3. The apparatus of claim 1, further comprising:

a housing, the first bracket and the second bracket both connected to the housing;

at least one port formed as part of the second bracket; and

a flow aperture formed as part of the lower housing;

wherein the at least one port is in alignment with the flow aperture when the first mounting bracket and the second mounting bracket have aligned the housing with the lower housing, such that the at least one port is inserted into the flow aperture as the housing is connected to the lower housing.

4. The apparatus of claim 3, further comprising:

a first groove formed as part of the at least one port;

a second groove formed as part of the at least one port;

a first O-ring disposed in the first groove; and

a second O-ring disposed in the second groove;

wherein 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 at least one port and the flow aperture, and isolating the at least one port from vibration from the flow aperture.

5. The apparatus of claim 3, further comprising:

a fastener connecting the second isolator and the second bracket to the lower housing;

wherein the fastener is substantially parallel to the at least one port disposed in the flow aperture.

6. The apparatus of claim 5, further comprising:

an aperture formed as part of the second bracket, the second isolator disposed in the aperture formed as part of the second bracket;

a washer having an aperture, the second isolator substantially surrounding the washer; and

an aperture formed as part of the lower housing;

wherein during the assembly of the second bracket to the lower housing, the aperture of the washer is in alignment with the aperture of the lower housing, and the 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 housing to the lower housing.

7. The mounting assembly for a valve assembly of claim 6, wherein as the fastener is inserted into the aperture formed as part of the lower housing, the washer absorbs 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.

8. The mounting assembly for a valve assembly of claim 1, wherein the lower housing is part of one selected from a group consisting of an air box, an intake manifold, and a vapor canister.

9. A mounting assembly for a valve assembly, comprising:

a housing, the housing being part of a valve assembly;

a first bracket connected to the housing;

a first isolator connected to the first bracket;

a second bracket connected to the housing;

a second isolator connected to the second bracket;

a slot formed as part of the first isolator;

a lower housing;

a fastener connecting the second isolator and the second bracket to the lower housing; and

a flange formed as part of the lower housing, the flange at least partially extending into the slot formed as part of the first isolator;

wherein the second bracket is properly aligned with the lower housing when the flange is aligned with the slot, and first isolator and the second isolator isolate the housing from vibration in the lower housing.

10. The mounting assembly for a valve assembly of claim 9, further comprising:

at least one port formed as part of the second bracket; and

a flow aperture formed as part of the lower housing;

wherein the at least one port 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 at least one port is inserted into the flow aperture as the flange is inserted into the slot formed as part of the first isolator.

11. The mounting assembly for a valve assembly of claim 10, wherein the fastener is substantially parallel to the at least one port disposed in the flow aperture.

12. The mounting assembly for a valve assembly of claim 9, further comprising:

a first groove formed as part of the at least one port;

a second groove formed as part of the at least one port;

a first O-ring disposed in the first groove; and

a second O-ring disposed in the second groove;

wherein 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 at least one port and the flow aperture, and isolating the at least one port from vibration from the flow aperture.

13. The mounting assembly for a valve assembly of claim 9, further comprising a first bracket aperture formed as part of the first bracket, the first isolator disposed in the first bracket aperture.

14. The mounting assembly for a valve assembly of claim 9, further comprising:

an aperture formed as part of the second bracket, the second isolator disposed in the aperture formed as part of the second bracket;

a washer having an aperture, the second isolator substantially surrounding the washer; and

an aperture formed as part of the lower housing;

wherein 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, and the fastener is inserted through the aperture formed as part of the washer and into the aperture formed as part of the lower housing as the flange is inserted into the slot of the first isolator, securing the housing to the lower housing.

15. The mounting assembly for a valve assembly of claim 14, wherein as the fastener is inserted into the aperture formed as part of the lower housing, the washer absorbs 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.

16. The mounting assembly for a valve assembly of claim 9, wherein the lower housing is part of one selected from a group consisting of an air box, an intake manifold, and a vapor canister.

17. A mounting assembly for a valve assembly, comprising:

a housing having at least one port, the housing being part of a valve assembly;

a first bracket formed as part of the housing;

a first bracket aperture formed as part of the first bracket;

a first isolator disposed in the first bracket aperture;

a second bracket connected to the housing;

an aperture formed as part of the second bracket;

a second isolator disposed in the aperture formed as part of the second bracket;

a slot formed as part of the first isolator;

a lower housing;

a flange disposed in the slot formed as part of the first isolator, the flange formed as part of the lower housing;

a fastener connecting the second isolator to the lower housing; and

a flow aperture formed as part of the lower housing;

wherein the at least one port 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 at least one port is inserted into the flow aperture as the flange is inserted into the slot formed as part of the first isolator, and the first isolator and second isolator isolate the housing from vibration from the lower housing.

18. The mounting assembly for a valve assembly of claim 17, further comprising:

a washer having an aperture, the second isolator substantially surrounding the washer; and

an aperture formed as part of the lower housing;

wherein 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, and the 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 housing to the lower housing.

19. The mounting assembly for a valve assembly of claim 18, wherein as the fastener is inserted into the aperture formed as part of the lower housing, the washer absorbs 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.

20. The mounting assembly for a valve assembly of claim 17, wherein the fastener is substantially parallel to the at least one port disposed in the flow aperture.

21. The mounting assembly for a valve assembly of claim 17, further comprising:

a first groove formed as part of the at least one port;

a second groove formed as part of the at least one port;

a first O-ring disposed in the first groove;

a second O-ring disposed in the second groove;

wherein 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 at least one port and the flow aperture, and isolating the at least one port from vibration from the flow aperture.

22. The mounting assembly for a valve assembly of claim 17, wherein the lower housing is part of one selected from a group consisting of an air box, an intake manifold, and a vapor canister.