Inner plunger of electromagnetic valve assembly for clutch of automobile differential and manufacturing method thereof

Abstract

An inner plunger of a clutch solenoid valve assembly for an automobile differential and a manufacturing method thereof. The present invention provides an inner plunger of a clutch solenoid valve assembly for an automobile differential, which contributes to the lightweight and cost saving of the solenoid valve assembly. The inner plunger has a diversified shape and reduces the friction with the inner shell and improves the function. The inner plunger of the clutch solenoid valve assembly for an automobile differential of the present invention is composed of an outer wheel of the inner plunger combined with a winding tube constituting the solenoid valve assembly and an inner wheel combined with the inner shell. The inner wheel is molded from an insulating synthetic resin with excellent moldability. A magnetic metal is inserted as an outer wheel on the outer edge of the inner wheel composed of the synthetic resin constituting the inner plunger, and the synthetic resin of the inner wheel is filled in the limiting groove formed on the outer wheel, so that the gasket formed on the inner wheel supports the outer wheel.

Description

Technical Field

[0001] The present invention relates to an inner plunger of a coil assembly of a clutch solenoid valve of an automobile differential and a manufacturing method thereof, and more specifically to an inner plunger which improves the quality and productivity of the inner plunger constituting the clutch solenoid valve assembly and realizes lightweight, and a manufacturing method thereof. Background Art

[0002] As is known to all, the differential of a car distributes the driving force of the engine differently according to the resistance of the wheels on both sides. A differential case is rotatably arranged inside a storage rack. The differential case is composed of a spyder having a pinion and a side gear meshing with both sides of the pinion. The side gears on both sides are connected to the hubs of the wheels through a drive shaft, thereby transmitting the engine power.

[0003] In the differential of an automobile that performs the functions described above, a solenoid valve assembly that performs the function of operating the clutch utilizes the magnetic force generated by the coil assembly internally to operate the outer plunger and the inner plunger or piston to connect or disconnect the differential locking device.

[0004] When explaining the structure of the inner plunger of the clutch solenoid valve assembly of the differential that performs the existing described function, the inner wheel of the inner plunger tightly connected to the inner shell is made of stainless steel so as not to be affected by magnetic force and move, and the outer wheel is made of magnetic metal for forming the electromagnetic force of the coil.

[0005] As described above, in order to avoid generating magnetic force on the inner wheel and to form magnetic force on the outer wheel, two metals of different materials are formed into one body, and the two metals are welded to each other through this method, or precision processing is required through precision processing technology in each step, and therefore, there is a disadvantage of high manufacturing cost.

[0006] In particular, the inner wheel and the outer wheel of the inner plunger are entirely made of metal, and thus are very heavy.

[0007] Therefore, there is a disadvantage of running counter to the lightweight of the vehicle and reducing the function of the solenoid valve assembly. In the case of stainless steel, due to poor formability, there are many problems in the structure of the inner plunger, such as the shape of the inner plunger can only be limited.

[0008] Prior art literature

[0009] Patent Literature

[0010] Korean Patent Publication No. 10-1983-0003671 (published on June 22, 1983)

[0011] Korean registered patent No. 10-1660641 (registered on September 21, 2016) Summary of the invention

[0012] Technical problem to be solved by the invention

[0013] In order to solve the above-mentioned problems, the purpose is to provide an inner plunger. The inner plunger of the clutch solenoid valve assembly of the automobile differential of the present invention contributes to the lightweight and cost saving of the solenoid valve assembly, and the shape of the inner plunger is diversified and the friction with the inner shell is reduced to enhance the function of the solenoid valve assembly.

[0014] Technical solutions to solve problems

[0015] In order to achieve the above object, the inner plunger of the clutch solenoid valve assembly for the automobile differential of the present invention is composed of an outer wheel combined with a bobbin and an inner wheel combined with an inner housing.

[0016] The inner ring of the inner plunger constructed as described above is molded from an insulating synthetic resin having excellent moldability, and a magnetic metal is inserted into the outer edge of the inner ring made of the synthetic resin constituting the inner plunger to serve as an outer ring.

[0017] In order to firmly connect the outer wheel made of the metal with the inner wheel made of insulating synthetic resin, three or more limit grooves are formed with a narrow entrance and becoming wider towards the inside. The synthetic resin constituting the inner wheel is filled in the limit grooves, and a gasket formed integrally with the inner wheel is formed at the lower end of the outer wheel.

[0018] An undercut groove is formed inside the inner wheel made of the synthetic resin between the upper and lower support parts to reduce friction with the inner shell.

[0019] The manufacturing method of the inner plunger of the solenoid valve assembly for a clutch is through injection molding of a mold, wherein the mold is composed of a mold body and a magnetic core, wherein the mold body has a space for an outer wheel for inserting the inner plunger and a support member for supporting the lower end of the outer wheel at the lower part of the space, and is composed of a space for forming a gasket formed integrally with the inner wheel and a space for molding the inner wheel; the magnetic core has a bottom cut groove molding portion, and a bottom cut groove is formed between the upper and lower support portions of the inner wheel to reduce friction with the inner shell.

[0020] The present invention is characterized in that an outer wheel made of magnetic metal is arranged in the space for the outer wheel of the inner plunger formed by the insert in the mold body constructed as described above, the lower end of the outer wheel is in close contact with the support member, and after a magnetic core having a bottom cut groove forming portion is combined in the middle of the mold body, the inner wheel is formed by non-magnetic synthetic resin by injection molding, and the inner plunger is manufactured.

[0021] Effects of the Invention

[0022] As described above, according to the present invention, the inner wheel of the inner plunger constituting the solenoid valve assembly is made of synthetic resin, and the outer wheel is made of magnetic metal, thereby improving the productivity of the solenoid valve assembly and promoting cost saving.

[0023] In particular, the outer wheel and the inner wheel can be firmly connected by the limiting groove formed on the outer wheel and the gasket formed on the inner wheel, thereby improving the quality of the solenoid valve assembly.

[0024] Furthermore, the inner wheel is molded by injection molding, thereby the shape of the inner plunger is diversified and lightweight, and the friction with the inner shell is reduced to perform a smooth sliding action. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A perspective view showing the structure of the inner plunger of the present invention;

[0026] Figure 2 A cross-sectional view showing the structure of the inner plunger of the present invention;

[0027] Figure 3 for Figure 2 The cross-sectional view of the AA line;

[0028] Figure 4 A partial cross-sectional view showing a solenoid valve assembly provided with an inner plunger of the present invention;

[0029] Figure 5 A partial cross-sectional view showing a mold for manufacturing the inner plunger of the present invention;

[0030] Figure 6 A partial cross-sectional view showing a state of molding the inner plunger of the present invention;

[0031] Figure 7 It is a partial cross-sectional view showing the inner plunger of the present invention being demolded from a mold.

[0032] Description of Reference Numerals

[0033] 1: Inner plunger

[0034] 2: Inner wheel

[0035] 2-1: Bottom cut groove

[0036] 2-2: Support

[0037] 2-3: Support part

[0038] 3: Outer wheel

[0039] 3-1: Limiting slot

[0040] 10: bobbin

[0041] 30: Mold body

[0042] 30-1: Outer wheel insertion space

[0043] 30-2: Inner wheel forming space

[0044] 30-3: Gasket forming space

[0045] 30-4: Support

[0046] 40-1: Bottom cutting groove forming part

[0047] 40: Magnetic core

[0048] 50:Mold DETAILED DESCRIPTION

[0049] Below, the inner plunger and the manufacturing method thereof of the present invention are described in more detail. The description is based on an embodiment of the present invention. The technical idea pursued by the present invention is not limited by the form recorded in this document, but should be understood as including various modifications, equivalents and / or alternatives of the embodiments of the present invention.

[0050] Furthermore, when describing the embodiments of the present invention, even if the effects of the structures of the present invention are not explicitly described, the effects predicted by the corresponding structures should be affirmed.

[0051] The structure of the inner plunger of the clutch solenoid valve assembly for the automobile differential of the present invention will be described in detail below with reference to the accompanying drawings.

[0052] Reference Figures 1 to 4 The inner plunger 1 of the clutch solenoid valve assembly of the present invention includes: an outer wheel 3 of the inner plunger, constituting the solenoid valve assembly, and a winding tube 10 for combining to form electromagnetic force; an inner wheel 2, which is integrally formed with the outer wheel 3 and combined with the inner shell 20, wherein the inner plunger thus constructed plays a role of reciprocating in the inner shell 20 through the electromagnetic force formed on the winding tube 10.

[0053] The inner ring 2 of the inner plunger 1 that functions as described above is made of an insulating synthetic resin having excellent moldability. As described above, the outer ring 3 made of a magnetic metal is inserted into the outer edge of the inner ring 2 made of synthetic resin.

[0054] The outer wheel 3 made of the metal has more than three limit grooves 3-1 distributed at equal angles to be firmly connected with the inner wheel 2 made of insulating synthetic resin. During the insert injection molding process, the limit grooves 3-1 are filled with synthetic resin to form the inner wheel 2.

[0055] The limiting groove 3-1 is of a form with a narrow entrance and a gradually expanding inner side. When the synthetic resin forming the inner wheel 2 is just filled to the limiting groove 3-1, they are firmly combined with each other. Moreover, even if the synthetic resin forming the inner wheel 2 shrinks and deforms, the occurrence of gaps or movement between them can be completely prevented. In particular, the form of the limiting groove 3-1, based on the characteristics of a narrow entrance and a gradually expanding inner side, prevents the inner wheel 2 from shrinking toward the center side, thereby minimizing the occurrence of gaps.

[0056] Moreover, when the inner wheel 2 is formed, a clamping platform 2-4 is formed at the upper end of the outer wheel 3, and a gasket 2-2 is formed at a position corresponding to the lower end of the outer wheel 3 in the form of an integral protrusion from the lower end of the inner wheel 2, supporting the upper and lower ends of the outer wheel 3 and completely preventing the outer wheel from slipping in the upper and lower directions.

[0057] An undercut groove 2-1 is formed between the upper and lower supporting parts 2-3 to reduce friction between the inner wheel 2 made of the synthetic resin and the inner shell.

[0058] Unexplained reference numeral 10 - 1 in the drawings denotes a coil.

[0059] The manufacturing method of the inner plunger of the clutch electromagnetic valve assembly of the present invention is carried out by die and insert molding.

[0060] pass Figure 5 and Figure 6 Next, a mold for insert molding the inner plunger will be described.

[0061] The mold 50 is composed of a mold body 30 and a magnetic core 40. The mold body 30 has an outer wheel insertion space 30-1 for inserting the outer wheel 3 of the inner plunger, a support member 30-4 for supporting the lower end of the outer wheel 3 is formed at the lower part of the outer wheel insertion space 30-1, and is composed of a gasket molding space 30-3 for forming a gasket 2-2 formed integrally with the inner wheel 2 and an inner wheel molding space 30-2 for molding the inner wheel 2 with synthetic resin. The magnetic core 40 is formed with an undercut groove molding part 40-1 to form an undercut groove 2-1 between the upper and lower support parts 2-3 of the inner wheel to reduce the friction between the inner wheel 2 and the inner shell.

[0062] After the outer wheel 3 made of magnetic metal is inserted into the mold 50 constructed as described above, the outer wheel 3 is insert-molded during the process of molding the inner wheel 2 with synthetic resin.

[0063] To be specific, an outer wheel 3 made of magnetic metal is placed in an outer wheel insertion space 30-1 formed in the mold body 30 and used for inserting an inner plunger, and the lower end of the outer wheel is tightly attached to the support member 30-4. After a magnetic core 40 having a bottom cut groove forming portion 40-1 is combined in the middle of the mold body 30, injection molding is performed by an injection molding machine.

[0064] The inner wheel 2 is formed of a non-magnetic synthetic resin by injection molding, the inner plunger 1 having an outer wheel 3 made of a magnetic metal as an insert is molded on the outer edge of the inner wheel 2 made of synthetic resin, and the inner plunger 1 is manufactured by demolding.

[0065] During this process, the limiting groove 3-1 formed in the outer wheel 3 is filled with synthetic resin to form the inner wheel 2, thereby firmly combining the inner wheel 2 and the outer wheel 3. At the same time, the gasket molding space 30-3 formed in the lower part of the mold body 30 is also filled with synthetic resin, and the gasket 2-2 is integrally molded at the lower end of the inner wheel 2, and the insert injection molding is completed in the form of supporting the outer wheel 3.

[0066] The function of the inner plunger of the clutch solenoid valve assembly for the automobile differential of the present invention constructed as described above is described in detail below.

[0067] First, the basic function of the clutch solenoid valve assembly of the automobile differential is specifically described.

[0068] In a state where the bobbin 10 is mounted on an automobile differential and constitutes the differential, when the differential needs to be operated, electricity is supplied to the bobbin 10 to generate electromagnetic force.

[0069] The magnetic force generated by the magnetic field generated in the bobbin 10 causes the inner plunger 1 to move along the inner housing 20 .

[0070] The above-mentioned function is a general function of the clutch solenoid valve assembly for an automobile differential, and the specific description is omitted, and only the function of the structure of the inner plunger is described.

[0071] First, when the inner plunger 1 moves along the inner shell 20 due to the electromagnetic force generated by the magnetic field generated by the winding tube 10, the inner wheel 2 constituting the inner plunger 1 is made of synthetic resin, thereby reducing the influence of the electromagnetic force and improving the responsiveness, thereby helping the inner plunger 1 to move along the inner shell 20.

[0072] In particular, the inner wheel 2 is made of a non-magnetic synthetic resin, and, more simply, a bottom cut groove 2-1 is formed inside the entire inner wheel 2, thereby reducing friction with the inner shell 20 when moving back and forth along the inner shell 20. As a result, the inner plunger is freed from frictional resistance and plays a role in helping to reciprocate along the inner shell 20.

[0073] Furthermore, since the inner wheel 2 of the inner plunger is formed of a non-magnetic synthetic resin, the shape of the inner plunger can be diversified due to its excellent moldability, thereby improving the function and productivity of the shape of the inner plunger.

[0074] A magnetic metal is embedded in the outer edge of the inner wheel 2 of the inner plunger to serve as the outer wheel 3. In particular, since more than three limit grooves 3-1 formed in the outer wheel 3 are filled with a synthetic resin forming the inner wheel 2, the outer wheel and the inner wheel are prevented from being separated in the diameter direction. Furthermore, a clamping table 2-4 and a gasket 2-2 are formed to firmly support the upper and lower ends of the outer wheel 3 to prevent the outer wheel and the inner wheel from being separated in the axial direction, thereby maintaining long-term durability.

[0075] Furthermore, since the outer ring 3 is formed of a magnetic metal inserted into the outer edge of the inner ring 2 of the inner plunger, the electromagnetic force generated in the bobbin 10 is not lost, and thus the inner plunger operates smoothly.

Claims

1. A method for manufacturing an inner plunger of a clutch solenoid valve assembly for a vehicle differential, characterized in that: The inner wheel (2) of the inner plunger is made of insulating synthetic resin by injection molding, and a magnetic metal is inserted into the outer edge of the inner wheel made of the synthetic resin as an outer wheel (3). The outer wheel made of the metal is used to be firmly connected with the inner wheel made of insulating synthetic resin to form three or more limit grooves (3-1) with narrow entrances and inner sides extending in the circumferential direction at equal angles. The synthetic resin constituting the inner wheel (2) is formed by injection molding. The upper and lower ends of the outer wheel are supported by a clamping table (2-4) supporting the upper end of the outer wheel and a gasket (2-2) supporting the lower end of the outer wheel, and an undercut groove (2-1) is formed between the upper and lower support parts (2-3) to reduce friction between the inner surface of the inner wheel made of the synthetic resin and the inner shell. The method for manufacturing the inner plunger of the clutch solenoid valve assembly of the above-mentioned automobile differential comprises the following steps: The step of preparing a mold body (30) and a magnetic core (40), wherein the mold body (30) comprises: an outer wheel insertion space (30-1) for mounting the outer wheel (3) of the inner plunger; a support member (30-4) for supporting the lower end of the outer wheel (3) at the lower part of the space; a gasket molding space (30-3) for forming a gasket (2-2) formed integrally with the inner wheel (2); an inner wheel molding space (30-2) for forming the inner wheel (2) by synthetic resin, and the magnetic core (40) has an undercut groove molding portion (40-1) so that an undercut groove (2-1) is formed between the upper and lower support portions (2-3) of the inner wheel, so as to reduce the friction between the inner wheel (2) and the inner shell; An outer wheel (3) made of magnetic metal is placed in a space (30-1) for installing an outer wheel of an inner plunger formed in a mold body (30) so that the lower end of the outer wheel is tightly mounted on a support member (30-4); A magnetic core (40) having an undercut groove forming portion (40-1) is combined in the middle of the mold body (30); Injection molding is performed by an injection molding machine, whereby an inner wheel (2) is molded from a non-magnetic synthetic resin, and an inner plunger (1) of an outer wheel (3) made of a magnetic metal is molded as an insert at the outer edge of the inner wheel (2) made of synthetic resin, and a synthetic resin for forming the inner wheel (2) is filled in a limiting groove (3-1) formed in the outer wheel (3) to firmly combine the inner wheel (2) and the outer wheel (3), and at the same time, a gasket molding space (30-3) formed in the lower part of the mold body (30) is filled with synthetic resin, and a gasket (2-2) is integrally molded at the lower end of the inner wheel (2) to complete the insert molding in the form of supporting the outer wheel (3); and The inner plunger (1) is demoulded from the mold.

Images