Exhaust gas regulator including an overmolded housing

#It is believed that an Exhaust Gas Regulator (“EGR”) consists of, among other components, a valve which is inserted into an exhaust gas flow passage. The valve is believed to control the flow rate of exhaust gas through the passage.

#An EGR is also believed to comprise an actuator shaft that is connected to and manipulates the valve, and a motor that drives the actuator shaft. It is believed that the position of the valve within the exhaust gas flow passage subjects the valve to very high temperatures. It is further believed that the actuator shaft conducts heat energy from the valve to the motor, thereby increasing the operational temperature of the motor. It is yet further believed this temperature increase can adversely affect the motor's performance and possibly damage the motor.

#The present invention provides a valve including a wall, a closure member, a motive force device, and a coupling member. The wall defines a flow passage that is disposed along a longitudinal axis. The closure member is disposed in the flow passage and is rotatable on a first axis that is oblique to the longitudinal axis. The closure member is rotatable between a first position that substantially prevents flow through the flow passage and a second position that generally permits flow through the flow passage. The motive force device rotates the closure member between the first position and the second position. The device includes a rotor that is rotatably supported by a bearing, a stator that is proximate to the rotor, and an overmolded housing that positions the stator with respect to the bearing. The coupling member conveys motive force from the device to rotation of the closure member.

#The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention.

#FIG. 1 is a schematic illustration of a regulator valve.

#FIGS. 2A, 2B, and 2C are cross-sectional views showing a variation of a sensor for a motive force device of the regulator valve illustrated in FIG. 1.

#FIG. 1 shows a regulator valve 10 according to a preferred embodiment. The regulator valve 10 can be operated with a motive force device 100 that can include an electric motor as shown, for example, in FIGS. 2A, 2B, and 2C.

#The regulator valve 10 includes a wall 12 defining a flow passage 14 disposed along a longitudinal axis A—A. A closure member 16 is disposed in the flow passage 14 for rotation about an axis B—B, which is oblique to the longitudinal axis A—A. The closure member 16 is movable, e.g., rotatable, to a first position to substantially prevent flow through the flow passage 14, and the closure member 16 is also movable to a second position to generally permit flow through the flow passage 14. The wall 12 can include a boss portion with a seal 18 for contiguously engaging the closure member 16 in the first position. The closure member 14 can be a butterfly valve, which can be coupled to a shaft 20 extending along the axis B—B.

#The motive force device 100 is mounted with respect to the wall 12 and connected to the closure member 16 such that it can rotate the closure member 16 between the first position and the second position about the axis B—B. The motive force device 100 can be an electric stepper motor, an electric torque motor, or another device that provides a motive force. The motive force device 100 can include a housing 102 having an interior surface 104 and an exterior surface 106. The interior surface 104 can enclose a driveshaft 108 that is coupled to a rotor 110, and can surround a stator 112.