A manifold module and a method of overmolding

Abstract

The present application relates to a manifold module and a secondary injection molding method, wherein a first flow channel, a second flow channel, a third flow channel and a plastic sealing plate are arranged, and the contact surface of the plastic sealing plate is a secondary injection molding product, the contact surface is located at the connection of the first inlet, the second inlet and the third inlet and the three-way valve, so as to ensure the connection of the three-way valve and each flow channel of the manifold assembly, and ensure the flow of the substances contained in the flow channel. Moreover, the glass fiber content ratio of the plastic used for the first injection molding of the contact surface is lower than that of the plastic used for the second injection molding, so that the contact surface can withstand extrusion and will not appear flat concave and convex due to shrinkage after plastic molding, and finally effectively improve the flatness, and overcome the technical defects of the shrinkage of the contact surface between the manifold and the valve in the manifold module of the prior art.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, and more specifically, to a manifold module and a secondary injection molding method. Background Technology

[0002] As a key technology for ensuring vehicle safety, enhancing driving experience, and achieving energy conservation and environmental protection, automotive thermal management technology is becoming increasingly important. In recent years, automotive manifold modules, with their high efficiency, integration, and intelligence, have been widely used and developed in automotive thermal management technology, becoming an important force driving innovation in automotive thermal management technology.

[0003] The manifold module integrates multiple thermal management components, including a manifold and valves. The number of valve ports matches the number of flow channels in the manifold, and both the manifold and valves have mating contact surfaces. This module must not only ensure smooth communication between the manifold and valves but also prevent the mating contact surfaces on the manifold from being deformed by pressure. However, the manifold's contact panel is a single-injection molded panel. Such injection-molded panels are prone to fluctuations in flatness due to unstable processes, ultimately leading to module leakage due to a series of reasons.

[0004] To address the flatness fluctuations of the injection-molded surface, existing technologies employ methods such as reducing the contact area between the manifold and the valve, or increasing the thickness of the injection-molded surface. However, both methods suffer from the technical drawback of shrinkage of the contact area between the manifold and the valve, making it difficult to meet the technical requirements for a tight seal between them. Summary of the Invention

[0005] The technical problem to be solved by the present invention is how to overcome the technical defect of shrinkage of the contact surface between the manifold and the valve in the prior art manifold module while ensuring smooth connection between the manifold and the valve. In order to overcome the above defects of the prior art, the present invention provides a manifold module and a secondary injection molding method, including a manifold module and a secondary injection molding method for the manifold module.

[0006] The present invention provides a manifold module, including a manifold assembly and a three-way valve;

[0007] The manifold assembly includes a support base and a first flow channel, a second flow channel, a third flow channel, and a plastic sealing plate disposed on the support base. The first flow channel has a first inlet, the second flow channel has a second inlet, and the third flow channel has a third inlet.

[0008] The first flow channel, the second flow channel, and the third flow channel all pass through the plastic sealing plate, and the first inlet, the second inlet, and the third inlet are respectively connected to one valve port of the three-way valve;

[0009] The plastic sealing plate is an inner and outer structure composed of an inner plate and an outer plate. The outer plate is provided with a contact surface that matches the contact surface of the three-way valve. The contact surface is flush with the first inlet, the second inlet and the third inlet.

[0010] Both the inner and outer layers are made of plastic, wherein the glass fiber content of the plastic used in the inner layer is lower than that of the plastic used in the outer layer.

[0011] The manifold module disclosed in this invention, by setting a first flow channel, a second flow channel, a third flow channel, and a molding compound, wherein the molding compound has an inner and outer structure composed of an inner layer plate and an outer layer plate, and the contact surface of the outer layer plate is flush with the first inlet, the second inlet, and the third inlet, thereby ensuring the connection between the three-way valve and each flow channel of the manifold assembly, and guaranteeing the flow of the substances contained in the flow channels. Furthermore, because the glass fiber content of the plastic used in the inner layer plate is lower than that of the plastic used in the outer layer plate, the molding compound can withstand extrusion and will not have unevenness due to shrinkage after plastic molding, ultimately effectively improving the flatness of the contact surface and overcoming the technical defect of shrinkage of the contact surface between the manifold and the valve in existing manifold modules.

[0012] In one possible implementation, the second flow channel is provided with a fourth inlet, through which the second flow channel passes and the fourth inlet is located at the bottom of the support; this solution can ensure that the second flow channel is fixed in the support and that the flow channel is unobstructed.

[0013] In one possible implementation, the first inlet, the second inlet, and the third inlet are laterally spaced on the outer layer plate; this solution can ensure the sealing contact characteristics of the plastic sealing plate for the three-way valve and manifold assembly while ensuring communication with the three-way valve.

[0014] In one possible implementation, the outer layer is made of plastic with a glass fiber content of 18%-19%, and the inner layer is made of plastic with a glass fiber content of 20%-24%. This design ensures that the inner and outer layers of the plastic sealant are structurally compatible, preventing deformation due to high temperatures and thus ensuring the sealing and flatness of their contact surfaces.

[0015] In one possible implementation, the outer layer plate is provided with multiple insert ports, and the three-way valve is provided with multiple inserts that fit tightly with the insert ports; this arrangement ensures that the three-way valve and the sealing plate are tightly connected, ensuring a tight seal.

[0016] In one possible implementation, the first flow channel, the second flow channel, the third flow channel, and the molding plate are fixed by crisscrossing reinforcing ribs, thereby ensuring that the relative positions of the first flow channel, the third flow channel, and the molding plate are fixed, ensuring the stability of the manifold assembly structure; ensuring the stability of the manifold assembly structure, and ensuring the flatness of the molding plate.

[0017] Another technical solution of the present invention is to provide a secondary injection molding method for a manifold module, comprising the following steps:

[0018] S1: Prepare a support base and a three-way valve, and set a first flow channel, a second flow channel and a third flow channel on the support base, respectively connecting the first flow channel, the second flow channel and the third flow channel to the three valve ports of the three-way valve;

[0019] S2: Using plastic with a glass fiber content of 18%-19% as raw material, an outer layer plate with a preset thickness and an internal cavity is formed on the support seat by injection molding machine and injection mold, extending from the contact surface of the three-way valve along the first flow channel, the second flow channel and the third flow channel. A plurality of injection ports for secondary injection are formed through the outer layer plate, and the plurality of injection ports are all connected to the cavity.

[0020] S3: Using plastic with a glass fiber content of 20%-24% as raw material, injection molding is performed through several injection ports using an injection molding machine to fill the cavity to form an inner layer plate, thereby obtaining a plastic seal plate.

[0021] The secondary injection molding method for manifold modules disclosed in this invention forms a molded plate through secondary injection molding. In this process, the panel formed by the first injection molding has cavities for secondary injection molding and several injection ports, thereby changing the injection molding process to improve the flatness and contour of the molded plate, ultimately improving the airtightness of the manifold module assembly. Compared with other flatness improvement methods, this method has the advantages of requiring less modification, not altering the final shape of the manifold module, saving mold repair costs, and ultimately achieving better improvement results.

[0022] In one possible implementation, step S1 includes the following steps:

[0023] S11: Prepare a support base, a first flow channel, a second flow channel, and a third flow channel. The first flow channel is provided with a first inlet, the second flow channel is provided with a second inlet and a fourth inlet, and the third flow channel is provided with a third inlet.

[0024] S12: Add mounting positions to the support base to fix the first flow channel, the second flow channel and the third flow channel respectively;

[0025] S13: A through hole that fits tightly with the second flow channel is vertically through the upper surface to the lower surface of the support base, and the second flow channel passes through the through hole and the fourth inlet is located at the bottom of the support base;

[0026] S14: Prepare a three-way valve whose port distribution of the communicating vessel is adapted to the distribution of the first inlet, the second inlet, and the third inlet, and connect the first inlet, the second inlet, and the third inlet to the three valve ports of the communicating vessel of the three-way valve respectively. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the manifold assembly structure disclosed in Embodiment 1 of the present invention;

[0028] Figure 2 This is a front view of the manifold assembly disclosed in Embodiment 1 of the present invention;

[0029] Figure 3 This is a top view of the manifold assembly disclosed in Embodiment 1 of the present invention;

[0030] Figure 4 This is a bottom view of the manifold assembly disclosed in Embodiment 1 of the present invention;

[0031] Figure 5 This is a schematic diagram of the three-way valve structure disclosed in Embodiment 1 of the present invention;

[0032] Figure 6 This is a schematic diagram of the molding compound structure disclosed in Embodiment 1 of the present invention;

[0033] Figure 7 This is a flowchart of the method disclosed in Embodiment 2 of the present invention;

[0034] Figure 8 This is a schematic diagram of a single-injection molded product in Embodiment 2 of the present invention;

[0035] Figure 9 This is a schematic diagram of the secondary injection molding result in Embodiment 2 of the present invention.

[0036] Explanation of reference numerals in the attached figures:

[0037] 1. Manifold assembly; 11. Support base; 12. First flow channel; 121. First inlet; 122. Fifth inlet; 13. Second flow channel; 131. Second inlet; 132. Fourth inlet; 14. Third flow channel; 141. Third inlet; 142. Sixth inlet; 15. Molding plate; 151. Inner layer plate; 152. Outer layer plate; 153. Contact surface; 154. Insert port; 2. Three-way valve; 21. Communicator; 211. Insert; 22. Controller; 3. Reinforcing rib; 4. Injection port. Detailed Implementation

[0038] First, those skilled in the art should understand that these embodiments are merely used to explain the technical principles of the embodiments of this application and are not intended to limit the scope of protection of the embodiments of this application. Those skilled in the art can make adjustments as needed to adapt to specific application scenarios.

[0039] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application based on the specific circumstances.

[0040] Furthermore, the term "tight fit" refers to a type of fit where there is no gap between a hole and a shaft, rod, or tube, resulting in a tight connection. Therefore, when it is mentioned that one component is connected to another component in a tight fit manner, it means that one component has a through hole or bore that fits tightly with the rod or tube of the other component, thereby achieving the connection between the two.

[0041] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a lower horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0042] The present application will be further described in detail below using two embodiments, in conjunction with the accompanying drawings and specific examples. Example

[0043] See Figures 1-6 As shown, this application discloses a manifold module, including a manifold assembly 1 and a three-way valve 2. The manifold assembly 1 includes a support base 11 and a first flow channel 12, a second flow channel 13, a third flow channel 14, and a plastic sealing plate 15 disposed on the support base 11. The first flow channel 12 has a first inlet 121 and a fifth inlet 122. See also... Figure 4 As shown, the second flow channel 13 passes through the support base 11. The second flow channel 13 has a second inlet 131 and a fourth inlet 132, with the fourth inlet 132 located at the bottom of the support base 11. The third flow channel 14 has a third inlet 141 and a sixth inlet 142, with the sixth inlet 142 opening upwards.

[0044] See Figure 1 , Figure 2 and Figure 6 As shown, in this embodiment, the first flow channel 12, the second flow channel 13, and the third flow channel 14 all pass through the molding compound 15. The molding compound 15 is an inner and outer structure composed of an inner layer plate 151 and an outer layer plate 152, and its structural schematic diagram is shown below. Figure 6 As shown. The outer plate 152 is provided with a contact surface 153 that mates with the contact surface of the three-way valve 2. The contact surface 153 is flush with the first inlet 121, the second inlet 131 and the third inlet 141, and the first inlet 121, the second inlet 131 and the third inlet 141 are distributed laterally at intervals on the contact surface 153.

[0045] See Figure 5 As shown, in this embodiment, the three-way valve 2 includes a communicating vessel 21 and a controller 22 connected to the communicating vessel 21. The controller 22 is used to regulate the flow rate in the pipe of the communicating vessel 21, and the contact surface of the three-way valve 2 is disposed on the communicating vessel 21. See also Figure 2 and Figure 5 As shown, the outer plate 152 has multiple insert ports 154, and in this embodiment, four are provided, distributed at the top corners of the outer plate 152. The communicating vessel 21 has multiple inserts 211 that fit tightly with the insert ports 154, thereby achieving a tight fit connection. The communicating vessel 21 of the three-way valve 2 has three valve ports, with the first inlet 121, the second inlet 131, and the third inlet 141 each connected to one valve port.

[0046] See Figure 6 As shown, in this embodiment, both the inner layer 151 and the outer layer 152 are made of plastic. The glass fiber content of the plastic used in the inner layer 151 is lower than that of the plastic used in the outer layer 152. Specifically, the glass fiber content of the plastic used in the outer layer 152 is 18%–19%, and the glass fiber content of the plastic used in the inner layer 151 is 20%–24%.

[0047] See Figure 1 and Figure 3 As shown, in this embodiment, the first flow channel 12, the second flow channel 13, the third flow channel 14 and the molding plate 15 are fixed by crisscrossing reinforcing ribs 3, thereby further ensuring the stability of the manifold assembly structure and guaranteeing the flatness of the molding plate.

[0048] The manifold module disclosed in this embodiment, by setting a first flow channel 12, a second flow channel 13, a third flow channel 14 and a plastic sealing plate 15, and the contact surface 153 of the plastic sealing plate 15 and the contact surface of the communicating vessel 21 of the three-way valve 2 cooperate with each other, and since the glass fiber content of the plastic used in the inner layer plate 151 is lower than that of the plastic used in the outer layer plate 152, the contact surface 153 of the plastic sealing plate 15, as the contact surface, will not have unevenness due to shrinkage after plastic molding, thus effectively improving the flatness and overcoming the technical defect of shrinkage of the contact surface between the manifold and the valve in the prior art manifold module. Example

[0049] See Figures 7-9 As shown, this embodiment further discloses a secondary injection molding method for a manifold module, see [link to documentation]. Figure 6 As shown, the method includes the following steps:

[0050] S1: Prepare a support base 11 and a three-way valve 2, and set a first flow channel 12, a second flow channel 13 and a third flow channel 14 on the support base 11, and connect the first flow channel 12, the second flow channel 13 and the third flow channel 14 to the three valve ports of the three-way valve 2 respectively.

[0051] Specifically, in this embodiment, step S1 includes the following steps:

[0052] S11: Prepare a support base 11, a first flow channel 12, a second flow channel 13, and a third flow channel 14. The first flow channel 12 is provided with a first inlet 121, the second flow channel 13 is provided with a second inlet 131 and a fourth inlet 132, and the third flow channel 14 is provided with a third inlet 141.

[0053] S12: Add mounting positions on the support base 11 to fix the first flow channel 12, the second flow channel 13 and the third flow channel 14 respectively.

[0054] S13: A through hole is vertically extending from the upper surface to the lower surface of the support 11, which is tightly fitted with the second flow channel 13, and the second flow channel 13 passes through the through hole and the fourth inlet 132 is located at the bottom of the support 11.

[0055] S14: Prepare a three-way valve 2 whose port distribution of the communicating vessel 21 is adapted to the distribution of the first inlet 121, the second inlet 131, and the third inlet 141, and connect the first inlet 121, the second inlet 131, and the third inlet 141 to the three valve ports of the communicating vessel 21 of the three-way valve 2 in a one-to-one manner.

[0056] S2: Using plastic with a glass fiber content of 18%-19% as raw material, an outer layer plate 152 with a preset thickness and containing a cavity is formed by injection molding on the support base 11 from the contact surface of the three-way valve 2 along the first flow channel 12, the second flow channel 13 and the third flow channel 14 through the injection molding machine and injection mold. Several injection ports 4 are formed through the outer layer plate 152 for secondary injection molding. All of the injection ports 4 are connected to the cavity.

[0057] S3: Using plastic with a glass fiber content of 20%-24% as raw material, the cavity is filled by injection molding through several injection ports 4 using an injection molding machine to form an inner layer plate 151, thereby obtaining a plastic sealing plate 15 and obtaining a manifold module.

[0058] As a specific example, outer layer 152 is obtained using plastics with glass fiber content ratios of 18%, 18.5%, and 19%, respectively. The outer layer 152 has pre-drilled cavities for secondary injection molding and 10 injection ports 4. These 10 injection ports 4 are distributed in a top row and a bottom row of 5. The molding process for plastics with a glass fiber content ratio of 18% is as follows: Figure 8 As shown. Subsequently, plastics with glass fiber content ratios of 20%, 22%, and 24% were used as raw materials, respectively, and injection molding was performed through several injection ports 4 using an injection molding machine to fill the cavities. The glass fiber content ratio was 20%, and the final product was as shown. Figure 9 As shown.

[0059] The secondary injection molding method for the manifold module disclosed in this embodiment forms a plastic seal plate 15 through secondary injection molding. During this process, the first injection molding panel has a cavity for secondary injection and several injection ports 4, thereby changing the injection molding process to improve the flatness and contour of the plastic seal plate, ultimately improving the airtightness of the manifold module assembly. Compared with other flatness improvement methods, this method has the advantages of requiring less modification, not altering the final shape of the manifold module, saving mold repair costs, and ultimately achieving better improvement results.

[0060] In the description of the embodiments of this application, it should be noted that the terms "inner" and "outer" and other terms indicating direction or positional relationship are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this application.

[0061] In the description of this application, the references to terms such as "an embodiment," "some embodiments," "in this embodiment," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0062] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A manifold module, comprising a manifold assembly (1) and a three-way valve (2); the manifold assembly (1) comprises a support base (11) and a first flow channel (12), a second flow channel (13), a third flow channel (14) and a plastic sealing plate (15) arranged on the support base (11), the first flow channel (12) is provided with a first inlet (121), the second flow channel (13) is provided with a second inlet (131), and the third flow channel (14) is provided with a third inlet (141); the first flow channel (12), the second flow channel (13) and the third flow channel (14) all pass through the plastic sealing plate (15), and the first inlet (121), the second inlet (131) and the third inlet (141) are connected with a valve port of the three-way valve (2) respectively; characterized in that, the plastic sealing plate (15) is an inner-outer structure composed of an inner layer plate (151) and an outer layer plate (152), the outer layer plate (152) is provided with a contact surface (153) matched with a contact surface of the three-way valve (2), and the contact surface (153) is flush with the first inlet (121), the second inlet (131) and the third inlet (141); the materials of the inner layer plate (151) and the outer layer plate (152) are both plastic, wherein the glass fiber content ratio of the plastic used for the inner layer plate (151) is lower than that of the plastic used for the outer layer plate (152); the inner layer plate (151) and the outer layer plate (152) are formed by injection molding, and in the forming process, the outer layer plate (152) is first formed by injection molding to form an inner cavity, and then the inner layer plate (151) is formed by filling the cavity.

2. The manifold module of claim 1, wherein, the second flow channel (13) is provided with a fourth inlet (132), the second flow channel (13) passes through the support base (11), and the fourth inlet (132) is located at the bottom of the support base (11).

3. The manifold module of claim 2, wherein, the first inlet (121), the second inlet (131) and the third inlet (141) are horizontally and spacedly distributed on the contact surface (153).

4. The manifold module of any one of claims 1-3, wherein, the outer layer plate (152) is provided with a plurality of insert ports (154), and the three-way valve (2) is provided with a plurality of insert pieces (211) tightly matched with the insert ports (154).

5. The manifold module of claim 4, wherein, the first flow channel (12), the second flow channel (13), the third flow channel (14) and the plastic sealing plate (15) are fixed by longitudinal and transverse intersecting reinforcing ribs (3).

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