Abstract: An improved electric solenoid for providing linear mechanical actuation. The outer polepiece of the solenoid is provided with an axial, self-lubricated, non-magnetic bearing for closely supporting and centering an actuating shaft extending coaxially from the solenoid armature. Preferably, the radial tolerance between the diameters of the bearing inner bore and the shaft is as small as in practically possible without inducing drag of the shaft in the bearing, permitting reduction of the air gap between the armature and the polepieces to a minimal thickness. Preferably, the armature is axially tapered to avoid contact of the armature with the polepieces as a result of residual tolerances between the bearing and shaft. A significant increase in actuating force is realized in comparison with a prior art solenoid, and the improved solenoid may be used in any desired orientation.

Abstract: A proportionally-controllable solenoid including primary and secondary pole pieces that surround an armature axially movable along an axial channel within the pole pieces. The pole pieces are separated axially by an air gap and are conically tapered toward the gap. The leading and trailing faces of the armature are substantially orthogonal to its direction of travel to minimize radial parasitic forces on these faces. Further, the armature is also lengthened such that the trailing face is always outside the axial channel in the secondary pole piece at all points of axial travel to minimize the pull-back effect of axial flux vectors on the trailing face.

Abstract: An expanded-range pintle valve comprising a plurality of stages. Each stage comprises a valve seat and head capable of regulating flow through the valve over its own dynamic range. The valve head of a higher-flow stage includes the valve seat for the next-lower flow stage. The heads and seats for the multiple stages are nested concentrically, the progressively lower-flow stages having progressively smaller diameters. All valve heads except the lowest-flow head have axial and radial bores permitting flow therethrough so that flow may be regulated first by actuating the lowest-flow stage, then by actuating successively higher flow stages. A single pintle shaft connected to a solenoid actuator is adapted to engage each of the valve heads sequentially as the actuator progresses, beginning with the lowest-flow head, thereby extending incrementally the dynamic range of the valve as each stage is successively engaged.

Abstract: An improved solenoid for providing linear actuation. The outer polepiece of the solenoid is provided with an axial journal bearing for supporting an actuating shaft extending from the solenoid armature. Radial tolerance between the bearing inner bore and the shaft is as small as in practically possible, which feature permits elimination of the prior art portion of the guiding sleeve extending into the outer polepiece, thereby retaining frictional losses with only the remaining sleeve portion in the inner polepiece. Small prior art air gaps at interfaces 42,44 between the polepieces and the housing are eliminated to minimize reluctance of the magnetic circuit. A significant increase in actuating force is realized in comparison with a prior art solenoid actuator.

Abstract: A subassembly module including a pintle bearing, bearing retaining spring, and bearing splash shield for an exhaust gas recirculation (EGR) valve for an internal combustion engine. The bearing is provided with a circumferential flange for sealing with an outer surface of the valve body, and with an annular step in the flange for receiving the rolled or crimped skirt of the bearing splash shield. The bearing retaining spring surrounding the valve pintle is compressed and captured within the splash shield as the skirt is formed onto the annular step to form the module. The axial length of the module is slightly greater than the assembled distance between the valve body and the actuator of the EGR valve, such that the module is compressed by installation of the actuator onto the valve body, allowing the compressed spring to urge the bearing face sealingly against the valve body. Advantageously, the subassembly module may be pre-assembled offline by known methods to reduce complexity during assembly of the valve.

Abstract: A modular EGR valve includes an actuator subassembly and a metering subassembly. The metering subassembly defines a metering port and a metering chamber. The metering port and the metering chamber have a predetermined relative configuration. The metering subassembly is configured for being coupled to the actuator subassembly and for being coupled to an engine.

Abstract: A system for containing leakage along a pintle shaft in a pintle-type gas control valve, such as an exhaust gas recirculation valve for an internal combustion engine or a reformate diverter valve for a fuel cell, comprising a novel seal element and means for sealing the element to the valve's pintle shaft bearing and to an interrupted pintle shaft. The system comprises two elements: a positive vapor block in the form of an elastomeric boot or folded diaphragm disposed across the pintle interruption, and a pintle shaft bearing disposable in the valve's body and sealingly secured to the boot or diaphragm. The system may include a coil spring disposed in compression within the boot or diaphragm.

Abstract: An improved solenoid for providing linear actuation. The outer polepiece of the solenoid is provided with a plurality of radially-dispersed labyrinthine passageways in communication between the exterior of the solenoid and an interior region including the armature and the interior of the windings. The polepiece is further provided with at least one passageway in communication between the exterior of the solenoid and an outer periphery of the windings within the housing. The two sets of passageways impede particles and droplets of moisture from entering the solenoid, while simultaneously permitting moisture such as condensation within the solenoid to evaporate and escape.

Abstract: A subassembly module including a pintle bearing, bearing retaining spring, and bearing splash shield for an exhaust gas recirculation (EGR) valve for an internal combustion engine. The bearing is provided with a circumferential flange for sealing with an outer surface of the valve body, and with an annular step in the flange for receiving the rolled or crimped skirt of the bearing splash shield. The bearing retaining spring surrounding the valve pintle is compressed and captured within the splash shield as the skirt is formed onto the annular step to form the module. The axial length of the module is slightly greater than the assembled distance between the valve body and the actuator of the EGR valve, such that the module is compressed by installation of the actuator onto the valve body, allowing the compressed spring to urge the bearing face sealingly against the valve body. Advantageously, the subassembly module may be pre-assembled offline by known methods to reduce complexity during assembly of the valve.

Abstract: An improved modular, radially-compliant, redundantly-sealing journal-type bearing assembly comprising two bearing elements retained in a housing and positively loaded in opposing directions by a compression spring disposed therebetween. A shaft to be supported and sealed against leakage by the bearing, such as a valve pintle shaft, is disposed in an axial bore in each of the bearing elements, which bores are fitted as closely to the diameter of the shaft as is possible without causing the shaft to bind in the bores. Each of the radial bearing faces opposite the spring forms a seal with a corresponding internal surface of the housing, defining thereby a redundant sealing system. The bearings are radially compliant within the housing by a predetermined small distance to allow the shaft to be operatively self-centered, such as by an attached valve head mating into a valve seat.

Abstract: A metering subassembly for use with a modular EGR valve includes a metering subassembly having an elongate metering shaft. A flanged end of the metering shaft is disposed a predetermined distance above a top surface of the metering subassembly. The metering subassembly is configured for being coupled to an actuator subassembly such that the flanged end of the metering shaft is disposed proximate the actuator subassembly. A gas arrestor includes a side wall interconnected with a collar. The collar surrounds a periphery of the flanged end. The side wall extends from the collar in a direction generally toward the top surface of the metering subassembly.

Abstract: A flow modifier for insertion into the chamber of a large pintle valve to change the apparent flow range of the valve to that of a smaller valve. The flow modifier includes a perforated cup-shaped restrictor disposed within the valve on the valve pintle and sealingly surrounding the valve seat such that all flow through the valve must pass through the passageways in the restrictor. The restrictor is held in place by a compression spring surrounding the pintle. The total open area of the passageways may be varied by varying their number and/or size and is preferably substantially less than the open area of the valve seat. The restrictor thus acts as a flow choke or fixed throttle to reduce the flow range of the valve. Different restrictors may be provided as required to size a single large valve having a large inherent flow range to a plurality of applications requiring valves having smaller flow ranges.

Abstract: A shield for a gas management pintle valve, such as an exhaust gas recirculation valve for an internal combustion engine, for mitigating leakage of gas and moisture along the valve pintle into the actuator, to prevent corrosion and failure of the actuator. The shield is a tubular member having an equatorial radial flange and is slidably mounted on the pintle in an annular chamber between the valve body and the actuator. The inner diameter of the tube is selected to be as close-fitting to the pintle as possible while still being slidable thereupon to be adapted to either of two operating positions. During engine shutdowns, the shield is drawn by gravity toward the valve body to form a first seal with the flange against the pintle bearing or a bearing splash shield, preventing or minimizing the escape of moist, hot gases under low pressure from the valve along the pintle.

Abstract: The present invention is directed to an annular metal-bristled brush for cleaning the pintle shaft of a pintle valve, such as an exhaust gas recirculation valve for an internal combustion engine, to prevent coking and failure of the valve. The brush surrounds the shaft, the tips of the bristles making contact with the shaft with sufficient force to dislodge incipient coke deposits but with insufficient force to inhibit the axial motion of the pintle shaft in actuation. Preferably, the brush is disposed in an annular space in the valve body between the pintle shaft bearing and the gas-metering chamber such that the shaft is brushed in both directions during each actuative cycle of the valve. Preferably, the annular space is slightly larger both axially and radially than the corresponding dimensions of the brush so that the brush is free to float without binding the pintle shaft.

Abstract: A leakage arresting system comprising a novel gas arrestor for installation on an interrupted pintle shaft in a pintle-type valve, such as an exhaust gas recirculation valve for an internal combustion engine, for preventing leakage of gas and moisture along the pintle shaft into the actuator, to prevent corrosion and failure of the actuator. The system comprises two elements: a pintle shaft which is interrupted outside the actuator, and a positive vapor block in the form of a cup-shaped arrestor disposed across the pintle interruption. The invention is applicable to both unbalanced and force-balanced valves.

Abstract: A system for containing leakage along a pintle shaft in a pintle-type gas control valve, such as an exhaust gas recirculation valve for an internal combustion engine or a reformate diverter valve for a fuel cell, comprising a novel seal element and means for sealing the element to the valve's pintle shaft bearing and to an interrupted pintle shaft. The system comprises two elements: a positive vapor block in the form of an elastomeric boot or folded diaphragm disposed across the pintle interruption, and a pintle shaft bearing disposable in the valve's body and sealingly secured to the boot or diaphragm. The system may include a coil spring disposed in compression within the boot or diaphragm.

Abstract: A flow modifier for insertion into the chamber of a large pintle valve to change the apparent flow range of the valve to that of a smaller valve. The flow modifier includes a perforated cup-shaped restrictor disposed within the valve on the valve pintle and sealingly surrounding the valve seat such that all flow through the valve must pass through the passageways in the restrictor. The restrictor is held in place by a compression spring surrounding the pintle. The total open area of the passageways may be varied by varying their number and/or size and is preferably substantially less than the open area of the valve seat. The restrictor thus acts as a flow choke or fixed throttle to reduce the flow range of the valve. Different restrictors may be provided as required to size a single large valve having a large inherent flow range to a plurality of applications requiring valves having smaller flow ranges.

Abstract: A pressure balancing metering subassembly for use with a modular actuator of an EGR valve includes a metering base which defines a metering port and a pressure chamber. An elongate poppet includes a first end normally disposed in sealing engagement with the metering port. The poppet is selectively reciprocated to disengage the first end from sealing engagement with the metering port to thereby fluidly connect the metering port with the pressure chamber. Pressure balancing means balance the pressure at the first end of the poppet with the pressure at a second end of the poppet.

Abstract: The present invention is directed to an annular metal-bristled brush for cleaning the pintle shaft of a pintle valve, such as an exhaust gas recirculation valve for an internal combustion engine, to prevent coking and failure of the valve. The brush surrounds the shaft, the tips of the bristles making contact with the shaft with sufficient force to dislodge incipient coke deposits but with insufficient force to inhibit the axial motion of the pintle shaft in actuation. Preferably, the brush is disposed in an annular space in the valve body between the pintle shaft bearing and the gas-metering chamber such that the shaft is brushed in both directions during each actuative cycle of the valve. Preferably, the annular space is slightly larger both axially and radially than the corresponding dimensions of the brush so that the brush is free to float without binding the pintle shaft.

Abstract: An improved electric solenoid for providing linear mechanical actuation. The outer polepiece of the solenoid is provided with an axial, self-lubricated, non-magnetic bearing for closely supporting and centering an actuating shaft extending coaxially from the solenoid armature. Preferably, the radial tolerance between the diameters of the bearing inner bore and the shaft is as small as in practically possible without inducing drag of the shaft in the bearing, permitting reduction of the air gap between the armature and the polepieces to a minimal thickness. Preferably, the armature is axially tapered to avoid contact of the armature with the polepieces as a result of residual tolerances between the bearing and shaft. A significant increase in actuating force is realized in comparison with a prior art solenoid, and the improved solenoid may be used in any desired orientation.