Coil structure, valve device and manufacturing method of coil structure
By filling the coil structure of the electronic expansion valve with elastic resin and using a raised structure for positioning, the problem of easy cracking of the stator coil sealing method during the hot and cold cycle is solved, and a higher seal stability and a simplified processing process is achieved.
Patent Information
- Application Number
- CN202311437321.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-10-31
- Publication Date
- 2025-05-02
AI Technical Summary
The stator coil sealing method of existing electronic expansion valves is prone to fatigue cracking during hot and cold cycle tests, and the processing technology is complicated and the production efficiency is low.
A coil structure is designed in which the stator coil is loaded into the coil housing, and the two are filled with elastic resin to form a gap to buffer the thermal expansion and contraction stress, and positioning and potting are achieved through the raised structure.
This coil structure reduces the risk of cracking of the coil shell during the hot and cold cycle, maintains the insulation and sealing effect, and simplifies the processing technology, avoiding the use of special mold shells.
Smart Images
Figure CN119914745A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of valve technology, and in particular to a coil structure, a valve device and a method for manufacturing the coil structure. Background Art
[0002] The electronic expansion valve includes a stator coil, which has a metal shell. There are currently many ways to seal the stator coil. The first way is to seal the stator coil by plastic injection molding to form an injection molded shell covering the outside of the metal shell; the second way is to set a plastic shell, which is attached to the outside of the metal shell and sealed by potting; the third way is to place the stator coil in a mold for potting to form an elastic resin shell covering the outside of the stator coil.
[0003] Among the above methods, the hard shell formed by injection molding in the first method and the plastic shell and metal shell in the second method are bonded together, which are prone to fatigue cracking during cyclic hot and cold shock tests; in the third method, the cracking of the elastic resin shell is improved, but a large number of mold shells are required as packaging containers during processing, and the shelling remains unchanged, and the production processability is poor. Summary of the invention
[0004] In order to solve the above technical problems, the present application provides a coil structure, a valve device and a method for manufacturing the coil structure, which have the advantages of being not easy to crack and easy to process.
[0005] The coil structure provided in the present application includes a coil shell and a stator coil located inside the coil shell, the stator coil includes a stator shell, a bobbin and a winding wound on the bobbin, the bobbin and the winding are located on the inside of the stator shell, and there is a gap between at least part of the outer surface of the stator shell and the inner surface of the shell, and the gap is filled with elastic resin.
[0006] The present application also provides a valve device, including a valve body and a coil structure, wherein the valve body includes a rotor component, the coil structure is the coil structure described above, and at least a portion of the rotor component is located on the inner side of the stator coil.
[0007] The present application also provides a method for manufacturing a coil structure, which is used to manufacture the coil structure described above, wherein the stator coil is installed in the coil housing and positioned relative to the coil housing, and an elastic resin is poured between the stator coil and the coil housing.
[0008] In the present application, the coil housing and the stator housing are not in contact, or are in partial contact, and the gap between the two is filled with elastic resin. In this way, when the product is subjected to long-term hot and cold cycles, the stress changes caused by the thermal expansion and contraction of the stator housing can be buffered by the elastic resin, and will not directly act or rarely act directly on the coil housing, thereby reducing or avoiding the insulation seal failure caused by cracking of the coil housing. That is, the coil structure has the buffering effect of elastic potting against hot and cold shocks, and has the advantage of easy processing. The coil housing and the stator housing themselves form a potted container, and no special mold shell is required, and no shelling is required. BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 This is a schematic diagram of the valve device in the embodiment of the present application, which is a perspective of axial section;
[0010] Figure 2 for Figure 1 Schematic diagram of the coil structure of the mid-valve device;
[0011] Figure 3 for Figure 2 A magnified view of the middle A area;
[0012] Figure 4 for Figure 2 A schematic diagram of the structure of the coil housing of the mid-coil structure;
[0013] Figure 5 for Figure 4 Top view of the center coil housing.
[0014] Figure 1-5 The accompanying drawings are described as follows:
[0015] 1-Coil structure;
[0016] 11- stator coil; 111- bobbin; 112- winding; 113- electromagnetic plate; 114- stator housing; 115- pin;
[0017] 12-coil housing; 121-first protrusion; 122-second protrusion; 122a-inclined surface; 123-side wall; 1231-main body; 1232-extension part; 124-top wall;
[0018] 13- elastic resin;
[0019] 14-lead component; 141-circuit board; 142-lead;
[0020] 15- Buckle;
[0021] 2-valve body; 21-valve body housing; 22-shaft component; 23-rotor component; 24-nut component; 25-valve seat component. DETAILED DESCRIPTION
[0022] In order to enable those skilled in the art to better understand the solution of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.
[0023] Please refer to Figure 1 , 2 , Figure 1 This is a schematic diagram of the valve device in the embodiment of the present application, which is a perspective of axial section; Figure 2 for Figure 1 Schematic diagram of the coil structure of the mid-valve device.
[0024] The valve device in this embodiment includes a coil structure 1 and a valve body 2. Figure 1 Specifically, it is an electronic expansion valve, and the valve device can also be other types of electronic valves. The valve body 2 includes a valve body shell 21, a shaft component 22, a rotor component 23, a nut component 24 and a valve seat component 25. The coil structure 1 includes a stator coil 11, a coil shell 12, an elastic resin 13, a lead component 14 and a buckle 15, etc. The stator coil 11 has an inner hole located in the middle, and at least part of the rotor component 23 is located on the inner side of the stator coil 11, that is, inserted into the inner hole of the stator coil 11.
[0025] Specifically, the stator coil 11 includes a bobbin 111, a winding 112, an electromagnetic pole plate 113, a stator housing 114, a pin 115, etc. The winding 112 is, for example, an enameled wire. Magnetic poles can be provided on the electromagnetic pole plate 113 and the stator housing 114 to be used as a magnetic conductive plate. The lead component 14 includes a circuit board 141 and a lead 142, which can be welded to the pin 115 in the stator coil 11 through the circuit board 141. The buckle 13 of the coil structure 1 can be fixed to the valve body 2, thereby establishing a connection with the valve body 2.
[0026] The lead part 14 of the coil structure 1 can be connected to the drive controller through the lead 142. After the drive controller is powered on, a pulse drive signal is sent to the stator coil 11, and the winding 112 is powered on to generate a magnetic field. The magnetic poles on the electromagnetic pole plate 113 and the stator housing 114 gather and amplify the magnetic field generated by the winding 111, and attract the corresponding magnetic poles on the rotor part 22. Since the pulse signal generated by the drive controller changes periodically, the stator coil 11 generates a periodically changing magnetic field, thereby driving the rotor part 23 in the valve body 2 to rotate forward or reverse. The rotor part 23 is fixedly connected to the shaft part 22, and the rotor part 23 can drive the shaft part 22 to rotate. The shaft part 22 and the nut part 24 are threadedly matched. When the rotor 23 rotates, the shaft part 22 will move along the axial direction, and then drive the valve needle to realize the opening and closing action of the valve port, and finally can adjust the refrigerant flow in the refrigeration and heating system such as air conditioning.
[0027] The coil structure 1 in this embodiment includes a coil housing 12 and a stator coil 11 located inside the coil housing 12, that is, the stator coil 11 is installed inside the coil housing 12. The stator coil 11 includes a stator housing 114, and the bobbin 111 and the winding 112 are located inside the stator housing 114. That is, the stator housing 114 is located inside the coil housing 12, and it is worth noting that in this embodiment, there is a gap δ between at least part of the stator housing 114 and the coil housing 12, and the gap δ is filled with an elastic resin 13, which can be combined with Figure 3 understand, Figure 3 for Figure 2 Magnified view of area A.
[0028] In this way, the coil housing 12 and the stator housing 114 are not in contact, or are in partial contact, and the gap between the two is filled with elastic resin 13. In this way, when the product is subjected to a long-term hot and cold cycle, the stress changes caused by the thermal expansion and contraction of the stator housing 114 can be buffered by the elastic resin 13, and will not directly act or rarely act directly on the coil housing 12, thereby reducing or avoiding the insulation seal failure caused by the cracking of the coil housing 12. That is, the coil structure 1 in this embodiment has both the buffering of hot and cold shocks by elastic potting and the advantage of easy processing. The coil housing 12 and the stator housing 114 themselves form a potted container, and no special mold shell is required, and no shelling is required. In addition, the elastic resin 13 described in this application can be made of elastic polyurethane, elastic silicone, etc., and this embodiment does not make specific restrictions on this.
[0029] Can continue to combine Figure 4 , 5 understand, Figure 4 for Figure 2 A schematic structural diagram of the coil housing 12 of the middle coil structure 1; Figure 5 for Figure 4 A top view of the center coil housing 12.
[0030] In this embodiment, the coil housing 12 includes a top wall 124 and a side wall 123 arranged around the top wall 124, that is, the side wall 123 is an annular structure. In addition, the bottom of the coil housing 12 is set to be open. Figure 4 In the embodiment, the coil housing 12 has no bottom wall, and the top wall 124 has a recessed portion, and the valve body housing 21 of the valve body 2 can extend into the recessed portion of the top wall 124. It should be noted that in this embodiment, the valve body housing 21 of the valve body 2 can extend into the recessed portion of the top wall 124. Figure 1 For the purpose of defining the orientation from a viewing angle, the top wall 124 is the uppermost wall, the bottom opening faces downward, the top wall 124 of the coil housing 12 is far away from the valve port, and the bottom opening is relatively close to the valve port. Figure 4 The middle coil housing 12 is relatively Figure 1 It is an inverted orientation to facilitate illustrating the structure inside the coil housing 12.
[0031] Figure 4 As can be seen, in this embodiment, the coil housing 12 is provided with a plurality of protrusions on the inner surface of the top wall 124, which can be defined as first protrusions 121. The first protrusions 121 are specifically provided at a position outside the concave portion of the top wall 124. When the liquid elastic resin is poured, the coil housing 12 is Figure 4 When the stator housing 12 is inverted with its opening facing upward, the stator coil 11 can be placed on the inner side of the coil housing 12 from the opening and can be supported on the first protrusion 121.
[0032] Look again Figure 4 , the side wall 123 of the coil housing 12 is also provided with a plurality of protrusions, which can be defined as second protrusions 122, and the plurality of second protrusions 122 are distributed along the circumference of the coil housing 12. After the stator coil 11 is placed from the opening of the coil housing 12 toward the top wall 124, the top of the stator housing 114 of the stator coil 11 will be supported on the first protrusion 121, and the stator housing 114 also has an annular side wall, and the side wall of the stator housing 114 will contact the second protrusion 122 of the side wall 123 of the coil housing 12, so that the first protrusion 121 and the second protrusion 122 can limit the stator coil 11 in the axial and radial directions, so as to achieve the purpose of positioning, so that the stator coil 11 is in a predetermined position. After positioning, the bottom opening of the coil housing 12 is still set upward. At this time, liquid elastic resin can be poured inward from the opening at the bottom of the coil housing 12. After the elastic resin is cured, the gap inside the stator coil 11 and the gap between the stator coil 11 and the coil housing 12 will be filled with elastic resin 13.
[0033] like Figure 2 As shown, in this embodiment, the side wall 123 of the coil housing 12 includes a main body 1231 and an extension 125. The main body 1231 is substantially cylindrical, and one side of the main body 1231 partially protrudes outward to form an extension 1232. The extension 1232 can be Figure 4 In the rectangular cylinder shown, the above-mentioned plug pins 115, the circuit board 141 of the lead component 14, and a part of the lead 142 are all located in the extension part 1232. The stator housing 114 matches the main body 1231 of the coil housing 12, is cylindrical, and the part of the stator housing 114 corresponding to the extension part 1232 has an opening, so that during potting, the liquid elastic resin can enter the extension part 1232, thereby covering the plug pins 115 and the lead component 14, and at the same time, the liquid elastic resin can also enter the stator housing 114 and cover the bobbin 111 and the winding 112.
[0034] Specifically, in this embodiment, the number of the first protrusion 121 and the second protrusion 122 on the inner surface of the coil housing 12 is set to three, and they are evenly distributed along the circumferential direction, so that the positioning of the stator coil 11 is more reliable. It can be known that the number of the first protrusion 121 and the second protrusion 122 can be more. In addition, the first protrusion 121 and the second protrusion 122 can be integrally formed with the coil housing 12, and the coil housing 12 can be made of plastic. The first protrusion 121 and the second protrusion 122 can be integrally formed with the main body of the coil housing 12 during injection molding. The coil housing 12 made of plastic has the advantages of being light, insulating, good in sealing, and easy to process. Accordingly, it is also easy to form the first protrusion 121 and the second protrusion 122.
[0035] In addition, if Figure 3 , 4 As shown, in this embodiment, the lower surface of the second protrusion 122 arranged on the side wall 123 of the coil housing 12 is an inclined surface 122a, and the inclined surface 122a is inclined from the inner surface of the side wall 123 toward the direction close to the top wall 124. In this way, when the stator coil 11 is installed into the coil housing 12, the inclined surface 122a has a certain guiding effect on the entry of the stator coil 11, so as to limit the stator coil 11 from the radial direction after being installed into place.
[0036] Look again Figure 3 The second protrusion 122 arranged on the side wall 123 can extend from the top wall 124 of the coil housing 12 toward the bottom, and only needs to extend a short distance, that is, the first protrusion 121 is arranged close to the top wall 124 and is connected to the top wall 124. In this way, in the process of installing the stator coil 11 into the coil housing 12, the side wall of the stator coil 11 will not start to contact the second protrusion 122 until the stator coil 11 is almost installed in place, so that the stator coil 11 is quickly installed, and it is avoided that the second protrusion 122 is contacted at the beginning of the installation, which may cause interference during the continued installation process.
[0037] In the above embodiment, the first protrusion 121 and the second protrusion 122 are both provided on the inner surface of the coil housing 12. It is known that the protrusion can also be provided on the outer surface of the stator housing 114. In fact, at least one of the stator housing 114 and the coil housing 12 can be provided with a protrusion. For example, the top outer surface and the side wall outer surface of the stator housing 114 are both provided with protrusions, which can contact and position with the top wall 124 and the side wall 123 of the coil housing 12. In other words, as long as any one is provided with a protrusion, the protrusion can contact the other, and the positioning of the coil housing 12 and the stator housing 114 can be achieved. Of course, in this embodiment, the protrusion is provided on the inner surface of the coil housing 12. The coil housing 12 can be made of plastic material, while the stator housing 114 is generally made of metal material. It is easier to process if the protrusion is provided on the coil housing 12.
[0038] When a protrusion is provided on either the coil housing 12 or the stator housing 114, the two are in contact at the position of the protrusion, while at the position other than the protrusion, there is a gap between the inner surface of the coil housing 12 and the outer surface of the stator housing 114, and they are not in contact. It can be seen that the size of the protrusion can be designed to be as small as possible while meeting the positioning requirements, so as to minimize the contact area between the stator housing 114 and the coil housing 12, so that the contact area between the protrusion and the coil housing 12 is very small relative to the total outer surface area of the stator housing 114, or even negligible, and the stress change caused by thermal expansion and contraction of the stator housing 114 can be further reduced to be transmitted to the coil housing 12.
[0039] This embodiment also provides a method for manufacturing a coil structure 1, which is used to manufacture the coil structure 1 of any of the above embodiments, and the manufacturing method is: install the stator coil 11 into the coil housing 12, and position the two relative to each other, and inject elastic resin between the stator coil 11 and the coil housing 12. A core rod can also be provided, and the core rod is inserted into the inner hole of the stator coil 11 and inserted into the recessed portion of the top wall 124 of the coil housing 12 to limit the stator coil 11, and the core rod is fitted with the inner side of the electromagnetic pole plate 13, and the side surface of the recessed portion of the top wall 124 of the coil housing 12 is matched, such as Figure 2 As shown, after potting, the elastic resin 13 covers a portion of the inner side of the stator coil 11 .
[0040] In addition, as described above, the coil housing 12 includes a top wall 124 and a side wall 123 arranged around the top wall 124. The bottom of the coil housing 12 is an opening, and the inner surfaces of the top wall 124 and the side wall 123 are arranged with multiple protrusions. The manufacturing method at this time is: the stator coil 11 is installed into the coil housing 12 from the opening, and supported by the first protrusion 121 of the top wall 124, and the second protrusion 122 of the side wall 123 is in contact with the outer surface of the stator housing 114 of the stator coil 11 for positioning; then, elastic resin is poured into the space between the coil housing 12 and the stator housing 114 from the opening of the coil housing 12.
[0041] In the above embodiment, positioning is achieved by setting the first protrusion 121 and the second protrusion 122, and the stator housing 114 and the coil housing 12 can be potted with elastic resin in a state of almost no contact. It can be seen that positioning is not limited to the method of setting protrusions. For example, the stator coil 11 can be fixed after being loaded into a predetermined position with the help of other tooling to ensure that the stator coil 11 and the coil housing 12 are not in contact in the fixed state. After the potting is completed, the tooling can be removed. However, it can be seen that positioning by setting protrusions, on the one hand, does not require special tooling for positioning, the cost is low, the operation is simple, and it will not interfere with the potting. On the other hand, the positioning of the protrusions is not affected by the installation deviation, the positioning is reliable, and the protrusions only need to play the role of contact positioning, and the size is small. The existence of the protrusions has little effect on the stress transferred from the stator housing 114 to the coil housing 12.
[0042] Specific examples are used herein to illustrate the principles and implementation methods of the present application, and the description of the above embodiments is only used to help understand the method and core ideas of the present application. It should be pointed out that for ordinary technicians in this technical field, without departing from the principles of the present application, several improvements and modifications can be made to the present application, and these improvements and modifications also fall within the scope of protection of the claims of the present application.
Claims
1. A coil structure, characterized in that: It includes a coil housing and a stator coil located inside the coil housing, the stator coil includes a stator housing, a bobbin and a winding wound on the bobbin, the bobbin and the winding are located inside the stator housing, and there is a gap between at least part of the outer surface of the stator housing and the inner surface of the housing, and the gap is filled with elastic resin.
2. The coil structure according to claim 1, characterized in that: At least one of the outer surface of the stator housing and the inner surface of the coil housing is provided with a protrusion for contacting the other, and the outer surface of the stator housing and the inner surface of the coil housing both have gaps at portions other than the protrusion.
3. The coil structure according to claim 2, characterized in that: Along the circumference of the coil housing, a plurality of protrusions are distributed on the inner surface of the side wall of the coil housing.
4. The coil structure according to claim 3, characterized in that: The protrusion arranged on the side wall of the coil housing extends from the top wall of the coil housing toward the bottom.
5. The coil structure according to claim 3, characterized in that: The lower surface of the protrusion arranged on the side wall of the coil housing is an inclined surface, and the inclined surface is inclined from the inner surface of the side wall of the coil housing to a direction close to the top wall of the coil housing.
6. The coil structure according to any one of claims 2 to 5, characterized in that: The coil housing comprises a top wall and a side wall arranged around the top wall. The bottom of the coil housing is an opening, and a plurality of protrusions are arranged on the inner surface of the top wall of the coil housing.
7. The coil structure according to claim 6, characterized in that: The coil housing is made of plastic material, and the protrusion is integrally formed on the inner surface of the coil housing; and / or the stator housing is made of metal material.
8. A valve device, characterized in that: It comprises a valve body and a coil structure, wherein the valve body comprises a rotor component, the coil structure is the coil structure according to any one of claims 1 to 7, and at least a part of the rotor component is located inside the stator coil.
9. A method for manufacturing a coil structure, used for manufacturing the coil structure according to any one of claims 1 to 7, characterized in that: The stator coil is installed in the coil housing and positioned relative to the coil housing, and elastic resin is poured between the stator coil and the coil housing.
10. The method for manufacturing a coil structure according to claim 9, characterized in that: The coil housing comprises a top wall and a side wall arranged around the top wall, the bottom of the coil housing is an opening, and the inner surfaces of the top wall and the side wall are both arranged with a plurality of protrusions; The stator coil is installed into the coil housing through the opening and supported by the protrusion of the top wall, and the protrusion of the side wall is in contact with the outer surface of the stator housing; An elastic resin is poured into the stator coil and the coil housing from the opening.