Fluid valve with magnetic drive unit

Abstract

The invention relates to a fluid valve comprising a drive unit (2) for a valve closure body, the drive unit (2) having a core (3), an electrical coil (4) partially surrounding the core (3) and an armature (5) which can be moved by energizing the coil (4) and the resulting magnetic force, the drive unit (2) having a base body (6) on which an accommodation (6.1) for the coil (4), at least one insertion opening (6.2) for the core (3) and an armature accommodation (6.3) are provided, the core (3) inserted into the at least one insertion opening (6.2) being fixed on the base body (6) by means of an encapsulation (7) such that the core (3) is in a defined position relative to the armature accommodation (6.3).

Description

Technical Field

[0001] The present invention relates to a fluid valve having a magnetic drive unit, wherein the valve closing body can be moved by means of the drive unit. Background Technology

[0002] Fluid valves with magnetic actuators are known. In particular, fluid valves are known to cause linear motion (i.e., displacement) of the armature by applying a magnetic field. This linear motion is converted into pivoting motion of the valve closing body. Depending on the pivoting motion of the valve closing body, the fluid passage in the fluid valve is opened or closed.

[0003] A major drawback of known fluid valves is their complex manufacturing process, resulting in high cost. Furthermore, at least one end of the armature must be calibrated by adjusting the stop to achieve defined valve-closing behavior. This further increases the cost of the fluid valve. Summary of the Invention

[0004] Therefore, the purpose of this invention is to provide a fluid valve that is inexpensive and can provide defined switching or shut-off behavior without requiring final adjustments.

[0005] According to one aspect, a fluid valve is disclosed, including a drive unit for a valve closing body. The drive unit has a core, an electrical coil partially surrounding the core, and an armature movable by energizing the coil and the resulting magnetic force. The armature is connected to the valve closing body such that movement of the armature causes movement of the valve closing body. The drive unit has a base having a housing for the coil, at least one insertion port for the core, and an armature housing. The base preferably forms a support structure for the drive unit. The armature housing houses and supports the armature. The core, inserted into at least one insertion port, is fixed to the base by an encapsulation portion, such that the core is in a defined position relative to the armature housing.

[0006] The technical advantage of this fluid valve is that, during the secondary molding process to fix the insertion position of the core in the base, the position of the core relative to the armature housing can be determined very precisely, thereby simplifying the manufacturing process of the fluid valve and avoiding the need to readjust the position of the core relative to the armature.

[0007] According to one embodiment, the core is fixed by an encapsulation portion to prevent displacement relative to the substrate, thereby positioning at least one pole face of the core in a predetermined position relative to the armature receiving portion. This positions the armature inserted into the armature receiving portion relative to at least one pole face in a defined position, thereby allowing a defined force to be introduced into the armature, or in other words, achieving a defined switching behavior. Preferably, the position of at least one pole face relative to the core is selected such that, when the coil is energized, i.e., when the armature moves toward the pole face, an air gap remains between the armature and the pole face. This air gap is preferably less than 1 mm, and particularly preferably less than 0.5 mm.

[0008] According to one embodiment, the encapsulation portion surrounds the core and coil like a cover and establishes a connection with the substrate. This ensures that the core and coil are protected from external factors by being encapsulated, and also allows the core to be fixed in the desired insertion position.

[0009] According to one embodiment, the core is U-shaped. This forms a yoke-like or stirrup-like core with a pair of pole faces. The two pole faces are arranged in a plane, spaced apart from each other. This allows a closed magnetic circuit to be achieved using an armature.

[0010] According to one embodiment, the armature spans a pair of pole faces of the core and is pivotable about a pivot extending perpendicular to the longitudinal axis of the armature by energizing the coil. In other words, the pivot is parallel to the plane containing the pole faces of the core. The pivot is preferably located below the pair of pole faces, which are arranged one above the other when viewed from the longitudinal axis of the armature. This allows the armature to pivot relative to the plane of the pole faces, thereby closing the magnetic circuit when the coil is energized.

[0011] According to one embodiment, the armature can pivot relative to the plane containing the pole faces of the core. This is achieved by pivoting the armature towards the pole faces in an energized state to a first pivot position, and then positioning it to a second pivot position in an de-energized state. In the second pivot position, the longitudinal axis of the armature extends obliquely from the plane of the pole faces. Preferably, the pivoting away from this plane is achieved by means of the elastic force of a spring that deforms when the coil is energized. In the first pivot position, the armature is preferably separated from the pole faces by a small distance, for example, less than 1 mm, particularly less than 0.5 mm, i.e., not directly in contact with the pole faces. In the first pivot position, the magnetic circuit is closed. In the second pivot position, the distance between the armature and the pole faces (particularly the farthest pole face) is at most 5 mm, particularly 4 mm, 3 mm, or 2 mm, and particularly preferably 1 mm or less, for example, 0.8 mm or essentially 0.8 mm. Due to the small stroke of the pivoting movement, a larger force is introduced into the armature, thereby generating a larger adjusting force.

[0012] According to one embodiment, the core is formed of multiple flat metal pieces arranged in a stacked manner. This allows the core to be manufactured at a lower cost compared to a core made in one piece.

[0013] According to one embodiment, the flat member is a stamped sheet metal component. Using a stamped sheet metal component further supports low-cost manufacturing of the core.

[0014] According to one embodiment, the flat members of the core are electrically bonded together. This gives the core similar electrical or magnetic properties to those of a core formed integrally from a single piece of material.

[0015] According to one embodiment, the armature housing has a support point for the armature, at which the armature is supported in a pivotable manner relative to the base. This allows the armature to pivot toward the pole face when energized and to pivot away from the pole face when de-energized. This pivoting movement is transmitted to the valve closing body, causing it to perform an opening or closing movement.

[0016] According to one embodiment, the support point is a sliding support point, which forms a surface support (Flächenlager) for the arc-shaped support portion of the armature. This simplifies the structure of the drive unit, as support is achieved by inserting the armature into the armature housing.

[0017] According to one embodiment, the substrate is formed from a plastic injection molded part. This plastic injection molded part forms a basic component of the drive unit. Using a plastic injection molded part helps to achieve low-cost manufacturing of the substrate.

[0018] According to one embodiment, the substrate has a tubular insertion portion for a core into which the core can be partially inserted. The insertion portion further forms a receiving portion, into which the winding of the coil is positioned. In this way, the substrate forms both a guiding structure for the insertable core and a coil receiving portion. This decisively simplifies and clarifies the manufacturing process of the fluid valve's drive unit.

[0019] According to one embodiment, the substrate has an insertion port for metal contacts configured to make electrical contact with a coil. This allows the metal contacts to be directly fixed to the substrate, further simplifying and clarifying the manufacturing process, as the metal contacts are precisely positioned and fixed to the substrate before subsequent plastic secondary molding.

[0020] According to one embodiment, the armature housing is shell-shaped, having a bottom region and a wall region protruding from the bottom region. On one hand, the armature housing forms a housing space for the armature; on the other hand, the armature housing serves as an interface for fixing a valve housing or for supporting a valve closing body.

[0021] According to another aspect, a method for manufacturing a fluid valve actuator is disclosed. The method includes the following steps: -Provide the substrate and core; - Wrap an electrical conductor around a substrate to form an electrical coil; - Insert the core into the substrate; - The core and coil are formed in a secondary molding process using injection molding, so that the resulting encapsulation portion forms a partial connection with the substrate. The injection molding tool used in the injection molding process creates a defined insertion position of the core relative to the armature receiving portion provided on the substrate.

[0022] For the purposes of this invention, expressions such as "approximately", "substantially", or "about" refer to deviations from the relevant precise value by + / -10%, preferably + / -5%, and / or deviations in the form of variations that are not significant to the function.

[0023] Further aspects, advantages, and applications of the invention will also be apparent from the following description of the embodiments and the accompanying drawings. All described and / or illustrated features, whether individually or in any combination, and regardless of how they are summarized or retrospectively referenced in the claims, are, in principle, the subject matter of this invention. The content of the claims also forms part of this specification. Attached Figure Description

[0024] The present invention will now be described in detail with reference to the accompanying drawings, which illustrate several embodiments. Figure 1 For along Figure 2 The illustrated longitudinal section of the fluid valve is taken by the AA section shown. Figure 2 For along Figure 1 The BB section shown is an illustrative cross-section of the actuation unit of the fluid valve. Figure 3 An illustrative perspective view of the base of the actuation unit for a fluid valve; Figure 4 This is an illustrative perspective view of the base of the actuation unit of a fluid valve, on which coils and contact elements are provided; Figure 5 An exemplary perspective view of the drive unit of the fluid valve base, and a flat piece or core stack to be inserted therein, which forms part of a stacked core; Figure 6 This is an exemplary perspective view of the base of the actuation unit for a fluid valve, showing a coil, contact elements, and an inserted core lamination. Figure 7 An illustrative block diagram showing the manufacturing steps of an actuation unit for a fluid valve. Detailed Implementation

[0025] Figure 1 and Figure 2 Cross-sectional views of fluid valve 1 are shown, in which... Figure 1 A longitudinal cross-sectional view centered through the fluid valve, as shown below. Figure 2 As shown by the AA section line in the diagram. Figure 2 This is along the lateral upper edge of fluid valve 1. Figure 1 A cross-sectional view perpendicular to the BB section line.

[0026] The fluid valve 1 includes an actuation unit 2 for a valve closing body 9 and a valve housing 10, the valve housing having at least one fluid passage. The valve closing body 9 extends into the valve housing 10 and is coupled to the actuation unit 2, enabling the valve closing body 9 to move, particularly pivot, by means of the actuation unit. Specifically, the valve closing body 9 can be in first and second pivot positions to open or close the valve opening depending on the pivot position. In the illustrated embodiment, the valve housing 10 has three ports, wherein a pair of ports are always in fluid communication with each other depending on the pivot position of the valve closing body 9. In contrast, the fluid valve 1 may also have only two ports, wherein the fluid connection between the ports is open or closed depending on the pivot position of the valve closing body 9.

[0027] Fluid valve 1 has the following function: the drive unit 2 is designed to influence the pivoting position of armature 5. The drive unit 2 is an electromagnetic drive unit; that is, when the coil 4 of the drive unit is energized, a magnetic force is generated, and the armature 5 moves from a second pivoting position to a first pivoting position using this magnetic force. The first pivoting position is illustrated in the diagram. Figure 1 The first pivot position is maintained while coil 4 is energized. Armature 5 is preferably spring-loaded so that it returns to the second pivot position after coil 4 is de-energized.

[0028] like Figure 1 As shown, the valve closing body 9 is connected to the armature 5, thereby allowing the valve closing body 9 to move via the armature 5, particularly to pivot. Specifically, the valve closing body 9 is in a first or second position in the valve housing 10 depending on the pivoting position of the armature 5, thereby defining the valve position or, in other words, defining the opening or closing of the fluid passage.

[0029] The structure of the drive unit 2 of fluid valve 1 will be described in detail below.

[0030] The drive unit 2 includes a base 6. The base 6 forms the basic supporting structure of the drive unit 2. The base is preferably designed as an injection-molded part, particularly a plastic injection-molded part. The base 6 has a tubular or substantially tubular receiving portion 6.1 for the coil 4. A first insertion port 6.2 is formed within the receiving portion 6.1, such as... Figure 5 As shown, one side of the U-shaped core 3 can be inserted into it.

[0031] The base 6 further includes an armature housing 6.3. This armature housing 6.3 is directly connected to the housing 6.1 and is designed to support the armature 5 in a manner that allows the armature 5 to pivot. The armature housing 6.3 is shell-shaped, particularly rectangular, and has a bottom region 6.3.2 and a plurality of wall regions 6.3.3. The wall regions 6.3.3 are connected to the bottom region, surround the bottom region 6.3.2 along their periphery, and protrude from the bottom region 6.3.2 toward the side away from the housing 6.1.

[0032] A second insertion port 6.2' is provided in the bottom area 6.3.2, such as... Figure 5 As shown, the second side of the U-shaped core 3 can be inserted therein. Therefore, the U-shaped core 3 is yoke-shaped, with one side of the core surrounded by the coil 4, so that when the coil 4 is energized, the core 3 and the armature 5 spanning the pole faces 3.1, 3.1' of the core 3 will form a closed magnetic circuit.

[0033] On the side of the receiving portion 6.1 away from the armature receiving portion 6.3, the base 6 has insertion ports for metal contacts 8. The metal contacts 8 can be inserted into these insertion ports in a form-fit manner. The metal contacts are shown in... Figure 1 and Figures 4 to 6 In the middle, metal contact 8 is used for electrical contact with coil 4.

[0034] In the illustrated embodiment, the core 3 is formed from a plurality of stacked flat members 3.2. Specifically, the flat members 3.2 are stamped parts made of metal flats, particularly metal sheets. To form the core 3, these flat members are stacked together with their flat surfaces overlapping, thereby forming a stack containing a plurality of flat members 3.2, which is arranged to form the core 3 (a so-called stacked core). The flat members 3.2 are electrically conductively attached directly to each other; therefore, the stacked core has the same or substantially the same electrical characteristics as a one-piece core. This significantly reduces the manufacturing cost of the core 3.

[0035] The armature 5 preferably also has a stack formed of multiple laminated flat members. These flat members are referred to below as armature laminations. In particular, the armature laminations are stamped parts made of metal flat members, especially metal sheets. To form the armature 5, these armature laminations are stacked together with their flat surfaces overlapping, thereby forming a stack containing multiple armature laminations (a so-called laminated armature). The armature laminations are electrically bonded directly to each other, therefore, the laminated armature 5 has the same or substantially the same electrical characteristics as a one-piece armature. This significantly reduces the manufacturing cost of the armature 5.

[0036] In a preferred embodiment, the armature 5 includes an armature support 5.2. The armature support 5.2 at least partially surrounds the stack of armature laminations formed by the stacked arms and secures these armature laminations relative to each other. The armature support 5.2 is preferably an injection-molded part, particularly a plastic injection-molded part.

[0037] The armature support 5.2 has a support portion 5.1 at the free end of the armature 5. With the aid of this support portion 5.1, the armature 5 is pivotally supported in the armature housing portion 6.3 of the base 6.

[0038] The support portion 5.1 has a sliding surface with an arc-shaped cross-section on its outer periphery, thus forming a sliding support point. The sliding surface abuts against the recessed support point 6.3.1 of the armature housing portion 6.3 in a form-fit manner; the shape of this support point is opposite to that of the support portion 5.1. This allows the armature 5 to pivot about a pivot SA, which is parallel to the plane containing the pole faces 3.1 and 3.1' of the core, or in other words, (pivot SA) is perpendicular to the longitudinal axis LA of the armature 5. This allows the armature 5 to move towards or away from the core. Figure 1 The upper pole face 3.1 shown in the figure is pivoted.

[0039] In order to apply the largest possible magnetic force to the armature 5 and to enable repeatable switching operation of the fluid valve 1 without the need for readjustment or adjustment after manufacturing, it is advantageous to position the core 3 as precisely as possible inside the base 6. In particular, it is advantageous to determine the insertion position of the core 3 within the base 6 as precisely and repeatably as possible during manufacturing, because this will determine the position of the pole faces 3.1, 3.1' relative to the support point 6.3.1 of the armature housing 6.3, and thus also the position of the pole faces relative to the armature 5.

[0040] In order to fix the core 3 or the flat member 3.2 forming the core 3 relative to the base 6, at least a portion of the portion of the base 6 protruding from the armature receiving portion 6.3 and the inserted core 3 and coil 4 are subjected to secondary forming. This not only fixes the insertion position of the core 3 or the flat member 3.2 forming the core 3 relative to the base 6, but also encapsulates the core 3 and coil 4 in an electrically insulating manner.

[0041] Preferably, the insertion position of the core 3 is adjusted so that the armature housing 6.3 and the electrode surfaces 3.1, 3.1' abut against the contact area of ​​the injection molding tool used for secondary molding. This enables repeatable insertion of the core 3 in the substrate 6, thereby allowing precise adjustment of the position of the electrode surfaces 3.1, 3.1' relative to the support point 6.3.1 of the armature housing 6.3.

[0042] The following will use Figure 7 The flowchart shown illustrates the steps of the manufacturing method for fluid valve 1.

[0043] First, a substrate 6 and a core 3 are provided (S10). If the core 3 is formed of a plurality of flat members 3.2, then these flat members 3.2 are provided.

[0044] An electrical conductor is then wound around the receiving portion 6.1 of the substrate 6 to generate an electrical coil 4 on the substrate 6 (S11).

[0045] After the coil 4 is manufactured, the core 3 is inserted into the base 6 (S12). The core is inserted into at least one insertion port 6.2, 6.2' formed on the base 6 from the side away from the armature receiving portion 6.3. Preferably, a plurality of flat pieces 3.2 forming the core 3 are inserted into the base 6, stacked adjacent to each other in a stacked manner.

[0046] After inserting the core 3 or forming the flat part 3.2 of the core 3, the core 3 and the coil 4 are subjected to secondary molding using an injection molding process (S13). This forms a partial connection between the encapsulation portion 7 produced during injection molding and the base 6, thereby permanently fixing the insertion position of the core 3 in the base 6. An injection molding tool is used during the injection molding process, designed to create a defined insertion position of the core 3 relative to the armature receiving portion 6.3 provided on the base 6. Specifically, the injection molding tool has a defined contact surface for the armature receiving portion 6.3 of the base 6 and contact surfaces for the pole faces 3.1, 3.1' of the core 3. Therefore, due to this injection molding tool, the core 3 is always in a defined position relative to the armature receiving portion 6.3 or the armature support point 6.3.1 formed thereon.

[0047] The present invention has been described above using embodiments. It is understood that many modifications and variations can be made without departing from the scope of protection defined in the claims.

[0048] Explanation of reference numerals in the attached figures 1 fluid valve 2 drive units 3-core 3.1, 3.1' polar surfaces 3.2 Flat parts 4 coils 5 armature 5.1 Support section 5.2 Armature support 6 matrix 6.1 Reception Section 6.2 First insertion port 6.2' Second insertion port 6.3 Armature Reception 6.3.1 Support Point 6.3.2 Bottom Area 6.3.3 Wall area 6.4 Insertion Port 7-pack sealing section 8 metal contacts 9 valve closing body 10 Valve housing The longitudinal axis of the LA armature The pivot of the SA armature

Claims

1. A fluid valve comprising a drive unit (2) for a valve closing body (9), the drive unit (2) having a core (3), an electric coil (4) partially surrounding the core (3), and an armature (5) capable of movement by energizing the coil (4) and the magnetic force generated therefrom, the drive unit (2) having a base (6) having a receiving portion (6.1) for the coil (4), at least one insertion port (6.2) for the core (3), and an armature receiving portion (6.3) thereon, wherein the core (3) inserted into the at least one insertion port (6.2) is fixed to the base (6) by means of an encapsulation portion (7) such that the core (3) is in a defined position relative to the armature receiving portion (6.3); The armature housing (6.3) has a support point (6.3.1) for the armature (5), the armature (5) being supported at the support point in a manner that allows it to pivot relative to the base (6); The substrate (6) has a tubular insertion portion for the core (3), the core (3) being partially inserted into the insertion portion, wherein the insertion portion further forms the receiving portion (6.1) for the winding of the coil (4) to be disposed.

2. The fluid valve according to claim 1, characterized in that, The core (3) is fixed by the encapsulation portion (7) to prevent displacement relative to the substrate (6), thereby placing at least one pole face (3.1, 3.1') of the core (3) in a predetermined position relative to the armature housing portion (6.3).

3. The fluid valve according to claim 1 or 2, characterized in that, The encapsulation portion (7) surrounds the core portion (3) and the coil (4) like a cover, and is connected to the substrate (6).

4. The fluid valve according to claim 1, characterized in that, The core (3) is U-shaped.

5. The fluid valve according to claim 1, characterized in that, The armature (5) spans a pair of pole faces (3.1, 3.1') of the core (3) and is capable of pivoting about a pivot (SA) that extends perpendicular to the longitudinal axis (LA) of the armature (5) by energizing the coil (4).

6. The fluid valve according to claim 1, characterized in that, The core (3) is formed by multiple metal flat pieces (3.2) arranged in a stacked manner.

7. The fluid valve according to claim 6, characterized in that, The flat material (3.2) is a stamped metal component.

8. The fluid valve according to claim 6 or 7, characterized in that, The flat members (3.2) of the core (3) are electrically attached together.

9. The fluid valve according to claim 1, characterized in that, The support point (6.3.1) is a sliding support point, which forms a surface support for the arc-shaped support portion (5.1) of the armature (5).

10. The fluid valve according to claim 1, characterized in that, The substrate (6) is formed by plastic injection molding.

11. The fluid valve according to claim 1, characterized in that, The substrate (6) has an insertion port (6.4) for a metal contact (8) which is configured to make electrical contact with the coil (4).

12. The fluid valve according to claim 1, characterized in that, The armature housing (6.3) is shell-shaped, having a bottom region (6.3.2) and a wall region (6.3.3) protruding from the bottom region.

13. A method for manufacturing a fluid valve drive unit, comprising the following steps: - Provides a substrate (6) and a core (3); - An electrical conductor is wound around the substrate (6) to form an electrical coil (4); - Insert the core (3) into the base (6); - The core (3) and the coil (4) are subjected to secondary molding using an injection molding process, such that the resulting encapsulation portion (7) forms a partial connection with the substrate (6), wherein the core (3) is positioned relative to the armature receiving portion (6.3) provided on the substrate (6) by means of an injection molding tool used in the injection molding process; and The armature housing (6.3) has a support point (6.3.1) for the armature (5), which can be moved by energizing the coil (4) and the resulting magnetic force, and the armature (5) is supported at the support point in a manner that allows it to pivot relative to the base (6).

Images