Separator plate, valve, and method for manufacturing the valve

Abstract

This invention provides a separate plate that utilizes the expandability of an expansion member to improve the function of a valve. [Solution] The separate plate (30) is provided between a plurality of valve bodies (10, 20) having liquid flow paths, and comprises a plate body (33) and expansion members (31, 32) that absorb liquid and expand, attached to at least one side of the plate body (33).

Description

[Technical Field]

[0001] The present disclosure relates to a separate plate, a valve, and a method for manufacturing a valve. [Background Art]

[0002] In an automatic transmission, there is a separate plate provided between a plurality of valve bodies.

[0003] The separate plate of Patent Document 1 has a foamed rubber layer adhered to both surfaces or one surface of the separate plate.

[0004] The separate plate of Patent Document 2 is formed into a plate-like laminated structure by coating or adhering an elastic body made of an elastomer such as rubber or plastic, or a composite material such as rubber asbestos or rubber organic fiber on one side surface or both side surfaces of the separate plate to integrate them. [Prior Art Documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Unexamined Patent Publication No. 10-122364 [Patent Document 2] Japanese Patent Publication No. Sho 61-109969 [Summary of the Invention] [Problem to be Solved by the Invention]

[0006] In the development of automobiles and the like that use automatic transmissions, continuous functional improvements / enhancements are required in response to social changes, and of course, such requirements also exist for valves for automatic transmissions. Under such circumstances, the inventors arrived at the idea of utilizing the expandability of an expansion member that absorbs liquid and expands to improve the function of a valve.

[0007] One aspect of this disclosure is based on the above-described idea and provides a separate plate that utilizes the expandability of an expansion member to improve the function of a valve, a valve having the separate plate, and a method for manufacturing the valve, not limited to automatic transmissions. [Means for solving the problem]

[0008] To solve the above problems, a separate plate according to one aspect of the present disclosure is a separate plate provided between a plurality of valve bodies having a liquid flow path, comprising a plate body and an expanding member attached to at least one side of the plate body, which absorbs liquid and expands.

[0009] To solve the above problems, a valve according to one aspect of the present disclosure comprises a plurality of valve bodies having a liquid flow path, and a separator plate provided between the plurality of valve bodies, the separator plate comprising a plate body and an expansion member that absorbs liquid and expands, attached to at least one side of the plate body.

[0010] To solve the above problems, a method for manufacturing a valve according to one aspect of the present disclosure includes the steps of: preparing a separate plate comprising a plate body and an expanding member that absorbs liquid and expands, attached to at least one side of the plate body; preparing a first valve body and a second valve body made of resin and having a liquid channel; arranging the separate plate between the first valve body and the second valve body; and welding the first valve body and the second valve body to each other. [Effects of the Invention]

[0011] According to one aspect of this disclosure, a separate plate or the like that can be used to improve the function of a valve by utilizing the expandability of an expansion member. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic diagram showing an example of the valve configuration related to this disclosure. [Figure 2] This is a schematic diagram showing an example of the configuration of the separate plate related to this disclosure. [Figure 3] This figure shows an example of a top view of the first valve body, the second valve body, and the separate plate. [Figure 4] This figure shows the inside of the first valve body and the second valve body before the first and second components absorb the liquid. [Figure 5] This figure shows the inside of the first valve body and the second valve body after the first and second members have absorbed the liquid. [Figure 6] This is a flowchart relating to the manufacturing method of the valve described herein. [Modes for carrying out the invention]

[0013] Hereinafter, one embodiment of this disclosure will be described in detail with reference to Figure 1, etc.

[0014] (Valve configuration) The configuration of valve 1 according to this disclosure will be described with reference to Figure 1. Figure 1 is a schematic diagram showing an example of the configuration of valve 1 according to this disclosure. In Figure 1, the upper side of the drawing is defined as up, and the lower side of the drawing is defined as down.

[0015] Valve 1 can be applied as a liquid control valve or the like, which regulates the flow of refrigerant within a valve that functions as a cooling water passage, thereby achieving efficient heat exchange. Valve 1 may also be a valve in an automatic transmission. Valve 1 regulates the flow of oil within a valve that functions as a hydraulic passage, thereby efficiently achieving power transmission, lubrication, cooling, and hydraulic operation.

[0016] Valve 1 comprises a first valve body 10, a second valve body 20, and a separate plate 30.

[0017] (First valve body 10, second valve body 20) The shape of the first valve body 10 is not limited. For convenience of description, it will be described as a rectangular parallelepiped below. The outer wall of the first valve body 10 is defined by a side surface 11 and a top surface 12. The first valve body 10 has a plurality of water passage walls therein, and a plurality of liquid flow passages are formed between the plurality of water passage walls 15. The first valve body 10 achieves efficient heat exchange within the valve 1 by adjusting the flow of liquid in the liquid flow passages 16.

[0018] The liquid is not limited, and may be water, oil, LLC (Long Life Coolant), or the like. The water may be, for example, general cooling water used inside machinery. The oil has functions such as cooling, lubrication and friction control for example, and may contain additives according to the purpose. LLC is a type of coolant mainly used in automobile cooling systems. LLC is generally a liquid based on ethylene glycol or propylene glycol, which improves cooling performance and may contain a corrosion inhibitor or an antifoaming agent.

[0019] The first valve body 10 (the side surface 11, the top surface 12, and the water passage walls 15) is not limited, and may be molded from an aluminum alloy, cast iron, resin, or the like. In the following description, it is assumed that the first valve body 10 is molded from resin. The resin may be, for example, polypropylene, polyamide, polycarbonate, polyester, polyphenylene sulfide, or the like. Resin can promote weight reduction and cost reduction of the first valve body 10. In addition, resin is resistant to corrosion and easy to mold, which enables the use of the first valve body 10 under specific conditions.

[0020] The quantity, length, mounting position and the like of the plurality of water passage walls 15 may be appropriately determined based on the design of the first valve body 10.

[0021] The shape of the second valve body 20 is not limited, but for the sake of explanation, it will be described below as a rectangular parallelepiped. The outer wall of the second valve body 20 is defined by the side surface 21 and the bottom surface 22. The second valve body 20 has a plurality of water channel walls 25 inside, and a plurality of liquid flow paths 26 are formed between the plurality of water channel walls 25. The second valve body 20 achieves efficient heat exchange inside the valve 1 by adjusting the flow of liquid in the liquid flow paths 26.

[0022] The liquid used in the second valve body 20 may be the same as the liquid used in the first valve body 10. The second valve body 20 (sides 21, bottom 22, and channel walls 25) may be made of the same material as the first valve body 10 described above. The number, length, and mounting positions of the multiple channel walls 25 may be appropriately determined based on the design of the second valve body 20.

[0023] In Figure 1, the contact points between the channel wall 15 and the separator plate 30, and between the channel wall 25 and the separator plate 30 are indicated by dashed circles. The contact between the channel wall 15 and the separator plate 30 forms a liquid channel 16. The contact between the channel wall 25 and the separator plate 30 forms a liquid channel 26. The mechanism by which the channel walls 15 and 25 contact the separator plate 30 will be described later.

[0024] (Separate plate 30) Next, the configuration of the separate plate 30 according to this disclosure will be described with reference to Figure 2. Figure 2 is a schematic diagram showing an example of the configuration of the separate plate 30 according to this disclosure.

[0025] The separator plate 30 is provided between the first valve body 10 and the second valve body 20. The separator plate 30 separates the liquid flow path 16 formed in the first valve body 10 from the liquid flow path 26 formed in the second valve body 20.

[0026] The separate plate 30 includes a first member 31, a second member 32, and a plate body 33 provided between the first member 31 and the second member 32.

[0027] The first member 31 and the second member 32 are formed from a material that absorbs liquid and expands. The first member 31 and the second member 32 may be, for example, a rubber sponge or a cellulose sponge. Alternatively, the first member 31 and the second member 32 may be a compressible fiber gasket (joint sheet or beater sheet, etc.) that expands (swells) by absorbing oil. Thus, as long as the first member 31 and the second member 32 function as expanding members that absorb liquid and expand, a variety of other materials may be used.

[0028] The first member 31 and the second member 32 may be expandable members, at least one of which absorbs liquid and expands. In this case, the non-expandable member of the first member 31 and the second member 32 may be made of another material (such as rubber or elastomer).

[0029] The first member 31 and the second member 32 may be expandable members, at least one of which expands when heat is applied as an external factor. Examples of materials that expand with heat include plastics (polypropylene, polyethylene, polyvinyl chloride, polycarbonate, polyphenylene sulfide, etc.) and rubber (natural rubber, synthetic rubber, etc.). Any of these materials that expand with heat may be used as appropriate, as long as they perform the function of an expandable member according to the disclosure described later.

[0030] The first member 31 and / or the second member 32, as expansion members, are attached to the plate body 33 as follows. Here, we will explain using the first member 31 as an example. The first member 31 is assumed to be a cellulose sponge. A cellulose sponge is made of natural materials consisting of cellulose derived from pulp and natural fibers (e.g., cotton) added as reinforcing fibers, and has an open-cell structure and excellent water absorption. Here, cellulose has hydrophilic groups (OH) and is known to be chemically compatible with moisture. Therefore, when a cellulose sponge is dried under pressure, hydrogen bonds form between cellulose molecules and it is maintained in a compressed state, while when exposed to moisture from this state, water molecules break the hydrogen bonds between cellulose molecules and it recovers from the compressed state.

[0031] First, the expanded cellulose sponge is cut to a thickness of, for example, 10 mm. Next, the cellulose sponge is dried and compressed to a thickness of, for example, 1 mm. Then, this compressed cellulose sponge is punched out into a predetermined shape to match the shape of the plate body 33. The cellulose sponge thus formed is attached to the plate body 33. When the cellulose sponge attached to the plate body 33 absorbs liquid, it returns to its original thickness of 10 mm. The expansion rate at this time is 10 times. This expansion rate can be appropriately changed depending on the thickness to which the cellulose sponge is compressed.

[0032] Conventionally, separate plates using foamed rubber are known. In such separate plates, the foamed rubber is pre-foamed and adhered to the separate body. Therefore, the foamed rubber provided in conventional separate plates does not expand as much as the first member 31 and second member 32 of this disclosure, even when external factors such as water or heat are applied.

[0033] The plate body 33 may be made of a metal plate such as cast iron, steel plate, or aluminum plate, but it may also be made of a material to which the first member 31 and the second member 32 can be attached, such as resin or synthetic resin.

[0034] Next, an example of the first valve body 10, the second valve body 20, and the separate plate 30 will be explained with reference to Figure 3. Figure 3 is a diagram showing an example of a top view of the first valve body 10, the second valve body 20, and the separate plate 30. The diagram indicated by reference numeral 300 is a top view of the first valve body 10. The diagram indicated by reference numeral 301 is a top view of the second valve body 20. The diagram indicated by reference numeral 302 is a top view of the separate plate 30.

[0035] Referring to the figure shown in reference numeral 300, as an example, the first valve body 10 is square in shape with a cross-section of 150 mm in length and 150 mm in width. The first valve body 10 has a plurality of waterway walls 15, and a plurality of liquid flow paths 16 are formed between the plurality of waterway walls 15. Thus, the first valve body 10 may have a plurality of complex liquid flow paths 16.

[0036] Referring to the figure shown by reference numeral 301, as an example, the second valve body 20 is square in shape with a cross-section of 150 mm in length and 150 mm in width. The second valve body 20 has a plurality of waterway walls 25, and a plurality of liquid flow paths 26 are formed between the plurality of waterway walls 25. Thus, the second valve body 20 may have a plurality of complex liquid flow paths 26.

[0037] The first valve body 10 and the second valve body 20 may be symmetrical with respect to the separate plate 30 (e.g., Figure 3), or they may not be symmetrical (e.g., Figure 1).

[0038] (Formation of liquid channel 16 and liquid channel 26) Next, the process by which the first member 31 and the second member 32 absorb liquid and expand, thereby forming the liquid channels 16 and 26, will be explained with reference to Figures 4 and 5. In Figures 4 and 5, the first member 31 and the second member 32 are assumed to be cellulose sponges that absorb liquid and expand.

[0039] Figure 4 shows the internal state of the first valve body 10 and the second valve body 20 before the first member 31 and the second member 32 absorb the liquid. The first member 31 and the second member 32 are in a compressed state before absorbing the liquid. At this time, the first member 31 is not in contact with the waterway wall 15, and the second member 32 is not in contact with the waterway wall 25.

[0040] Figure 5 shows the interior of the first valve body 10 and the second valve body 20 after the first member 31 and the second member 32 have absorbed the liquid. The first member 31 and the second member 32 have expanded due to the absorption of the liquid. As a result, the first member 31 comes into contact with the water channel wall 15, and the second member 32 comes into contact with the water channel wall 25. In addition, the first member 31 comes into contact with the water channel wall 15, and the contact area is recessed to conform to the shape of the water channel wall 15. Similarly, the second member 32 comes into contact with the water channel wall 25, and the contact area is recessed to conform to the shape of the water channel wall 25.

[0041] As shown in Figure 5, the first member 31 comes into contact with the channel wall 15, and the contact area becomes recessed to conform to the shape of the channel wall 15, thereby forming a liquid channel 16 through which the liquid passes. Similarly, the second member 32 comes into contact with the channel wall 25, and the contact area becomes recessed to conform to the shape of the channel wall 25, thereby forming a liquid channel 26 through which the liquid passes. As can be seen by comparing Figure 4 and Figure 5, the first member 31 absorbs liquid and expands, thereby coming into contact with the channel wall 15 and forming a liquid channel 16. Similarly, the second member 32 absorbs liquid and expands, thereby coming into contact with the channel wall 25 and forming a liquid channel 26.

[0042] (Effect of valve 1) Next, the effects of the valve 1 of this disclosure will be explained.

[0043] The first valve body 10 and the second valve body 20 are made of resin and may be welded to each other. By making the first member 31 and the second member 32 rubber sponge, cellulose sponge, or compressible fiber gasket (joint sheet or beater sheet, etc.), the welding of the first valve body 10 and the second valve body 20 is less likely to be hindered by the first member 31 and the second member 32. Furthermore, with the above configuration, the reaction force at the contact points and surrounding areas between the first valve body 10 and the first member 31, and between the second valve body 20 and the second member 32 is reduced, thereby reducing the possibility of deformation of the first valve body 10 and the second valve body 20. In addition, welding contributes to reducing the weight of the valve 1 compared to mechanical fastening.

[0044] Furthermore, in valve 1, the first member 31 and the second member 32 are attached to the plate body 33 in a compressed state and expand upon absorbing liquid. Since the first member 31 and the second member 32 are in a compressed state and not expanded in their dry state before contact with liquid, they do not hinder the assembly of valve 1 when the separator plate 30 is provided between the first valve body 10 and the second valve body 20. After the separator plate 30 is provided between the first valve body 10 and the second valve body 20 and the first member 31 and the second member 32 come into contact with liquid, the first member 31 and the second member 32 expand to form liquid flow paths 16 and 26.

[0045] In other words, the separate plate 30 can utilize the expandability of the first member 31 and the second member 32, which absorb liquid and expand, to improve the function of the valve 1. One example of the function of the valve 1 is the formation of liquid flow paths 16 and 26 obtained by the expansion of the first member 31 and the second member 32.

[0046] As mentioned above, at least one of the first member 31 and the second member 32 may be an expandable member (such as a cellulose sponge) that absorbs liquid and expands. In this case as well, the side on which the expandable member is provided can be expected to benefit from the improved function of the valve 1 as described above. On the side of the first member 31 and the second member 32 on which the expandable member is not used, the gap between the expandable member and the waterway wall 15 (or waterway wall 25) should be sealed in advance to ensure a seal with the liquid flow path 16 (or liquid flow path 26).

[0047] These effects are easier to understand when compared to conventional valves. For example, suppose a separator plate made of foamed rubber is placed between two resin valve bodies. Then, suppose the two valve bodies are welded together. In this case, the foamed rubber, which has already foamed before coming into contact with the liquid, generates a reaction force when the two valve bodies are welded together, which may make welding the two valve bodies difficult.

[0048] Furthermore, conventional sealing methods for liquid flow channels include gasket sealing and welding sealing, but each can present the following problems.

[0049] In conventional valves, sealing the liquid flow path with a gasket presents the following problems: First, aligning the gasket with the water channel wall is difficult. Second, a sealing surface is required on the water channel wall, which can lead to increased valve size, higher costs, and reduced internal space within the valve due to the increased wall thickness.

[0050] In conventional valves, sealing liquid passages by welding presents several problems. First, aligning the water channel wall with the welded area is difficult. Second, welding the entire complex water channel wall is challenging. Third, the need for a welded surface on the water channel wall increases its thickness, potentially leading to increased valve size, higher costs, and reduced internal space within the valve. Finally, handling foreign matter generated during welding is also difficult.

[0051] The valve 1 according to this disclosure can solve these conventional problems by having the above configuration.

[0052] (Manufacturing method for valve 1) Next, the manufacturing method of valve 1 will be explained with reference to Figure 6. Figure 6 is a flowchart relating to the manufacturing method of the valve according to this disclosure.

[0053] First, a separate plate 30 is prepared, comprising a plate body 33 and a first member 31 and a second member 32 attached to both sides of the plate body 33, which absorb liquid and expand (S10). At least one of the first member 31 and the second member 32 may be made of a material that absorbs liquid and expands.

[0054] Next, a first valve body 10 made of resin and having a liquid passage 16, and a second valve body 20 having a liquid passage 26 are prepared (S20).

[0055] Next, a separator plate 30 is placed between the first valve body 10 and the second valve body 20 (S30).

[0056] Finally, the first valve body 10 and the second valve body 20 are welded together (S40).

[0057] Based on the above, the valve 1 according to this disclosure can be manufactured.

[0058] (summary) A separate plate according to Embodiment 1 of the present disclosure is a separate plate provided between a plurality of valve bodies having a liquid flow path, comprising a plate body and an expansion member attached to at least one side of the plate body, which absorbs liquid and expands.

[0059] By having the above configuration, the separate plate according to Embodiment 1 of the present disclosure can utilize the expandability of the expanding member, which absorbs liquid and expands, to improve the function of the valve on which the separate plate is provided.

[0060] Functions of a valve include, for example, the formation of a liquid flow path obtained by the expansion of an expansion member, or the reduction of reaction force when the expansion member and the valve body come into contact.

[0061] In the separate plate according to Embodiment 2 of the present disclosure, in Embodiment 1 described above, the expansion member is attached to the plate body in a compressed state and expands by absorbing the liquid.

[0062] According to the above configuration, the expansion member is in a compressed state and not expanded in the dry state before contact with the liquid, so it does not hinder assembly when a separator plate is provided between multiple valve bodies. After the separator plate is provided between the multiple valve bodies and the expansion member comes into contact with the liquid, the expansion member expands to form a liquid flow path.

[0063] In Embodiment 3 of the present disclosure, the separate plate, in Embodiment 1 or 2 described above, has an expansion member that is a rubber sponge, a cellulose sponge, a joint sheet, or a beater sheet.

[0064] Rubber sponge, cellulose sponge, joint sheet, or beater sheet can be effectively used as an expanding material that absorbs liquid (water, oil, etc.) and expands.

[0065] In the fourth embodiment of the present disclosure, in any of embodiments 1 to 3, when the expansion member absorbs the liquid flowing through the liquid channel and expands, the expansion member deforms at the contact points with the plurality of valve bodies to match the shape of the plurality of valve bodies.

[0066] According to the above configuration, the separate plate according to Embodiment 4 of the present disclosure can reduce the reaction force at the contact point between the expansion member and the valve body. As a result, the separate plate according to Embodiment 4 of the present disclosure can reduce stress concentration, deformation, wear, and / or damage to the valve body and / or expansion member at and around the contact point.

[0067] The valve according to Embodiment 5 of the present disclosure comprises a plurality of valve bodies having a liquid flow path, and a separator plate provided between the plurality of valve bodies, the separator plate comprising a plate body and an expansion member that absorbs liquid and expands, which is attached to at least one side of the plate body.

[0068] By having the above configuration, the valve according to Embodiment 5 of the present disclosure can utilize the expandability of the expanding member that absorbs liquid and expands to improve the function of the valve.

[0069] In the valve according to embodiment 6 of this disclosure, the plurality of valve bodies are made of resin and are welded to one another.

[0070] According to the above configuration, the valve according to Embodiment 6 of the present disclosure can reduce the generation of reaction forces at the contact points between valve bodies and their surroundings, thereby reducing deformation of the valve bodies. Furthermore, welding can reduce the weight of the valve compared to mechanical fastening.

[0071] Furthermore, when multiple valve bodies (for example, upper and lower valve bodies) are welded together, the expansion member does not expand. Therefore, the expansion member does not hinder the assembly of multiple valve bodies.

[0072] In the valve according to embodiment 7 of the present disclosure, in embodiment 5 or 6 above, the expansion member absorbs the liquid flowing through the liquid channel and expands to form the liquid channel.

[0073] According to the above configuration, the valve according to embodiment 7 of this disclosure can form a liquid flow path by the expansion of the expansion member.

[0074] A method for manufacturing a valve according to Embodiment 8 of the present disclosure includes the steps of: preparing a separate plate comprising a plate body and an expanding member that absorbs liquid and expands, attached to at least one side of the plate body; preparing a first valve body and a second valve body made of resin and having a liquid channel; arranging the separate plate between the first valve body and the second valve body; and welding the first valve body and the second valve body to each other.

[0075] By having the above configuration, the method for manufacturing a valve according to Embodiment 8 of the present disclosure can achieve the same effects as the valve according to Embodiment 6 of the present disclosure.

[0076] This disclosure is not limited to the embodiments described above, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of this disclosure. [Explanation of Symbols]

[0077] 1 valve 10. First valve body 15, 25 Channel wall 16, 26 Liquid flow path 20. Second valve body 30 Separate Plates 31 First Member 32 Second Member 33 Plate body

Claims

1. A separator plate provided between multiple valve bodies having a liquid flow path, The plate body and A separate plate comprising an expandable member that absorbs liquid and expands, attached to at least one side of the plate body.

2. The separate plate according to claim 1, wherein the expansion member is attached to the plate body in a compressed state and expands by absorbing the liquid.

3. The separator plate according to claim 1 or 2, wherein the expansion member is a rubber sponge, a cellulose sponge, a joint sheet, or a beater sheet.

4. The separate plate according to claim 1 or 2, wherein when the expanding member absorbs the liquid flowing through the liquid channel and expands, the expanding member deforms at the contact points with the plurality of valve bodies to match the shape of the plurality of valve bodies.

5. Multiple valve bodies having liquid flow paths, A valve comprising a separator plate provided between a plurality of valve bodies, the separator plate comprising a plate body and an expanding member that absorbs liquid and expands, attached to at least one side of the plate body.

6. The valve according to claim 5, wherein the plurality of valve bodies are made of resin and are welded to one another.

7. The valve according to claim 5 or 6, wherein the expansion member absorbs the liquid flowing through the liquid channel and expands to form the liquid channel.

8. A method for manufacturing a valve, A step of preparing a separate plate comprising a plate body and an expanding member that absorbs liquid and expands, which is attached to at least one side of the plate body, A step of preparing a first valve body and a second valve body, which are made of resin and have a liquid channel, The process involves arranging the separator plate between the first valve body and the second valve body, A method for manufacturing a valve, comprising the step of welding the first valve body and the second valve body to each other.

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