Electric valve and machining method of electric valve
By using copper-clad aluminum or aluminum winding wires, combined with the design of the connecting frame and ramp portion, the problem of high cost of winding wires in the electronic expansion valve is solved, and the effect of reducing costs and maintaining conductive performance is achieved.
Patent Information
- Application Number
- CN202311823479.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-27
- Publication Date
- 2025-06-27
AI Technical Summary
In existing electronic expansion valves, the winding wires of the drive coils are made of copper enameled wires, resulting in higher costs.
Use copper-clad aluminum or aluminum winding wires, and a connecting frame and a ramp are installed in the coil components. The winding wire, winding wire frame and pin are connected by injection molding to resist the extrusion pressure and impact force during resin injection and prevent the winding wire from breaking.
It reduces the usage and weight of winding wires, reduces costs, and ensures the conductive performance of winding wires, meeting the needs of electronic expansion valves.
Smart Images
Figure CN120212306A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of valves, and in particular to an electric valve and a processing method thereof. Background Art
[0002] An electronic expansion valve includes a drive coil and a valve body component. When the drive coil is energized, it generates excitation to drive a rotor component in the valve body component to rotate, and then controls the control of a valve shaft component over a valve port. Currently, the winding wire of the drive coil is made of copper enameled wire. Since copper enameled wire is relatively expensive, the winding has always been a component with a relatively high cost in the electronic expansion valve. Summary of the Invention
[0003] The purpose of the present application is to provide an electric valve and a processing method thereof, which can reduce costs.
[0004] The present application provides an electric valve, including a coil component. The coil component includes a winding wire frame, a winding wire wound around the winding wire frame, and a pin. The winding wire frame is further provided with a connection frame for connecting the pin, and the winding wire is connected to the pin; the connection frame is provided with a ramp portion, and the winding wire extends along and abuts against the ramp portion and is connected to the pin; the winding wire is made of copper-clad aluminum material or aluminum material, and the winding wire frame, the winding wire, and the pin are injection-molded and connected.
[0005] The present application also provides a processing method for an electric valve, which is used to process the electric valve described in any one of the above; the method includes the following steps:
[0006] Lead out the winding wire on the winding wire frame and abut it against the ramp portion, and connect the winding wire to the corresponding pin;
[0007] Assemble to form a coil assembly;
[0008] Put the coil assembly into an injection mold and inject resin for injection molding.
[0009] In the electric valve of the present application, the coil component is provided with a connection frame, and the connection frame is provided with a ramp portion. After the winding wire extends out from the winding wire frame, it can extend along and abut against the ramp portion and be connected to the pin. The winding wire abuts against the ramp portion, and the ramp portion has a supporting effect on the winding wire. In this way, during the injection molding process, it can resist the extrusion force and impact force during resin injection, and prevent the winding wire from breaking or being damaged. On this basis, the winding wire can be made of copper-clad aluminum or aluminum material, which is more brittle than the conventional copper enameled wire, but has a lighter weight and the electrical conductivity meets the use requirements of the electric valve, so as to reduce the usage amount of the winding wire, reduce the weight and also reduce the cost. Description of the Drawings
[0010] Figure 1This is a schematic structural diagram of an electric valve in the first embodiment of the present application, and the electric valve is specifically an electronic expansion valve;
[0011] Figure 2 For Figure 1 a schematic diagram of the coil component of the electric valve in
[0012] Figure 3 a cross-sectional view of the winding wire made of copper-clad aluminum material;
[0013] Figure 4 For Figure 1 a schematic diagram of the connection state of the winding wire holder, connection holder, winding, and pin before injection molding in
[0014] Figure 5 For Figure 4 an enlarged view of part A in
[0015] Figure 6 For Figure 5 an enlarged view of part B in
[0016] Figure 7 a schematic diagram of the connection state of the winding wire holder, winding, connection holder, and pin before injection molding of the electric valve in the second embodiment of the present application;
[0017] Figure 8 For Figure 7 an enlarged view of part C in
[0018] Figure 9 For Figure 8 an enlarged view of part D in
[0019] The descriptions of the reference numerals in the above drawings are as follows:
[0020] Coil component 1, Coil injection molding part 11, Winding 111, Winding wire 1111, Aluminum core 1111a, Copper layer 1111b, Insulating paint film 1111c, Winding wire holder 112, First annular flange part 1121, Second annular flange part 1122, Cylindrical part 1123, Magnetic conductive plate 113, Encapsulating resin 114, Pin 115, First pin segment 1151, Second pin segment 1152, Connection holder 116, Slope part 116a, Base 1161, Arc-shaped groove 1161a, Socket 1162, End wall 1162a, Wire groove 1162b, Side wall 1162c, Jack 1162d, Inclined step 1162e, Notch 1162f, Lead component 12, Circuit board 121, Buckle 13, Secondary injection molding encapsulation layer 14, Waterproof cap 15;
[0021] Valve body component 2, Housing 21, Shaft component 22, Rotor component 23, Nut 24, Valve seat 25, Valve port 251;
[0022] First channel 3, Second channel 4; Detailed implementation manners
[0023] To enable those skilled in the art to better understand the solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings and specific implementation manners.
[0024] Please refer to Figure 1 and Figure 2 , Figure 1 which is a schematic structural diagram of an electric valve in the first embodiment of the present application. The electric valve is specifically an electronic expansion valve; Figure 2 is Figure 1 a schematic diagram of the coil component 1 of the electric valve in
[0025] The electric valve in this embodiment includes a valve body component 2 and a coil component 1. The valve body component 2 includes a housing 21, a shaft component 22, a rotor component 23, a nut component 24, and a valve seat component 25. Among them, the rotor component 23 is located inside the housing 21, and most of the shaft component 22 and the nut component 24 are also located inside the housing 21. A valve port 251 is provided on the valve seat component 25, and the valve port 251 communicates with a first channel 3 and a second channel 4. The first channel 3 specifically includes a horizontally extending section in this embodiment, and the second channel 4 includes a vertically extending section.
[0026] The coil component 1 includes a winding wire frame 112 and a winding 111 (i.e., a coil) wound around the winding wire frame 112. The coil component 1 further includes a lead component 12. The winding 111 of the winding wire frame 112 is connected to the lead component 12 through a pin 115. The lead component 12 can be connected to a drive controller (not shown in the figure). After the drive controller is powered on, a pulse drive signal is sent to the coil component 1. The winding 111 is energized to generate a magnetic field. The coil component 1 may further include a magnetic conduction plate 113. Magnetic poles are provided on the magnetic conduction plate 113. The magnetic poles converge and amplify the magnetic field generated by the winding 111, attracting the corresponding magnetic poles on the rotor component 23. Since the pulse signal generated by the drive controller changes periodically, the coil component 1 generates a periodically changing magnetic field, thereby driving the rotor 23 in the valve body component 2 of the electric valve to rotate forward or backward. The rotor 23 is fixedly connected to the shaft component 22, and the rotor component 23 drives the shaft component 22 to rotate. The shaft component 22 and the nut component 24 are in a threaded fit. While the rotor component 23 rotates, the shaft component 22 will move axially, so as to drive the valve needle 21 to approach or move away from the valve port 251, and then realize the opening and closing actions of the valve port 251 to control the on-off of the first channel 3 and the second channel 4, so as to be able to adjust the refrigerant flow rate in a refrigeration or heating system such as an air conditioner.
[0027] It should be noted that the coil component 1 in this embodiment is injection-molded. The coil component 1 includes a coil injection-molded part 11. The coil injection-molded part 11 includes a winding wire frame 112, a winding 111 formed by winding a winding wire 1111 around the winding wire frame 112, and a pin 115. That is, the winding wire frame 112, the winding 111, and the pin 115 are injection-molded and connected into one body. It is worth mentioning that the coil injection-molded part 11 actually includes two sets of winding wire frames 112, windings 111, and pins 115, which are arranged axially and injection-molded together. The coil injection-molded part 11 includes a encapsulation resin 114 that encapsulates the outer periphery of the two sets of winding wire frames 112, windings 111, and pins 115 after injection molding. In addition, the winding wire 1111 of the winding 111 is made of copper-clad aluminum or aluminum, that is, it can be copper-clad aluminum enameled wire or aluminum enameled wire.
[0028] As Figure 3 shown, Figure 3 Figure 7 is a cross-sectional view of the winding wire 1111 made of copper-clad aluminum.
[0029] The copper-clad aluminum winding wire 1111 includes an aluminum core, that is, an aluminum core 1111a. The outer side of the aluminum core 1111a is coated with a copper layer 1111b. Among them, the volume ratio of the copper layer 1111b to the copper-clad aluminum winding wire 1111 is variable. The outer side of the copper layer 1111b is coated with an insulating paint film 1111c. The part where the copper layer 1111b and the aluminum core 1111a are in contact is a copper-aluminum bonding layer. The copper layer 1111b and the aluminum core 1111a can be formed by forging and drawing a copper-clad aluminum mother rod to become thinner. During the drawing process, the contact position between the copper layer 1111b and the aluminum core 1111a forms a copper-aluminum bonding layer, and the copper-aluminum bonding layer forms a dense interatomic bond, thereby forming an inseparable whole of the copper layer 1111b and the aluminum core 1111a. The copper-clad aluminum winding wire 1111 has good electrical conductivity, and its resistivity is slightly greater than that of a copper winding wire. It can be wound into the winding 111 of the coil component 1 like a copper winding wire. When winding the winding 111 with the same DC resistance, the number of turns used for the copper-clad aluminum winding wire 1111 can be reduced. At the same time, because the density of the copper-clad aluminum winding wire 1111 is low, therefore, the usage amount of the winding wire 1111 of the whole winding 111 is reduced, and the cost is low. The winding wire 1111 made of aluminum also has a similar effect. There will be a specific comparison example of the usage amount of the winding wire 1111 later.
[0030] Although the winding wire 1111 made of copper-clad aluminum or aluminum has the advantages of less consumption and low cost, compared with copper, the copper-clad aluminum or aluminum material is more brittle. When the winding wire holder 112, the winding 111, and the pin 115 are injection-molded and connected, a part of the winding wire 1111 of the winding 111 needs to extend out of the winding wire holder 112 so that its wire head can establish a connection with the pin 115. At this time, the extended part of the winding wire 1111 will hang outside the winding wire holder 112 and be located between the winding wire holder 112 and the pin 115. Then, when the liquid resin is injected into the mold during injection molding, it has a large impact force and extrusion force. The part of the relatively brittle copper-clad aluminum or aluminum winding wire 1111 extending out of the winding wire holder 112 may break or be damaged under the vertical impact and extrusion. Therefore, using copper-clad aluminum or aluminum for the winding wire 1111 has application difficulties. For this reason, in this embodiment, a slope portion 116a is also provided to support the part of the winding wire 1111 extending out of the winding wire holder 112 to prevent it from breaking or being damaged during the injection molding process.
[0031] Please refer to Figures 4 - 6 Understand, Figure 4 For Figure 1 a schematic diagram of the connection state of the winding wire holder 112, the connection bracket 116, the winding 111, and the pin 115 before injection molding in the figure; Figure 5 For Figure 4 an enlarged view of part A in the figure; Figure 6 For Figure 5 an enlarged view of part B in the figure.
[0032] The winding wire holder 112 in this embodiment is provided with a connection bracket 116. The connection bracket 116 is used to connect the pin 115, and the winding wire 1111 of the winding 111 is connected to the pin 115, that is, the winding wire 1111 can be connected to the pin 115 on the connection bracket 116 after extending out of the winding wire holder 112. The connection bracket 116 is provided to position the pin 115 and facilitate the connection between the winding wire 1111 and the pin 115. The connection bracket 116 and the winding wire holder 112 can be separately provided, or the connection bracket 116 can also be a part of the winding wire holder 112, that is, integrally provided.
[0033] It should be emphasized that the connection bracket 116 in this embodiment is provided with a slope portion 116a. After the winding wire 1111 extends out of the winding wire holder 112, it can extend along and be connected to the pin 115 by leaning against the slope portion 116a. The winding wire 1111 leans against the slope portion 116a, and the slope portion 116a has a supporting effect on the winding wire 1111. In this way, during the injection molding process, it can resist the extrusion force and impact force when the resin is injected and prevent the winding wire 1111 from breaking or being damaged.
[0034] Specifically, the winding bobbin 112 in the present embodiment includes a cylindrical portion 1123 and annular flange portions located at two axial ends of the cylindrical portion 1123. The annular flange portion is specifically in a circular ring shape, and the two annular flange portions are respectively a first annular flange portion 1121 and a second annular flange portion 1122. The winding wire 1111 is wound around the cylindrical portion 1123 to form the entire winding 111, and the two annular flange portions along the axial direction limit the winding 111 in the axial direction, so that an annular accommodating space is formed between the two annular flange portions and the cylindrical portion 1123 to accommodate the wound winding 111. Among them, one annular flange portion is provided with a connecting frame 116, and specifically the first annular flange portion 1121 is selected to provide the connecting frame 116, such as Figure 5 As described above, part of the edge of the first annular flange portion 1121 extends radially to form a long plate structure, which is the base 1161 of the connecting frame 116. One side surface of the base 1161 is set as a corrugated tooth surface, so that the strength of injection molding can be enhanced during injection molding. The connecting frame 116 is defined as the direction toward the second annular flange portion 1122 in the axial direction as the bottom, and the direction away from the second annular flange portion 1122 as the top, then the upper surface of the base 1161 is provided with a corrugated tooth surface, and each winding frame 112 and connecting frame 116 in this application is defined as up and down based on this reference.
[0035] Continue to refer Figure 5 , 6 , the connecting frame 116 includes a socket 1162. If the coil component 1 includes multiple phases, each phase will lead out a wire end. At this time, the winding 111 can lead out multiple wire ends to establish connections with the corresponding sockets 1162. The figure schematically shows that the connecting frame 116 includes three sockets 1162, and the three sockets 1162 are arranged on the connecting frame 116 at intervals. When assembled with another group of winding bobbins 112, the socket 1162 of the connecting frame 116 on the other group of winding bobbins 112 can be located between two adjacent sockets 1162 of the group of connecting frames 116.
[0036] The socket 1162 is used to position the pin 115. Part of the pin 115 is located inside the socket 1162 for positioning, and part of the pin 115 is located outside the socket 1162. A part located outside the socket 1162 extends out of the socket 1162 along the axial direction to connect with the winding wire 1111, and the other part is used to connect with the lead component 12. Specifically, as Figure 6 As shown, the portion of the pin 115 used for connecting to the winding wire 111 specifically extends upward from the socket 1162, and the portion used for connecting to the lead component 12 extends approximately in the radial direction.
[0037] like Figure 5As shown, the pin 115 in this embodiment is generally L-shaped, including a first pin segment 1151 and a second pin segment 1152 that are substantially perpendicular. The first pin segment 1151 extends axially to connect with the winding wire 1111, and the second pin segment 1152 is connected to the lead component 12. A jack 1162d is provided in the socket 1162, and the second pin segment 1152 can be inserted into and pass through the socket 1162 along the jack 1162d. At this time, the winding wire 1111 needs to extend from below the socket 1162. Then, a part of the outer wall of the socket 1162 forms the above-mentioned ramp portion 116a. The ramp portion 116a gradually inclines towards the part where the first pin segment 1151 extends out of the socket 1162. Then, the winding wire 1111 can lean against the ramp portion 116a, so as to contact the pin 115 in a supported state and then wind around the pin 115 for electrical connection.
[0038] In this embodiment, the connecting frame 116 is arranged at the edge of the first annular flange portion 1121, and the head of the winding wire 1111 is located near the first annular flange portion 1121. Then, the winding wire 1111 can directly extend from the edge position of the first annular flange portion 1121 to the position of the connecting frame 116 and then to the position of the socket 1162, so as to Figure 5 From a perspective, that is, extending upward to the position of the socket 1162. The socket 1162 has a first end facing the winding wire frame 112 and a second end facing away from the winding wire frame 112. The first end is closer to the first annular flange portion 1121. Then, the winding wire 1111 can reach the position of the first end through a shorter path. The entire end wall 1162a of the first end is set as an inclined surface, and the inclined surface can serve as the ramp portion 116a. The above-mentioned jack 1162d for the pin 115 to pass through penetrates this end wall 1162a.
[0039] As Figure 6 shown, the end wall 1162a of the first end of the socket 1162 is set as an inclined surface, which inclines obliquely upward from the position where it is connected to the base 1161 towards the position of the pin 115. At this time, the jack 1162d also penetrates a part of the upper surface of the socket 115 and forms an opening on the upper surface. In this way, both sides of the opening can limit the first pin segment 1151 to better ensure the stability of the pin 115 positioning. At this time, the end wall 1162a is penetrated by the jack 1162d, forming two parts on both sides of the jack 1162d, and one of the parts can be used as the ramp portion 116a. Figure 6 In, the socket 1162 axially protrudes upward from the base 1161 of the connecting frame 116. After being led out from the winding wire frame 112, the winding wire 1111 extends upward and leans against the ramp portion 116a, and then winds around the part where the first pin segment 1151 extends out of the socket 1162 to connect with the pin 115. Figure 6In this case, it is defined that the first pin segment 1151 includes a first side and a second side. The first side faces one side wall of the jack 1162d, and the second side faces the other side wall opposite to the jack 1162d. The winding wire 1111 extends upward from a position near the first side, abuts against the ramp portion 116, and then approaches the second side of the first pin segment 1151, and winds multiple turns in the direction from the second side to the first side. This is beneficial for the winding wire 1111 to be straightened and supported on the ramp portion 116, preventing it from slipping due to resin impact and affecting the support effect.
[0040] For continued reference Figure 6 The socket 1162 includes a first end and a second end which are oppositely arranged, and a top and a bottom which are axially oppositely arranged. The top faces upward and the bottom faces downward. The socket 1162 further includes two side walls 1162c connecting the first end and the second end. The two side walls 1162c of two adjacent sockets 1162 are oppositely arranged. Further, a wire groove 1162b extending axially is formed in the side wall 1162c of the socket 1162 in this embodiment. A part of the winding wire 1111 is located in the wire groove 1162b, and the wire groove 1162b is connected to the ramp portion 116a. In this embodiment, the wire groove 1162b axially penetrates one side wall 1162c of the socket 1162, and upwardly penetrates the end wall 1162a of the socket 1162 where the ramp portion 116a is provided, and then is connected to the ramp portion 116a. Then, after coming out of the winding wire holder 112, the winding wire 1111 first enters the wire groove 1162b upward, continues to extend upward to abut and support on the surface of the ramp portion 116a, and then winds around the first pin segment 1151. Since there is still a small distance between the end wall 1162a where the ramp portion 116a is provided and the winding wire holder 112, setting the wire groove 1162b can limit and protect the winding wire 116a as much as possible within this distance, reducing the injection molding impact.
[0041] Take another look Figure 6, the connecting bracket 116 is provided with a base 1161. One end of the base 1161 is connected to the edge of the first annular flange portion 1121, and the other end of the base 1161 is connected to the socket 1162. An arc-shaped groove 1161a extending axially is provided on the end wall at the other end of the base 1161. One arc-shaped side of the arc-shaped groove 1161a is in transitional connection with one side of the wire groove 1162b, that is, the side of the arc 1161a perpendicular to the axis is connected to the wire groove 1162b. With such a setting, after the winding wire 1111 is led out from the winding wire holder 112, it can transition to the wire groove 1162b from the position of the arc-shaped groove 1161a, further improving the protection of the winding wire 1111. The shape setting of the arc-shaped groove 1161a is also conducive to reducing the wear of the winding wire 1111. It can be seen that the cross-section of the wire groove 1162b can also be set to an arc shape. Of course, the cross-section of the wire groove 1162b can also be set to a rectangle or other shapes. Chamfers can be provided at the positions where the wire groove 1162b or the arc-shaped groove 1161a is just in contact with or just separated from the winding wire 1111 to avoid and reduce the wear of the winding wire 1111.
[0042] It should be understood that the setting position of the slope portion 116a can be designed according to the relative position of the end of the winding wire 1111 and the pin 115. The slope portion 116a is provided in the path of the winding wire 1111 from the winding wire holder 112 to the pin 115 to minimize or eliminate the length of the portion of the winding wire 1111 between the winding wire holder 112 and the pin 115 that is in a suspended and unsupported state. Since there are distances between the winding wire holder 112 and the pin 115 both axially and radially, the slope portion 116a that supports the winding wire 1111 is inclined, but the slope portion 116a is obviously not limited to a straight slope structure. It can be set straight or have a certain curvature, etc. This embodiment does not make specific limitations. It can be understood that in order to achieve the purpose of support and anti-impact, there are various ways to set the slope portion 116a, and Figure 6 only an example of the setting method of the slope portion 116a is shown, and there can be other ways.
[0043] For example, reference can be continued to Figures 7 - 9 , Figure 7 is a schematic diagram of the connection state of the winding wire holder 112, the winding 111, the connecting bracket 116, and the pin 115 of the electric valve in the second embodiment of the present application before injection molding; Figure 8 is Figure 7 an enlarged view of part C in Figure 9 is Figure 8 an enlarged view of part D in
[0044] The structure of the electric valve in the second embodiment is basically the same as that in the first embodiment. Only the differences will be described here, and for the same parts, reference can be made to the first embodiment and will not be elaborated further. Different from the first embodiment, the structure of the socket 1162 in this embodiment is slightly different. The ramp portion 116a of the socket 1162 is not formed on one end wall of the socket 1162, but is provided on the side wall 1162c of the socket 1162. As Figure 8 shown, the socket 1162 includes a side wall 1162c, and the side wall 1162c is provided with an inclined step 1162e, and the inclined step 1162e is the ramp portion 116a. It can be seen that the side wall 1162c can also be provided with an inclined groove, and the groove side wall of the inclined groove serves as the ramp portion 116a. In this way, after the winding wire 1111 is led out from the winding wire frame 112, it can extend in the direction close to the socket 1162, and be abutted and supported on the inclined step 1162e, and then extend to the top of the socket 1162, and then wind around the first pin segment 1151 to establish an electrical connection. The function of the ramp portion 116a in this embodiment is the same as that in the first embodiment. And in this embodiment, when the winding wire 1111 winds from the ramp portion 116a to the first pin segment 1151, a part of it can also be supported on the top of the socket 1162 until it is wound and connected to the first pin segment 1151, and there is almost no overhanging part, and the protection is more reliable.
[0045] Furthermore, as Figure 8 shown, a notch 1162f is also provided at the edge where the top of the socket 1162 is connected to the inclined step 1162e. The notch 1162f communicates with the inclined step 1162e. After the winding wire 1111 is led out from the inclined step 1162e, it can be located in the notch 1162f, and continue to extend from the notch 1162f to the top of the socket 1162 and be connected to the pin 115. The side walls on both sides of the notch 1162f can limit the winding wire 1111, so that it extends to the pin 115 in a relatively stable state. Of course, if an inclined groove is provided, the inclined groove itself can form a notch 1162f at the edge of the top of the socket 1162, and there is no need to separately provide a notch 1162f.
[0046] Same as the first embodiment, a wire groove 1162b can also be provided on the side wall 1162c of the socket 1162 in this embodiment, and an arc groove 1161a connected to the side part of the wire groove 1162b can also be provided at one end of the base 1161 facing the socket 1162. The function is the same as that in the first embodiment and will not be elaborated further.
[0047] Please continue to refer to Figure 1 , in this embodiment, the coil component 1 actually includes two winding wire frames 112, and the two winding wire frames 112 are butted together axially, Figure 6The first pin segment 1151 in [description] extends axially upward, while the first pin segment 1151 on the other winding bobbin 112 extends downward, and the two are butted together. The second pin segments 1152 of the multiple pins 115 can be evenly inserted into the circuit board 121 along the radial direction and then connected to the lead component 12 to connect to the drive controller. The coil component 1 further includes a magnetic conductive plate 113. The magnetic conductive plate 113 includes two parts. One part includes a cylinder and an annular plate located at one end of the cylinder. The cylinder is located inside the cylindrical part 1123 of the winding bobbin 112, and the annular plate covers the outside of one annular flange part of the winding bobbin 112. The cylinder of the other part of the magnetic conductive plate 113 is located outside the winding 111, and the annular plate covers the other annular flange part of the winding bobbin 112. In this way, the two parts of the magnetic conductive plate 113 cover each winding bobbin 112 and its winding 111. After injection molding, the magnetic conductive plate 113 is also injection molded together with the winding bobbin 112. After injection molding, an encapsulating resin 114 is also formed. The encapsulating resin 114 forms the outer shell of the coil component 1. The injection molded winding bobbin 112, winding 111, magnetic conductive plate 113, and encapsulating resin 114 are the coil injection molded part 11. As Figure 1 shown, the coil component 1 further includes a secondary injection molding encapsulation 14 for injection molding the lead component 12, the pins 115, and the circuit board 121. The coil component 1 further includes a buckle 13, a waterproof cap 15, etc. The buckle 13 is used to fixedly connect the coil component 1 and the valve body component 2, and the waterproof cap 15 covers the top of the coil component 1.
[0048] As described above, in this embodiment, a ramp portion 116a is provided on the connecting frame 116 to support the winding wire 1111, so that the winding wire 1111 can be made of copper-clad aluminum or aluminum material that is relatively brittle but has good electrical conductivity and is light in weight.
[0049] Taking the electronic expansion valve as an example, the outer diameter D0 of a general electronic expansion valve is 17.3 mm, 15.4 mm, etc. In this embodiment, D0 = 17.3 mm is taken as an example for illustration.
[0050] In the existing electronic expansion valve, the coil component is wound with copper enameled wire to form a winding. The specification values of the single-phase winding can be seen in the following table:
[0051]
[0052]
[0053] After the copper-clad aluminum winding wire 1111 is adopted in the embodiment of the present application, the specification values of the single-phase winding are shown in the following table:
[0054] DC Resistance / Ω 46 Ω Winding Wire Gauge / mm Φ0.16 (25% Cu) Winding Wire Material Copper - Clad Aluminum Number of Turns of Winding Wire / Turns 440 Rated Voltage / V DC 12V Output Torque / mNm 14.8 Weight of Single - Phase Winding / g 2.5 Total Weight of Winding / g (4 Phases in Total) 10g
[0055] From the comparison of the winding parameter specification values in the above general case, after using the copper-clad aluminum winding wire 1111, by designing the parameters of the winding 111, when the required DC resistance of the winding 111 is achieved, the output torque of the winding 111 reaches the same level as that of the above-mentioned copper enameled wire, and the normal product driving function can be realized. Moreover, since the density of the copper-clad aluminum winding wire 1111 is low, therefore, in the case of achieving the same driving ability, the total weight of the winding 111 is reduced, and the cost can be reduced.
[0056] Through the above example of specification values, when using a copper winding wire to meet the general requirements of an electronic expansion valve, the ratio of the weight of the winding to the outer diameter of the outer shell of the valve body component is:
[0057] m0 / D0 = 22.4 g / 17.3 mm ≈ 1.29 g / mm.
[0058] When using the copper-clad aluminum winding wire 1111 to meet the same requirements of the electronic expansion valve, the ratio of the weight of the winding 111 to the outer diameter of the outer shell 21 of the valve body component 2 is:
[0059] m0 / D0 = 10 g / 17.3 mm ≈ 0.58 g / mm.
[0060] It can be seen from this that when using the copper-clad aluminum winding wire 1111, the decrease amplitude of the ratio of the weight of the winding 111 to the outer diameter of the outer shell 21 of the valve body component reaches 55%.
[0061] The above is calculated with a copper proportion of 25%. In the copper-clad aluminum winding wire 1111 of this embodiment, the proportion of the copper layer 1111b is greater than or equal to 10%. According to the change of the proportion of the copper layer 1111b, when the rated voltage is DC12V, the number of turns of the winding 111 is between 380 turns and 500 turns, that is, the weight of the above-mentioned winding wire 1111 can be further reduced.
[0062] Next, the aluminum winding 111 is calculated. When the aluminum is used as the winding wire 1111, the single-phase specification values of the winding 111 are shown in the following table:
[0063] DC Resistance / Ω 46 Ω Winding Wire Gauge / mm Φ0.16 Winding Wire Material Aluminum Number of Turns of Winding / Turns 420 Rated Voltage / V DC 12V Output Torque / mNm 14.2 Weight of Single - Phase Winding / g 1.8 Total Weight of Winding / g (4 Phases in Total) 7.2g
[0064] Comparing the parameter specification values of the copper enameled wire winding and the copper-clad aluminum winding in the above general case, after using the aluminum winding wire 1111, by designing the parameters of the winding 111, when the required DC resistance of the winding 111 is achieved, the output torque of the winding 111 can also reach a roughly same level, and the normal product driving function can be realized.
[0065] At this time, the ratio of the weight of the winding 111 to the outer diameter of the outer shell 21 of the valve body component is:
[0066] m0 / D0 = 7.2 g / 17.3 mm ≈ 0.42 g / mm.
[0067] It can be seen that when using the winding wire made of aluminum material, the ratio of the weight of the winding to the outer diameter of the outer shell 21 of the valve body component 2 decreases by up to 67.4%. When the above-mentioned winding wire made of aluminum material is wound to form a winding, when the rated voltage is DC 12V and other parameters change, the number of turns of the winding also has a certain floating range, between 390 turns and 450 turns.
[0068] It can be known that by adjusting the volume ratio of the copper layer 1111b in the copper-clad aluminum winding wire 1111 and the DC resistance tolerance, when using the copper-clad aluminum or aluminum winding wire 1111 under the condition of meeting the general requirements of the electronic expansion valve, the ratio of the weight of the winding 111 to the outer diameter of the outer shell 21 of the valve body component 2 is:
[0069] m0 / D0 = 0.35 g / mm - 1.05 g / mm.
[0070] The present application also provides a processing method for an electric valve, which is used to process the electric valve in any of the above embodiments; the method includes the following steps:
[0071] The winding wire 1111 is wound around the winding wire holder 112 to form a winding 111;
[0072] The winding wire 1111 on the winding wire holder 112 is led out and abutted against the slope portion 116a of the connecting frame 116, and the winding wire 1111 is connected to the corresponding pin 115;
[0073] Assemble to form a coil assembly; the coil assembly may also include the above-mentioned magnetic conductive plate 113, etc.;
[0074] Two sets of coil assemblies are axially butted and placed in an injection mold, and resin is injected for injection molding to form a coil injection molded part 11. It can be understood that the setting of the slope portion 116a is mainly to enable the winding wire 1111 to be supported when facing the impact of the resin, so the slope portion 116a can be set in the direction of the resin impact, so that Figure 6 for example, the direction of the resin coming can be downward, and the slope portion 116a is obliquely upward, which can not only make the winding wire 1111 obliquely upward to approach the pin 115, but also resist the downward impact force of the resin.
[0075] The coil injection molded part 11 can also be secondarily injection molded with the circuit board 121 and the lead component 12 to form a coil component 1.
[0076] In this text, specific examples are used to elaborate on the principles and implementation modes of this application. The description of the above embodiments is only used to help understand the method and its core idea of this application. It should be noted that for those of ordinary skill in the art of this technology, without departing from the principles of this application, several improvements and modifications can still be made to this application, and these improvements and modifications also fall within the protection scope of the claims of this application.
Claims
1. An electric valve, characterized in that, It includes a coil component (1), the coil component (1) includes a winding wire frame (112), a winding wire (1111) wound around the winding wire frame (112), and a pin (115). The winding wire frame (112) is further provided with a connecting frame (116), the connecting frame (116) is used to connect the pin (115), and the winding wire (1111) is connected to the pin (115); the connecting frame (116) is provided with a slope portion (116a), and the winding wire (1111) abuts against the slope portion (116a) and extends to be connected to the pin (115); the winding wire (1111) is made of copper-clad aluminum or aluminum, and the winding wire frame (112), the winding wire (1111) and the pin (115) are injection-molded and connected.
2. The electric valve according to claim 1, characterized in that, The winding wire frame (112) includes a cylindrical portion (1123), and a first annular flange portion (1121) and a second annular flange portion (1122) located at both axial ends of the cylindrical portion (1123). The first annular flange portion (1121) is provided with the connecting frame (116), and the connecting frame (116) is connected to the edge of the first annular flange portion (1121); the connecting frame (116) includes a socket (1162), a part of the pin (115) is located inside the socket (1162), a part of the pin (115) axially extends out of the socket (1162), and a part of the outer wall of the socket (1162) forms the slope portion (116a).
3. The electric valve according to claim 2, characterized in that, The end wall (1162a) of one end of the socket (1162) facing the first annular flange portion (1121) includes the slope portion (116a).
4. The electric valve according to claim 2, wherein The socket (1162) includes a side wall (1162c), the side wall (1162c) is provided with an inclined groove, or the side wall (1162c) is provided with an inclined step (1162e), and the groove side wall of the inclined groove or the inclined step (1162e) is the slope portion (116a).
5. The electric valve according to claim 3 or 4, characterized in that, The side wall (1162c) is provided with the inclined step (1162e), the pin (115) axially extends out of the top of the socket (1162), a notch (1162f) is opened at the position where the top is connected to the side wall (1162c), the notch (1162f) communicates with the inclined step (1162e), and the winding wire (1111) extends from the notch (1162f) to be supported on the top and connected to the pin (115).
6. The electric valve according to any one of claims 2-4, characterized in that, The side wall (1162c) of the socket (1162) is provided with an axially extending wire groove (1162b), a part of the winding wire (1111) is located in the wire groove (1162b), and the wire groove (1162b) is connected to the slope portion (116a).
7. The electric valve according to claim 6, characterized in that, The connecting bracket (116) includes a base (1161). One end of the base (1161) is connected to the first annular flange portion (1121), and the other end of the base (1161) is connected to the socket (1162). An arc-shaped groove (1161a) is provided on the end wall of the other end of the base (1161), and one arc-shaped side of the arc-shaped groove (1161a) is in transitional connection with one side of the wire groove (1162d).
8. The electric valve according to any one of claims 1-4, characterized in that, The winding wire (1111) is made of copper-clad aluminum. The winding wire (1111) includes an aluminum core (1111a), a copper layer (1111b), and an insulating paint film (1111c). The copper layer (1111b) wraps around the outside of the aluminum core (1111a), and the insulating paint film (1111c) wraps around the outside of the copper layer (1111b).
9. The electric valve according to any one of claims 1-4, characterized in that, The electric valve includes a valve body component (2). The valve body component (2) includes a housing (21). The ratio of the weight of the winding wire (1111) to the outer diameter of the housing (21) is 0.35 g / mm to 1.05 g / mm.
10. A processing method for an electric valve, characterized in that, For machining the electric valve according to any one of claims 1-9 above; including the following steps: Lead out the winding wire (1111) on the winding wire holder (112) and make it abut against the slope portion (116a), and connect the winding wire (1111) to the corresponding pin (115). Assemble to form a coil assembly. Place the coil assembly into an injection mold and inject resin for injection molding.