WO2002062551A1 - Device for controlling a gaseous stream and a production method therefor - Google Patents

Device for controlling a gaseous stream and a production method therefor Download PDF

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Publication number
WO2002062551A1
WO2002062551A1 PCT/DE2002/000428 DE0200428W WO02062551A1 WO 2002062551 A1 WO2002062551 A1 WO 2002062551A1 DE 0200428 W DE0200428 W DE 0200428W WO 02062551 A1 WO02062551 A1 WO 02062551A1
Authority
WO
WIPO (PCT)
Prior art keywords
flap
bearing body
housing
shaft
injection
Prior art date
Application number
PCT/DE2002/000428
Other languages
German (de)
French (fr)
Inventor
Sam Soubjaki
Original Assignee
Robert Bosch Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2002062551A1 publication Critical patent/WO2002062551A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0017—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor moulding interconnected elements which are movable with respect to one another, e.g. chains or hinges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14754—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles being in movable or releasable engagement with the coating, e.g. bearing assemblies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D9/00—Controlling engines by throttling air or fuel-and-air induction conduits or exhaust conduits
    • F02D9/08—Throttle valves specially adapted therefor; Arrangements of such valves in conduits
    • F02D9/10—Throttle valves specially adapted therefor; Arrangements of such valves in conduits having pivotally-mounted flaps
    • F02D9/1005—Details of the flap
    • F02D9/101—Special flap shapes, ribs, bores or the like
    • F02D9/1015—Details of the edge of the flap, e.g. for lowering flow noise or improving flow sealing in closed flap position
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D9/00—Controlling engines by throttling air or fuel-and-air induction conduits or exhaust conduits
    • F02D9/08—Throttle valves specially adapted therefor; Arrangements of such valves in conduits
    • F02D9/10—Throttle valves specially adapted therefor; Arrangements of such valves in conduits having pivotally-mounted flaps
    • F02D9/1035—Details of the valve housing
    • F02D9/106—Sealing of the valve shaft in the housing, e.g. details of the bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K1/00—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces
    • F16K1/16—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members
    • F16K1/18—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members with pivoted discs or flaps
    • F16K1/22—Lift valves or globe valves, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces with pivoted closure-members with pivoted discs or flaps with axis of rotation crossing the valve member, e.g. butterfly valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K27/00—Construction of housing; Use of materials therefor
    • F16K27/02—Construction of housing; Use of materials therefor of lift valves
    • F16K27/0209—Check valves or pivoted valves
    • F16K27/0218—Butterfly valves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7506—Valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D9/00—Controlling engines by throttling air or fuel-and-air induction conduits or exhaust conduits
    • F02D9/08—Throttle valves specially adapted therefor; Arrangements of such valves in conduits
    • F02D9/10—Throttle valves specially adapted therefor; Arrangements of such valves in conduits having pivotally-mounted flaps
    • F02D9/107—Manufacturing or mounting details

Definitions

  • Control of the gas flows to be supplied and discharged is required on internal combustion engines, be they direct-injection internal combustion engines or gasoline-injection internal combustion engines.
  • the intake air volume is controlled via a throttle valve
  • the exhaust gas flow is also controlled via valve systems.
  • Controlling the exhaust gas volume flow is necessary in particular in exhaust gas backfilling systems in which a part of the exhaust gas flow is admixed with the intake air flow again.
  • the control of supply air or exhaust gas flows on internal combustion engines generally takes place via flap systems, the flaps of which can be inclined in the pipe systems that conduct the gas flows. The manufacturing costs of such valve systems are not negligible.
  • DE 30 39 868 AI relates to a vibration damper and a method for its production. These are produced by an injection molding process, the inner part and outer part of the vibration damper first being made from a rigid or rigid thermoplastic material such as polystyrene. A resilient intermediate piece is then formed from a thermoplastic elastomer, for example a copolymer of butadiene and styrene, and produced on the outer and inner parts in a subsequent injection molding step.
  • a thermoplastic elastomer for example a copolymer of butadiene and styrene
  • DE 197 03 296 AI relates to a method for sealing a throttle valve shaft carrying a throttle valve and throttle valve connector.
  • a throttle valve shaft penetrating recesses in the throttle valve assembly is sealed with a hardening sealant. sealed. The sealant prevents air from flowing through a manufacturing gap between the throttle valve shaft and the recesses.
  • EP 0 575 235 B1 relates to a rotatable throttle element for the fuel injection systems of internal combustion engines.
  • a shaft with cylindrical seats is provided, which receives a section for receiving a throttle valve, the section having a constant, non-rotationally symmetrical cross section which is larger than the cross section of the part of the shaft located on one side of the section.
  • the throttle valve has a central bore whose cross-section corresponds to that of the section.
  • the shaft is made entirely of plastic and is cast in one piece with a cam for hanging or winding up a control cable located on the other side of said section, the throttle valve itself being made of filled plastic.
  • the plastic is preferably a thermoplastic.
  • the section of the throttle valve shaft has a cylindrical shape with parallel flats; the throttle valve in turn has a flattened hub with a central bore, which in cross section has the shape of a circle flattened parallel to the wings of the throttle valve:
  • DE 42 24 171 AI relates to an injection molded part as well as a method and an injection molding tool for producing the injection molded part.
  • the proposed method can be used to produce injection molded parts which have at least two colors and / or at least two different plastics and are produced in at least two successive process steps in which the colors and / or the plastics are injected one after the other into an injection mold.
  • the resulting injection molded part remains in the closed mold, after which a cavity adjacent to the injection molded part is created or released and the second color and / or the second plastic is injected into it.
  • the injection mold has at least one slide which changes the cavity in the mold provided for the injection molded part. This procedure ensures that the injection mold can remain closed between the two injection molding processes and thus the surfaces of the pre-sprayed part cannot come into contact with the ambient air.
  • Conventional throttle valve systems generally include a housing, the throttle valve, the throttle valve shaft, the bearing body and a number of fastening and sealing elements. Before these components are assembled, a number of sometimes lengthy machining steps and calibration steps are required, such as drilling out bearing seats, grinding the throttle shaft, as well as drilling out or otherwise machining the throttle valve bore in the housing.
  • Today Plastics are increasingly being used for the production of throttle valve systems, manufacturing inaccuracies result from the fastening elements and in surfaces which are movable relative to one another, the fit of which is only achieved in various subsequent processing steps.
  • a flap system controlling a gas flow can be manufactured with a minimum of further assembly steps. Furthermore, after the formation of a throttle valve that swivels in a housing and controls a gas flow, no further processing steps that improve the surface quality of the precisely manufactured component are required.
  • the components forming the flap system are inexpensively manufactured in accordance with the one-component injection molding process, as a result of which a final assembly of individual components such as the valve shaft and throttle valve within the housing can be completely dispensed with.
  • the manufacturing accuracy of the throttle valve shaft only has to meet increased requirements in the area of the seating surfaces receiving the bearing body; a throttle valve shaft with tolerances can be used, on which the throttle valve is injection molded directly, and joining operations between the valve and the shaft requiring manufacturing accuracy can be completely dispensed with.
  • a slot for inserting the throttle valve is no longer required on the shaft receiving the throttle valve.
  • a particularly tight flap system which allows the lowest leakage flows can be achieved if, before the plastic is injected into the mold, the bearing bodies provided at the ends of the throttle shaft are encapsulated in plastic with a lubricating agent, which is contaminated with lubricant.
  • the bearing bodies can be designed with higher degrees of freedom, which allows greater design variability.
  • the flap system manufactured according to the manufacturing method proposed according to the invention, can be designed almost without play.
  • drive elements such as curves, gearwheels or the like, which may be required for areas of application other than the use of expansion engines for motor vehicles, can be injection-molded on during the production using the one-component injection molding process.
  • the flap arrangement manufactured according to the invention can be manufactured with a low weight.
  • Non-cylindrical throttles can also be flexibly injected in the housing, which would be associated with considerable joining problems if they were installed conventionally.
  • the plastic used in accordance with the one-component injection molding process can be selected depending on the intended use of the flap arrangement to be produced in accordance with the temperatures present in the intended use. In this way, pure supply air flaps can be made from less expensive plastics; Valve systems subjected to higher thermal loads can be manufactured from correspondingly more temperature-resistant plastics.
  • FIG. 1 shows a plan view of a flap arrangement in the open position in the housing surrounding it
  • FIG. 2 shows a sectional illustration of the flap arrangement shown in FIG.
  • FIG. 2.1 shows a detail of the flap arrangement according to FIG. 2,
  • FIG. 3 shows a cross-section through the flap arrangement according to FIG. 1, which is in the open position
  • FIG. 3.1 shows the slope of the peripheral surface of the flap arrangement
  • FIG. 4 shows a perspective top view of the flap arrangement controlling a gas flow according to FIG. 1,
  • FIG. 5 shows a top view of the housing surrounding the flap
  • FIG. 6 shows a section through the shaft that receives the flap and is rotatably mounted on both sides in the molded housing pin
  • Figure 6.1 is an enlarged view of the bearing area of the valve shaft. design variants
  • FIG. 1 shows a plan view of a flap arrangement in the open position in the surrounding housing.
  • a valve 4 serving to control a gas flow is received on a valve shaft 3.
  • the flap shaft 3 is formed symmetrically to the center line 5 and is mounted at bearings 7 in pins 10 molded onto the housing 1.
  • a number of fasteners are formed on the outside of the housing 1.
  • the flap 4 received on the shaft passing through the free flow cross section 2 is pivoted into its maximum open position, so that, as shown in FIG. 1, the largest possible flow cross section 2 is released.
  • the flap 4 is provided with ribbing 6 on both sides, which improves the mechanical strength of the flap surface of the flap 4.
  • the ribbing 6 can also be accommodated on only one side of the flap 4, in a departure from the illustration according to FIG. 1.
  • the shaft 3, on which the flap 4 is molded - shown in its maximum open position - is rotatably supported in the bearing bodies (not shown here) in the injection pins 10 on the housing 1.
  • FIG. 2 shows a referee representation of the flap arrangement shown in FIG. 1.
  • bearing bodies 9 preferably consist of a material impregnated with a lubricant additive such as oil, for example sintered bronze.
  • a lubricant additive such as oil, for example sintered bronze.
  • bearing bodies 9 made of steel can also be used.
  • the bearing bodies 9 are applied in the end regions thereof.
  • the assembly which has been preassembled in this way is inserted into an injection mold, which is then closed, so that the housing 1, including the molded-on pins 10 formed thereon, and the flap surface 11 of the flap 4 can be formed in a single operation in accordance with the one-component injection molding process in the injection mold.
  • the flap flat 11 is produced, which is thereby directly connected to the tolerance-sensitive area of the shaft 3. This procedure only requires machining the shaft 3 in the areas which serve as seat surfaces 28 for the bearing bodies 9. NEN.
  • the injected plastic encloses the bearing body 9 in the area of the bearing points 7.
  • individual or circumferential elements can be attached to the injection pin 10.
  • fende projections 13 are formed which engage in corresponding individual or circumferential recesses on the bearing bodies 9. This prevents twisting and axial displacement and thus potential leakage between the injection pin 10 and the bearing body 9.
  • the lubricant which is preferably applied to the bearing body 9 when it is mounted on the shaft 3, the sealing effect between the injection pin 10 and the bearing body 9 is additionally increased.
  • a relative movement of the bearing bodies 9 in the injection pins 10 is avoided by the projections 13 formed during the extrusion coating, which engage in individual recesses or annular recesses 14 of the bearing bodies 9. Furthermore, the positive connection between the outside of the bearing body 9 and the inside of the injection pins 10 prevents axial movement of the shaft 3 receiving the molded flap surface 11. The shaft 3 can only rotate relative to the bearing bodies 9 arranged in a rotationally fixed manner in the injection pins 10.
  • the flap surface 11 is oriented with respect to the flow cross-section 2 within the housing 1 so that it assumes an open position. Particularly good results have been achieved when the flap surface 11 was molded around the shaft 3 passing through the flow cross-section 2 if the flap surface 11 was in its maximum open position during the molding of the shaft 3.
  • Reference numeral 15 designates a contact surface according to FIG. 2, which adjoins between the flap surface 11 and the surfaces of the bearing bodies 9 which protrude into the flow cross section 2.
  • a detail of the flap arrangement according to FIG. 2 can be seen in more detail from the illustration according to FIG. 2.
  • FIG. 2.1 shown on an enlarged scale, that a positive connection has been established between the outside of the bearing body 9 located on the shaft 3 and the inside of the injection pin 10.
  • This positive-locking connection between the injection pin 10 and the bearing body 9 which occurs during the encapsulation of the bearing body 9 represents a sealing element in addition to a bearing point of the shaft 3.
  • a gap seal is established, which ends in a sealing surface 16 on the side of the bearing body 9 facing the flap surface 11. Supported by the contact surface 15 between the flap surface 11 and the end face of the bearing body 9, the flap arrangement according to the invention for controlling a gas flow is also secured on this side against escaping gaseous medium.
  • the bearing bodies 9 are designed to rest against the flap surface 11, i.e. the inner wall of the housing 1, 10 are designed to penetrate.
  • the first projection 13 on the injection peg 10 as close as possible to the inner wall of the housing 1, 10 formed simultaneously in the injection mold with the flap surface 11, a maximum sealing effect can be achieved directly on the injection peg 10.
  • FIG. 3 shows a cross section through a flap according to FIG. 1, which is in its open position.
  • a flow of gas flows through the flow cross section 2 of the housing 1, which is simultaneously injected with the flap surface 11, for example the supply air or the exhaust gas of an internal combustion engine.
  • the flap 4 By rotating the flap 4 by actuating the flap shaft 3, the flow cross section 2 is reduced or enlarged within the housing 1.
  • the peripheral surface 25 of the flap surface 11 is provided with a sealing bevel 20, the one shown in FIG Flap 4 can be moved clockwise from its open position into a closed position within the flow cross section 2 of the housing 1.
  • the contour of the sealing bevel 20 can be generated on the circumferential surface 25 of the flap surface 11 at various predefinable helix angles 22.
  • the flap 4 can be provided with ribbing 6 on both sides.
  • the ribbing 6 can also be provided only on one side of the flap 4 in order to improve the mechanical properties of the flap arrangement.
  • the representation according to FIG. 3.1 shows the representation of the slope on the peripheral surface of the flap arrangement in more detail.
  • the peripheral surface 25 of the flap surface 11 of the flap 4 can have different sealing be trained obliquely.
  • the helix angle 22 on the sealing slope 20 with respect to the inner wall 17 of the housing 1 is optimal in terms of the sealing effect and in terms of minimizing the torque to be used is held.
  • the helix angle 22 of the sealing bevel 20 is preferably in the range between 0 and 15 °.
  • the sealing bevel 20 can already be formed during the encapsulation of the flap shaft 3 when the flap surface 11 of the flap 4 is formed, so that further machining steps which increase the accuracy of fit are unnecessary. If the sealing bevel 20 is provided with a tip 21 on its rear part, as seen in the direction of rotation, satisfactory results can be achieved with regard to the leakage currents that arise, even after prolonged operation of the throttle valve arrangement produced according to the invention.
  • FIG. 4 shows a perspective representation of a flap arrangement controlling a gas flow.
  • a number of fastenings 8 are provided on the outer wall of the housing 1 with injection pins 10, by means of which a flap arrangement is produced, which, according to the invention, is produced in one operation and requires only a preassembly of shaft 3 and bearing body 9 Component can be integrated into a supply air or exhaust system on an internal combustion engine.
  • the shaft journals of the shaft 3 are designated by reference numeral 23, on which the drive for pivoting the flap 4 into the shaft 3 can be introduced. This is preferably done via a servomotor, with which the flap 4 can be set in any rotational position within the flow cross member 2. In its closed position, the peripheral surface 25, provided with a sealing bevel 20 according to FIG.
  • the housing 1 seals against the inner wall 17 of the housing 1 and prevents a flow of gas through the free cross section 2, be it supply air or exhaust gas from an internal combustion engine.
  • the formation of the housing 1 with injection pins 10 and the flap surface 11 of the flap 4 in one work step leads in particular to a flap arrangement with the least play, i.e. minimizing leakage flows between these component components.
  • the wall thickness 26 on the housing 1 can be adjusted during the injection molding process.
  • the ribbing patterns 6 and 31 in the region of the flap surface 11 can also be provided with a different geometry, for example to generate a swirl.
  • the design of the geometry of the ribs 6 and 31 in the area of the flap surface 11 is based on the intended use of the flap arrangement produced according to the invention.
  • the fastenings 8 have a slightly trapezoidal contour on their outer surfaces.
  • the flap arrangement produced in one operation can be removed more easily from the injection mold.
  • FIG. 6 a detail emerges through the shaft 3 which accommodates the flap 4 and is rotatably mounted on both sides in molded housing pins 10.
  • the reference numerals 28 denote the seating surfaces for the bearing body 9 in the region of the bearing journal 23 of the shaft 3. Only in the area of the seat surface 28 is the shaft 3 to be fitted with the bearing bodies 9 to be machined on its surface. Since the flap surface 11 of the flap 4 is injection molded onto the shaft 3 within the free flow cross section 2, there is no need for complex machining of the shaft 3 in the section of the shaft 3 lying between the bearing bodies 9, since joining operations are completely unnecessary.
  • the attachments 8, which are provided with slightly beveled contours on their outer sides for easier demolding of the workpiece manufactured in one operation, are distributed symmetrically on the outer circumference 27 of the housing 1 with injection pins 10.
  • the fastenings 8 shown here which are arranged at 90 ° to one another, depending on the size and flow cross-section 2 of the housing 1 with injection spigot 10, it is also possible to inject several fastenings 8, for example at 60 ° to one another, on the outer wall 27 of the housing 1, 10. This depends on the dimensions and the stress on the housing 1, 10.
  • the pins 23 of the shaft 3, which protrude beyond the injection pins 10 of the housing 1, can be provided with curves or plastic drive elements in the same operation so that they can be equipped with these components.
  • Reference numerals 13 and 14 denote the positive connections in the area of the injection pins 10, which prevent relative movement of the bearing bodies 9 with respect to the injection pins 10. A rotational movement of the shaft 3 is only possible with respect to the bearing body 9.
  • FIG. 6.1 An enlarged representation of the bearing area of the valve shaft according to FIG. 6 can be seen in greater detail from the illustration according to FIG. 6.1.
  • the reproduction of the storage area according to FIG. 6.1 essentially corresponds to the storage shown in FIG. 2.1, but rotated by 90 °.
  • a sealing surface 16 is formed between the injection peg 10 and the outer surface 30 of the bearing body 9.
  • projections 13 formed on the injection pin 10 with corresponding recesses 14 on the outside 30 of the bearing body 9 form a positive connection.
  • the sealing effect of a gap seal configured in this way is considerably increased.
  • the formation of the positive connection takes place during the simultaneous injection of injection pin 10 in the manufacture of the housing and the formation of the flap surface 11 of the flap 4 connected to the shaft 3 in one direction.
  • the flap 4 is in the direction of the double arrow 32 between its maximum open position and its, the Flow cross section 2 closing, closed position moved back and forth.
  • Servomotors are suitable for moving the shaft 3, the drive torque of which is to be kept as low as possible for reasons of the drive design.
  • the ribbing 6 or 31 stiffening the flap surface 11 can be optimized for a wide variety of uses, both improving the flow properties of the fluid passing through the flow cross-section 2 with respect to turbulence or mixing, and stiffening the flap surface 11 of the flap 4 can.
  • the inner bore of the bearing body 9, which sits on the region 28 of the shaft 3 to be machined, is designated by reference numeral 29.
  • the flap arrangements for controlling a gas flow which are manufactured in accordance with the manufacturing method proposed according to the invention, can be used in addition to their use on internal combustion engines and on piping systems for gaseous media. LIST OF REFERENCE NUMBERS

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Manufacturing & Machinery (AREA)
  • Lift Valve (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Control Of Throttle Valves Provided In The Intake System Or In The Exhaust System (AREA)

Abstract

The invention relates to a method for producing a valve assembly (4) for controlling a gaseous stream (24), e.g. in an internal combustion engine. According to said method, seat surfaces (28) in the end regions of a shaft (3) are provided with bearing bodies (9). This pre-assembled subassembly is introduced into an injection-moulding mould. The pre-assembled subassembly, together with the shaft (3) and the bearing bodies (9) located thereon, is encapsulated by injection moulding in a conventional injection moulding process, to simultaneously form a valve surface (11) and a housing (1, 10) that surrounds said surface and the bearing bodies (9).

Description

Vorrichtung zur Steuerung eines Gasstroms und Herstellverfahren derselben Device for controlling a gas flow and manufacturing method thereof
Technisches GebietTechnical field
An Verbrer ungskraftmaschinen, seien es direkteinspritzende Verbrennungskraftmaschinen oder an benzineinspritzenden Verbrennungskraftmaschinen ist eine Steuerung von zu- zuführenden und abzuführenden Gasströmen erforderlich. Beispielsweise wird über eine Drosselklappe das Ansaugluftvolumen gesteuert, ferner wird über Klappensysteme der Abgasstrom gesteuert. Eine Steuerung des Abgasvolumenstromes ist insbesondere bei Ab- gasrückfülirsystemen notwendig, in denen ein Teil des Abgasstromes dem Ansaugluftstrom wieder beigemischt wird. Die Steuerung von Zuluft- oder Abgasströmen an Verbrennungs- kraftmascl inen erfolgt in der Regel über Klappensysteme, deren Klappen in den die Gasströme leitenden Rohrsystemen schräg gestellt werden können. Die Herstellkosten solcher Klappensysteme sind nicht unerheblich.Control of the gas flows to be supplied and discharged is required on internal combustion engines, be they direct-injection internal combustion engines or gasoline-injection internal combustion engines. For example, the intake air volume is controlled via a throttle valve, and the exhaust gas flow is also controlled via valve systems. Controlling the exhaust gas volume flow is necessary in particular in exhaust gas backfilling systems in which a part of the exhaust gas flow is admixed with the intake air flow again. The control of supply air or exhaust gas flows on internal combustion engines generally takes place via flap systems, the flaps of which can be inclined in the pipe systems that conduct the gas flows. The manufacturing costs of such valve systems are not negligible.
Stand der TechnikState of the art
DE 30 39 868 AI bezieht sich auf einen Vibrationsdämpfer und ein Verfahren zu seiner Herstellung. Diese werden durch ein Spritzgußverfahren hergestellt, wobei zunächst Innenteil und Außenteil des Vibrationsdämpfers aus einem starren oder steifen thermoplastischen Material wie Polystyrol hergestellt werden. Danach wird ein federndes Zwischen- stück aus einem thermoplastischen Elastomer, beispielsweise einem Mischpolymerisat aus Butadien und Styrol geformt und an den äußeren und inneren Teilen in einer folgenden Spritzformstufe hefgestellt.DE 30 39 868 AI relates to a vibration damper and a method for its production. These are produced by an injection molding process, the inner part and outer part of the vibration damper first being made from a rigid or rigid thermoplastic material such as polystyrene. A resilient intermediate piece is then formed from a thermoplastic elastomer, for example a copolymer of butadiene and styrene, and produced on the outer and inner parts in a subsequent injection molding step.
DE 197 03 296 AI betrifft ein Verfahren zum Abdichten einer eine Drosselklappe tragen- den Drosselldappenwelle und Drosselklappenstutzen. Bei einem Drosselklappenstutzen für eine Brennl raftmaschine eines Kraftfahrzeuges ist eine Ausnehmungen des Drosselklappenstutzens durchdringende Drosselklappenwelle mit einem aushärtenden Dichtmittel ab- gedichtet. Das Dichtmittel verhindert ein Durchströmen von Luft durch einen fertigungsbedingten Spalt zwischen der Drosselklappenwelle und den Ausnehmungen.DE 197 03 296 AI relates to a method for sealing a throttle valve shaft carrying a throttle valve and throttle valve connector. In a throttle valve assembly for an internal combustion engine of a motor vehicle, a throttle valve shaft penetrating recesses in the throttle valve assembly is sealed with a hardening sealant. sealed. The sealant prevents air from flowing through a manufacturing gap between the throttle valve shaft and the recesses.
EP 0 575 235 Bl bezieht sich auf ein drehbares Drosselorgan für die Kraftstoffeinspritz- anläge von Brennkraftmaschinen. Es ist eine Welle mit zylindrischen Sitzen vorgesehen, die einen Abschnitt zur Aufnahme einer Drosselklappe aufnimmt, wobei der Abschnitt einen gleichbleibenden nicht rotationssymmetrischen Querschnitt hat, der größer als der Querschnitt des auf einer Seite des Abschnitts befindlichen Teiles der Welle ist. Die Drosselklappe hat eine zentrale Bohrung, deren Querschnitt demjenigen des Abschnittes ent- spricht. Die Welle besteht insgesamt aus Kunststoff und ist einstückig mit einem Nocken zum Einhängen oder Aufwickeln eines auf der anderen Seite des besagten Abschnittes gelegenen Steuerseils gegossen, wobei die Drosselklappe selbst aus gefülltem Kunststoff besteht. Der Kunststoff ist bevorzugt ein thermoplastischer Kunststoff. Der Abschnitt der Drosselklappenwelle hat eine zylindrische Form mit parallelen Abflachungen; die Drossel- klappe ihrerseits weist eine abgeflachte Nabe mit zentraler Bohrung auf, die im Querschnitt die Form eines parallel zu den Flügeln der Drosselklappe abgeflachten Kreises hat:EP 0 575 235 B1 relates to a rotatable throttle element for the fuel injection systems of internal combustion engines. A shaft with cylindrical seats is provided, which receives a section for receiving a throttle valve, the section having a constant, non-rotationally symmetrical cross section which is larger than the cross section of the part of the shaft located on one side of the section. The throttle valve has a central bore whose cross-section corresponds to that of the section. The shaft is made entirely of plastic and is cast in one piece with a cam for hanging or winding up a control cable located on the other side of said section, the throttle valve itself being made of filled plastic. The plastic is preferably a thermoplastic. The section of the throttle valve shaft has a cylindrical shape with parallel flats; the throttle valve in turn has a flattened hub with a central bore, which in cross section has the shape of a circle flattened parallel to the wings of the throttle valve:
DE 42 24 171 AI bezieht sich auf ein Spritzgußteil sowie ein Verfahren und ein Spritzgieß Werkzeug zum Herstellen des Spritzgußteiles. Mittels des vorgeschlagenen Verfahrens lassen sich Spritzgußteile fertigen, die mindestens zwei Farben und/oder mindestens zwei unterschiedliche Kunststoffe aufweisen und in wenigstens zwei aufeinanderfolgenden Prozeßschritten, in denen die Farben und/oder die Kunststoffe nacheinander in ein Spritzgießwerkzeug eingespritzt werden, hergestellt sind. Nach dem Prozeßschritt des Einspritzens der ersten Farbe und/oder des ersten Kunststoffes verbleibt das entstandene Spritzgußteil im geschlossenen Werkzeug, wonach ein an das Spritzgußteil angrenzender Hohlraum erzeugt oder freigegeben und in diesen die zweite Farbe und/oder der zweite Kunststoff eingespritzt wird. Dazu weist das Spritzgießwerkzeug mindestens einen Schieber auf, der den für das Spritzgußteil vorgesehenen Hohlraum im Werkzeug verändert. Durch diese Vorgehensweise läßt sich erreichen, daß das Spritzgießwerkzeug zwischen den beiden Spritz- gießvorgängen geschlossen bleiben kann und somit die Oberflächen des vorgespritzten Teiles nicht mit der Umgebungsluft in Berührung kommen können.DE 42 24 171 AI relates to an injection molded part as well as a method and an injection molding tool for producing the injection molded part. The proposed method can be used to produce injection molded parts which have at least two colors and / or at least two different plastics and are produced in at least two successive process steps in which the colors and / or the plastics are injected one after the other into an injection mold. After the process step of injecting the first color and / or the first plastic, the resulting injection molded part remains in the closed mold, after which a cavity adjacent to the injection molded part is created or released and the second color and / or the second plastic is injected into it. For this purpose, the injection mold has at least one slide which changes the cavity in the mold provided for the injection molded part. This procedure ensures that the injection mold can remain closed between the two injection molding processes and thus the surfaces of the pre-sprayed part cannot come into contact with the ambient air.
Konventionelle Drosselklappensysteme umfassen in der Regel ein Gehäuse, die Drosselklappe, die Drosselklappenwelle, Lagerkörper sowie eine Anzahl von Befestigungs- und Abdichtelemente. Bevor diese Komponenten montiert werden, sind eine Reihe zum Teil langwieriger Bearbeitungsschritte sowie Kalibrierungsschritte erforderlich, wie das Aufbohren von Lagersitzen, das Schleifen der Drosselldappenwelle sowie ein genaues Aufboh- rεn oder anderweitiges Bearbeiten der Drosselklappenbohrung im Gehäuse. Obwohl heute zur Fertigung von Drosselklappensystemen zunehmend Kunststoffe eingesetzt werden, rühren Fertigungsungenauigkeiten von den Befestigungselementen und in relativ zueinander beweglichen Oberflächen her, deren Paßgenauigkeit erst in verschiedenen nachfolgenden Bearbeitungsschritten erreicht wird.Conventional throttle valve systems generally include a housing, the throttle valve, the throttle valve shaft, the bearing body and a number of fastening and sealing elements. Before these components are assembled, a number of sometimes lengthy machining steps and calibration steps are required, such as drilling out bearing seats, grinding the throttle shaft, as well as drilling out or otherwise machining the throttle valve bore in the housing. Although today Plastics are increasingly being used for the production of throttle valve systems, manufacturing inaccuracies result from the fastening elements and in surfaces which are movable relative to one another, the fit of which is only achieved in various subsequent processing steps.
Darstellung der ErfindungPresentation of the invention
Mit dem gemäß der Erfindung vorgeschlagenen Verfahren läßt sich ein einen Gasstrom steuerndes Klappensystem mit einem Minimum weiterer Montageschritte fertigen. Ferner sind nach dem Ausbilden einer in einem Gehäuse verschwenkbar angeordneten, einen Gasstrom steuernden Drosselklappe keine weiteren, die Oberflächengüte der paßgenau gefertigten Komponente verbessernden Bearbeitungsschritte erforderlich. Die das Klappensystem bildenden Komponenten werden gemäß des Ein-Komponentenspritzgießverfahrens kostengünstig hergestellt, wodurch eine Endmontage einzelner Komponenten wie Klap- penwelle, Drosselklappe innerhalb des Gehäuses vollständig entfallen kann. An die Fertigungsgenauigkeit der Drosselklappenwelle sind lediglich erhöhte Anforderungen im Bereich der Lagerkörper aufnehmenden Sitzflächen zu stellen; es kann eine mit Toleranzen behaftete Drosselklappenwelle eingesetzt werden, an der die Drosselklappe direkt angespritzt ist und Fertigungsgenauigkeiten erfordernde Fügeoperationen zwischen Klappe und Welle vollständig entfallen können. Insbesondere ist nunmehr an der die Drosselklappe aufnehmenden Welle kein Schlitz zum Einführen der Drosselklappe mehr erforderlich.With the method proposed according to the invention, a flap system controlling a gas flow can be manufactured with a minimum of further assembly steps. Furthermore, after the formation of a throttle valve that swivels in a housing and controls a gas flow, no further processing steps that improve the surface quality of the precisely manufactured component are required. The components forming the flap system are inexpensively manufactured in accordance with the one-component injection molding process, as a result of which a final assembly of individual components such as the valve shaft and throttle valve within the housing can be completely dispensed with. The manufacturing accuracy of the throttle valve shaft only has to meet increased requirements in the area of the seating surfaces receiving the bearing body; a throttle valve shaft with tolerances can be used, on which the throttle valve is injection molded directly, and joining operations between the valve and the shaft requiring manufacturing accuracy can be completely dispensed with. In particular, a slot for inserting the throttle valve is no longer required on the shaft receiving the throttle valve.
Ein besonders dichtes, geringste Leckageströme zulassendes Klappensystem kann erzielt werden, wenn vor dem Einspritzen des Kunststoffes in das Formwerkzeug die an den En- den der Drosselldappenwelle vorgesehenen Lagerkörper mit einem Schmiennittel behaftet mit Kunststoff umspritzt werden. Hinsichtlich ihrer Dimensionierung sind die Lagerkörper mit höheren Freiheitsgraden auslegbar, was eine höhere Konstruktionsvariabilität zuläßt. Das Klappensystem, gefertigt gemäß des erfindungsgemäß vorgeschlagenen Herstellver- fahrens, läßt sich nahezu spielfrei ausfuhren. Ferner lassen sich an diesem eventuell für andere Einsatzbereiche als am Einsatz von Verbreiinungskraftmaschinen für Kraftfahrzeuge erforderliche Antriebselemente wie Kurven, Zahnräder oder dergleichen während der Fertigung im Ein-Komponentenspritzgießverfahren problemlos anspritzen. Durch Verzicht auf metallische Befestigungselemente kann die erfindungsgemäß gefertigte Klappenanord- nung in geringem Gewicht hergestellt werden. Es lassen sich auch nicht-zylindrisch ausge- bildete Drosselklappen im Gehäuse beweglich einspritzen, was bei konventionell erfolgender Montage mit erheblichen Fügeproblemen verbunden wäre. Der gemäß des Ein-Komponentenspritzverfahrens eingesetzte Kunststoff kann je nach Einsatzzweck der herzustellenden Klappenanordnung entsprechend der im Einsatzzweck vorliegenden Temperaturen ausgewählt werden. So lassen sich reine Zuluft-Klappen aus preisgünstigeren Kunststoffen herstellen; thermisch höher belastete Klappensysteme können aus entsprechend temperaturbeständigeren Kunststoffen hergestellt werden.A particularly tight flap system which allows the lowest leakage flows can be achieved if, before the plastic is injected into the mold, the bearing bodies provided at the ends of the throttle shaft are encapsulated in plastic with a lubricating agent, which is contaminated with lubricant. With regard to their dimensions, the bearing bodies can be designed with higher degrees of freedom, which allows greater design variability. The flap system, manufactured according to the manufacturing method proposed according to the invention, can be designed almost without play. Furthermore, drive elements, such as curves, gearwheels or the like, which may be required for areas of application other than the use of expansion engines for motor vehicles, can be injection-molded on during the production using the one-component injection molding process. By dispensing with metallic fastening elements, the flap arrangement manufactured according to the invention can be manufactured with a low weight. Non-cylindrical throttles can also be flexibly injected in the housing, which would be associated with considerable joining problems if they were installed conventionally. The plastic used in accordance with the one-component injection molding process can be selected depending on the intended use of the flap arrangement to be produced in accordance with the temperatures present in the intended use. In this way, pure supply air flaps can be made from less expensive plastics; Valve systems subjected to higher thermal loads can be manufactured from correspondingly more temperature-resistant plastics.
Zeichnungdrawing
Anhand der Zeichnung wird die Erfindung nachstehend en detail erläutert.The invention is explained in detail below with reference to the drawing.
Es zeigt:It shows:
Figur 1 eine Draufsicht auf eine in Offenstellung befmdliche Klappenanordnung in dem diese umgebenden Gehäuse,FIG. 1 shows a plan view of a flap arrangement in the open position in the housing surrounding it,
Figur 2 • eine Schnittdarstellung der in Figur 1 dargestellten Klappenanordnung-2 shows a sectional illustration of the flap arrangement shown in FIG.
Figur 2.1 ein Detail der Klappenanordnung gemäß Figur 2,FIG. 2.1 shows a detail of the flap arrangement according to FIG. 2,
Figur 3 einen Quersclmitt durch die in Offenstellung befmdliche Klappenanordnung gemäß Figur 1,FIG. 3 shows a cross-section through the flap arrangement according to FIG. 1, which is in the open position,
Figur 3.1 die Darstellung der Schräge der Umfangsfläche der Klappenanordnung,FIG. 3.1 shows the slope of the peripheral surface of the flap arrangement,
Figur 4 eine perspektivische Draufsicht der einen Gasstrom steuernden Klappenanordnung gemäß Figur 1,FIG. 4 shows a perspective top view of the flap arrangement controlling a gas flow according to FIG. 1,
Figur 5 eine Draufsicht auf das die Klappe umgebende Gehäuse,FIG. 5 shows a top view of the housing surrounding the flap,
Figur 6 einen Schnitt durch die die Klappe aufnehmende, beidseitig im angespritzten Gehäusezapfen drehbar gelagerte Welle,FIG. 6 shows a section through the shaft that receives the flap and is rotatably mounted on both sides in the molded housing pin,
Figur 6.1 eine vergrößerte Darstellung des Lagerungsbereiches der Klappenwelle. AusfuhrungsvariantenFigure 6.1 is an enlarged view of the bearing area of the valve shaft. design variants
Aus der Darstellung gemäß Figur 1 geht eine Draufsicht auf eine in Offenstellung befindli- ehe Klappenanordnung in dem sie umgebenden Gehäuse näher hervor.1 shows a plan view of a flap arrangement in the open position in the surrounding housing.
Eine zur Steuerung eines Gasstromes dienende Klappe 4 ist an einer Klappenwelle 3 aufgenommen. Die Klappenwelle 3 ist symmetrisch zur Mittellinie 5 ausgebildet und an Lagerungsstellen 7 in am Gehäuse 1 angespritzten Zapfen 10 gelagert. An der Außenseite des Gehäuses 1 ist eine Anzahl von Befestigungen ausgebildet. Die an der den freien Strömungsquerschnitt 2 durchsetzten Welle aufgenommene Klappe 4 ist in ihre maximale Offenstellung geschwenkt, so daß gemäß der Darstellung in Figur 1 ein größtmöglicher Strömungsquerschnitt 2 freigegeben ist. In der Draufsicht gemäß Figur 1 ist die Klappe 4 an beiden Seiten mit einer Verrippung 6 versehen, welche die mechanische Belastbarkeit der Klappenfläche der Klappe 4 verbessert. Die Verrippung 6 kann auch abweichend von der Darstellung gemäß Figur 1 an lediglich einer Seite der Klappe 4 aufgenommen sein. Die Welle 3, an welcher die Klappe 4 - dargestellt in ihrer maximalen Offenposition - angespritzt ist, ist in hier nicht dargestellten Lagerkörpern in den Anspritzzapfen 10 am Gehäuse 1 verdrehbar gelagert.A valve 4 serving to control a gas flow is received on a valve shaft 3. The flap shaft 3 is formed symmetrically to the center line 5 and is mounted at bearings 7 in pins 10 molded onto the housing 1. A number of fasteners are formed on the outside of the housing 1. The flap 4 received on the shaft passing through the free flow cross section 2 is pivoted into its maximum open position, so that, as shown in FIG. 1, the largest possible flow cross section 2 is released. In the plan view according to FIG. 1, the flap 4 is provided with ribbing 6 on both sides, which improves the mechanical strength of the flap surface of the flap 4. The ribbing 6 can also be accommodated on only one side of the flap 4, in a departure from the illustration according to FIG. 1. The shaft 3, on which the flap 4 is molded - shown in its maximum open position - is rotatably supported in the bearing bodies (not shown here) in the injection pins 10 on the housing 1.
Aus der Darstellung gemäß Figur 2 geht eine Schiri ttdarstellung der in Figur 1 dargestellten Klappenanordnung hervor.2 shows a referee representation of the flap arrangement shown in FIG. 1.
Aus der Schnittdarstellung gemäß Figur 2 der Klappenanordnung gemäß Figur 1 ist ent- nehmbar, daß die Welle 3 an ihren Endbereichen mit Lagerkörpern 9 versehen ist. Die Lagerkörper 9 bestehen vorzugsweise aus einem mit einem Schmiermittelzusatz wie beispielsweise Öl imprägnierten Werkstoff, so zum Beispiel gesinterter Bronze. Anstelle von Lagerkörpern aus gesinterter Bronze lassen sich auch Lagerkörper 9 aus Stahl einsetzen.From the sectional view according to FIG. 2 of the flap arrangement according to FIG. 1 it can be seen that the shaft 3 is provided with bearing bodies 9 at its end regions. The bearing bodies 9 preferably consist of a material impregnated with a lubricant additive such as oil, for example sintered bronze. Instead of bearing bodies made of sintered bronze, bearing bodies 9 made of steel can also be used.
Auf der Welle 3, die durchaus mit Toleranzen behaftet sein kann, werden in deren Endbereichen die Lagerkörper 9 aufgebracht. Die solcherart vormontierte Baugruppe wird in ein Spritzgießwerkzeug eingelegt, welches sodann geschlossen wird, so daß das Gehäuse 1 einschließlich der daran ausgebildeten Anspritzzapfen 10 sowie die Klappenfläche 11 der Klappe 4 in einem Arbeitsgang gemäß des Ein-Komponentenspritzgießverfahrens im Spritzgießwerkzeug ausgebildet werden kann. Beim Spritzgießvorgang wird die Klappen- flache 11 erzeugt, welche dadurch unmittelbar mit dem toleranzbehafteten Bereich der Welle 3 verbunden ist. Durch diese Vorgehensweise ist lediglich eine Bearbeitung der Welle 3 in den Bereichen erforderlich, welche als Sitzflächen 28 für die Lagerkörper 9 die- nen. Während des Umspritzens der aus Lagerkörper 9 und Welle 3 gebildeten, vormontierten Baugruppe im Spritzgießwerkzeug umschließt der eingespritzte Kunststoff im Bereich der Lagerungsstellen 7 die Lagerkörper 9. Zur Fixierung der Lagerkörper 9 in den Anspritzzapfen 10 des Gehäuses 1 können an den Anspritzzapfen 10 einzelne oder umlau- fende Vorsprünge 13 ausgebildet werden, die in korrespondierende einzelne oder umlaufende Vertiefungen an den Lagerkörpern 9 eingreifen. Dadurch wird eine Verdrehung sowie eine axiale Verschiebung und damit eine potentielle Leckage zwischen Anspritzzapfen 10 und Lagerkörper 9 vermieden. Unterstützt durch das Schmiermittel, welches bevorzugt auf die Lagerkörper 9 bei deren Montage auf der Welle 3 aufgebracht ist, wird die Dicht- Wirkung zwischen Anspritzzapfen 10 und Lagerkörper 9 zusätzlich erhöht. Durch die während des Umspritzens ausgebildeten Vorsprünge 13, die in einzelne Ausnehmungen oder ringförmig umlaufende Ausnehmungen 14 der Lagerkörper 9 eingreifen, wird eine Relativbewegung der Lagerkörper 9 in den Anspritzzapfen 10 vermieden. Ferner wird durch die formschlüssige Verbindung zwischen der Außenseite der Lagerkörper 9 und der Innenseite der Anspritzzapfen 10 eine Axialbewegung der die angespritzte Klappenfläche 1 1 aufnehmenden Welle 3 verhindert. Die Welle 3 vermag sich lediglich relativ zu den in den Anspritzzapfen 10 drehfest angeordneten Lagerkörpern 9 zu verdrehen.On the shaft 3, which may well be subject to tolerances, the bearing bodies 9 are applied in the end regions thereof. The assembly which has been preassembled in this way is inserted into an injection mold, which is then closed, so that the housing 1, including the molded-on pins 10 formed thereon, and the flap surface 11 of the flap 4 can be formed in a single operation in accordance with the one-component injection molding process in the injection mold. During the injection molding process, the flap flat 11 is produced, which is thereby directly connected to the tolerance-sensitive area of the shaft 3. This procedure only requires machining the shaft 3 in the areas which serve as seat surfaces 28 for the bearing bodies 9. NEN. During the encapsulation of the preassembled assembly formed from the bearing body 9 and shaft 3 in the injection molding tool, the injected plastic encloses the bearing body 9 in the area of the bearing points 7. For fixing the bearing body 9 in the injection pin 10 of the housing 1, individual or circumferential elements can be attached to the injection pin 10. fende projections 13 are formed which engage in corresponding individual or circumferential recesses on the bearing bodies 9. This prevents twisting and axial displacement and thus potential leakage between the injection pin 10 and the bearing body 9. Supported by the lubricant, which is preferably applied to the bearing body 9 when it is mounted on the shaft 3, the sealing effect between the injection pin 10 and the bearing body 9 is additionally increased. A relative movement of the bearing bodies 9 in the injection pins 10 is avoided by the projections 13 formed during the extrusion coating, which engage in individual recesses or annular recesses 14 of the bearing bodies 9. Furthermore, the positive connection between the outside of the bearing body 9 and the inside of the injection pins 10 prevents axial movement of the shaft 3 receiving the molded flap surface 11. The shaft 3 can only rotate relative to the bearing bodies 9 arranged in a rotationally fixed manner in the injection pins 10.
In bevorzugter Ausgestaltung des erfmdungsgemäß vorgeschlagenen Verfahrens ist die Klappenfläche 11 in bezug auf den Strömungsquersclinitt 2 innerhalb des Gehäuses 1 so orientiert, daß sie eine Offenstellung annimmt. Besonders gute Ergebnisse beim Umsprit- zen der Klappenfläche 11 an die den Strömungsquersclinitt 2 durchsetzende Welle 3 haben sich eingestellt, wenn sich die Klappenfläche 11 während des Umspritzens der Welle 3 in ihrer maximalen Offenstellung befunden hat.In a preferred embodiment of the method proposed according to the invention, the flap surface 11 is oriented with respect to the flow cross-section 2 within the housing 1 so that it assumes an open position. Particularly good results have been achieved when the flap surface 11 was molded around the shaft 3 passing through the flow cross-section 2 if the flap surface 11 was in its maximum open position during the molding of the shaft 3.
Mit Bezugszeichen 15 ist gemäß Figur 2 eine Anlagefläche bezeichnet, welche sich zwischen der Klappenfläche 11 und den in den Strömungsquerschnitt 2 hineinragenden Flächen der Lagerkörper 9 einstellt.Reference numeral 15 designates a contact surface according to FIG. 2, which adjoins between the flap surface 11 and the surfaces of the bearing bodies 9 which protrude into the flow cross section 2.
Aus der Darstellung gemäß Figur 2 geht ein Detail der Klappenanordnung gemäß Figur 2 näher hervor.A detail of the flap arrangement according to FIG. 2 can be seen in more detail from the illustration according to FIG. 2.
Der in vergrößertem Maßstab wiedergegeben Figur 2.1 ist entnehmbar, daß sich zwischen der Außenseite des auf der Welle 3 befindlichen Lagerkörpers 9 und der Innenseite des Anspritzzapfens 10 eine formschlüssige Verbindung eingestellt hat. Diese während des Umspritzens des Lagerkörpers 9 sich einstellende formschlüssige Verbindung zwischen Anspritzzapfen 10 und Lagerkörper 9 stellt neben einer Lagerungsstelle der Welle 3 ein Dichtelement dar. Je nach Anzahl der am Anspritzzapfen 10 ausgebildeten Vorsprünge 13 und zu dieser Anzahl korrespondierender Ausnehmungen 14 an der Umfangsfläche des Lagerkörpers 9 stellt sich eine Spaltdichtung ein, die an der der Klappenfläche 11 zuweisenden Seite des Lagerkörpers 9 in eine Dichtfläche 16 ausläuft. Unterstützt durch die Anlagefläche 15 zwischen Klappenfläche 11 und Stirnseite des Lagerkörpers 9 ist die erfin- dungsgemäß hergestellte Klappenanordnung zum Steuern eines Gasstromes auch an dieser Seite gegen austretendes, gasförmiges Medium gesichert.It can be seen from FIG. 2.1, shown on an enlarged scale, that a positive connection has been established between the outside of the bearing body 9 located on the shaft 3 and the inside of the injection pin 10. This positive-locking connection between the injection pin 10 and the bearing body 9 which occurs during the encapsulation of the bearing body 9 represents a sealing element in addition to a bearing point of the shaft 3. Depending on the number of projections 13 formed on the injection pin 10 and to this number of corresponding recesses 14 on the circumferential surface of the bearing body 9, a gap seal is established, which ends in a sealing surface 16 on the side of the bearing body 9 facing the flap surface 11. Supported by the contact surface 15 between the flap surface 11 and the end face of the bearing body 9, the flap arrangement according to the invention for controlling a gas flow is also secured on this side against escaping gaseous medium.
Aus der Darstellung gemäß Figur 2.1 geht zudem hervor, daß zur Erhöhung der Abdichtwirkung die Lagerkörper 9 an der Klappenfläche 11 anliegend ausgebildet sind, d.h. die Innenwandung des Gehäuses 1, 10 durchsetzend ausgebildet sind. Durch die Ausbildung des ersten Vorsprunges 13 am Anspritzzapfen 10 möglichst nah an der Innenwandung des gleichzeitig mit der Klappenfläche 11 im Spritzgießwerkzeug ausgebildeten Gehäuses 1,10 ist eine maximale Abdichtwirkung unmittelbar am Anspritzzapfen 10 erzielbar.From the illustration according to FIG. 2.1 it can also be seen that, in order to increase the sealing effect, the bearing bodies 9 are designed to rest against the flap surface 11, i.e. the inner wall of the housing 1, 10 are designed to penetrate. By forming the first projection 13 on the injection peg 10 as close as possible to the inner wall of the housing 1, 10 formed simultaneously in the injection mold with the flap surface 11, a maximum sealing effect can be achieved directly on the injection peg 10.
Aus der Darstellung gemäß Figur 3 geht ein Querschnitt durch eine in ihrer Offenstellung befmdliche Klappe gemäß Figur 1 näher hervor.3 shows a cross section through a flap according to FIG. 1, which is in its open position.
Der Strömungsquerschnitt 2 des gleichzeitig mit der Klappenfläche 11 gespritzten Gehäuses 1 wird von einem Gasstrom durchströmt, beispielsweise der Zuluft oder des Abgases einer Verbrennungskraftmaschine. Durch eine Verdrehung der Klappe 4 durch Betätigung der Klappenwelle 3 erfolgt eine Verminderung oder Vergrößerung des Strömungsquerschnittes 2 innerhalb des Gehäuses 1. In der Darstellung gemäß Figur 3 ist die Umfangsfläche 25 der Klappenfläche 1 1 mit einer Dichtschräge 20 versehen, wobei die in Figur 3 dargestellte Klappe 4 im Uhrzeigersinn von ihrer Offenstellung in eine Schließstellung inner- halb des Strömungsquerschnittes 2 des Gehäuses 1 bewegbar ist. Während des Umspritzens der Klappenwelle 3 im Spritzgießwerkzeug kann die Kontur der Dichtschräge 20 unter verschieden vorgebbaren Schrägungswinkeln 22 an der Umfangsfläche 25 der Klappenfläche 11 erzeugt werden. Durch die Ausbildung einer Dichtschräge 20 an der Umfangsfläche 25 der Klappenfläche 11 läßt sich insbesondere im geschlossenen Zustand der Klappe 4 im Gehäuse 1 eine verbesserte Dichtwirkung sowie das Vermeiden von Fehlluftströmen erzielen. Aus der Darstellung gemäß Figur 3 geht zudem hervor, daß gemäß dieses Ausfüh- rungsbeispieles die Klappe 4 auf beiden Seiten mit einer Verrippung 6 versehen sein kann. Die Verrippung 6 kann auch lediglich an einer Seite der Klappe 4 vorgesehen werden, um die mechanischen Eigenschaften der Klappenanordnung zu verbessern.A flow of gas flows through the flow cross section 2 of the housing 1, which is simultaneously injected with the flap surface 11, for example the supply air or the exhaust gas of an internal combustion engine. By rotating the flap 4 by actuating the flap shaft 3, the flow cross section 2 is reduced or enlarged within the housing 1. In the illustration according to FIG. 3, the peripheral surface 25 of the flap surface 11 is provided with a sealing bevel 20, the one shown in FIG Flap 4 can be moved clockwise from its open position into a closed position within the flow cross section 2 of the housing 1. During the encapsulation of the flap shaft 3 in the injection molding tool, the contour of the sealing bevel 20 can be generated on the circumferential surface 25 of the flap surface 11 at various predefinable helix angles 22. By forming a sealing slope 20 on the peripheral surface 25 of the flap surface 11, an improved sealing effect and the avoidance of incorrect air flows can be achieved, in particular in the closed state of the flap 4 in the housing 1. 3 also shows that, according to this exemplary embodiment, the flap 4 can be provided with ribbing 6 on both sides. The ribbing 6 can also be provided only on one side of the flap 4 in order to improve the mechanical properties of the flap arrangement.
Aus der Darstellung gemäß Figur 3.1 geht die Darstellung der Schräge an der Umfangsfläche der Klappenanordnung näher hervor. Je nach eingesetztem Spritzgießwerkzeug kann die Umfangsfläche 25 der Klappenfläche 11 der Klappe 4 mit unterschiedlichen Dicht- schrägen ausgebildet werden. Um die Betätigungskräfte der Klappe 4 um die Welle 3 klein zu halten, ist dafür Sorge zu tragen, daß der Schrägungswinkel 22 an der Dichtschräge 20 in bezug auf die Innenwandung 17 des Gehäuses 1 in einem Optimum hinsichtlich der Dichtwirkung sowie hinsichtlich der Minimierung des aufzuwendenden Drehmoments ge- halten wird. Der Schrägungswinkel 22 der Dichtschräge 20 liegt bevorzugt im Bereich zwischen 0 und 15°. Die Dichtschräge 20 kann bereits während des Umspritzens der Klappwelle 3 bei der Ausbildung der Klappenfläche 11 der Klappe 4 geformt werden, so daß sich weitere, die Paßgenauigkeit erhöhende Bearbeitungsschritte erübrigen. Wird die Dichtschräge 20 an ihrem in Verdrehrichtung gesehen hinteren Teil mit einer Spitze 21 versehen, können selbst nach längerem Betrieb der erfmdungsgemäß hergestellten Drossel- klappenanordnung befriedigende Resultate hinsichtlich sich einstellender Leckageströme erreicht werden.The representation according to FIG. 3.1 shows the representation of the slope on the peripheral surface of the flap arrangement in more detail. Depending on the injection mold used, the peripheral surface 25 of the flap surface 11 of the flap 4 can have different sealing be trained obliquely. In order to keep the actuating forces of the flap 4 around the shaft 3 small, care must be taken that the helix angle 22 on the sealing slope 20 with respect to the inner wall 17 of the housing 1 is optimal in terms of the sealing effect and in terms of minimizing the torque to be used is held. The helix angle 22 of the sealing bevel 20 is preferably in the range between 0 and 15 °. The sealing bevel 20 can already be formed during the encapsulation of the flap shaft 3 when the flap surface 11 of the flap 4 is formed, so that further machining steps which increase the accuracy of fit are unnecessary. If the sealing bevel 20 is provided with a tip 21 on its rear part, as seen in the direction of rotation, satisfactory results can be achieved with regard to the leakage currents that arise, even after prolonged operation of the throttle valve arrangement produced according to the invention.
Aus der Darstellung gemäß Figur 4 geht eine perspektivische Wiedergabe einer einen Gasstrom steuernden Klappenanordnung hervor.4 shows a perspective representation of a flap arrangement controlling a gas flow.
Wie aus der Darstellung gemäß Figur 1 bereits bekannt, sind an der Außenwandung des Gehäuses 1 mit Anspritzzapfen 10 eine Anzahl von Befestigungen 8 vorgesehen, mit welchen das erfindungsgemäß in einem Arbeitsgang hergestellte, lediglich eine Vormontage von Welle 3 und Lagerkörper 9 benötigende, eine Klappenanordnung darstellende Bauteil in ein Zuluft- oder Abgassystem an einer Verbrennungskraftmaschine integriert werden kann. Mit Bezugszeichen 23 sind die Wellenzapfen der Welle 3 bezeichnet, an welchen der Antrieb zum Verschwenken der Klappe 4 in die Welle 3 eingeleitet werden kann. Dies erfolgt vorzugsweise über einen Stellmotor, mit welchem die Klappe 4 innerhalb des Strö- mungsquersclmittes 2 in beliebige Drehlagen stellbar ist. In ihrer Schließstellung liegt die Umfangsfläche 25, versehen mit einer Dichtschräge 20 gemäß Figur 3.1 an der Innenwandung 17 des Gehäuses 1 dichtend an und verhindert das Durchströmen des freien Querschnittes 2 durch einen Gasstrom, sei es Zuluft oder Abgas einer Verbrennungskraftmaschine. Die in einem Arbeitsgang erfolgende Ausbildung von Gehäuse 1 mit Anspritzzap- fen 10 sowie der Klappenfläche 11 der Klappe 4 führt insbesondere zu einer Ausgestaltung einer Klappenanordnung mit geringstem Spiel, d.h. einer Minimierung sich einstellender Leckageströme zwischen diesen Bauteilkomponenten. Je nach thermischen Beanspruchungen während des Betriebs an einer Verbrennungskraftmaschine oder anderen, ein gasförmiges Medium erzeugenden oder benötigenden Arbeitsmaschinen läßt sich die Wandstärke 26 am Gehäuse 1 während des Spritzgieß Vorganges einstellen.As is already known from the illustration according to FIG. 1, a number of fastenings 8 are provided on the outer wall of the housing 1 with injection pins 10, by means of which a flap arrangement is produced, which, according to the invention, is produced in one operation and requires only a preassembly of shaft 3 and bearing body 9 Component can be integrated into a supply air or exhaust system on an internal combustion engine. The shaft journals of the shaft 3 are designated by reference numeral 23, on which the drive for pivoting the flap 4 into the shaft 3 can be introduced. This is preferably done via a servomotor, with which the flap 4 can be set in any rotational position within the flow cross member 2. In its closed position, the peripheral surface 25, provided with a sealing bevel 20 according to FIG. 3.1, seals against the inner wall 17 of the housing 1 and prevents a flow of gas through the free cross section 2, be it supply air or exhaust gas from an internal combustion engine. The formation of the housing 1 with injection pins 10 and the flap surface 11 of the flap 4 in one work step leads in particular to a flap arrangement with the least play, i.e. minimizing leakage flows between these component components. Depending on the thermal stresses during operation on an internal combustion engine or other machines that generate or require a gaseous medium, the wall thickness 26 on the housing 1 can be adjusted during the injection molding process.
Um sich während des Ein-Komponentenspritzgießverfahι-ens einstellende Grate aus Kunststoffrückständen zwischen den relativ zueinander bewegbaren Komponenten Welle 3 mit Klappenfläche 11 und Innenwandung 17 des Gehäuses 1 zu entfernen, können diese durch ein kurzes Hin- und Herbewegen der Klappenfläche 11 durch Verdrehung der Welle 3 in den Anspritzzapfen 10 entfernt werden. Eine weitere Nachbearbeitung der in einem Arbeitsgang gemäß des Ein-Komponentenspritzgießverfahrens erzeugten Klappenanordnung ist nicht erforderlich. Zur Verbesserung des Strömungsverhaltens des Gasstroms durch den Strömungsquerschnitt 2 der erfindungsgemäß vorgeschlagenen Klappenanordnung können die Verrippungsmuster 6 bzw. 31 im Bereich der Klappenfläche 11 auch mit anderer Geometrie, beispielsweise zur Erzeugung eines Dralls versehen werden. Die Auslegung der Geometrie der Verrippung 6 bzw. 31 im Bereich der Klappenfläche 11 richtet sich nach dem beabsichtigten Einsatzzweck der erfindungsgemäß hergestellten Klappenanordnung.In order to avoid burrs from plastic residues between the components 3 which can be moved relative to one another during the one-component injection molding process To remove the flap surface 11 and the inner wall 17 of the housing 1, these can be removed by briefly moving the flap surface 11 back and forth by rotating the shaft 3 in the injection pin 10. A further post-processing of the flap arrangement produced in one operation in accordance with the one-component injection molding process is not necessary. To improve the flow behavior of the gas flow through the flow cross-section 2 of the flap arrangement proposed according to the invention, the ribbing patterns 6 and 31 in the region of the flap surface 11 can also be provided with a different geometry, for example to generate a swirl. The design of the geometry of the ribs 6 and 31 in the area of the flap surface 11 is based on the intended use of the flap arrangement produced according to the invention.
Aus der Darstellung gemäß Figur 5 geht eine Draufsicht auf das die Klappenordnung umgebende Gehäuse näher hervor. Das einstückig ausgebildete Gehäuse 1, 10, die die Lagerkörper 9 der Welle 3 aufnehmenden Anspritzzapfen 10 umfaßt, ist mit einzelnen Befesti- gungen 8 versehen. In Bezug auf die Teilungsfxige des Spritzgießwerlczeuges, welche mit der Mittellinie 5 zusammenfällt, haben die Befestigungen 8 an ihren Außenflächen eine leicht trapezförmig ausgebildete Kontur. Durch diese begünstigt, läßt sich die in einem Arbeitsgang hergestellte Klappenanordnung leichter aus dem Spritzgießwerkzeug entnehmen.5 shows a plan view of the housing surrounding the valve arrangement. The one-piece housing 1, 10, which comprises the injection body 10 receiving the bearing body 9 of the shaft 3, is provided with individual fastenings 8. With regard to the division of the injection molding tool, which coincides with the center line 5, the fastenings 8 have a slightly trapezoidal contour on their outer surfaces. Favored by this, the flap arrangement produced in one operation can be removed more easily from the injection mold.
Aus der Darstellung gemäß Figur 6 geht ein Sclinitt durch die die Klappe 4 aufnehmende, beidseitig in angespritzten Gehäusezapfen 10 drehbar gelagerte Welle 3 hervor. Mit Bezugszeichen 28 sind die Sitzflächen für die Lagerkörper 9 im Bereich der Lagerungszapfen 23 der Welle 3 bezeichnet. Lediglich im Bereich der Sitzfläche 28 ist die mit den Lager- körpem 9 zu bestückende Welle 3 an ihrer Oberfläche zu bearbeiten. Da die Klappenfläche 11 der Klappe 4 innerhalb des freien Strömungsquerschnittes 2 an die Welle 3 angespritzt wird, erübrigt sich im zwischen den Lagerkörpern 9 liegenden Abschnitt der Welle 3 eine aufwendige Bearbeitung der Welle 3, da sich Fügeoperationen vollständig erübrigen. Die zur leichteren Entformung des in einem Arbeitsgang gefertigten Werkstückes an ihren Au- ßenseiten mit leicht angeschrägten Konturen versehenen Befestigungen 8 sind symmetrisch am Außenumfang 27 des Gehäuses 1 mit Anspritzzapfen 10 verteilt. Anstelle der hier gezeigten, in 90° zueinander versetzt angeordneten Befestigungen 8 lassen sich je nach Größe und Strömungsquerschnitt 2 des Gehäuses 1 mit Anspritzzapfen 10 auch mehrere, beispielsweise um 60° zueinander versetzte Befestigungen 8 an der Außenwandung 27 des Gehäuses 1, 10 anspritzen. Dies hängt von der Dimensionierung und der Beanspruchung des Gehäuses 1, 10 ab. Die über die Anspritzzapfen 10 des Gehäuses 1 hinausstehenden Zapfen 23 der Welle 3 können im gleichen Arbeitsgang mit Kurven oder aus Kunststoff bestehenden Antriebselementen versehen werden, so daß zur Bestückung mit diesen An- triebs- bzw. Steuerelementen ebenfalls keine separaten Arbeitsgänge erforderlich sind. Mit Bezugszeichen 13 bzw. 14 sind im Bereich der Anspritzzapfen 10 die formschlüssigen Verbindungen bezeichnet, welche eine Relativbewegung der Lagerkörper 9 in bezug auf die Anspritzzapfen 10 verhindern. Eine Rotationsbewegung der Welle 3 ist lediglich in bezug auf die Lagerkörper 9 möglich.From the illustration according to FIG. 6, a detail emerges through the shaft 3 which accommodates the flap 4 and is rotatably mounted on both sides in molded housing pins 10. The reference numerals 28 denote the seating surfaces for the bearing body 9 in the region of the bearing journal 23 of the shaft 3. Only in the area of the seat surface 28 is the shaft 3 to be fitted with the bearing bodies 9 to be machined on its surface. Since the flap surface 11 of the flap 4 is injection molded onto the shaft 3 within the free flow cross section 2, there is no need for complex machining of the shaft 3 in the section of the shaft 3 lying between the bearing bodies 9, since joining operations are completely unnecessary. The attachments 8, which are provided with slightly beveled contours on their outer sides for easier demolding of the workpiece manufactured in one operation, are distributed symmetrically on the outer circumference 27 of the housing 1 with injection pins 10. Instead of the fastenings 8 shown here, which are arranged at 90 ° to one another, depending on the size and flow cross-section 2 of the housing 1 with injection spigot 10, it is also possible to inject several fastenings 8, for example at 60 ° to one another, on the outer wall 27 of the housing 1, 10. This depends on the dimensions and the stress on the housing 1, 10. The pins 23 of the shaft 3, which protrude beyond the injection pins 10 of the housing 1, can be provided with curves or plastic drive elements in the same operation so that they can be equipped with these components. drive or control elements are also no separate operations required. Reference numerals 13 and 14 denote the positive connections in the area of the injection pins 10, which prevent relative movement of the bearing bodies 9 with respect to the injection pins 10. A rotational movement of the shaft 3 is only possible with respect to the bearing body 9.
Aus der Darstellung gemäß Figur 6.1 geht eine vergrößerte Wiedergabe des Lagerungsbereiches der Klappenwelle gemäß Figur 6 näher hervor. Die Wiedegabe des Lagerungsbereiches gemäß Figur 6.1 entspricht im wesentlichen der in Figur 2.1 dargestellten Lagerung, jedoch um 90° verdreht. Auch gemäß der Darstellung in Figur 6.1 wird eine Dichtfläche 16 zwischen Anspritzzapfen 10 und Außenfläche 30 des Lagerkörpers 9 gebildet. An die Dichtfläche 16 in axiale Richtung des Lagerkörpers 9 sich anschließend gesehen bilden am Anspritzzapfen 10 ausgebildete Vorsprünge 13 mit dazu korrespondierenden Ausnehmungen 14 an der Außenseite 30 des Lagerkörpers 9 eine formschlüssige Verbindung. Je nach Anzalil der in axiale Richtung zwischen Lagerkörper 9 und Anspritzzapfen 10 ausgebildeten formschlüssigen Verbindungen 13, 14 wird die Dichtwirkung einer solcherart konfigurierten Spaltdichtung erheblich erhöht. Die Ausbildung der formschlüssigen Verbindung erfolgt beim gleichzeitigen Spritzen von Anspritzzapfen 10 bei der Herstellung des Gehäuses sowie der Ausbildung der einstöckig mit der Welle 3 verbundenen Klappenfläche 11 der Klappe 4. Die Klappe 4 wird in Richtung des Doppelpfeiles 32 zwischen ihrer maximalen Offenstellung und ihrer, den Strömvmgsquerschnitt 2 verschließenden, Schließstellung hin- und herbewegt. Zur Bewegung der Welle 3 eignen sich Stellmotoren, deren Antriebsmoment aus Gründen der Antriebsauslegung möglichst gering zu halten ist. Die die Klappenfläche 11 versteifende Verrippung 6 bzw. 31 kann nach verschiedensten Einsatz- zwecken optimiert erfolgen, wobei sowohl eine Verbesserung der Strömungseigenschaften des den Strömungsquerschnitt 2 passierenden Fluides hinsichtlich Turbulenz bzw. Vermischung erzielbar ist, als auch eine Versteifung der Klappenfläche 11 der Klappe 4 erfolgen kann. Mit Bezugszeichen 29 ist die Innenbohrung des Lagerkörpers 9 bezeichnet, welche auf dem zu bearbeitenden Bereich 28 der Welle 3 sitzt.An enlarged representation of the bearing area of the valve shaft according to FIG. 6 can be seen in greater detail from the illustration according to FIG. 6.1. The reproduction of the storage area according to FIG. 6.1 essentially corresponds to the storage shown in FIG. 2.1, but rotated by 90 °. According to the illustration in FIG. 6.1, a sealing surface 16 is formed between the injection peg 10 and the outer surface 30 of the bearing body 9. When viewed on the sealing surface 16 in the axial direction of the bearing body 9, projections 13 formed on the injection pin 10 with corresponding recesses 14 on the outside 30 of the bearing body 9 form a positive connection. Depending on the number of form-fitting connections 13, 14 formed in the axial direction between the bearing body 9 and the gudgeon pin 10, the sealing effect of a gap seal configured in this way is considerably increased. The formation of the positive connection takes place during the simultaneous injection of injection pin 10 in the manufacture of the housing and the formation of the flap surface 11 of the flap 4 connected to the shaft 3 in one direction. The flap 4 is in the direction of the double arrow 32 between its maximum open position and its, the Flow cross section 2 closing, closed position moved back and forth. Servomotors are suitable for moving the shaft 3, the drive torque of which is to be kept as low as possible for reasons of the drive design. The ribbing 6 or 31 stiffening the flap surface 11 can be optimized for a wide variety of uses, both improving the flow properties of the fluid passing through the flow cross-section 2 with respect to turbulence or mixing, and stiffening the flap surface 11 of the flap 4 can. The inner bore of the bearing body 9, which sits on the region 28 of the shaft 3 to be machined, is designated by reference numeral 29.
Die entsprechend des erfindungsgemäß vorgeschlagenen Herstellverfahrens gefertigten Klappenanordnungen zur Steuerung eines Gasstromes können neben der Anwendung an Verbrennungskraftmaschinen auch an Rohrleitungssystem für gasförmige Medien Verwendung finden. BezugszeichenlisteThe flap arrangements for controlling a gas flow, which are manufactured in accordance with the manufacturing method proposed according to the invention, can be used in addition to their use on internal combustion engines and on piping systems for gaseous media. LIST OF REFERENCE NUMBERS
Gehäusecasing
StrömungsquerschnittFlow area
Klappenwelleflap shaft
Klappe (Offenstellung)Flap (open position)
Mittelliniecenter line
VerrippungsmusterVerrippungsmuster
Lagerungsstellestorage place
Befestigungattachment
Lagerkörperbearing body
AnspritzzapfenAnspritzzapfen
Klappenflächeflap surface
TrennschichtInterface
Vorsprunghead Start
AμsnehmungAμsnehmung
Anlageflächencontact surfaces
Dichtflächesealing surface
Innenwandung GehäuseInner wall housing
Querschnitt KlappenwelleCross section of valve shaft
KlappenflächenquerschnittFold cross-section area
Dichtschrägesealing chamfer
Spitzetop
Schrägungswinkelhelix angle
Wellenzapfenshaft journal
Gasstromgas flow
Umfangsflächeperipheral surface
WandstärkeWall thickness
Außenwandungouter wall
Sitzfläche LagerkörperSeat bearing body
Bohrung LagerkörperBore bearing body
Außenfläche LagerkörperOuter surface of the bearing body
Verrippungribbing
Drehrichtung direction of rotation

Claims

Patentansprüche claims
1. Verfahren zur Herstellung einer Klappenanordnung (4) zum Steuern eines Gasstromes (24) mit nachfolgenden Verfahrensschritten:1. Method for producing a flap arrangement (4) for controlling a gas flow (24) with the following method steps:
- dem Versehen einer Welle (3) an Sitzflächen (28) mit Lagerkörpern (9),- Providing a shaft (3) on seat surfaces (28) with bearing bodies (9),
- dem Einführen der vormontierten Baugruppe (3, 9) in ein Spritzgießwerkzeug,- inserting the preassembled module (3, 9) into an injection mold,
- dem Umspritzen des vormontierten, die Welle (3) mit Lagerkörper (9) umfassenden Baugruppe im Wege des Ein-Komponentenspritzgießverfahrens unter gleichzeitiger Ausbildung einer Klappe (4) und eines diese sowie die Lagerkörper (9) mngebenden Gehäuses (1, 10).- The encapsulation of the preassembled, the shaft (3) with bearing body (9) comprising the assembly by means of the one-component injection molding process with simultaneous formation of a flap (4) and one of these and the bearing body (9) mngebenden housing (1, 10).
2. Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, daß beim Umspritzen der Lagerkörper (9) zwischen diesen und den sie umgebenden Anspritzzapfen (10) eine formschlüssige, eine Schwenkbewegung (32) der Klappe (4) ennöglichende Verbindung erzeugt wird.2. The method according to claim 1, characterized in that a positive connection, a pivoting movement (32) of the flap (4) enabling connection is produced during the encapsulation of the bearing body (9) between the latter and the surrounding injection pin (10).
3. Verfal ren gemäß Anspruch 2, dadurch gekennzeichnet, daß Vorsprünge (13) der Anspritzzapfen (10) in Ausnehmungen (14) der Lagerkörper (9) eingreifen.3. Verfal ren according to claim 2, characterized in that projections (13) of the injection pin (10) engage in recesses (14) of the bearing body (9).
4. Verfaliren gemäß Anspruch 1, dadurch gekennzeichnet, daß die Lagerkörper (9) vor dem Umspritzen im Spritzgießwerkzeug mit einem Schmiermittel (12) behandelt werden.4. Verfaliren according to claim 1, characterized in that the bearing body (9) are treated with a lubricant (12) before overmolding in the injection mold.
5. Verfahren gemäß Anspruch 1, dadurch gekennzeiclmet, daß die Klappe (4) während des Umspritzens in eine Offenstellung im Strömungsquerschnitt (2) des Gehäuses (1, 10) ausgebildet wird.5. The method according to claim 1, characterized gekennzeiclmet that the flap (4) is formed during the extrusion coating in an open position in the flow cross section (2) of the housing (1, 10).
6. Verfahren gemäß Anspruch 5, dadurch gekennzeichnet, daß die Klappe (4) in bezug auf das Gehäuse (1, 10) in einer maximalen Offenstellung orientiert ist.6. The method according to claim 5, characterized in that the flap (4) with respect to the housing (1, 10) is oriented in a maximum open position.
7. Verfahren gemäß Anspruch 1, dadurch gekennzeiclmet, daß die Lagerkörper (9) der Welle (3) an einer Innenwandung (17) des Gehäuses (1,10) angrenzend positioniert werden. 7. The method according to claim 1, characterized gekennzeiclmet that the bearing body (9) of the shaft (3) on an inner wall (17) of the housing (1,10) are positioned adjacent.
8. Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, daß an der Klappenfläche (11) der Klappe (4) an einer oder beiden Seiten eine Verrippung (6, 31) ausgebildet wird.8. The method according to claim 1, characterized in that on the flap surface (11) of the flap (4) on one or both sides a ribbing (6, 31) is formed.
9. Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, daß bei der Ausbildung der Klappenfläche (11) der Klappe (4) deren Umfangsfläche (25) mit einer Dichtschräge9. The method according to claim 1, characterized in that in the formation of the flap surface (11) of the flap (4) whose peripheral surface (25) with a sealing bevel
(20) versehen wird.(20) is provided.
10. Vorrichtung zum Steuern eines Gasstromes (24), gefertigt gemäß einem oder melueren der Ansprüche 1 bis 9, dadurch gekennzeichnet, daß die Lagerkörper (9) aus mit einem Schmiermittel imprägnierter, gesinterter Bronze oder aus Stahl gefertigt sind.10. Device for controlling a gas flow (24), manufactured according to one or melueren of claims 1 to 9, characterized in that the bearing body (9) are made of sintered bronze or steel impregnated with a lubricant.
11. Vonichtung gemäß Anspruch 10, dadurch gekennzeiclmet, daß zwischen der Außenfläche (30) der Lagerkörper (9) und der Innenfläche des Anspritzzapfens (10) des Gehäuses (1) eine eine Spaltdichtung erzeugende Anzahl von Vorsprüngen (13) und Aus- nehmungen (14) ausgebildet sind.11. Seal according to claim 10, characterized gekennzeiclmet that between the outer surface (30) of the bearing body (9) and the inner surface of the injection pin (10) of the housing (1) a number of projections (13) and recesses (a gap seal) 14) are formed.
12. Vorrichtung gemäß Anspruch 11, dadurch gekennzeichnet, daß zwischen der Innenwandung (17) des Gehäuses (1,10) und der Außenfläche (30) der Lagerkörper (9) eine Dichtfläche (16) vorgesehen ist. 12. The apparatus according to claim 11, characterized in that a sealing surface (16) is provided between the inner wall (17) of the housing (1,10) and the outer surface (30) of the bearing body (9).
PCT/DE2002/000428 2001-02-07 2002-02-06 Device for controlling a gaseous stream and a production method therefor WO2002062551A1 (en)

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