Description:A COVER STRUCTURE FOR AN EXHAUST GAS RECIRCULATION VALVE

TECHNICAL FIELD
[0001] The present subject matter described herein relates to a cover structure for an exhaust gas recirculation (EGR) valve used in an internal combustion engine of a vehicle. The present invention is particularly related to a cover structure to prevent the entry of foreign particles in a drain hole of the EGR valve.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Exhaust Gas Recirculation (EGR) valves play a crucial role in the operation of internal combustion engines with port fuel injection. The valve helps reduce emissions of harmful pollutants by recirculating a portion of exhaust gases back into the engine's combustion chambers. However, EGR valves have drain holes (Ref. Fig. 1) that are necessary to allow any condensate or water droplets that may accumulate inside the valve to exit.
[0004] One common issue associated with EGR valves is the intrusion of dust, debris, or contaminants through these drain holes. This can lead to valve malfunction and reduced engine performance, ultimately affecting the vehicle's emissions and fuel efficiency. Existing solutions to this problem involve various forms of covers or seals for these drain holes. A few of the existing solutions are mentioned below.
[0005] Many EGR valve designs incorporate seals or gaskets around the drain hole area to prevent the ingress of dust and contaminants. These seals are typically made of rubber or other resilient materials and are designed to create a barrier that blocks foreign particles from entering the valve. However, over time, these seals can wear out, become brittle, or lose their effectiveness, potentially leading to dust intrusion.
[0006] Some existing solutions may involve the use of filters or filter elements placed over or inside the EGR valve's drain hole. These filters act as a physical barrier, trapping dust and contaminants while allowing condensate or water droplets to pass through. However, these filters may need frequent maintenance or replacement, and they could reduce airflow or require additional space within the engine compartment.
[0007] Another approach to addressing dust intrusion is to redesign the EGR valve itself to minimize the risk of foreign particle entry. This might involve altering the shape, size, or location of the drain hole or incorporating internal features to redirect airflow and contaminants away from critical components, which is a costly measure.
[0008] Therefore, there is a need to overcome the drawbacks associated with the existing solutions to prevent the entry of dust particles inside the EGR valve.

OBJECTS OF THE DISCLOSURE
[0009] It forms an object of the present disclosure to overcome the aforementioned and other drawbacks/limitations in the existing solutions available in the form of related prior arts.
[0010] It is a primary objective of the present disclosure is to prevent the entry of dust, dirt, and contaminants into a drain hole of an Exhaust Gas Recirculation (EGR) valve.
[0011] In is another object of the present disclosure to allow for the drainage of condensate or water droplets that may accumulate within the EGR valve while preventing the entry of larger particles.
[0012] It is another object of the present disclosure to provide a cover structure on the EGR valve that has the structural integrity to withstand the rigors of the engine compartment environment and remain securely attached.
[0013] It is another object of the present disclosure to prevent reverse assembly.
[0014] It is another object of the present disclosure to provide a cover structure that is compatible with the exiting EGR valves and can be readily integrated into existing engine designs.
[0015] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY
[0016] A solution to one or more drawbacks of existing technology and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0017] The present disclosure provides a solution in the form of a cover structure for an Exhaust Gas Recirculation (EGR) valve, the cover structure comprises a curved portion and an embossed mounting surface extending from both distal ends of the curved portion, the embossed mounting surfaces are parallel to each other, the curved portion and the embossed mounting surfaces combinedly define a U-shape structure, the curved portion covers an outer periphery of the EGR valve and a foam seal affixed to an inner surface of the curved portion, the foam seal sandwiched in between the inner surface of the curved portion and the outer periphery of the EGR to prevent the entry of foreign particles in the drain hole of the EGR valve.
[0018] In an aspect, the foam seal is provided on a portion of the inner surface of the cover structure to surround the drain hole of the EGR valve.
[0019] In an aspect, the embossed mounting surfaces are configured to securely attach the cover structure to the EGR valve by means of fasteners.
[0020] In an aspect, multiple structural ribs are uniformly distributed on an outer surface of the curved portion.
[0021] In an aspect, a plurality of longitudinal ribs are provided along an outer surface of the embossed mounting surfaces.
[0022] In an aspect, the cover structure defines a U shape.
[0023] In an aspect, the cover structure includes a snap-fit structure, comprising a circular clamp structure defining an entry in between two end portions to receive the outer periphery of the EGR valve, the distance (d) is defined in between the two end portions which is smaller than diameter (D) of the circular clamp structure, the end portions of the circular clamp structure extend radially outward to define a V shape entry.
[0024] In an aspect, the circular clamp structure is connected to a vertical portion of the cover structure from one side.
[0025] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0026] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0027] Fig. 1 illustrates a drain hole on an EGR valve of a vehicle according to the present invention;
[0028] Fig. 2 illustrates a cover structure mounted on an EGR valve of a vehicle according to the present invention;
[0029] Fig. 3a illustrates a perspective view of the cover structure according to the present disclosure;
[0030] Fig. 3b illustrates a plurality of longitudinal ribs on the embossed mounting surfaces according to the present disclosure;
[0031] Fig. 4 illustrates a snap-fir structure of the cover structure according to the present disclosure;
[0032] Fig. 5 illustrates multiple structural ribs on the curved portion according to the present disclosure.
[0033] The figures depict embodiments of the present subject matter for illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF INVENTION
[0034] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0035] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0036] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0037] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0038] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration of specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0039] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure.
[0040] The present invention discloses a cover structure to cover a drain hole on an Exhaust Gas Recirculation (EGR) valve and prevent the entry of foreign particles in the drain hole of the EGR valve.
[0041] Referring to FIG. 1 and FIG. 2, the present invention relates to a cover structure (200) designed to seal a drain hole (102) on an Exhaust Gas Recirculation (EGR) valve (101).
[0042] FIG. 2 and FIG. 3, illustrate the cover structure (200, 300) that is mounted to the EGR valve (101). Further, the cover structure (200, 300) features a curved portion (301) that has two distal ends (306a, 306b). Moreover, a plurality of embossed mounting surfaces (302a, 302b) extend from both the distal ends (306a, 306b). The plurality of embossed mounting surfaces (302a, 302b) are parallel to each other and, in combination with the curved portion (301), create a U-shape structure (309).
[0043] Further, the material of the cover structure (200, 300) is PPGF-30. Further, the use of PPGF-30 material for the cover structure (200, 300) enhances resilience in demanding environments, including exposure to heat and chemicals commonly found in the engine of a vehicle.
[0044] The curved portion (301) is designed to encircle the outer periphery of the EGR valve (101) when the cover structure (200, 300) is installed. In various embodiments, the curvature of the curved portion (301) may vary based on the specific shape and size of the EGR valve (101) to ensure a snug and secure fit.
[0045] A foam seal (303) is affixed on an portion (305) of an inner surface (304) of the curved portion (301) of the cover structure (200, 300). This placement is crucial because it positions the foam seal (303) at the precise interface between the cover structure (200, 300) and the outer periphery of the EGR valve (101) that specifically covers the drain hole (102 as provided in Fig, 1).
[0046] The foam seal (303) serves as a sealing mechanism that plays a pivotal role in maintaining the integrity of the EGR valve (101). When the cover structure (200, 300) is attached to the EGR valve (101), the foam seal (303) is essentially sandwiched between the inner surface (304) of the curved portion (301) and the outer periphery of the EGR valve (101).
[0047] The primary objective of the foam seal (303) is to create a robust barrier against the intrusion of foreign particles, contaminants, or debris into the drain hole (102 as provided in Fig. 1) of the EGR valve (101). This is particularly critical because the drain hole (102 as provided in Fig. 1) serves as an exhaust passage, and any foreign matter entering it could disrupt the functionality of the EGR valve (101).
[0048] As the cover structure (200, 300) is securely fastened to the EGR valve (101), the foam seal (303) undergoes a controlled compression. This compressive action results from the physical contact between the inner surface (304) of the curved portion (301) and the outer surface of the EGR valve (101). During this compression, the foam seal (303) generates a sealing pressure. This sealing pressure is precisely engineered to ensure that the foam seal (303) conforms tightly to the contours of the outer surface of the EGR valve (101). In doing so, the foam seal (303) effectively seals off the drain hole (102 as provided in Fig. 1) in a manner that foreign particles cannot penetrate.
[0049] The foam seal (303) is often fabricated from specialized elastomeric materials known for their sealing properties. These materials are selected for their ability to compress and conform to irregular surfaces, creating a reliable and robust seal.
[0050] Further, the plurality of embossed mounting surfaces (302a, 302b) are configured to securely attach the cover structure (200, 300) to the EGR valve (101) using fasteners. This embodiment introduces a mechanism for firm attachment, which may include fasteners such as nuts and bolts.
[0051] The fasteners used to attach the cover structure (200, 300) to the EGR valve (101) may vary in type and design, depending on the specific application and requirements.
[0052] Furthermore, a plurality of longitudinal ribs (307) is provided along the outer surface of the plurality of embossed mounting surfaces (302a, 302b). The longitudinal ribs (307) can enhance the structural integrity and stability of the plurality of embossed mounting surfaces (302a, 302b).
[0053] Ref. Fig. 5, multiple structural ribs (502) are evenly distributed on the outer surface (503) of the curved portion (301). The multiple structural ribs (502) contribute to the rigidity and strength of the cover structure (200, 300).
[0054] Also, a cut-out (501) is located at one end of the curved portion (301), which is adjacent to the embossed mounting surface (302b). The purpose of the cut-out (501) may vary depending on design or manufacturing considerations.
[0055] Ref. Fig. 4, the cover structure (200, 300) includes a snap-fit structure (400). The cover structure (200, 300) incorporates a snap-fit structure (400) as an integral feature. The snap-fit structure (400) is designed to facilitate the secure attachment of the cover structure (200, 300) to the EGR valve (101).
[0056] The snap-fit structure (400) consists of a circular clamp structure (401) connected to the vertical portion of the cover structure (200, 300) from one side. It defines an entry (402) between two end portions (403a, 403b) to receive or accommodate the outer periphery of the EGR valve (101).
[0057] The distance (d) is a critical dimension within the snap-fit structure (400). It is defined as the space between the two end portions (403a, 403b) of the circular clamp structure (401). Importantly, this distance (d) is intentionally smaller than the diameter (D) of the circular clamp structure (401). The end portions (403a, 403b) of the circular clamp structure (401) extend radially outward. This outward extension creates a V-shaped entry when viewed from the side. This V shape is instrumental in providing the snap-fit engagement.
[0058] The dimensions and geometry of the snap-fit structure (400), including the distance (d) and diameter (D), may vary in different embodiments to accommodate different sizes and shapes of the EGR valve (101).
[0059] Ref. Fig. 5, illustrates an assembled cover structure (200, 300) mounted on the EGR valve (101) through the plurality of embossed mounting surfaces (302a, 302b). The curved portion (301) includes multiple structural ribs (502) that are uniformly distributed on the outer surface (503) of the curved portion (301) to improve the rigidity and strength of the cover structure (200, 300). Further, the cover structure (200, 300) features a snap-fit structure (400) designed for effortless assembly onto the EGR valve (101).

TECHNICAL ADVANTAGES
[0060] The primary function of the present invention is to seal the drain hole on the EGR valve effectively. By doing so, it prevents the entry of foreign particles, contaminants, or debris into the EGR valve. This helps maintain the proper functioning of the EGR system, reducing the risk of clogs or damage.
[0061] The cover structure incorporates ribs and a robust U-shape. These features enhance the durability and rigidity of the cover, making it capable of withstanding the harsh conditions within an engine compartment.
[0062] The inclusion of the snap-fit structure ensures a secure attachment between the cover and the EGR valve. This snap-fit mechanism simplifies the installation process, for hand-free assembly and preventing unintended dislodgment.
[0063] The cover structure offers an efficient and cost-effective solution for sealing EGR valves. It reduces maintenance and replacement costs associated with EGR valve issues caused by particle ingress.
[0064] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to disclosures containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. Also, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0065] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the disclosure, and other dimensions or geometries are possible. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature. , Claims:We claim:
1. A cover structure (200, 300) for an Exhaust Gas Recirculation (EGR) valve (101), the cover structure (200, 300) comprising:
a curved portion (301) and an embossed mounting surface (302a, 302b) extending from both distal ends (306a, 306b) of the curved portion (301), the embossed mounting surfaces (302a, 302b) are parallel to each other;
the curved portion (301) and the embossed mounting surfaces (302a, 302b) combinedly define a U-shape structure (309),
the curved portion (301) covers an outer periphery of the EGR valve (101); and
a foam seal (303) affixed to an inner surface (304) of the curved portion (301), the foam seal (303) sandwiched in between the inner surface of the curved portion (301) and the outer periphery of the EGR valve (101) to prevent entry of foreign particles in drain hole (102) of the EGR valve (101).
2. The cover structure (200, 300) as claimed in claim 1, wherein the foam seal (303) provided on a portion (305) of the inner surface (304) of the cover structure (100) to surround the drain hole (102) of the EGR valve (101).
3. The cover structure (200, 300) as claimed in claim 1, wherein the embossed mounting surfaces (302a, 302b) are configured to securely attach the cover structure (200, 300) to the EGR valve (101) by means of fasteners.
4. The cover structure (200, 300) as claimed in claim 1, wherein a plurality of longitudinal ribs (307) is provided along an outer surface of the embossed mounting surfaces (302a, 302b).
5. The cover structure (200, 300) as claimed in claim 1, wherein multiple structural ribs (502) are uniformly distributed on an outer surface (503) of the curved portion (301).
6. The cover structure (200, 300) as claimed in claim 1, wherein the cover structure (200, 300) defines a U shape.
7. The cover structure (200, 300) as claimed in claim 1, wherein the cover structure (200, 300) includes a snap-fit structure (400), comprising:
a circular clamp structure (401), define an entry (402) in between two end portions (403a, 403b) to receive the outer periphery of the EGR valve (102),
wherein a distance (d) is defined in between the two end portions (403a, 403b) such that distance (d) is smaller than diameter (D) of the circular clamp structure (401); and
the end portions (403a, 403b) of the circular clamp structure (401) extend radially outward to define a V-shaped entry.
8. The cover structure (200, 300) as claimed in claim 7, wherein the circular clamp structure (401) is connected to a vertical portion of the cover structure (200, 300) from one side.