DE102009057491A1 - Throttle device is provided with throttle body with ring element and outer cylinder, where throttle body is provided with cross-pervading throttle shaft with attached butterfly valve - Google Patents

Abstract

The throttle device is provided with a throttle body with a ring element (50) and an outer cylinder. The throttle body is provided with a cross-pervading throttle shaft (22) with an attached butterfly valve. The outer cylinder consists of duroplastic. An independent claim is also included for a method for manufacturing a throttle device.

Description

The invention relates to a throttle valve device in which a throttle valve mounted on a throttle shaft is rotatably disposed in a throttle body and a method for producing such a throttle device.

Throttle valve devices are used in internal combustion engines to control the supply of air to the engine. It remains in the throttle body a dependent of the rotational position of the throttle effective flow area. In a closed position of the throttle valve, the air supply - except for leakage air - completely prevented.

Conventionally, throttle bodies are made of metal, especially aluminum. Recent proposals now use other materials.

In the EP 1783 407 is a throttle body formed from a first and second housing part made of a thermoplastic and an interposed ring made of aluminum or a thermosetting plastic. In the ring, a throttle valve made of aluminum or a thermoplastic is rotatably mounted. The ring has for this purpose opposite receptacles for the throttle shaft, which serve as a bearing.

In the DE 103 59 609 a throttle valve device is described in which a throttle body is also formed of a first and a second housing part, between which a cylindrical seat is arranged flush. The existing polyetherimide or a thermosetting cylindrical seat has opposite recesses for bearings for supporting the throttle shaft. The first and second housing parts are made of polyamide, polyphenylene sulfide or polybutylene terephthalate. The bearings are designed as needle sleeve bearings.

In the WO 2004/113702 a throttle valve adjusting device is described, in which a throttle shaft is mounted at two bearing points between a lower and upper half of the housing made of plastic, for example. Duroplast. The throttle is formed of thermosetting or thermoplastic material and may be molded integrally with a sleeve on the throttle shaft or screwed or welded to a metal sleeve on the throttle shaft.

It is an object of the invention to propose a throttle device and a manufacturing method thereof, which are inexpensive and achieve a good rate of leakage air.

This object is achieved by a throttle valve device according to claim 1 and a method for manufacturing a throttle valve device according to claim 11. Dependent claims relate to advantageous embodiments of the invention.

According to the invention, the throttle body comprises a two-part ring element made of duroplastic, which is surrounded by an outer cylinder, which is also formed from a thermoset material.

Here, the throttle shaft is arranged on the ring element and penetrates this transversely to the throttle body. The ring element is split so that at least two parts of it receive the throttle shaft between them.

It has been found that the construction according to the invention has considerable advantages in terms of a simple and cost-effective production on the one hand and high dimensional accuracy and tightness on the other.

The thermoset ring element has a high temperature resistance which is well suited for use on a motor vehicle and has a relatively low thermal expansion or shrinkage. The outer cylinder formed around it also consists of a thermoset material, preferably of the same material as the ring element. It encloses the ring element and thus acts sealingly. Duroplast has also proved to be a suitable plastic material here, in particular because stresses can be reduced during encapsulation of the ring element due to the low shrinkage.

The subdivision of the ring element into at least two parts, between which the throttle shaft is received, allows in a simple way the production of a high-precision unit from a wall which becomes part of the throttle body, and a precisely recorded in the form and arrangement accurately fit therein throttle. In the closed position, the throttle valve is located on the inner wall of the ring element. The high accuracy of fit results in a good seal.

According to one embodiment of the invention, at least one rolling bearing is arranged on the throttle valve shaft, which is accommodated in a bearing receptacle formed between the parts of the ring element. By a rolling bearing, which is preferably designed as a deep groove ball bearing, an accurate, smooth-running mounting of the throttle shaft is possible. Preferably, the throttle valve shaft is mounted on one side in a fixed bearing and on the opposite side in a floating bearing. It has proved to be preferred, a rolling bearing as a fixed bearing only on one side of the shaft to arrange and to guide the shaft on the opposite side in a directly formed on the ring element recording (sliding bearing as a floating bearing). The rolling bearing is in this case preferably axially fixed to the shaft, that is not arranged displaceably. It has been found that a very accurate axial positioning of the shaft and the throttle valve mounted therein within the ring member is possible in that the rolling bearing is positioned in a correspondingly accurately shaped bearing mount.

According to a development of the invention, at least one shaft sealing ring is provided on the throttle valve shaft. This serves as a seal at the preferably only remaining opening, namely the passage of the throttle valve shaft. It is particularly preferred to arrange the shaft sealing ring in a receptacle between the parts of the ring element, more preferably such that a roller bearing is sealed by the ring with respect to the throttle body. In addition, a second shaft sealing ring may be provided on the throttle shaft, preferably in a recess provided for this purpose of the outer cylinder.

The throttle valve is preferably made of plastic, more preferably by spraying on the throttle valve shaft, which may, for example, consist of steel. More preferably, the material of the throttle valve is a thermoset material. It is particularly preferred to produce at least the ring element and the throttle flap of identical thermoset material. Then there is a suitable material pairing for the leakage rate and it does not come at different temperatures to leakage air fluctuations due to different expansion coefficients of the material. It is also preferred to also produce the outer cylinder also made of identical thermoset material in order to benefit from the same properties here as well.

The ring element is preferably divided into only two parts. The division can be done here on the one hand transversely to the axial direction of the throttle body, d. H. that the two parts of the ring element itself are preferably arranged annularly and one above the other in the axial direction of the throttle body. Advantage of this embodiment is the increased stability of the annular sub-elements.

Alternatively, the division can also take place in the axial direction of the throttle body, preferably two partial rings, preferably 180 ° half rings, are provided, which are juxtaposed in the region of the passage of the throttle valve shaft. The advantage here is the relatively short seam, which also extends transversely to the direction of contact of the throttle valve on the ring element, so that leaks are minimized by the inhomogeneity arising in the region of the assembly.

The throttle valve device may include a housing for a sensor and adjusting device, also referred to as gear and sensor space, which is attached to the throttle body. Preferably, the housing is formed integrally with the outer cylinder. It preferably includes a sensor unit for the position of the throttle valve and an adjusting device, in particular an electric motor for setting a desired position of the throttle valve and a corresponding transmission. The housing preferably has an electrical connection device, preferably an electrical plug connection. For the electrical connection of the sensor unit to the electrical connection and / or the adjustment device to the electrical connection, a connecting grid element is preferably provided, which is embedded in plastic material. This may be the plastic material of a housing base or housing cover or a separate plastic part within the housing.

The measuring and adjusting device preferably has an electronic circuit for processing the sensor signals or for controlling the adjusting device or for both purposes, which is formed as a leadframe module unit. In this case, line strands and electrical and electronic components mounted thereon, in particular preferably an integrated circuit, are encapsulated in a molded body.

According to one embodiment of the invention, the throttle valve on a shape with two throttle blades, which are mounted off-center on the throttle shaft. In particular, it is preferred that the throttle blades are not aligned, but extend tangentially from the throttle shaft. The two throttle blades preferably run in mutually parallel but spaced-apart planes. It has been found that this shape of the throttle valve allows a particularly good seal in the closed position by the thus given kinematic path of the end regions.

In the method according to the invention, the parts of the ring element are first formed of the thermosetting material and separately thereof a throttle shaft with attached thereto throttle. The throttle shaft is disposed on the parts so as to be sandwiched therebetween. The ring element thus formed is embedded in a further step in an outer cylinder made of thermoset, preferably by molding.

Embodiments of the invention will be described in more detail with reference to drawings. Show here

1a . 1b . 1c a first embodiment of a throttle device in perspective side view and plan view;

2a . 2 B a throttle valve with throttle shaft and bearings in perspective and in side view;

2c a sectional view of the throttle 2a . 2 B in the closed position in a throttle body;

3a . 3b in perspective parts of a ring element;

3c an exploded view of a ring member with throttle shaft;

3d a side view of the ring element 3c ;

4 a cross-sectional view of a throttle body;

5a . 5b a perspective view of an outer cylinder of the throttle valve unit with housing in different stages of production;

6 in a perspective view of a second embodiment of a throttle device

7 in a perspective exploded view of a ring member of the second embodiment.

1a . 1b . 1c show a throttle valve unit 10 with a throttle body 12 , a throttle valve rotatably disposed therein 14 and a housing disposed thereon 16 , Next are located on the throttle body eyelets 18 as fasteners and a plug 20 as electrical connection.

The throttle body 12 is designed as a hollow cylinder. It is arranged inside an internal combustion engine of a motor vehicle in the intake path for the combustion air. The throttle 14 is here on a throttle shaft 22 rotatable within the throttle body 12 arranged so that they depending on the rotational position of the cross section of the throttle body 12 for the supply of air releases or completely or partially blocks.

Inside the case 16 a sensor and adjusting device is arranged, with the over the electrical connection 20 the position of the throttle 14 can be queried and set to a desired value.

The following are individual steps in the manufacture of the throttle device 10 described.

First, as in 2a . 2 B illustrated a throttle element 24 made by putting on a throttle shaft 22 made of steel in an injection mold, the throttle valve 14 is sprayed from a thermoset plastic. The throttle shaft 22 has in this case at its periphery undercuts (not shown), in the surrounding thermoset material of the throttle 14 be embedded and lead to a positive fit, so that the throttle 14 not opposite to the throttle shaft 22 can twist. The undercuts can, for example, be designed as an edged shaft section, as a bore, as a toothing element, etc.

While the shape of the throttle 14 in the plan view ( 1b ) is substantially circular, so that the throttle 14 in its closed position, the circular inner cross-section of the throttle body 12 she is in the in 2a . 2 B shown preferred embodiment not as a pure plate on the shaft 22 educated. Rather, the throttle includes 14 two throttle wings 26a . 26b on the shaft 22 are mounted off-center, ie that the central axis of the shaft 22 not in the level of the throttle wings 26a . 26b lies. These extend from the shaft 22 tangential to the outside, leaving them in parallel but spaced planes 28a . 28b lie. This form of throttle has been found to be beneficial for sealing within the throttle body 12 proved.

2c shows the throttle 14 shortly before reaching the closed position on the wall of the throttle body 12 (dashed line) and in the closed position. The narrowest system on the wall of the throttle body 12 arises here at the front edge 33a . 33b each throttle blade 26a . 26b , In the closed position ( 2c ) is this edge 33a in front of the middle plane 27 , This avoids that when contacting the end portions 30a . 30b with the wall of the throttle body 12 by friction, a self-locking can result, leading to the jamming of the throttle 14 could lead.

On the throttle shaft 22 is also a rolling bearing, preferably a deep groove ball bearing 32 attached axially fixed by pressing. The distance between the throttle 14 and the rolling bearing 32 is determined by this. Next is a shaft seal 31 on the throttle shaft 22 applied.

Separately ring parts 34a . 34b as in 3a . 3b represented, produced by injection molding of a thermoset material. These are each hollow cylinder elements, each with two opposite Achsausnehmungen 36 . 37 , Of these is at a first Achsausnehmung 36 a bearing eye 38 and at a second axle recess 37 a camp recording 40 arranged. Of these, the bearing eye 38 closed at the end, while the bearing receptacle 40 another axle recess at the end 42 having. At the warehouse reception 40 is also a gasket holder 41 educated.

The ring parts 34a . 34b are substantially identical in cross section, but have different axial lengths in the example shown. On a part of the top of the ring parts 34a . 34b are made of Duroplast material sealing beads 44a . 44b Formed 180 ° -symmetrisch, while on another part of the upper side of the ring part elements 34a . 34b matching sealing grooves 46a . 46b are formed.

As in 3c shown, the ring part elements 34a . 34b assembled and take the throttle element 24 between themselves. This is the camp 32 at the warehouse reception 40 the two ring part element 34a . 34b taken while the opposite end of the shaft 22 in the at the ring part elements 34a . 34b formed bearing eye 38 is held. The sealing ring 31 will be in the gasket holder 41 added. The beads 44a . 44b and the grooves 46a . 46b engage each other, so that the ring part element 34a . 34b are arranged exactly in alignment and without displacement.

In an alternative embodiment (not shown), the ring part elements are exactly the same, resulting in a simplified production. By a like in 3c shown symmetrical half division of the beads 44a . 44b and grooves 46a . 46b , which are arranged exactly 180 degrees rotationally symmetrical to each other, the identical ring sub-elements can be fitted into each other.

In this way, as in 3d illustrated a ring element 50 with one disposed therein around the throttle shaft 22 rotatable throttle 14 created. By the used thermoset material of the throttle 14 and the ring element 50 a high dimensional accuracy is achieved. In addition, the position of the throttle valve 14 within the ring element 50 by the reception of the camp 32 in the recording 40 set exactly. The throttle shaft 22 is in the rolling bearing 32 (Fixed bearing) and opposite in plain bearing 37 (Floating bearing) stored.

The thus finished ring element 50 is in a subsequent step with a housing unit 52 ( 5a ) overmoulded. The housing unit 52 includes an outer cylinder 100 which is formed around the ring member 50 around and thereby seals it. This encloses the outer cylinder 100 the ring element 50 almost complete; only for the free end of the throttle shaft 22 remains an opening, allowing the shaft to adjust the throttle 14 can be driven.

4 shows in a longitudinal sectional view around the ring element 50 formed outer cylinder 100 that is the ring element 50 completely enclosed. On the outer cylinder 100 is a recess 37 for receiving a second shaft seal 35 intended. Together with the first shaft seal 31 is such a very good seal on the throttle shaft 22 guaranteed.

The outer cylinder 100 forms together with the ring element 50 the throttle body 12 , wherein the ring element 50 into the wall of the throttle body 12 is embedded.

The housing unit 52 includes next to the outer cylinder 100 integrally formed herewith also the lower part of the housing 16 for the sensor and adjustment device for the throttle shaft 22 , The housing element 52 becomes the ring element 50 formed by injection molding and is made of the same thermoset material as this. It encloses the ring element 50 completely and thus ensures a seal and mechanical fixation.

Subsequently, in the housing 16 additional elements introduced ( 5b ), including in particular an electric servomotor (of which in 5b only one drive pinion 54 can be seen), a rotation sensor 56 for the position of the throttle shaft 22 , The housing 16 is then through a lid 58 locked.

An electrical connection from the plug 20 to a control electronics 60 for the engine and the sensor 56 is here by grid rails 62 created. These are formed as stampings made of metal. While in 4b are shown freely for the sake of clarity, they are preferably molded in a plastic element.

The sensor 56 for the position of the throttle shaft 22 can, for example, be designed as a magnetic sensor according to the Hall or GMR principle, as an optical or as an inductive rotation sensor. The mechanical structure of the sensor element and its Connection to the rails 62 is hereby formed as a leadframe module.

Such a leadframe module comprises, on the one hand, an integrated circuit with the actual sensor element and, on the other hand, additional electrical components for its connection, such as, for example, resistors and capacitors. These components are arranged on stamped conductor tracks and embedded together with these in a molded body. Details on the formation of such a lead frame module can be found in the German patent applications DE 10 2006 030 081 and DE 10 2006 030 133 ,

Variations are possible for the embodiments shown. In particular, the throttle shaft in addition to the in 2 B shown form with two staggered throttle wings 26a . 26b also have other shapes, in particular a simple plate shape.

6 shows a second embodiment of a throttle valve unit 10 ' , In the example shown without housing for a sensor and gear compartment. This includes a throttle body formed from an outer cylinder 100 ' made of thermoset material, which is around a ring element 50 ' is formed of the same thermoset material.

In the second embodiment, the ring member 50 ' not as in the first embodiment described above, transverse to the axial direction of the throttle body 12 divided, but the division runs parallel to this axial direction. This shows 7 in a perspective view of the identically formed ring part elements 34a ' . 34b ' , as well as the ring part elements 34a . 34b the first embodiment, shaft recesses 36 . 37 and arranged on each half a bearing eye 38 and half a bearing recess 40 exhibit.

The ring part elements 34a ' . 34b ' are formed as half hollow cylinder. They have a 180 ° rotationally symmetrical arrangement of sealing beads 44a ' and matching sealing grooves 46a ' on, making them the ring element 50 ' can be assembled while keeping the throttle with its shaft 22 and the arranged thereon bearing between them.

In both embodiments takes place in the closed state of the throttle 14 a seal on the inner wall of the ring member 50 , Due to the exact dimensional accuracy possible by the structure and due to the suitable thermoset material, a very good seal is achieved.

As the thermosetting material in particular BMC molding compositions and phenolic molding compositions are preferred which have a high strength and very low shrinkage. Particularly preferred is shrinkage-free BMC material.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1783407 [0004]
• DE 10359609 [0005]
• WO 2004/113702 [0006]
• DE 102006030081 [0054]
• DE 102006030133 [0054]

Claims (12)

Throttle device with - a throttle body ( 12 ) with a ring element ( 50 ) made of duroplastic, which from an outer cylinder ( 100 ) is surrounded, - and the throttle body ( 12 ) on the ring element ( 50 ) transversely penetrating throttle shaft ( 22 ) with an attached throttle valve ( 14 ), characterized in that - the outer cylinder ( 100 ) consists of thermoset, - and the ring element ( 50 ) of at least two parts ( 34a . 34b ), wherein the parts of the throttle valve shaft ( 22 ) between them. Device according to claim 1, wherein - on the throttle shaft ( 22 ) at least one rolling bearing ( 32 ), - the rolling bearing ( 32 ) in one between the parts ( 34a . 34b ) ( 40 ) is recorded. Device according to Claim 2, in which - the throttle shaft ( 22 ) in the ring element ( 50 ) on one side in the rolling bearing ( 40 ) and on the opposite side in a receiving formation ( 36 . 38 ) of the ring element ( 50 ). Device according to one of the preceding claims, in which - on the throttle shaft ( 22 ) at least one shaft seal ( 31 ) is provided. Device according to one of the preceding claims, in which - the throttle valve ( 14 ) made of thermoset material around the throttle shaft ( 22 ) is formed. Device according to Claim 5, in which - the throttle valve ( 14 ) is made of the same thermoset material as the ring element ( 50 ). Device according to one of the preceding claims, in which - the ring element ( 50 ) in the axial direction of the throttle body ( 12 ) is shared. Device according to one of the preceding claims 1-6, wherein - the ring element ( 50 ) transverse to the axial direction of the throttle body ( 12 ) is shared. Device according to one of the preceding claims, in which - the outer cylinder ( 100 ) the ring element ( 50 ) except for a passage opening for the throttle shaft ( 22 ) completely surrounds. Device according to one of the preceding claims, in which - the throttle valve has two throttle blades ( 26a . 26b ), which is off-center of the throttle shaft ( 22 ), the throttle wings ( 26a . 26b ) eccentrically on the throttle shaft ( 22 ) are mounted. Method for producing a throttle valve device, in which - two parts ( 34a . 34b ) are formed from a thermoset material, - the two parts ( 34a . 34b ) to a ring element ( 50 ), wherein a throttle shaft ( 22 ) with an attached throttle valve ( 14 ) between the two parts ( 34a . 34b ), so that the throttle shaft ( 22 ) the ring element ( 50 ) penetrates transversely, - and the ring element ( 50 ) in an outer cylinder ( 100 ) is embedded from thermosetting plastic. Method according to claim 11, in which - the outer cylinder ( 100 ) around the ring element ( 50 ) is molded around by injection molding.

Images