Control valve with filtering function, manufacturing method of filtering assembly and manufacturing method of control valve

Abstract

The control valve with the filtering function comprises a valve body part and a filtering assembly, at least part of the filtering assembly is located in an inner cavity of the valve body part, the filtering assembly comprises a base body and a support, the base body comprises a filtering cavity, and the support comprises a plate body part and a connecting part. At least part of the plate body part is located in the filtering cavity, the plate body part comprises an overflowing opening, the connecting part comprises a first connecting part, the first connecting part extends in the axial direction of the base body, at least part of the first side edge of the first connecting part is a first continuous face, and the support serves as an insert and is integrally formed with the base body in an injection molding mode. According to the control valve with the filtering function, the anti-pulling force of the connecting position of the support and the base body is increased, the connecting strength of the support and the base body is improved, and therefore the filtering reliability of the control valve with the filtering function is improved, and in addition, the invention further provides a manufacturing method of the filtering assembly and a manufacturing method of the control valve.

Description

Technical Field

[0001] This invention relates to the field of valve technology with filtering function, and more specifically, to a method for manufacturing a control valve with filtering function, a filtering assembly, and a control valve. Background Technology

[0002] A valve with a filtering function includes a valve body component and a filter screen assembly located within the valve body component. Figure 1 This is a three-dimensional schematic diagram of a filter assembly in the background art. The filter assembly includes a base 1' and a filter element 2' located inside the base 1'. The base 1' is connected and fixed to the filter element 2' by injection molding. Figure 2 This is a three-dimensional schematic diagram of the filter element skeleton in the background art. The filter element 2' includes a filter element skeleton 21', and the filter element skeleton 21' has an open structure at the junction of its edge and the seat 1'.

[0003] Especially when the valve cavity is frozen below zero degrees, the filter element skeleton 21' has insufficient tensile strength when frozen. As a result, after the ice expands in the frozen environment, the filter element skeleton 21' is prone to stretching and deformation, which may cause the filter element skeleton 21' to detach from the weak point of the opening and the joint with the seat 1' or break at the joint with the seat 1'. Summary of the Invention

[0004] The first objective of this invention is to provide a control valve that has an internal filter assembly and can improve the reliability of the connection between the support and the substrate of the filter assembly.

[0005] The present invention provides a control valve with a filtering function, comprising a valve body component and a filtering assembly. The filtering assembly is at least partially located in the inner cavity of the valve body component. The filtering assembly includes a base and a support. The base includes a filtering cavity. The support includes a plate portion and a connecting portion. The plate portion is at least partially located in the filtering cavity and includes a flow port. The connecting portion includes a first connecting portion that extends axially along the base. At least a first side of the first connecting portion is a first continuous surface. The support is integrally injection molded with the base as an insert, and the first continuous surface is at least partially located within the base.

[0006] The control valve with filtration function provided in this application has a first continuous surface at least partially located in the matrix, and the first side is reliably connected to the matrix, which increases the tensile strength at the connection between the support and the matrix, improves the connection strength between the support and the matrix, and thus improves the filtration reliability of the control valve with filtration function.

[0007] A second objective of this invention is to provide a method for manufacturing a filter assembly that improves the reliability of the connection between the support and the substrate.

[0008] A method for manufacturing a filter component includes the following steps:

[0009] Fabrication of the support: The metal plate is processed into the blank plate, the blank plate is reserved with a first connecting part, the first connecting part is processed to have at least a first side edge having a first continuous surface, and a plate body including an outlet is processed in a part of the blank plate.

[0010] A filter assembly is formed by injection molding the support as an insert matrix, and the first continuous surface is at least partially located within the matrix.

[0011] In the above-mentioned method for manufacturing the filter assembly, the support is used as an insert injection molding substrate, and the first continuous surface is located in the substrate, thereby improving the connection strength between the support and the substrate and thus improving the overall strength of the filter assembly.

[0012] A third objective of this invention is to provide a method for manufacturing a control valve that improves filtration reliability.

[0013] A method for manufacturing a control valve includes the following steps:

[0014] Manufacturing valve body components: The processing of the blank also includes processing the first valve body, the second valve body, the valve cap, and the valve core. The processing of the valve core includes processing the valve core flow channel, the inlet, the outlet, and the lower through hole. The lower through hole includes an upper orifice communicating with the valve core flow channel and a lower orifice communicating with the outer surface of the valve core.

[0015] Connect the first valve body and the second valve body, and install the valve core in the inner cavity;

[0016] Fabrication of the support: The metal sheet is processed into a blank sheet, the blank sheet includes a first connecting part, the first connecting part is processed to form a first side edge having at least a first continuous surface, and a portion of the blank sheet is processed to form a plate body including an outlet;

[0017] A filter assembly is formed by injection molding the bracket as an insert matrix, and the first continuous surface is at least partially located within the matrix.

[0018] After injection molding, the matrix forms an outer ring portion, and the end of the outer ring portion forms a protrusion extending along the axial direction of the matrix.

[0019] The filter assembly is inserted into the valve core flow channel through the lower through hole. After the valve cap is threadedly connected and fixed to the second valve body, the protrusion is limited or fixedly connected to the second valve body through the valve cap, thereby fixing the filter assembly and at least partially installing the filter assembly in the inner cavity.

[0020] The above-described method for manufacturing the control valve enhances the connection strength between the support and the base of the filter assembly, thereby improving the overall strength of the filter assembly. The filter assembly is at least partially located within and fixed to the valve body, ensuring the stability of the filter assembly when filtering impurities and guaranteeing filtration reliability. Attached Figure Description

[0021] Figure 1 Background Art: A three-dimensional schematic diagram of a filter assembly;

[0022] Figure 2 Background Art: A three-dimensional schematic diagram of a filter element;

[0023] Figure 3 : A cross-sectional schematic diagram of the control valve provided by the present invention in the open state;

[0024] Figure 4 : Figure 3 A 3D schematic diagram of the middle filter assembly;

[0025] Figure 5 : Figure 3 Cross-sectional view of the middle filter assembly;

[0026] Figure 6 : Figure 5 Cross-sectional view of the middle filter assembly at point AA;

[0027] Figure 7 : Figure 6 A schematic diagram at point B in the middle;

[0028] Figure 8 : Figure 3 Bottom view of the middle filter assembly;

[0029] Figure 9 : Figure 3 A three-dimensional schematic diagram of the filter element;

[0030] Figure 10 : Figure 9 A three-dimensional schematic diagram of the central support.

[0031] Figure 3-10 The attached figures are labeled as follows:

[0032] 1-Valve body component, 10-Inner cavity, 101-First port, 102-Second port, 11-First valve body, 12-Second valve body, 121-Recess, 13-Valve cap,

[0033] 2-Filter assembly, 21-Base, 210-Filter chamber, 2101-First filter chamber, 2102-Second filter chamber, 211-Protrusion, 212-Cylinder body, 213-First fixing part, 214-First flow channel, 215-Second flow channel, 216-End cap, 2161-Third fixing part, 217-Second fixing part, 218-Groove, 219-Outer ring, 22-Bracket, 2201-First arc part, 2202-First flat part, 2203-Second flat part, 2204-Second arc part, 221-Plate body, 2211-First plate body, 2212-Second plate body, 2213-Upper section, 2214- Lower section, 222-connecting part, 2221-first connecting part, 22211-first connecting surface, 22212-second connecting surface, 22213-first side edge, 22214-first continuous surface, 2222-third connecting part, 22221-top edge, 22222-third continuous surface, 2223-second connecting part, 22231-second side edge, 22232-second continuous surface, 223-flow port, 224-connecting hole, 2241-first connecting hole, 2242-second connecting hole, 2243-third connecting hole, 23-filter screen, 231-first mesh part, 232-second mesh part, 2321-flanged edge, 24-base.

[0034] 3-Valve core, 30-Valve core flow channel, 301-Inlet, 302-Outlet

[0035] 4-Valve stem. Detailed Implementation

[0036] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Obviously, the accompanying drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. The directional terms such as "up" and "down" used herein are... Figure 3 The positions of the components shown are defined only for clarity and convenience in expressing the technical solution. It should be understood that the directional terms used herein should not limit the scope of protection claimed in this application.

[0037] Figure 3 A cross-sectional schematic diagram of the control valve provided by the present invention in the open state; Figure 4 for Figure 3 A 3D schematic diagram of the middle filter assembly; Figure 5 for Figure 4 A three-dimensional schematic diagram of the middle filter assembly after it has been cut off at the middle. Figure 6 for Figure 5 A schematic diagram at point A in the middle; Figure 7 for Figure 3Cross-sectional view of the middle filter assembly; Figure 8 for Figure 3 Bottom view of the middle filter assembly; Figure 9 for Figure 3 A three-dimensional schematic diagram of the filter element; Figure 10 for Figure 9 A three-dimensional schematic diagram of the central support.

[0038] It should be noted that, with Figure 3 For example, the transverse direction of the control valve is the axial direction of the first valve body 11 or the second valve body 12, and the longitudinal direction of the control valve is the axial direction of the base 21 of the filter assembly 2.

[0039] As shown in the figure, the control valve in this embodiment is described using a ball valve as an example, including a valve body component 1, a filter assembly 2, a valve core 3, and a valve stem 4; the valve body component 1 includes a first valve body 11, a second valve body 12, and a valve cap 13. The first valve body 11 and the second valve body 12 are assembled by threaded connection, and the valve cap 13 is threadedly connected to the second valve body 12. The valve body component 1 has an inlet and an outlet communicating with its inner cavity 10. The end of the first valve body 11 is provided with a first port 101, and the end of the second valve body 12 is provided with a second port 102. In this embodiment, the first port 101 is the inlet when the fluid medium flows into the control valve, and the second port 102 is the outlet when the fluid medium flows out of the control valve, as an example. The valve core 3 includes a valve core flow channel 30, in which... Figure 1 When the control valve is in the open state, the first port 101 can be connected to the second port 102 through the valve core flow channel 30.

[0040] The valve core 3 is approximately spherical and located within the inner cavity 10. The valve core 3 also includes an inlet 301, an outlet 302, and a lower through-hole. The valve core flow channel 30 connects the inlet 201 and the outlet 202. The lower through-hole is located in... Figure 3 From the perspective shown, located below the valve core flow channel 20, the upper opening of the lower through hole communicates with the valve core flow channel 30, and the outer surface of the valve core 3 has the lower opening of the lower through hole. The valve stem 4 is positioned as follows... Figure 3 From the perspective shown, the valve stem 4 is located above the valve core 3, with one end passing through the second valve body 12 and connected to the valve core 3.

[0041] In this embodiment, the filter assembly 2 includes a substrate 21 and a support 22. The substrate 21 is a cylindrical shape with a notch and includes a filter cavity 210. The support 22 includes a plate portion 221 and a connecting portion 222. The plate portion 221 is at least partially located in the filter cavity 210. The plate portion 221 includes a flow port 223, which is formed by etching. The number of flow ports 223 is set to a plurality of them, and the cross-sectional shape of the flow ports 223 can be as follows: Figure 10The square shape shown can, of course, be other shapes; the connecting part 222 includes a first connecting part 2221, which extends along the axial direction of the base 21. The first side 22213 of the first connecting part 2221 is at least partially a first continuous surface 22214. The base 21 is an injection molded part, and the first continuous surface 22214 is at least partially located inside the base 21, specifically injected into the base 21, in order to reduce or avoid the situation where the bracket 22 and the base 21 separate or the bracket 22 and the base 21 break.

[0042] Unlike the filter element skeleton structure and the connection between the filter element skeleton structure and the base in the background technology, the bracket 22 in this embodiment is a metal plate, which can be made of stainless steel plate, and is not formed by splicing or welding multiple small stainless steel plates together. In this embodiment, the first side 22213 of the first connecting part 2221 is a straight edge, and the first continuous surface 22214 forms a plane without gaps or protrusions. The first continuous surface 22214 serves as the surface of the first side 22213, so that the surface of the first side 22213 is completely without gaps or protrusions. Thus, the first side 22213 has no openings, ensuring that the tensile strength of the first side 22213 meets the requirements of the freezing environment, improving the connection strength between the bracket 22 and the base 21, and improving the freezing resistance of the filter assembly 2.

[0043] Meanwhile, in this embodiment, the support 22 is an etched plate processed by etching, and the flow port 223 is formed by etching. In the background art, the filter element skeleton is a woven mesh structure with openings. The above-mentioned filter element skeleton is stretched into a mesh by steel plate, so that the surface of the filter element skeleton is arranged in a wave pattern, that is, the thickness of each part of the filter element skeleton is inconsistent. However, the support 22 of this embodiment has a flat plate surface and a relatively uniform thickness. Compared with the filter element skeleton of the background art, it has a better longitudinal tensile strength in the control valve. It should also be noted that, firstly, if the plate surface has inconsistent thickness, it is easy to cause overflow and scrap during production. Therefore, the support 22 with good plate surface flatness consistency in this embodiment can improve the injection molding consistency and first pass rate of the filter assembly 2. Secondly, furthermore, the support 22 is a metal plate with a thickness of not less than 0.5mm. The plate thickness of the support 22 is thicker than the thickness of the woven mesh structure filter element skeleton in the background art, so the strength of the support 22 can also be guaranteed.

[0044] In this embodiment, the base 21 includes a first fixing portion 213, and a first connecting portion 2221 is bent relative to the plate portion 221, which increases the contact range between the first connecting portion 2221 and the first fixing portion 213. The first connecting portion 2221 includes a first connecting surface 22211 and a second connecting surface 22212 facing opposite directions. In the radial direction of the base 21, the second connecting surface 22212 is closer to the center of the base 21 than the first connecting surface 22211. While ensuring the reliability of the connection between the base 21 and the support 22, the first fixing portion 213 at least partially covers the first connecting surface 22211. Furthermore, the coverage area of ​​the first fixing portion 213 can be larger; specifically, the first fixing portion 213 covers the first connecting surface 22211 and at least part of the second connecting surface 22212, ensuring the connection strength between the base 21 and the support 22.

[0045] Based on the above, the plate body 221 has a first end face and a second end face. The first end face and the second end face are arranged opposite to each other in the lateral direction of the control valve, and the first end face is closer to the inlet than the second end face. Taking the first connecting part 2221 as an example, the first end face is connected to the second connecting surface 22212, and the first end face is connected to the first connecting surface 22211. Figure 7 As shown, the first connecting part 2221 is bent relative to the plate part 221, so that the second connecting surface 22212 and the first end face form a first included angle α, and the first connecting part 2221 faces the inlet to improve the reliability of the connection.

[0046] Based on the above, Figure 4-7 Taking this embodiment as an example, the first connecting part 2221 is completely embedded in the first fixing part 213, so that the first connecting surface 22211 and the second connecting surface 22212 are tightly fitted with the injection plastic at the first fixing part 213. This makes the connection between the bracket 22 and the base 21 more reliable and ensures the tensile strength of the filter assembly 2 after molding. It should be noted that the width of the plate part 221 is greater than the diameter of the inner cavity 10. Therefore, the part where the plate part 221 is connected to the first connecting part 2221 will be embedded in the first fixing part 213 along with the first connecting part 2221. When the injection plastic at the first fixing part 213 at least partially fills the flow port 223 of the connection part, the tensile strength at the connection between the bracket 22 and the base 21 can be increased. Therefore, the connection strength between the bracket 22 and the base 21 can be further guaranteed.

[0047] In this embodiment, the connecting portion 222 further includes a second connecting portion 2223. In the radial direction of the base 21, the second connecting portion 2223 is preferably symmetrically arranged with respect to the center of the base 21 and the first connecting portion 2221. Specifically, the second connecting portion 2223 extends along the axial direction of the base 21. The second side 22231 of the second connecting portion 2223 is at least partially a second continuous surface 22232. Except for the different connection positions, the structure of the second side 22231 and the second continuous surface 22232 of the second connecting portion 2223 is the same as that of the first side 22213 and the first continuous surface 22214 of the first connecting portion 2221. The connection configuration and function of the second connecting portion 2223 are the same as those of the first connecting portion 2221, and will not be elaborated further here. The base 21 also includes a second fixing part 217, which at least partially covers the second connecting part 2223, so that the bracket 22 is fixed by the connection between the first connecting part 2221 and the first fixing part 213, and the connection between the second connecting part 2223 and the second fixing part 217, which can ensure the reliability of the connection between the ends of the bracket 22 on both radial sides and the base 21.

[0048] The inner wall of the filter chamber 210 includes a first arcuate wall 2201, a second arcuate wall 2204, a first planar wall 2202, and a second planar wall 2203. The first arcuate wall 2201 and the second arcuate wall 2204 are arranged opposite to each other, and the first planar wall 2202 and the second planar wall 2203 are arranged opposite to each other. The first planar wall 2202 serves as the inner wall of the first fixing part 213, and the second planar wall 2203 serves as the inner wall of the second fixing part 217. In the radial direction of the base 21, the distance between the first planar wall 2202 and the second planar wall 2203 is smaller than the distance between the first arcuate wall 2201 and the second arcuate wall 2204. Figure 6 As shown, let H be the distance from the inner wall of the first fixing part 213 to the center of the base 21, and let R be the radius from the inner wall of the base 21 to the center of the base 21. Then, H < R. That is, the wall thickness of the base 21 at the first fixing part 213 and the second fixing part 217 is greater than the wall thickness of other parts of the base 21, thereby increasing the range of contact between the base 21 and the support 22 when the base 21 covers the support 22, thus improving the reliability of the connection. Furthermore, the first planar wall 2202 and the second planar wall 2203, based on the above, can also prevent the first connecting part 2221 and the second connecting part 2223 from being partially exposed on the outer surface of the base 21 due to problems with the injection molding process or the positioning of the support 22 during injection molding, which would affect the injection molding effect of the base 21 and the reliability of the connection.

[0049] In this embodiment, the base 21 includes a cylindrical portion 212 and an end cap portion 216. The cylindrical portion 212 includes an upper end and a lower end, and the end cap portion 216 is integrally formed with or limitedly connected to the upper end. Figure 5From the shown perspective, the end cap 216 is located above the cylindrical body 212. In this embodiment, the cylindrical body 212 and the end cap 216 are integrally formed during injection molding. During the manufacturing process, a bent metal support 22 can be placed into the injection mold cavity as an insert, and then the cylindrical body 212 and the end cap 216 can be integrally formed by plastic injection molding, which simplifies the molding of the filter assembly 2 and improves the structural strength.

[0050] The connecting portion 222 further includes a third connecting portion 2222, and the end cap portion 216 includes a third fixing portion 2161. The top edge 22221 of the third connecting portion 2222 is at least partially a third continuous surface 22222. Except for the connection position, the top edge 22221 and the third continuous surface 22222 of the third connecting portion 2222 have the same structure and function as the first side edge 22213 and the first continuous surface 22214 of the first connecting portion 2221. The connection situation and function of the third connecting portion 2222 are the same as those of the first connecting portion 2221, and will not be described in detail here. The third continuous surface 22222 is at least partially located within the third fixing portion 2161. It should be noted that the top edge 22221 of the third connecting portion 2222 does not protrude from the upper end surface of the base 21, which facilitates injection molding while ensuring the connection reliability of the connection point.

[0051] The cylindrical portion 212 has a groove 218 at its lower end. The filter assembly 2 also includes a base 24, which is connected to the groove 218 in a limiting manner. The base 24 can be attached to the groove 218 by applying adhesive to ensure that the base 24 will not separate from the base 21. The plate portion 221 extends axially along the base 21. At least one end of the plate portion 221 mates with the groove 218, and the other end of the plate portion 221 is connected to the end cap portion 216. The first fixing portion 213 also partially covers at least a portion of the plate portion 221, or the first fixing portion 213 also partially fills at least a portion of the flow port 223 through the plate portion 221.

[0052] The plate portion 221 includes a first plate portion 2211 and a second plate portion 2212. The first plate portion 2211 is bent relative to the second plate portion 2212, and a second included angle b is formed between the end face of the first plate portion 2211 facing the inlet and the end face of the second plate portion 2212 facing the inlet. The cylindrical portion 212 has a first flow channel 214 and a second flow channel 215, which communicate with the filter chamber 210. The valve body component 1 has an inlet and an outlet. The first flow channel 214 communicates with the inlet, and the second flow channel 215 communicates with the outlet. The bent portions of the first plate portion 2211 and the second plate portion 2212 are close to the outlet. Compared with a planar plate, this plate portion 221 increases the contact surface between the plate surface and the fluid medium, thereby better filtering impurities.

[0053] Based on the above, the connecting part 222 has a connecting hole 224. Along the projection direction of the axial direction of the connecting hole 224, the outer contour of the projection surface of the connecting hole 224 is located within the outer contour of the projection surface of the bracket 22. That is, by connecting the connecting hole 224 to the base 21, the tensile strength at the joint is further increased without any openings on the outer contour of the bracket 22's projection surface. The specific details are configured as follows, depending on the location of the connecting part 222:

[0054] The aforementioned connecting hole 224 includes a first connecting hole 2241, a second connecting hole 2242, and a third connecting hole 2243. At the junction of the first connecting portion 2221, the second connecting portion 2223, and the cylindrical portion 212, the first connecting portion 2221 has a first connecting hole 2241. Several first connecting holes 2241 are formed axially on the base 21. In the projection direction of the first connecting hole 2241 axially, there is a first gap between the outer contour of the projection surface of the first connecting hole 2241 and the outer contour of the projection surface of the first connecting portion 2221, which satisfies the condition that the first gap is > 0 mm. The first fixing portion 213 at least partially fills the first connecting hole 2241. On one side of the radial direction of the base 21, the tensile strength at the junction of the first connecting portion 2221 and the first fixing portion 213 can be increased through the first connecting hole 2241. The second connecting part 2223 has a third connecting hole 2243. Several third connecting holes 2243 are opened in the axial direction of the base 21. In the projection direction of the axial direction of the third connecting hole 2243, there is a second gap between the outer contour of the projection surface of the third connecting hole 2243 and the outer contour of the projection surface of the second connecting part 2223. The second gap is greater than 0 mm. The second fixing part 217 at least partially fills the third connecting hole 2243. Similarly, on the other side of the radial direction of the base 21, the tensile strength at the joint between the second connecting part 2223 and the second fixing part 217 can also be increased through the third connecting hole 2243.

[0055] At the junction of the third connecting portion 2222 and the end cap portion 216, the third connecting portion 2222 has a second connecting hole 2242. Several second connecting holes 2242 are radially formed in the base 21. In the axial projection direction of the second connecting hole 2242, there is a third interval between the outer contour of the projection surface of the second connecting hole 2242 and the outer contour of the projection surface of the third connecting portion 2222, satisfying that the third interval > 0 mm. The third fixing portion 2161 at least partially fills the second connecting hole 2242. In the axial direction of the base 21, the second connecting hole 2242 increases the tensile strength at the junction of the third connecting portion 2222 and the third fixing portion 2161.

[0056] As an example, at the junction of the third connecting part 2222 and the end cap part 216, the plate part 221 includes an upper section 2213, the upper section 2213 being the aforementioned third connecting part 2222, and the flow port 223 of the upper section 2213 being the aforementioned second connecting hole 2242. The third fixing part 2161 at least partially fills the flow port 223, which can also achieve the purpose of the present invention to improve the tensile strength at the junction of the third connecting part 2222 and the third fixing part 2161.

[0057] Meanwhile, the end face of the base 24 facing the end cap 216 has a groove 218, and the bracket 22 includes a lower section 2214. The lower section 2214 is clearance-fitted with the groove 218, and the filter chamber 210 has an opening at the bottom of the base 21. The base 24 can at least partially close the opening. Through the cooperation between the lower section 2214 and the base 24, combined with the above, the four sides of the bracket 22 can be connected and supported, so that the connection between the bracket 22 and the base 21 is more stable and the tensile strength in freezing environment is improved.

[0058] In this embodiment, the filter assembly 2 further includes a filter screen 23, which includes a first mesh portion 231 and a second mesh portion 232. The first mesh portion 231 is at least partially connected to the plate portion 221 and covers the flow port 223. In the axial direction of the substrate 21, the cross-sectional area of ​​a single flow port 223 is larger than the cross-sectional area of ​​a single filter mesh hole of the filter screen 23. Impurities in the fluid medium flowing through the flow port 223 are filtered through the first mesh portion 231. At least a portion of the connecting portion 222 is connected to the second mesh portion 232, and the second mesh portion 232 and the connecting portion 222 are injection molded to the substrate 21. The second mesh portion 232 increases the contact area between the connecting portion 222 and the injection molded plastic of the substrate 21, thereby further improving the connection strength.

[0059] It should be noted that the first mesh part 231 of the filter screen 23 is closer to the inlet of the valve body component 1 than the bracket 22. It can filter impurities in the fluid medium before the fluid medium flows into the flow port 223, so as to avoid impurities remaining in the flow port 223 and affecting the flow rate of the fluid medium.

[0060] In this embodiment, the filter 23 uses a single-piece filter (such as...). Figure 6-7As shown, the first mesh section 231 and the second mesh section 232 are interconnected, with the first mesh section 231 at least partially connected to the first end face. Based on the cooperation of the second mesh section 232 with the first connecting section 2221, the second connecting section 2223, and the third connecting section 2222 at different positions, an example is given regarding the connection between the second mesh section 232 and the first connecting section 2221. The second mesh section 232 has an outer mesh sheet 2321, an inner mesh sheet 2322, and a flanged section 2321. The flanged section 2321 is connected to the outer mesh sheet 2321 and the inner mesh sheet 2322 on both sides, respectively. The outer mesh sheet 2321 is at least partially connected to the first connecting surface 22211, the inner mesh sheet 2322 is at least partially connected to the second connecting surface 22212, and the flanged section 2321 is at least partially connected to the first side edge 22213, thereby improving the reliability of the connection between the first connecting section 2221 and the first fixing section 213. It is understandable that the connection between the second mesh section 232 and the second connecting section 2223, as well as the connection between the second mesh section 232 and the first connecting section 2221, is equivalent to the connection between the second mesh section 232 and the first connecting section 2221. Its function and the effect it can achieve are the same, and will not be elaborated further here. Therefore, the support 22 can further increase the reliability of its connection with the substrate 21 through the filter screen 23, thereby improving the freeze-thaw tensile strength of the connection point between the substrate 21 and the support 22.

[0061] As an example, it is understood that when filter 23 employs two or more combined filter screens, since each filter screen is a non-integral structure, one filter screen can be at least partially connected to the first end face and the second connecting surface 22212, and another filter screen can be at least partially connected to the second end face and the first connecting surface 22211. This variation can also achieve the aforementioned purpose of increasing the reliability of the connection between the support 22 and the base 21 through filter screen 23.

[0062] In this embodiment, the cylindrical portion 212 includes a first flow channel 214 and a second flow channel 215. Laterally, the first flow channel 214 and the second flow channel 215 are located on opposite sides of the support 22 and communicate with the filter chamber 210. The first flow channel 214 communicates with the inlet, and the second flow channel 215 communicates with the outlet. The plate portion 221 divides the filter chamber 210 into a first filter chamber 2101 and a second filter chamber 2102. The first filter chamber 2101 communicates with the first flow channel 214, and the second filter chamber 2102 communicates with the second flow channel 215. Radially, the cross-sectional area of ​​the first filter chamber 2101 is larger than that of the second filter chamber 2102, allowing more impurities to temporarily accumulate in the first filter chamber 2101 after the fluid medium flowing in from the inlet is filtered by the filter screen 23, thus reducing the cleaning frequency. Simultaneously, as in... Figure 3From the perspective of the first filter chamber 2101, there is a first opening located below the support 22, and the second filter chamber 2102 has a second opening located below the support 22. When the lower end face of the lower section 2214 is not flush with the bottom end face of the base 21 / inner end wall of the valve cap 13, the first opening and the second opening are connected to each other. Therefore, the second opening is closed by the base 24 so that the base 24 isolates the flow space between the first opening and the second opening. The base 24 can prevent impurities in the first filter chamber 2101 from flowing into the second filter chamber 2102 through the flow space, and further prevent impurities from flowing from the second flow channel 215 to the outlet, thus affecting the impurity filtration effect of the filter assembly 2.

[0063] In this embodiment, a portion of the filter assembly 2 extends into the valve core flow channel 30 through the lower through hole. The valve core flow channel 30 has a connecting groove on the inner wall away from the lower through hole along the axial direction of the lower through hole. Another portion of the filter assembly 2 can be clearance-fitted with the connecting groove. A further portion of the filter assembly 2 extends out of the valve core 3 through the lower through hole. The end face of the second valve body 12 relative to the valve cap 13 has a recess 121. The base 21 includes an outer ring portion 219, which is located at the bottom of the cylindrical body portion 212. The upper surface of the outer ring portion 219 is provided with a groove along the lower through hole. The axially extending protrusion 211 of the base 21 is at least partially located in the recess 121, so that the filter assembly 2 can restrict the rotational displacement of the base 21 through the cooperation of the recess 121 and the protrusion 211; the outer ring 219 is located between the valve cap 13 and the second valve body 12, that is, in the axial direction of the base 21, one end of the outer ring 219 abuts against the inner end wall of the valve cap 13, and the other end of the outer ring 219 abuts against the bottom end face of the second valve body 12 inside the valve cap 13, thereby restricting the upward and downward displacement of the filter assembly 2 in the axial direction.

[0064] The aforementioned control valve is mainly used in water heating systems. The internal medium is mainly water. Based on environmental protection requirements, and in situations where it is not allowed to add antifreeze (which would cause pollution during replacement), the connection reliability between the bracket 22 and the base 21 can be improved in a frozen environment, thereby improving the reliability of the control valve's filtration function.

[0065] The following describes the manufacturing method of the filter component in this embodiment, including the following steps:

[0066] Preparation of bracket 22: The metal plate is processed into a blank plate, the blank plate is reserved with a first connecting part 2221, the first connecting part 2221 is processed to form a first side 22213 having at least a first continuous surface 22214, and the other areas of the blank plate are processed to form a plate body 221 including the flow port 223 by etching process.

[0067] The filter assembly 2 is formed by injection molding the substrate 21 with the support 22 as an insert, and the first continuous surface 22214 is at least partially located within the substrate 21. The support 22 can be connected to the substrate 21 through the first continuous surface 22214, thereby improving the connection strength between the support 22 and the substrate 21, improving the strength of the filter assembly 2 itself, and ensuring that the tensile strength meets the requirements of the freezing environment.

[0068] The processing of the blank plate also includes: a second connecting part 2223 and a third connecting part 2222. The second connecting part 2223 is arranged in the same direction as the first connecting part 2221, and a second side 22231 with a second continuous surface 22232 is processed on the second connecting part 2223. The first connecting part 2221 and the second connecting part 2223 are located on both sides of the cylindrical part 212 of the base 21. The third connecting part 2222 is processed with a top edge 22221 with a third continuous surface 22222. The third connecting part 2222 is located on the end cap part 216 of the base 21. When the base 21 is injection molded, the second continuous surface 22232 and the third continuous surface 22222 are located at least partially inside the base 21. The bracket 22 is connected and fixed to the base 21 together with the first connecting part 2221 through the second connecting part 2223 and the third connecting part 2222. This ensures that the two radial ends and the top of the bracket 22 can be reliably connected to the base 21, thus guaranteeing the reliability of the connection between the base 21 and the bracket 22.

[0069] The blank plate is made of stainless steel with a thickness of not less than 0.5 mm. The processing of the blank plate also includes: machining a first connecting hole 2241 in the area of ​​the first connecting part 2221, machining a third connecting hole 2243 in the area of ​​the second connecting part 2223, and machining a second connecting hole 2242 in the area of ​​the third connecting part 2222. The connecting holes in the areas of each connecting part can increase the tensile strength at the joint between the bracket 22 and the base 21.

[0070] The processing of the blank plate also includes bending the edges of the blank plate to form a first connecting part 2221 and a second connecting part 2223. The first connecting part 2221 and the second connecting part 2223 are bent in the same direction relative to the plate body 221. This increases the contact range between the first connecting part 2221 and the first fixing part 213, and the contact range between the second connecting part 2223 and the second fixing part 217, making the connection range between the bracket 22 and the base 21 larger, thereby ensuring the stability of the joint after the bracket 22 and the base 21 are connected.

[0071] The processing of the blank plate also includes bending the plate body 221 to form a first plate body 2211 and a second plate body 2212. This increases the contact surface between the plate body 221 and the fluid medium, thereby improving the filtration of impurities.

[0072] Insert clamping: The insert includes a filter screen 23 connected to the bracket 22. The insert is pre-clamped in the first mold. The first connecting portion 2221, the second connecting portion 2223, and the third connecting portion 2222 are exposed outside the first mold. Before the substrate 21 is prepared, the second mold is closed with the first mold. The first connecting portion 2221, the second connecting portion 2223, and the third connecting portion 2222 are located in the mold cavity after the first mold and the second mold are closed. This ensures that the first connecting portion 2221, the second connecting portion 2223, and the third connecting portion 2222 can be injection molded to the substrate 21, and avoids other areas of the bracket 22 from being covered by the injection molding material.

[0073] The preparation of the substrate 21 includes processing the plastic by heating it to a molten state and applying high pressure to the molten plastic. The molten plastic is injected through an injection molding machine with controlled pressure and speed to fill the mold cavity, thereby integrally injection molding the protrusion 211, the end cap 216, and the cylindrical body 212. The substrate 21 and the support 22 are injection molded together. The preparation also includes installing a base 24 that is connected to the substrate 21 for positioning. The filter assembly 2 isolates the flow space between the first and second openings through the base 24, preventing impurities in the first filter chamber 2101 from flowing into the second filter chamber 2102, and further preventing impurities from flowing out of the second flow channel 215, thus affecting the impurity filtration effect of the filter assembly 2.

[0074] The manufacturing method of the control valve in this embodiment is described below, including the following steps:

[0075] Manufacturing valve body component 1: The processing of the blank also includes processing the first valve body 11, the second valve body 12, the valve cap 13, and the valve core 3. The processing of the valve core 3 includes processing the valve core flow channel 30, the inlet 301, the outlet 302, and the lower through hole. The lower through hole includes an upper orifice that communicates with the valve core flow channel 30, and the lower through hole also includes a lower orifice that communicates with the outer surface of the valve core 3.

[0076] After connecting the first valve body 11 and the second valve body 12, the valve core 3 is installed in the inner cavity 10;

[0077] Preparation of bracket 22: The metal plate is processed into a blank plate, the blank plate includes a first connecting part 2221, the first connecting part 2221 is processed to form a first side 22213 having at least a first continuous surface 22214, and a plate body part 221 including an outlet 223 is processed in a part of the blank plate.

[0078] The filter assembly 2 is formed by injection molding the substrate 21 with the bracket 22 as an insert, and the first continuous surface 22214 is at least partially located within the substrate 21;

[0079] After injection molding, the substrate 21 forms an outer ring 219, and the end of the outer ring 219 forms a protrusion 211 extending along the axial direction of the substrate 21;

[0080] The filter assembly 2 is inserted into the valve core flow channel 30 through the lower through hole. After the valve cap 13 is threadedly connected and fixed to the second valve body 12, the protrusion 211 is limited or fixedly connected to the second valve body 12 by the valve cap 13, thereby fixing the filter assembly 2 and at least partially installing the filter assembly 2 in the inner cavity 10. The filter assembly 2 is at least partially located in the valve body component 1. The rotational displacement of the base 21 is restricted by the cooperation between the recess 121 and the protrusion 211, and the upward and downward axial displacement of the filter assembly 2 is restricted by the outer ring 219, so as to ensure the stability of the filter assembly 2 when filtering impurities in the fluid and improve the filtration reliability.

[0081] The technical features of the above embodiments can be combined. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0082] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and controls without departing from the concept of the present invention, and these modifications and controls all fall within the scope of protection of the present invention.

Claims

1. A control valve with a filtering function, comprising a valve body component (1) and a filter assembly (2), characterized in that, The filter assembly (2) is at least partially located in the inner cavity (10) of the valve body component (1). The filter assembly (2) includes a base (21) and a support (22). The base (21) includes a filter cavity (210). The support (22) includes a plate portion (221) and a connecting portion (222). The plate portion (221) is at least partially located in the filter cavity (210). The plate portion (221) includes an outlet (223). The connecting portion (222) includes a first connecting portion (2221). The first connecting portion (2221) extends along the axial direction of the base (21). The first side (22213) of the first connecting portion (2221) is at least partially a first continuous surface (22214). The support (22) is integrally injection molded with the base (21) as an insert. The first continuous surface (22214) is at least partially located within the base (21).

2. The control valve with filtering function according to claim 1, characterized in that, The first connecting part (2221) has a first connecting hole (2241). Along the projection direction of the first connecting hole (2241) axial direction, the outer contour of the projection surface of the first connecting hole (2241) is located within the outer contour of the projection surface of the first connecting part (2221). The substrate (21) at least partially fills the first connecting hole (2241).

3. The control valve with filtering function according to claim 1 or 2, characterized in that, The base (21) includes a first fixing part (213), and the first connecting part (2221) is bent relative to the plate part (221); The first connecting portion (2221) includes a first connecting surface (22211) and a second connecting surface (22212). In the radial direction of the base (21), the second connecting surface (22212) is closer to the center of the base (21) than the first connecting surface (22211). The first fixing portion (213) at least partially covers the first connecting surface (22211).

4. The control valve with filtering function according to claim 1 or 2, characterized in that, The base (21) includes a first fixing part (213), and the first connecting part (2221) is bent relative to the plate part (221); The first connecting portion (2221) includes a first connecting surface (22211) and a second connecting surface (22212). In the radial direction of the base (21), the second connecting surface (22212) is closer to the center of the base (21) than the first connecting surface (22211). The first fixing portion (213) covers the first connecting surface (22211) and at least part of the second connecting surface (22212).

5. The control valve with filtering function according to claim 1, characterized in that, The base (21) is cylindrical, and the connecting part (222) further includes a second connecting part (2223), which extends along the axial direction of the base (21). The second side (22231) of the second connecting part (2223) is at least partially a second continuous surface (22232). The base (21) further includes a second fixing part (217), and the second continuous surface (22232) is at least partially located within the second fixing part (217). The inner wall of the filter chamber (210) includes a first arcuate wall (2201), a second arcuate wall (2204), a first planar wall (2202), and a second planar wall (2203). The first arcuate wall (2201) and the second arcuate wall (2204) are arranged opposite to each other, and the first planar wall (2202) and the second planar wall (2203) are arranged opposite to each other. The first planar wall (2202) serves as the inner wall of the first fixing part (213), and the second planar wall (2203) serves as the inner wall of the second fixing part (217). In the radial direction of the base (21), the distance between the first planar wall (2202) and the second planar wall (2203) is less than the distance between the first arcuate wall (2201) and the second arcuate wall (2204).

6. The control valve with filtering function according to any one of claims 1-5, characterized in that, The base (21) includes a cylindrical part (212) and an end cap part (216), the end cap part (216) being connected to the end of the cylindrical part (212); the connecting part (222) further includes a third connecting part (2222), the end cap part (216) including a third fixing part (2161), the top edge (22221) of the third connecting part (2222) being at least partially a third continuous surface (22222), the third continuous surface (22222) being at least partially located within the third fixing part (2161).

7. The control valve with filtering function according to claim 6, characterized in that, The third connecting part (2222) has a second connecting hole (2242). Along the projection direction of the axial direction of the second connecting hole (2242), the outer contour of the projection surface of the second connecting hole (2242) is located within the outer contour of the projection surface of the third connecting part (2222). The third fixing part (2161) at least partially fills the second connecting hole (2242).

8. The control valve with filtering function according to any one of claims 1-5, characterized in that, The bracket (22) is a metal plate, and the plate body (221) includes the flow port (223) formed by etching; the filter assembly (2) also includes a base (24), the base (21) includes a cylindrical body (212) and an end cap (216), the cylindrical body (212) includes an upper end and a lower end, the end cap (216) is integrally formed with or limitedly connected to the upper end, the base (24) is limitedly connected to the lower end, and the base (24) has a groove ( 218), the plate portion (221) extends axially along the base (21), at least one end of the plate portion (221) is engaged with the groove portion (218), and the other end of the plate portion (221) is connected to the end cap portion (216); the first fixing portion (213) also partially covers at least a portion of the plate portion (221), or the first fixing portion (213) also partially fills at least a portion of the flow port (223) through the plate portion (221); The plate portion (221) includes a first plate portion (2211) and a second plate portion (2212), wherein the first plate portion (2211) is bent relative to the second plate portion (2212); the cylindrical portion (212) includes a first flow channel (214) and a second flow channel (215), wherein the first flow channel (214) and the second flow channel (215) are connected to the filter chamber (210); the valve body component (1) has an inlet and an outlet, wherein the first flow channel (214) is connected to the inlet, and the second flow channel (215) is connected to the outlet; the bent portions of the first plate portion (2211) and the second plate portion (2212) are close to the outlet.

9. The control valve with filtering function according to any one of claims 1-5, characterized in that, The valve body component (1) has an inlet, and the plate portion (221) has a first end face and a second end face. In the transverse direction of the control valve, the first end face is closer to the inlet than the second end face. The filter assembly (2) further includes a filter screen (23), which includes a first mesh portion (231) and a second mesh portion (232). The first mesh portion (231) is connected to at least a portion of the first end face. The first mesh portion (231) covers the outlet (223). In the axial direction of the base (21), the cross-sectional area of ​​a single outlet (223) is larger than the cross-sectional area of ​​a single filter hole of the filter screen (23). At least a portion of the connecting portion (222) is connected to the second mesh portion (232). The second mesh portion (232) and the connecting portion (222) are injection molded to the base (21).

10. The control valve with filtering function according to any one of claims 1-9, characterized in that, The control valve is a ball valve. The valve body component (1) includes a first valve body (11), a second valve body (12), and a valve cap (13). The first valve body (11) is connected to the second valve body (12), and the valve cap (13) is threadedly connected to the second valve body (12). The control valve further includes a valve core (3), which is located in the inner cavity (10). The valve core (3) includes a valve core flow channel (30), an inlet (301), an outlet (302), and a lower through hole. In the longitudinal direction of the control valve, the lower through hole is located below the valve core flow channel (30). The upper opening of the lower through hole communicates with the valve core flow channel (30). The outer surface of the valve core (3) has the lower opening of the lower through hole. The valve core flow channel (20) communicates with the inlet (201) and the outlet (202). The valve core flow channel (30) has a connecting groove on the inner wall away from the lower through hole along the axial direction of the lower through hole. One of the filter components (2) Part of the filter assembly (2) extends into the valve core flow channel (20) through the lower through hole, and another part of the filter assembly (2) can cooperate with the connecting groove. A third part of the filter assembly (2) extends out of the valve core (3) through the lower through hole. The base (21) includes an outer ring (219). The end of the outer ring (219) is provided with a protrusion (211) extending axially along the base (21). The end face of the second valve body (12) relative to the valve cap (13) has a recess (121). The protrusion (211) is at least partially located in the recess (121). The outer ring (219) is located between the valve cap (13) and the second valve body (12).

11. A method for manufacturing a filter assembly, characterized in that, Includes the following steps: Preparation of the support (22): The metal plate is processed into a blank plate, the blank plate including a first connecting part (2221), the first connecting part (2221) is processed to form a first side (22213) having at least a first continuous surface (22214), and a plate body (221) including an outlet (223) is processed in a part of the blank plate; The filter assembly (2) is formed by injection molding the support (22) as an insert into the substrate (21), and the first continuous surface (22214) is at least partially located within the substrate (21).

12. The method for manufacturing the filter assembly according to claim 11, characterized in that, The processing of the blank plate also includes a second connecting part (2223) and a third connecting part (2222). The second connecting part (2223) is arranged in the same direction as the first connecting part (2221), and a second side (22231) with a second continuous surface (22232) is processed on the second connecting part (2223). The first connecting part (2221) and the second connecting part (2223) are at least partially located on both sides of the cylindrical part (212) of the base (21). The third connecting part (2222) is processed with a top edge (22221) with a third continuous surface (22222). The third connecting part (2222) is at least partially located on the end cap part (216) of the base (21). After the base (21) is injection molded, the second continuous surface (22232) and the third continuous surface (22222) are at least partially located inside the base (21).

13. The method for manufacturing the filter assembly according to claim 12, characterized in that, The processing of the blank plate also includes: bending the edge of the blank plate to form the first connecting part (2221) and the second connecting part (2223), wherein the first connecting part (2221) and the second connecting part (2223) are bent in the same direction relative to the plate body part (221).

14. The method for manufacturing the filter assembly according to claim 13, characterized in that, The blank plate is a stainless steel plate with a thickness of not less than 0.5 mm. The processing of the blank plate also includes preparing connecting holes (224). A first connecting hole (2241) is processed in the area where the first connecting part (2221) is located, a third connecting hole (2243) is processed in the area where the second connecting part (2223) is located, and a second connecting hole (2242) is processed in the area where the third connecting part (2222) is located. The insert is clamped: The insert includes a filter screen (23) connected to the bracket (22). The insert is pre-clamped in the first mold. The first connecting part (2221), the second connecting part (2223) and the third connecting part (2222) are exposed outside the first mold. Before the substrate (21) is prepared, the second mold is closed with the first mold. The first connecting part (2221), the second connecting part (2223) and the third connecting part (2222) are located in the mold cavity after the first mold and the second mold are closed.

15. A method for manufacturing a control valve, characterized in that, Includes the following steps: Preparation of valve body component (1): The processing of the blank also includes processing the first valve body (11), the second valve body (12), the valve cap (13), and the valve core (3). The processing of the valve core (3) includes processing the valve core flow channel (30), the inlet (301), the outlet (302), and the lower through hole. The lower through hole includes an upper opening that communicates with the valve core flow channel (30) and a lower opening that communicates with the outer surface of the valve core (3). Connect the first valve body (11) and the second valve body (12), and install the valve core (3) in the inner cavity (10); Preparation of the support (22): The metal plate is processed into a blank plate, the blank plate including a first connecting part (2221), the first connecting part (2221) is processed to form a first side (22213) having at least a first continuous surface (22214), and a plate body (221) including an outlet (223) is processed in a part of the blank plate; A filter assembly (2) is formed by injection molding a substrate (21) with the bracket (22) as an insert, and the first continuous surface (22214) is at least partially located within the substrate (21); After injection molding, the substrate (21) forms an outer ring (219), and the end of the outer ring (219) forms a protrusion (211) extending along the axial direction of the substrate (21); The filter assembly (2) is inserted into the valve core flow channel (30) through the lower through hole. After the valve cap (13) is threadedly connected and fixed to the second valve body (12), the protrusion (211) is limited or fixedly connected to the second valve body (12) through the valve cap (13) to fix the filter assembly (2) and at least partially install the filter assembly (2) in the inner cavity (10).

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