Rotary valve for single-point coolant diversion in engine cooling system

• US 6,539,899 B1
• Filed: 02/11/2002
• Issued: 04/01/2003
• Est. Priority Date: 02/11/2002
• Status: Expired due to Term

• Current Assignee: Hanon Systems (Hahn & Co. Auto Holdings Co. Ltd.)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Bartsch, Leonhard, Jalilevand, Ali, Haigh, Mathew E., Harmer, Nicholas P., Green, Martin, Vint, Matti K., Piccirilli, Davide F., Bejster, Joseph V., Liederman, Keith E.
• Primary Examiner(s): Argenbright, Tony M.
• Assistant Examiner(s): BENTON, JASON
• Application Number:
  US10/074,902
• Time in Patent Office: 414 Days
• Field of Search: 123/41.1, 123/41.08, 123/41.02
• US Class Current: 123/41.1
• CPC Class Codes: F01P 2007/146 using valves
• CPC Class Codes: F01P 2025/66 Vehicle speed
• CPC Class Codes: F01P 2060/08 Cabin heater
• CPC Class Codes: F01P 7/167 by adjusting the pre-set temperature according to engine parameters, e.g. engine load, engine speed
• CPC Class Codes: F16K 11/085 with cylindrical plug
• CPC Class Codes: F16K 11/0853 having all the connecting conduits situated in a single plane perpendicular to the axis of the plug

Abstract

A rotary valve provides single point flow control of coolant within the cooling system of an internal combustion engine. The valve distributes coolant flow from the engine in predetermined flow modes to either 1) the radiator and heater simultaneously, 2) a bypass circuit only, 3) the heater only, or 4) the radiator and bypass simultaneously. The single-point coolant control results in advantages of shorter warm-up times, a lower pressure drop (reducing power consumption by the pump), reduced engine emissions and fuel consumption, improved cabin heater performance, and improved engine durability due to reduced thermal shocks to the engine components by virtue of more precise control of engine operating temperature.

Claims

1. A rotary valve for single-point coolant switching of coolant flowing in an engine cooling system, comprising:

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in a radiator circuit, a bypass port for allowing coolant flow in a bypass circuit, and a heater port for allowing coolant flow in a heater circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said predetermined flow paths include a first mode for distributing said coolant to said radiator port and said heater port while blocking coolant from said bypass port, a second mode for distributing said coolant to said bypass port while blocking coolant from said radiator port and said heater port, a third mode for distributing said coolant to said heater port while blocking coolant from said radiator port and said bypass port, and a fourth mode for distributing said coolant to said radiator port and said bypass port while blocking coolant from said heater port; and

wherein said first mode corresponds to a failsafe position for said flow diverter if said actuator fails, said rotary valve further comprising a return mechanism for biasing said flow diverter to said failsafe position.

2. The rotary valve of claim 1 wherein a flow rate of coolant distributed to an outlet port in at least one of said modes is proportional to a variable overlapping cross-sectional area of a respective fluid passage and said outlet port.

3. The rotary valve of claim 2 wherein said flow rate to a particular outlet port receiving coolant flow in a particular mode is variable in response to respective rotational positions within said particular mode.

4. The rotary valve of claim 2 wherein a flow rate to said bypass port in said fourth mode is greater than a flow rate to said bypass port in said second mode to provide greater heat flow into said coolant in said second mode.

5. An engine cooling system for a vehicle, said cooling system distributing heat from an engine using a coolant, said cooling system comprising:

a pump for circulating said coolant;

an engine circuit for conducting said coolant through said engine;

a radiator circuit for conducting said coolant through a radiator;

a bypass circuit for returning said coolant to said engine circuit without passing through said radiator circuit;

a heater circuit for conducting said coolant through a heater core;

a rotary valve for single-point coolant switching of said coolant, said rotary valve comprising;

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in said radiator circuit, a bypass port for allowing coolant flow in said bypass circuit, and a heater port for allowing coolant flow in said heater circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said predetermined flow paths include a first mode for distributing said coolant to said radiator port and said heater port while blocking coolant from said bypass port, a second mode for distributing said coolant to said bypass port while blocking coolant from said radiator port and said heater port, a third mode for distributing said coolant to said heater port while blocking coolant from said radiator port and said bypass port, and a fourth mode for distributing said coolant to said radiator port and said bypass port while blocking coolant from said heater port; and

wherein said first mode corresponds to a failsafe position for said flow diverter if said actuator fails, said rotary valve further comprising a return mechanism for biasing said flow diverter to said failsafe position; and

a controller responsive to predetermined vehicle parameters for generating said control signal to select one of said modes in response to said predetermined vehicle parameters.

6. The cooling system of claim 5 wherein a flow rate of coolant distributed to an outlet port in at least one of said modes is proportional to a variable overlapping cross-sectional area of a respective fluid passage and said outlet port.

7. The cooling system of claim 6 wherein said flow rate to a particular outlet port receiving coolant flow in a particular mode is variable in response to respective rotational positions within said particular mode.

8. The cooling system of claim 6 wherein a flow rate to said bypass port in said fourth mode is greater than a flow rate to said bypass port in said second mode to provide greater heat flow into said coolant in said second mode.

9. A rotary valve for single-point coolant switching of coolant flowing in an engine cooling system, comprising:

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in a radiator circuit and a bypass port for allowing coolant flow in a bypass circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said fluid passages provide a first range of said rotational positions of said flow diverter in a first mode of said rotary valve for distributing said coolant from said inlet port to said bypass port while blocking coolant distribution to said radiator port and provide a second range of said rotational positions of said flow diverter in a second mode of said rotary valve for distributing said coolant from said inlet port to both said bypass port and said radiator port, and wherein at least one selected one of said fluid passages and said bypass outlet have a variable overlapping cross-sectional area between said first and second modes to provide a plurality of selectable flow rates to said bypass port including at least a first flow rate in said first mode and a second flow rate higher than said first flow rate in said second mode, wherein said first flow rate provides increased heat flow into said coolant.

10. The rotary valve of claim 9 wherein said overlapping cross-sectional areas in said first and second ranges provide respective first and second plateaus, each plateau providing a respective constant overlapping cross-sectional area within respective subranges of rotational positions.

11. The rotary valve of claim 9 wherein said overlapping cross-sectional areas provide a sloped variance within at least a portion of said first and second ranges of rotational positions.

12. The rotary valve of claim 9 wherein said actuator is comprised of an electric motor and drivetrain coupled to said flow diverter.

13. An engine cooling system for a vehicle, said cooling system distributing heat from an engine using a coolant, said cooling system comprising:

a pump for circulating said coolant;

an engine circuit for conducting said coolant through said engine;

a radiator circuit for conducting said coolant through a radiator;

a bypass circuit for returning said coolant to said engine circuit without passing through said radiator circuit;

a rotary valve for single-point coolant switching of said coolant, said rotary valve comprising;

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in said radiator circuit and a bypass port for allowing coolant flow in said bypass circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said fluid passages provide a first range of said rotational positions of said flow diverter in a first mode of said rotary valve for distributing said coolant from said inlet port to said bypass port while blocking coolant distribution to said radiator port and provide a second range of said rotational positions of said flow diverter in a second mode of said rotary valve for distributing said coolant from said inlet port to both said bypass port and said radiator port, and wherein at least one selected one of said fluid passages and said bypass outlet have a variable overlapping cross-sectional area between said first and second modes to provide a plurality of selectable flow rates to said bypass port including at least a first flow rate in said first mode and a second flow rate higher than said first flow rate in said second mode, wherein said first flow rate provides increased heat flow into said coolant; and

a controller responsive to predetermined vehicle parameters for generating said control signal to select one of said modes in response to said predetermined vehicle parameters.

14. The cooling system of claim 13 wherein said overlapping cross-sectional areas in said first and second ranges provide respective first and second plateaus, each plateau providing a respective constant overlapping cross-sectional area within respective subranges of rotational positions.

15. The cooling system of claim 13 wherein said overlapping cross-sectional areas provide a sloped variance within at least a portion of said first and second ranges of rotational positions.

16. The cooling system of claim 13 wherein said first mode is selected by said controller when said engine is initially started and warming up to a desired operating temperature.

17. The cooling system of claim 13 wherein said second mode is selected by said controller when said engine has reached a desired operating temperature.

18. A method of circulating coolant in a cooling system for an internal combustion engine, said cooling system including a pump for circulating said coolant, an engine circuit for conducting said coolant through said engine, a radiator circuit for conducting said coolant through a radiator, and a bypass circuit for returning said coolant to said engine circuit without passing through said radiator circuit, said method comprising the steps of:

starting said engine;

circulating said coolant through said bypass circuit at a first rate and substantially preventing circulation through said radiator circuit during an initial period; and

circulating said coolant through said bypass circuit at a second rate while circulating said coolant through said radiator circuit during a subsequent period, wherein said second rate is greater than said first rate and said first rate provides increased heat flow into said coolant from said engine.

19. A rotary valve for single-point coolant switching of coolant flowing in an engine cooling system, comprising:

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in a radiator circuit, a bypass port for allowing coolant flow in a bypass circuit, and a heater port for allowing coolant flow in a heater circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said predetermined flow paths include a first mode for distributing said coolant to said radiator port and said heater port while blocking coolant from said bypass port, a second mode for distributing said coolant to said bypass port while blocking coolant from said radiator port and said heater port, a third mode for distributing said coolant to said heater port while blocking coolant from said radiator port and said bypass port, and a fourth mode for distributing said coolant to said radiator port and said bypass port while blocking coolant from said heater port;

wherein a flow rate of coolant distributed to an outlet port in at least one of said modes is proportional to a variable overlapping cross-sectional area of a respective fluid passage and said outlet port; and

wherein a flow rate to said bypass port in said fourth mode is greater than a flow rate to said bypass port in said second mode to provide greater heat flow into said coolant in said second mode.

20. An engine cooling system for a vehicle, said cooling system distributing heat from an engine using a coolant, said cooling system comprising:

a pump for circulating said coolant;

an engine circuit for conducting said coolant through said engine;

a radiator circuit for conducting said coolant through a radiator;

a bypass circuit for returning said coolant to said engine circuit without passing through said radiator circuit;

a heater circuit for conducting said coolant through a heater core;

a rotary valve for single-point coolant switching of said coolant, said rotary valve comprising;

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in said radiator circuit, a bypass port for allowing coolant flow in said bypass circuit, and a heater port for allowing coolant flow in said heater circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said predetermined flow paths include a first mode for distributing said coolant to said radiator port and said heater port while blocking coolant from said bypass port, a second mode for distributing said coolant to said bypass port while blocking coolant from said radiator port and said heater port, a third mode for distributing said coolant to said heater port while blocking coolant from said radiator port and said bypass port, and a fourth mode for distributing said coolant to said radiator port and said bypass port while blocking coolant from said heater port;

wherein a flow rate of coolant distributed to an outlet port in at least one of said modes is proportional to a variable overlapping cross-sectional area of a respective fluid passage and said outlet port; and

wherein a flow rate to said bypass port in said fourth mode is greater than a flow rate to said bypass port in said second mode to provide greater heat flow into said coolant in said second mode; and

a controller responsive to predetermined vehicle parameters for generating said control signal to select one of said modes in response to said predetermined vehicle parameters.

21. A rotary valve for single-point coolant switching of coolant flowing in an engine cooling system, comprising:

a valve body having an inlet port and a plurality of outlet ports, said outlet ports including a radiator port for allowing coolant flow in a radiator circuit, a bypass port for allowing coolant flow in a bypass circuit, and a heater port for allowing coolant flow in a heater circuit;

a flow diverter rotationally received in said valve body and including a plurality of fluid passages providing predetermined flow paths between said inlet port and said outlet ports in response to a rotational position of said flow diverter; and

an actuator responsive to a control signal for setting said rotational position;

wherein said predetermined flow paths include a first mode for distributing said coolant to said radiator port and said heater port while blocking coolant from said bypass port, a second mode for distributing said coolant to said bypass port while blocking coolant from said radiator port and said heater port, a third mode for distributing said coolant to said heater port while blocking coolant from said radiator port and said bypass port, and a fourth mode for distributing said coolant to said radiator port and said bypass port while blocking coolant from said heater port; and

wherein a flow rate of coolant distributed to each outlet port in each of said modes is proportional to a variable overlapping cross-sectional area of a respective fluid passage and each respective outlet port, at least one of said fluid passages having an outlet profile such that its respective overlapping cross sectional area with a respective outlet port changes at a rate unequal to a rate at which an overlapping cross sectional area of a different fluid passage and a different outlet port simultaneously change, whereby flow rates provided to different output ports are independently controlled.