Butterfly valve assembly, in particular for a gas flow in a fuel cell system

A fuel cell system for a vehicle, comprising:

• at least one butterfly valve assembly including:
• a butterfly valve housing defining a channel for accommodating a flow of gas therethrough;
• a butterfly valve adjustable in said butterfly valve housing between a closed position preventing said flow of gas through said channel and at least one open position opening up said channel for allowing passage of said flow of gas through said channel;
• a pivot shaft rotatable about a pivot shaft axis (A) and having first and second pivot shaft end portions corresponding to first and second bearing regions, said pivot shaft having an outer peripheral surface;
• said butterfly valve having a disk-shaped butterfly valve element supported on said pivot shaft;
• a pivot shaft drive;
• said first pivot shaft end portion being coupled to said pivot shaft drive and being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said first bearing region;
• said second pivot shaft end portion being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said second bearing region;
• at least one of said first and second bearing regions including a bearing unit made of structural material and rotatably supporting said pivot shaft and
• at least one seal supported in said bearing unit and lying against said outer peripheral surface of said pivot shaft;
• said at least one seal comprising a holding portion encompassed by said structural material and a sealing portion lying against said pivot shaft;
• wherein one of the following applies:
• i) said bearing unit comprises at least one bearing ring made of said structural material, said holding portion of said at least one seal being encompassed by said structural material by insert-molding said holding portion in said structural material and, thereby, embedding said holding portion into the structural material of said at least one bearing ring;
• ii) said bearing unit comprises at least two bearing rings, said holding portion of said at least one seal being encompassed by said structural material by being held between said at least two bearing rings.

A fuel cell system including for a vehicle, the fuel cell system comprising:

• an anode region to be supplied with hydrogen or a gas containing hydrogen;
• a cathode region to be supplied with oxygen or a gas containing oxygen;
• a butterfly valve assembly associated with said cathode region;
• and,
• said butterfly valve assembly including:
• a butterfly valve housing defining a channel for accommodating a flow of gas therethrough;
• a butterfly valve adjustable in said butterfly valve housing between a closed position preventing said flow of gas through said channel and at least one open position opening up said channel for allowing passage of said flow of gas through said channel;
• a pivot shaft rotatable about a pivot shaft axis (A) and having first and second pivot shaft end portions corresponding to first and second bearing regions, said pivot shaft having an outer peripheral surface;
• said butterfly valve having a disk-shaped butterfly valve element supported on said pivot shaft;
• a pivot shaft drive;
• said first pivot shaft end portion being coupled to said pivot shaft drive and being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said first bearing region;
• said second pivot shaft end portion being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said second bearing region;
• at least one of said first and second bearing regions including a bearing unit made of structural material and rotatably supporting said pivot shaft and
• at least one seal supported in said bearing unit and lying against said outer peripheral surface of said pivot shaft;
• said at least one seal comprising a holding portion encompassed by said structural material and a sealing portion lying against said pivot shaft;
• wherein one of the following applies:
• i) said bearing unit comprises at least one bearing ring made of said structural material, said holding portion of said at least one seal being encompassed by said structural material by insert-molding said holding portion in said structural material and, thereby, embedding said holding portion into the structural material of said at least one bearing ring;
• ii) said bearing unit comprises at least two bearing rings, said holding portion of said at least one seal being encompassed by said structural material by being held between said at least two bearing rings.

A method of manufacturing a butterfly valve, wherein said butterfly valve comprises:

• a butterfly valve housing defining a channel for accommodating a flow of gas therethrough;
• a butterfly valve adjustable in said butterfly valve housing between a closed position preventing said flow of gas through said channel and at least one open position opening up said channel for allowing passage of said flow of gas through said channel;
• a pivot shaft rotatable about a pivot shaft axis (A) and having first and second pivot shaft end portions corresponding to first and second bearing regions, said pivot shaft having an outer peripheral surface;
• said butterfly valve having a disk-shaped butterfly valve element supported on said pivot shaft;
• a pivot shaft drive;
• said first pivot shaft end portion being coupled to said pivot shaft drive and being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said first bearing region;
• said second pivot shaft end portion being rotatably supported about said pivot shaft axis (A) on said butterfly valve housing in said second bearing region;
• at least one of said first and second bearing regions including a bearing unit made of structural material and rotatably supporting said pivot shaft and at least one seal supported in said bearing unit and lying against said outer peripheral surface of said pivot shaft, said at least one seal comprising a holding portion encompassed by said structural material and a sealing portion lying against said pivot shaft;
• wherein said method comprises encompassing said holding portion of said at least one seal by said structural material by one of:
• i) providing said bearing unit with at least one bearing ring made of said structural material and insert-molding said holding portion in said structural material and, thereby, embedding said holding portion into the structural material of said a least one bearing ring of said bearing unit;
• ii) providing said bearing unit with at least two bearing rings and positioning said holding portion of said at least one seal such as to be held between said at least two bearing rings of said bearing unit.