EP2557298B1 - Flap device with at least two separately produced flaps fitted together for joint motion - Google Patents

Description

The present invention relates to a flap device according to the preamble of claim 1.

The aforesaid flapper device, which may comprise a plurality of flaps, and typically one flapper portion, is preferably adapted for use in motor vehicles for controlling gas flows of all types, such as fresh gas supply to the internal combustion engine, by relative displacement of the at least two flaps relative to Change housing. It is also known, components of such a flap device, such as the flaps on the one hand and the housing on the other hand, inexpensive injection molding manufacture.

A disadvantage of the production by injection molding of a plurality of mutually connected common movement flaps is a certain deformation, which can occur after demolding of a flap assembly with mehrreren, at least two, flaps from an injection mold.

In particular, when the flap assembly is to be received rotatably about a flap axis in the housing of the flap device, the flaps are usually arranged in the axial direction one behind the other, whereby the flap assembly in the axial direction may have a large length. Since the deformation occurring due to thermal distortion and possibly occurring distortions after demoulding from the injection mold usually increases with increasing dimension in a spatial direction, straight flap arrangements with at least two or more flaps are subject to the described geometric change after demoulding to a particularly undesirable extent.

In the process, geometric deformations (deformations) of the component occurring after removal from the mold lead to problems in realizing the relative movement of the flap arrangement relative to the housing carrying it.

A flap device of the generic type is in the document WO 2006/024468 A1 disclosed. Another flap device is from the document WO 93/01402 A1 known.

The object of the present invention is to provide a valve device which is easy to manufacture and to assemble.

According to the present invention, this object is achieved by a flap device according to claim 1.

This means that the flaps, which are connected to one another at the finished flap relative to the housing relative to the housing, individually, d. H. separately from each other, produced and coupled together only after their production.

The housing may also consist of several housing parts, about one housing part per flap. However, it is also conceivable to combine several or even all of the flow channel sections substantially in a common housing part and to supplement this merely by further mounting parts in order to enable a relatively movable attachment of the flaps to the housing part.

The at least two flaps on the finished flap device are rotatable about a flap axis relative to the housing, the flap having a flap body and at least one flap shaft portion connected thereto for common movement. The flap body is that portion of the flap, with which the above-described change in the flow cross-section is effected by changing the relative arrangement and which is designed for this purpose.

The flap shaft sections, which are formed integrally with the flap body for reasons of dimensional accuracy and dimensional stability and to avoid unwanted assembly work, are adapted to receive the flap with the flap body rotatably mounted on the housing.

A particularly stable mounting of the flap for relative rotation relative to the housing is inventively obtained in that the flap has two with respect to the flap axis substantially collinear flap shaft sections, wherein the flap body is provided axially between the flap shaft sections. Due to the arrangement of the valve body axially between the valve shaft sections also resulting from operational possibly occurring loads flap bend can be avoided or at least significantly reduced, which could otherwise affect the relative twistability of the flap relative to the housing.

In many cases, the flap device or a semifinished product made for its manufacture may have more than two flaps, such as when several similar flow channels lead to each cylinder of a multi-cylinder internal combustion engine and the gas flow rate in each of the flow channels is to be variable.

A structurally simple and the following assembly work considerably simplifying solution may be such that one of two connected to a valve body flap shaft portion, preferably at a free axial end thereof, has a coupling geometry and that the respective other flap shaft portion has a coupling counter-geometry, wherein the coupling geometry and the coupling counter-geometry can be positively coupled to a common rotational movement about the valve axis.

Thus, each flap preferably has at one end a coupling geometry and at the other a coupling counter-geometry, so that only one type of flap needs to be manufactured and this flap can be axially lined up as often as required by coupling geometry and coupling counter-geometry so as to provide the desired number of flaps of the respective flap assembly reach.

From a production point of view advantageous preferably the coupling geometry and / or the coupling counter-geometry is integral with the flap having it, preferably formed with the flap shaft portion having it.

A safe and reliable torque transmission from a flap to each their axially adjacent, which may be a prerequisite for joint movement, can be obtained in a simple manner that a geometry of coupling geometry and coupling counter geometry a recess and the other geometry is a torque transmitting in the recess insertable projection, preferably a projection complementary to at least a portion of the recess periphery. By appropriate choice of the axial length of the recess and projection, the surface loading of coupling geometry and coupling counter-geometry occurring at the torque-transmitting coupling point can be kept low.

For example, for torque transmission, the projection, as well as the recess, have a cross-sectional shape when viewing a valve axis orthogonal cross-section, which is bounded by a polygon. In general, the projection may be formed prismatic, wherein projection and recess may have insertion bevels for easy installation. This means that the projection tapers with increasing axial distance from the valve body, while the recess tapers with increasing approach to the valve body.

The preferred complementary configuration of recess and projection should not mean that in the coupled state of recess and projection no voids in the coupling structure more, because usually the recess must always be performed axially a little longer than the projection. Rather, it should be stated that the majority of the recess is taken after the coupling of material of the projection.

For actuating the flap arrangement in the flap device, it is advantageous if the flap device has an actuating component with which by an actuating device, such as an actuator, an actuating torque for relative rotation of flaps and housing in the flap device can be introduced, thus at a single actuating point the To operate flap assembly of the flap device.

The actuating component can already be connected to at least one flap of the flap device or still be connectable to this. Then it is for ease of assembly work, but also for the usability of a substantially "universal" flap, not only for coupling to another flap, but also for coupling to the operating member advantageous if the actuating member has a geometry of coupling geometry and coupling counter-geometry.

According to the invention, a plurality of individually produced flaps in addition to the aforementioned positive locking geometries by material connection, such as by the low-distortion laser welding, or by gluing or otherwise operationally inextricably linked together to ensure operation of the flap device with the most accurate possible change in the gas flow flowing through the flow channel section gas flow to be able to.

The flap axis is provided at a distance from the flap body, wherein the flap body is curved so that the flap body in a passage position in which the flow cross-section of the Strömungskanalabschnifts is maximum, abuts against the wall of the housing or snuggles against them at a short distance.

To provide a precise, so dimensional or / and dimensional, relative movement between the flap and the housing, it may then, when the flap is provided on the finished flap device about a flap axis rotatable relative to the housing on this, be advantageous if at least one flap, Preferably, all the flaps, a flap assembly of a flap device comprises a flap shaft member.

The flap shaft component can be, for example, a metal component or a component made of another material which is more dimensionally stable than the cured casting material of the flap.

In that case it is possible to apply the flap to the flap shaft component, in particular to inject it, or to encase the flap shaft component with the flap, in particular to overmold it.

In the former case of the casting, the flap shaft member is not completely surrounded by casting material contributing to the formation of the flap, while in the case of overmolding the flap shaft component is completely surrounded by casting material contributing to the formation of the flap.

The encapsulation is preferred because the encapsulated valve shaft component is largely protected by the casting material of the flap and also on the outer surface of the valve shaft member reinforced flap no unwanted material pairing occurs, which can lead to unwanted wear in relative movement of the flap and housing.

For demarcation it should be emphasized that a common spraying or encapsulation of two or more flaps on a common flap shaft component is not a form-fit geometry connection in the sense of the present application. Rather, the flaps of the flap device according to the invention must be present at the beginning of assembly of the flap arrangement in isolation.

Preferably, adjacent flaps are connected or connectable by an axial plug connection for common movement.

For better weldability of adjacent flaps, the form fit geometries and the region of flap shaft sections adjoining them preferably have a surface made of a uniform material. Preferably, the entire flap is made of this material.

Fig. 1

eine Ausführungsform einer erfindungsgemäßen Klappenvorrichtung in perspektivischer Ansicht im Teilschnitt,

Fig. 2

eine perspektivische Darstellung der Klappen, Lagerbuchsen und des Betätigungsbauteils der Klappenvorrichtung der Ausführungsform von Fig. 1, und

Fig. 3

die beiden dem Betätigungsbauteil axial am nächsten liegenden Klappen der Klappenanordnung von Fig. 2 in der Explosionsansicht.

The present invention will be explained in more detail with reference to the accompanying figures. It shows:

Fig. 1

an embodiment of a flap device according to the invention in a perspective view in partial section,

Fig. 2

a perspective view of the flaps, bushings and the actuating member of the flap device of the embodiment of Fig. 1 , and

Fig. 3

the two axially closest to the actuating member flaps of the flap assembly of Fig. 2 in the exploded view.

In the Fig. 1 to 3 An embodiment of the present invention is illustrated and generally designated 110.

The flap device 110 shown here has four substantially parallel flow channel sections 126, 128, 130 and 133, which may be formed in a common housing 120.

Alternatively, the housing 120 may be subdivided in such a way that one or more subgroups of flow channel sections are formed in a housing part. It can also be thought to form a separate housing for each flow channel section.

As will be explained below, the housing 120 may be designed in several parts to facilitate the assembly of the embodiment of a flap device 110 shown here.

The flaps 132, 134, 136 and 137 are with correspondingly the shape of the associated flow channel portion curved flap bodies 132 a, 134 a, 136 a and 137 a, which are arranged at a distance from the flap axis K, around which the entire flap assembly 139 is rotatable relative to the housing 120. In the in Fig. 1 As shown, the valve bodies 132a, 134a, 136a and 137a closely abut the housing 120 to form a thin gap 141.

The valve bodies can then be in the in Fig. 1 shown passage position in which the respective flow channel sections in the housing 120 substantially have a maximum flow cross-section, create a conforming to the respective wall sections of the housing 120. Thus, in the passage position of the flap arrangement 139, preferably no flap component protrudes into the flow channel section assigned to it.

The embodiment of a flap device 110 according to the invention discussed here will be described below with reference to FIGS Fig. 1 the leftmost flap 137 will be described. Insofar as flaps other than the described flap 137 differ from this, it will be possible to refer specifically to the differences within the scope of this description.

The flap 137 comprises the already mentioned flap body 137a, from which project to both, with respect to the flap axis K, axial sides flap shaft portions 137b.

The flap shaft portions 137b are formed integrally with the flap body 137a via land portions 137c.

Both longitudinal ends of the flap shaft sections 137b, which are remote from the flap body 137a, have form fit geometries which can serve for the torque-transmitting connection with the respectively adjacent flap, here for example flap 136, or / and with an actuating component 162.

In the in Fig. 1 As shown, both positive locking geometries can be formed as projections 164.

Then, the flaps 137 and 134 may be formed substantially identically, and the flaps 136 and 132 may be formed substantially identically, with the difference between adjacent flaps 137 and 136 (see FIGS Fig. 3 ) may consist in that the flap 136 instead of projections 164 coupling recesses 166 has.

In the illustrated example, the flap 136 has recesses 166 at both longitudinal ends of the flap shaft sections 136b remote from the flap body 136a into which the projections 164 of adjacent flaps may be inserted in the axial direction to connect the flaps to transmit torque.

The in the Fig. 1 to 3 The situation shown may be changed with respect to the required assembly to the effect that each flap has a projection 164 at one longitudinal end of a flap shaft portion and a corresponding recess 166 at the respective other longitudinal end. If then, based on the position to the valve body, always the same flap shaft sections have a projection and the other have a recess, it is sufficient to produce a kind of flaps. Essentially identical flaps can thus be put together to form a flap arrangement 139.

After the mating of adjacent flaps or / and an actuating member 162, the components inserted for torque transmission are additionally permanently connected by gluing, welding or any other suitable method when used as intended.

Preferably, a laser welding method is recommended here, which is the occurring minimizes thermal distortion and thus the highest possible dimensional stability, combined with a smooth Relativverdrehbarkeit the flap assembly 139 relative to the housing 120, guaranteed.

It is also conceivable, although not preferred due to the increased assembly effort, to form all the flaps with coupling recesses 166 and insert separately formed connecting blocks in the form of the coupling projections 164 into the coupling recesses 166 of adjacent flaps. Although then in this solution, all the flaps are essentially geometrically identical, but the assembly effort is undesirably high due to the coupling blocks to be introduced.

The coupling projections 164 are preferably constructed prismatic, so that they can transmit torque when combined with the corresponding coupling recesses 166 on the sides of their lateral surfaces. In the example shown, the coupling projections 164 are designed as a cuboid. However, it is also conceivable to design the coupling projections 164 as a triangular prism, pentagonal prism or as an irregular prism.

It is also sufficient to form the recesses 166 in such a way that portions of the inner lateral surface of a recess 166 abut portions of the lateral surface of the coupling projections 164 and a torque can be transmitted to the valve axis K between two flaps coupled in this manner.

However, in order to achieve the most exact possible geometry of the assembled flap arrangement 139, flap projections 164 and flap recesses 166 are essentially complementary in the mounted state, ie complementary to each other, this does not mean that the coupling recess 166 is in one with a coupling projection 164 United state is completely filled by the coupling projection 164. Usually, the coupling recess 166 is formed axially longer for manufacturing reasons However, it is advantageous if coupling projection 164 and coupling recess 166 have at least one axial section in which almost the entire circumference of a coupling projection 164 rests against the circumference of the coupling recess 166.

In this way, the flaps can be made individually and mounted with little effort to a flap assembly 139 of any length.

The flap assembly 139, which in the Fig. 1 and 2 four flaps and an actuating member 162 may, in alternative embodiments, as in Fig. 3 shown, only two flaps 137 and 136 and an actuating member 162 or may have only three, five, six or more flaps, each with or without operating member 162nd

As also shown in the figures, the actuating component also has a corresponding form-fit geometry, in this case a coupling recess 166.

As in the Fig. 2 and 3 As shown, each flap shaft section may be surrounded by a housing supplementing member 121 and 123, respectively.

The housing supplemental components 121 and 123 may be substantially identical and differ only in terms of their direction of curvature. For example, the housing supplemental components 121 and 123 may be mirror-inverted with respect to a game mirror symmetry plane orthogonal to the channel axis K.

Then, when each flap has the complementary components 121 and 123 assigned to it, the flaps required to form a flap arrangement 139 can be combined with one another via the form-fit geometries described above, and preferably fixed in a non-detachable manner. The same applies to an actuating member 162, which end to the flap assembly 139 may be connected to transmit torque. Then, the thus formed flap assembly 139 in the housing base member 125, which in Fig. 1 is shown, are used, in which case the respective housing supplemental components 121 and 123 complement the housing base member 125 to a housing with complete flow channel sections.

Between the housing extension components 121 and 123 and the flap shaft sections 137b, 136b, 134b, 132b passing through them, a bearing bush 152 can be provided to improve the relative mobility of the flap and the housing.

In the present case, the flaps, for example the flap 137, may have been cast in a common casting step with the housing supplemental components 121 and 123 in a common mold, for example by injection molding. For this purpose, preferably before the casting step in the mold a set of bearing bushes 152, which after demolding the housing extension members 121 and 123 geometrically separated from the flap shaft portions 137b, etc., placed at corresponding locations in the mold and cast around casting material, in particular encapsulated.

Thus, the supplemental components abut an outer surface 152a of the bushing 152, while the flap shaft portions 137b engage an inner surface 152b (see FIG Fig. 3 ) of the bushings 152 abut.

Claims (4)

1. A valve device (110) for use in motor vehicles, the finished valve device (110) comprising a housing (120), which surrounds a flow duct portion (126, 128, 130, 133), and additionally comprising at least two valves (132, 134, 136, 137) accommodated on the housing (120) and rotatable relative thereto about a valve axis (K) such that, by relative adjustment of the valves (132, 134, 136, 137) relative to the housing (120), the effective flow area of the flow duct portion (126, 128, 130, 133) may be modified, wherein each of the at least two valves (132, 134, 136, 137) comprises two valve shaft portions (132b, 134b, 136b, 137b) which are substantially coaxial relative to the valve axis (K), with which the respective valve (132, 134, 136, 137) is supported rotatably on the housing (120), and comprises a valve body (132a, 134a, 136a, 137a), which is provided axially between the valve shaft portions (132b, 134b, 136b, 137b) and which is accommodated in the flow duct portion (126, 128, 130, 133) to modify the flow area, and wherein further the valve axis is provided at a distance from the valve body, wherein the valve body is formed in a curved manner, so that the valve body in a passage position, in which the flow cross-section is at maximum, abuts against the wall of the housing or osculates against the wall at a small distance,
   characterised in that adjacent valves (132, 134, 136, 137) are produced separately and are coupled together for joint movement by interlocking geometries (164, 166), and in addition to the provided interlocking geometries (164, 166) are connected together operationally non-detachably, by bonding, wherein the two valve shaft portions (132b, 134b, 136b, 137b) are formed in one piece with the valve body (132a, 134a, 136a, 137a) provided axially between them.
2. A valve device according to any one of the preceding claims, characterised in that one of two valve shaft portions (132b, 134b, 136b, 137b) connected to a valve body (132a, 134a, 136a, 137a) comprises a coupling geometry (164 or 166), preferably at a free axial end thereof, and the respective other valve shaft portion (132b, 134b, 136b, 137b) comprises a counter coupling geometry (166 or 164), the coupling geometry (164 or 166) and the counter coupling geometry (166 or 164) being couplable in interlocking manner for joint rotational movement about the valve axis (K).
3. A valve device according to claim 2, characterised in that one geometry (166) of coupling geometry (164 or 166) and counter coupling geometry (166 or 164) comprises a recess (166) and the respective other geometry (164) comprises a torque-transmitting projection (164) introducible into the recess (166), preferably a projection complementary to at least one portion of the recess circumference.
4. A valve device according to either one of claims 2 or 3, characterised in that the valve device (110) comprises an actuating element (162), which may be or is connected to at least one valve (132, 134, 136, 137) to introduce an actuating moment for relative rotation of the valves (132, 134, 136, 137) and the housing (120), the actuating element (162) also comprising one geometry out of coupling geometry (164 or 166) and counter coupling geometry (166 or 164).

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