Throttle valve control device

Abstract

Throttle control device, which includes the following: a throttle valve control arrangement (10) comprising: a case (12); an adapter (20) which is integrally formed with the housing (12); a rotation locking feature (38) which is integrally formed with the housing (12); a recess (40) which is integrally formed as part of the housing (12) such that the recess (40) substantially surrounds the anti-rotation feature (38); several external recesses (64) which are integrally formed as part of the adapter (20); and several sections with reduced thickness, each of the several sections being part of a corresponding one of the several outer recesses (64); wherein the anti-rotation feature (38), the recess (40) and each of the multiple outer recesses (64) are formed integrally with the housing (12) during a forming process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to provisional application 62 / 668,511, filed May 8, 2018. The disclosure of the above application is incorporated herein by reference. FIELD OF THE INVENTION

[0002] The invention generally relates to an electronic throttle body having an integrally formed anti-rotation feature, wherein the anti-rotation feature is formed during a molding or casting process along with a plurality of external recesses to reduce the thickness in various regions of the electronic throttle body, thereby reducing porosity. BACKGROUND OF THE INVENTION

[0003] Electronic throttle bodies are well known, and typically involve a channel or conduit in fluid communication with the throttle body for directing air into the throttle body, which controls the flow of air into an engine. The conduit is commonly connected to the throttle body using a connector, and the conduit is prevented from rotating relative to the throttle body by some type of anti-rotation feature engaged with the conduit.

[0004] Typical throttle bodies have parts manufactured as a single component, but certain parts formed as part of the throttle body are more complex and expensive to manufacture. Some throttle body parts are formed using a casting process, and others are formed using various machining processes. Additional machining processes increase costs and require additional steps during manufacturing. Some throttle bodies have an anti-rotation feature formed during subsequent manufacturing processes, such as machining, or the anti-rotation feature is formed as part of one of several separate components of the throttle assembly that are assembled together.The use of subsequent manufacturing processes or the production of multiple components increases costs, prolongs production time, and increases the overall manufacturing complexity of the throttle body assembly. Furthermore, throttle body assemblies assembled from multiple components are generally unable to meet stringent packaging requirements.

[0005] Some throttle bodies are manufactured using an injection molding or die casting process, which often results in undesirable porosity when metals are used due to the wall thickness of certain parts of the throttle body.

[0006] The documents DE 10 2018 217 241 A1, US 5 341 773 A, DE 198 03 356 A1 and DE 698 16 410 T2 concern throttle valve arrangements.

[0007] Accordingly, there is a need for a throttle body that is easier to manufacture, includes an anti-rotation feature formed without the use of additional machining processes, and further includes one or more features that reduce porosity. SUMMARY OF THE INVENTION

[0008] An object of the invention is to provide a throttle body that is easy to manufacture, includes an anti-rotation feature, can be formed without the use of additional machining processes, and further includes one or more features that reduce porosity. This object is achieved by the independent claims. Preferred embodiments are subject to the dependent claims. In one embodiment, the present invention is a throttle control assembly including a housing, an adapter formed integrally with the housing, and an anti-rotation feature formed integrally with the housing. A recess is integrally formed as part of the housing such that the recess substantially surrounds the anti-rotation feature. A first tapered portion and a second tapered portion are both integrally formed with the adapter.

[0009] A first groove is integrally formed as part of the adapter such that the first groove partially surrounds the adapter, the first groove being adjacent to the second tapered portion, and a rib portion is integrally formed as part of the adapter such that the rib portion partially surrounds the adapter and the rib portion is adjacent to the first groove. Further, the throttle control assembly includes a plurality of outer recesses integrally formed as part of the adapter, and each of the outer recesses includes a plurality of regions having a reduced thickness. In one embodiment, each of these regions reduces porosity in the adapter, and each of these regions reduces the amount of casting material and reduces the weight of the throttle control assembly. Reducing the amount of casting material reduces costs, and the weight reduction improves fuel economy.The anti-rotation feature, the recess, and each of the plurality of outer recesses are formed integrally with the housing during a molding process.

[0010] In one embodiment, the throttle control assembly further includes a housing portion that is part of the adapter and a central passage. A portion of the central passage extends through the housing portion of the adapter, and a portion of the central passage extends through the housing.

[0011] In one embodiment, the throttle control assembly includes a second groove formed integrally as part of the housing such that the second groove partially surrounds the housing, and the rib portion is disposed between the first and second grooves.

[0012] In one embodiment, a portion of the plurality of outer recesses is formed as part of the second tapered portion, and a portion of the plurality of outer recesses is formed as part of the rib portion.

[0013] Further areas of applicability of the present invention will become apparent from the detailed description provided below. It should be understood that, while the detailed description and specific examples indicate the preferred embodiment of the invention, they are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be better understood from the detailed description and the accompanying drawings, in which: Fig. 1 is a first perspective view of an electronic throttle body having an anti-rotation feature in accordance with embodiments of the present invention; Fig. 2 is a second perspective view of an electronic throttle body having an anti-rotation feature in accordance with embodiments of the present invention; Fig. 3 is a side view of an electronic throttle body having an anti-rotation feature in accordance with embodiments of the present invention; Fig. 4 is an enlarged side view of a portion of an electronic throttle body having an anti-rotation feature in accordance with embodiments of the present invention; Fig. 5 is a third perspective view of an electronic throttle body with an anti-rotation feature according to embodiments of the present invention; and Fig. 6 is an enlarged perspective view of a portion of an electronic throttle body having an anti-rotation feature in accordance with embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The following description of the preferred embodiment(s) is merely exemplary and is in no way intended to limit the invention, its application, or uses.

[0016] An electronic throttle control assembly with an integrally formed anti-rotation feature according to the present invention is shown generally at 10 in the figures. The assembly 10 includes a throttle body housing 12, and formed as part of the housing 12 is a central passage, shown generally at 14, through which air flows during operation of the assembly 10. A shaft (not shown) is provided extending through part of the central passage 14, the shaft being rotatable, and a valve plate (also not shown) is attached to the shaft.

[0017] The shaft is mounted in a bore 16 formed as part of the housing 12. The housing 12 further contains a cavity, and an actuator (not shown) is disposed within the cavity. The actuator is used to control a gear assembly, which is then connected to the shaft, thereby controlling the position of the valve plate in the central passage 14. By changing the position of the valve plate, the airflow through the central passage 14 is controlled.

[0018] The assembly 10 further includes an adapter, generally shown at 20, the adapter 20 being suitable for connection to a conduit. The adapter 20 includes a housing portion 22, and formed as part of the housing portion 22 is an opening 24 that forms part of the central passage 14 and has a substantially constant inner diameter. The remainder of the central passage 14 is formed as part of the housing 12 and extends therethrough. The housing portion 22 further includes a first diameter portion 26 located adjacent a first tapered portion 28. The housing portion 22 further includes a second tapered portion 30 located adjacent the first diameter portion 26. Each of the tapered portions 28, 30 facilitates the connection between a conduit and the throttle control assembly 10.During assembly, the housing portion 22 is inserted into an end portion of the conduit, and the tapered portions 28, 30 and the anti-rotation feature 38 ensure proper alignment between the housing portion 22 and the conduit during the assembly process at the facility where the throttle control assembly 10 is manufactured.

[0019] A first groove 32 is located adjacent to the second tapered portion 30, a rib portion 34 is located adjacent to the first groove 32, and a second groove 36 is located adjacent to the rib portion 34. The anti-rotation feature 38 is formed integrally with the housing 12 and the adapter 20, protrudes from the housing 12, and is located adjacent to the housing portion 22.

[0020] A recess, shown generally at 40, is formed integrally with the housing 12 and the adapter 20. A portion of the recess 40 is located adjacent a first end 42A of the first groove 32 and a first end 44A of the rib portion 34. A portion of the recess 40 is further located adjacent a second end 42B of the first groove 32 and a second end 44B of the rib portion 34. An end portion 46 of the second groove 36 further terminates in a bottom wall 62 located adjacent a portion of the recess 40. The grooves 32, 36 and the rib portion 34 are also used to connect the conduit to the assembly 10. The grooves 32, 36 can receive a snap ring, a clamp, or any other type of connecting device for securing the conduit to the assembly 10.

[0021] The throttle control assembly 10 is formed using various manufacturing processes. The housing 12, the second groove 36, the anti-rotation feature 38, and the recess 40 are formed during a casting process.

[0022] After the casting process is complete, various portions of the throttle control assembly 10 still need to be formed. A machining process is then used to form the housing portion 22, the first groove 32, and the rib portion 34. The recess 40 ensures adequate space for various tools used as part of the machining process to form the housing portion 22, the first groove 32, and the rib portion 34. The second groove 36 partially surrounds the housing 12, and the first groove 32 and the rib portion 34 almost completely surround the housing portion 22, except for the areas occupied by the anti-rotation feature 38 and the recess 40.

[0023] The second groove 36 (formed during the casting process) does not completely surround the housing 12. An outer portion 48 partially surrounds the housing 12 in an area along the outside of the housing 12 (where the second groove 36 was not formed during the casting process), so that the outer portion 48 is located adjacent to a portion of the rib portion 34 in a similar manner to the second groove 36. The outer portion 48 is formed during the machining process along with the housing portion 22, the first groove 32, and the rib portion 34. A portion of the outer portion 48 extends along the outside of the housing 12 in an area where the portion having the cavity is integrally formed with the housing 12. Another portion of the outer portion 48 also extends along the outside of the housing 12 along an area where a gear housing 50 is integrally formed with the housing 12.

[0024] An axis 52 extends through the central passage 14, and the anti-rotation feature 38 can be formed at many possible locations along the outer surface of the housing 12 during the casting process.

[0025] The second tapered portion 30 and the rib portion 34 do not completely surround the housing portion 22. Also, a plurality of outer recesses 64 are integrally formed as part of the housing portion 22, as shown in the Fig.1-2. The outer recesses 64 are formed during the casting process to reduce the thickness of the material in the areas of the second tapered section 30 and the rib section 34, thereby reducing the risk of porosity during casting. Reducing the material used in the areas of the second tapered section 30 and the rib section 34 also reduces the cost and overall weight of the throttle control assembly 10.

[0026] After forming the throttle control assembly 10, there are multiple spring contact points 54 in the first groove 32 between the second tapered portion 30 and the rib portion 34, and a spring clip (not shown) may be used to connect the conduit to the housing portion 22. The spring contact points 54 are located in areas of the second tapered portion 30 and the rib portion 34 where material still remains after forming the outer recesses 64 (that is, the portions of the second tapered portion 30 and the rib portion 34 where the outer recesses 64 were not formed). In this embodiment, there are four spring contact points 54, but it is within the scope of the invention that the first groove 32 may have more or fewer spring contact points 54 depending on how many outer recesses 64 are formed as part of the housing portion 22.

[0027] By forming the anti-rotation feature 38 during the casting process and forming the entire throttle control assembly 10 as a single component, the number of steps in the manufacturing process of the throttle control assembly 10 is reduced, thereby reducing manufacturing costs.

[0028] Furthermore, the dimensions of the anti-rotation feature 38 can be varied to suit different packaging and design requirements as well as different types of cables with different connecting devices.

[0029] Although it has been described above that the housing 12, the second groove 36, the anti-rotation feature 38, and the recess 40 are formed during a molding process, it is within the scope of the invention that these components may also be formed during other processes, such as, but not limited to, metal injection molding and 3D printing.

[0030] The description of the invention is merely exemplary, and thus variations that do not depart from the spirit of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

[1] Throttle control device comprising: a throttle control arrangement (10) comprising: a housing (12); an adapter (20) formed integrally with the housing (12); an anti-rotation feature (38) formed integrally with the housing (12); a recess (40) formed integrally as part of the housing (12) such that the recess (40) substantially surrounds the anti-rotation feature (38); a plurality of outer recesses (64) formed integrally as part of the adapter (20); and a plurality of reduced thickness sections, each of the plurality of sections being part of a corresponding one of the plurality of outer recesses (64); wherein the anti-rotation feature (38), the recess (40) and each of the plurality of outer recesses (64) are formed integrally with the housing (12) during a molding process. [2] The throttle control device of claim 1, wherein the adapter (20) further comprises a first tapered portion (28), the first tapered portion (28) facilitating attachment of a conduit to the adapter (20). [3] A throttle control device according to claim 1, further comprising: a second tapered portion (30) formed integrally with the adapter (20); a first groove (32) which is integrally formed as part of the adapter (20), wherein the first groove (32) is located adjacent to the second tapered portion (30); and a rib portion (34) integrally formed as part of the adapter (20) such that the rib portion (34) is located adjacent to the first groove (32); wherein the first groove (32) and the rib portion (34) partially surround the adapter (20). [4] Throttle control device according to claim 3, further comprising: a second groove (36) formed integrally as part of the housing (12) such that the second groove (36) is located adjacent to the rib portion (34); wherein the second groove (36) partially surrounds the housing (12). [5] The throttle control device of claim 1, wherein each of said plurality of sections reduces porosity in said adapter (20). [6] Throttle control device according to claim 1, further comprising: a housing portion (22) which is part of the adapter (20); and a central passage (14); wherein a portion of the central passage (14) extends through the housing portion (22) of the adapter (20) and a portion of the central passage (14) extends through the housing (12). [7] The throttle control device of claim 1, wherein a portion of the plurality of outer recesses (64) is formed as part of the second tapered portion (30). [8] The throttle control device of claim 1, wherein a portion of the plurality of outer recesses (64) is formed as part of the rib portion (34). [9] Throttle control device (10) comprising: a housing (12); an adapter (20) formed integrally with the housing (12); an anti-rotation feature (38) formed integrally with the housing (12); a recess (40) formed integrally as part of the housing (12) such that the recess (40) substantially surrounds the anti-rotation feature (38); a first tapered portion (28) formed integrally with the adapter (20); a second tapered portion (30) formed integrally with the adapter (20); a first groove (32) formed integrally as part of the adapter (20) such that the first groove (32) partially surrounds the adapter (20), the first groove (32) being located adjacent the second tapered portion (30); a rib portion (34) integrally formed as part of the adapter (20) such that the rib portion (34) partially surrounds the adapter (20) and the rib portion (34) is located adjacent to the first groove (32); a plurality of outer recesses (64) formed integrally as part of the adapter (20); and a plurality of reduced thickness sections, each of the plurality of sections being part of a corresponding one of the plurality of outer recesses (64); wherein the anti-rotation feature (38), the recess (40) and each of the plurality of outer recesses (64) are formed integrally with the housing (12) during a molding process. [10] The throttle control assembly (10) of claim 9, wherein each of said plurality of sections reduces porosity in said adapter (20). [11] Throttle control assembly (10) according to claim 9, further comprising: a housing portion (22) which is part of the adapter (20); and a central passage (14); wherein a portion of the central passage (14) extends through the housing portion (22) of the adapter (20) and a portion of the central passage (14) extends through the housing (12). [12] Throttle control assembly (10) according to claim 9, further comprising: a second groove (36) formed integrally as part of the housing (12) such that the second groove (36) partially surrounds the housing (12); wherein the rib portion (34) is arranged between the first groove (32) and the second groove (36). [13] The throttle control assembly (10) of claim 9, wherein a portion of the plurality of outer recesses (64) is formed as part of the second tapered portion (30) and a portion of the plurality of outer recesses (64) is formed as part of the rib portion (34).

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