Closed loop pressure control system and electrically operated pressure control valve with integral pressure sensor and method of making same

Abstract

A solenoid operated valve has a pressure transducer sensing valve outlet pressure integrally formed in the valve body, such as by overmolding. Upon connection of the transducer and solenoid to an electronic controller, the controller generates a valve energization signal in response to a desired valve pressure output and the transducer input for providing closed loop control of the valve outlet pressure. An ASIC may also be integrally formed in the valve body, such as by overmolding for providing integrated signal conditioning; and, the optional ASIC, if employed, may also include the circuitry for the electronic controller for providing a “smart” pressure control valve.

1 . An electrically operated valve assembly for use in closed loop pressure control comprising:
 (a) an operator effective upon selective electrical energization to effect movement of an actuator member associated therewith;   (b) a valve body having an inlet, an outlet, and a valving chamber communicating with said inlet and outlet;   (c) a valve member disposed in said valving chamber and moveable by said actuator member between a first position increasing and a second position decreasing fluid pressure communication between said inlet and outlet;   (d) a pressure transducer integrally formed in the material of said valve body and substantially enclosed by said valve body, said pressure transducer communicating with a pressure at said outlet and operable, upon electrical connection therewith, to provide an electrical signal indicative of said pressure sensed in said outlet; and   (e) a first terminal operably connecting said operator and said transducer, and a second terminal configured for external circuit connection thereto.   
   
   
       2 . The valve assembly defined in  claim 1 , wherein said valve body is formed by molding. 
   
   
       3 . The valve assembly defined in  claim 2 , wherein said pressure transducer is overmolded in the material of said valve body. 
   
   
       4 . The valve assembly defined in  claim 1 , wherein said operator includes a solenoid with a moveable armature. 
   
   
       5 . The valve assembly defined in  claim 4 , wherein said actuator member is operatively connected to said armature. 
   
   
       6 . The valve assembly defined in  claim 1 , wherein said valve body is molded of a non-metallic material. 
   
   
       7 . The valve assembly defined in  claim 1 , wherein said valve body is molded of substantially plastic material. 
   
   
       8 . The valve assembly defined in  claim 1 , wherein said pressure transducer includes a solid state sensing element. 
   
   
       9 . The valve assembly defined in  claim 1 , further comprising an ASIC integrally formed in said valve body. 
   
   
       10 . The valve assembly defined in  claim 1 , wherein said pressure transducer and said first terminal are mounted on a substrate board. 
   
   
       11 . The valve assembly defined in  claim 1 , wherein said operator is electrically connected to said first terminal by plug-in connection to said valve body. 
   
   
       12 . The valve assembly defined in  claim 1 , wherein said transducer is mounted on a circuit board including an ASIC configured to provide closed loop control of the valve assembly upon connection to an electronic controller. 
   
   
       13 . The valve assembly defined in  claim 1 , wherein said electrical signal from said pressure transducer is configured to produce said selective electrical energization of said operator. 
   
   
       14 . A method of making a valve assembly for closed loop pressure control comprising:
 (a) forming a valve body with a valving chamber communicating with an inlet and outlet;   (b) disposing a valve member in the valving chamber for movement between a position increasing and a position decreasing fluid pressure communication between the inlet and outlet;   (c) disposing an electrical operator on the valve body configured to effect said movement of the valve member upon energization;   (d) integrally forming a pressure transducer in the material of the valve body to substantially enclose the pressure transducer in the valve body and sensing pressure at the outlet and providing an electrical indication thereof, and disposing an electrical terminal on the valve body for electrical connection thereto.   
   
   
       15 . The method defined in  claim 14 , wherein said forming the valve body includes molding. 
   
   
       16 . The method defined in  claim 15 , wherein said integrally forming the pressure transducer includes overmolding the valve body over the transducer. 
   
   
       17 . The method defined in  claim 14 , wherein said integrally forming the pressure transducer in the valve body includes mounting a solid state device on a substrate. 
   
   
       18 . The method defined in  claim 17 , further comprising mounting an ASIC on the substrate and connecting said pressure transducer to said ASIC and effecting closed loop control operation of the valve. 
   
   
       19 . The method defined in  claim 14 , wherein said integrally forming the pressure transducer includes overmolding a solid state sensor. 
   
   
       20 . The method defined in  claim 14 , wherein said forming the valve body includes molding the valve body of nonmetallic material. 
   
   
       21 . The method defined in  claim 14 , wherein said forming the valve body includes molding the valve body of substantially plastic material. 
   
   
       22 . The method defined in  claim 14 , wherein said disposing the electrical operator includes disposing a solenoid. 
   
   
       23 . The method defined in  claim 14 , wherein said integrally forming a transducer includes integrally forming a piezoelectric transducer. 
   
   
       24 . The method defined in  claim 14 , wherein said disposing the electrical operator includes disposing a solenoid with a moveable armature configured such that moving the armature effects said valve member movement. 
   
   
       25 . The method defined in  claim 14 , wherein said disposing the electrical operator includes electrically plug-in connecting the operator to the valve body. 
   
   
       26 . The method defined in  claim 14 , wherein said forming the valve body includes forming the valve body of a material selected from one of polyetheramide and polythalamide material. 
   
   
       27 . The method defined in  claim 26 , wherein said forming the valve body further includes filling the material with about 10-40% by volume of glass particles. 
   
   
       28 . A closed loop fluid pressure control system comprising:
 (a) a fluid pressure operated actuator operative for effecting a function to be controlled;   (b) a source of pressurized fluid;   (c) an electrically operated pressure control valve having a body with an inlet connected to receive said pressurized fluid and an outlet connected to said fluid pressure operated actuator;   (d) a pressure transducer integrally formed in said body and substantially enclosed by said body, said pressure transducer being operative, upon connection of a circuit thereto, for providing an electrical indication of the pressure at said outlet; and,   (e) an electronic controller disposed in said circuit to receive said electrical indication from said pressure transducer and operative in response thereto to generate and supply an electrical control signal to said electrically operated pressure control valve for a desired outlet pressure, thereby providing closed loop pressure control of said actuator.   
   
   
       29 . The system defined in  claim 28 , wherein said pressure transducer is mounted on a substrate. 
   
   
       30 . The system defined in  claim 29 , wherein said substrate includes an ASIC. 
   
   
       31 . The system defined in  claim 28 , wherein said electronic controller is located remote from said electrically operated pressure control valve. 
   
   
       32 . The system defined in  claim 28 , wherein said electrically operated pressure control valve includes a solenoid. 
   
   
       33 . The system defined in  claim 32 , wherein said pressure transducer is mounted on a substrate including a connector terminal and said solenoid electrically connects to said terminal in plug-in arrangement. 
   
   
       34 . The system defined in  claim 28 , further comprising an ASIC formed integrally in said body. 
   
   
       35 . The system defined in  claim 34 , wherein said ASIC includes said electronic controller. 
   
   
       36 . The system defined in  claim 28 , wherein said pressure transducer includes a die mounted on a ceramic ring. 
   
   
       37 . An electrically operated fluid pressure control valve capable of closed loop pressure control upon energization comprising:
 (a) a valve body defining an inlet, an outlet and a valving chamber communicating with said inlet and outlet;   (b) a valve member disposed in said valving chamber and moveable therein between a position increasing and a position decreasing fluid flow between said inlet and outlet;   (c) an electrical operator associated with said valve body and operable, upon energization, for effecting the movement of said valve member;   (d) a pressure transducer disposed in said outlet and configured to sense a pressure at said outlet; and   (e) an electronic controller disposed in a circuit with said pressure transducer and said electrical operator, wherein said pressure transducer and said controller are integrally formed in said valve body and wherein said pressure transducer is substantially enclosed by said valve body.   
   
   
       38 . The valve defined in  claim 37 , wherein said valve body is molded of nonmetallic material. 
   
   
       39 . A method of making an electrically operated pressure control valve for closed loop pressure control comprising:
 (a) forming a valve body of nonmetallic material with an inlet, outlet and a valving chamber communicating with said inlet and outlet;   (b) disposing a valve member in said chamber for movement therein to increase or decrease flow between said inlet and outlet;   (c) disposing an electrical operator in association with said valve body and, upon energization, effecting said movement of said valve member; and   (d) integrally forming a pressure transducer and an electronic controller in said nonmetallic material of said valve body to substantially enclose said pressure transducer in said valve body and connecting said electronic controller in circuit with said transducer and said electrical operator.   
   
   
       40 . The method defined in  claim 39 , wherein said integrally forming an electronic controller includes overmolding an ASIC. 
   
   
       41 . The method defined in  claim 39 , wherein said integrally forming a pressure transducer and an electronic controller includes mounting a piezoelectric device and an ASIC on a substrate. 
   
   
       42 . The method defined in  claim 41 , wherein said integrally forming includes overmolding said piezoelectric device, said ASIC and said substrate. 
   
   
       43 . The method defined in  claim 42 , wherein said overmolding includes applying a viscous material and overmolding with a plastic material. 
   
   
       44 . The method defined in  claim 39 , wherein said disposing an electrical operator includes disposing a solenoid. 
   
   
       45 . The method defined in  claim 39 , wherein said disposing an electrical operator includes engaging a solenoid in plug-in engagement with said valve body. 
   
   
       46 . The method defined in  claim 39 , wherein said integrally forming a pressure transducer includes mounting a die on a ceramic ring.