A gas proportional valve and a gas appliance using the same

Abstract

The application relates to a gas proportional valve and a gas appliance applying the same, which comprises a valve mechanism, a coil assembly fixed at the lower end of the valve mechanism, a skeleton, a magnetic coil wound around the outer periphery of the skeleton and an injection shell encapsulating the magnetic coil, a support, a supporting part supporting the lower end of the injection shell and a mounting part extending upwards from the outer periphery of the supporting part and fixedly connected with the valve cover, so that the injection shell is clamped and fixed between the support and the valve cover, the whole encapsulation of the skeleton after the winding of the magnetic coil by the injection shell effectively improves the insulation, moisture resistance and mechanical protection performance of the magnetic coil, prevents oxidation and enhances long-term reliability in a high-temperature and high-humidity environment.

Description

Technical Field

[0001] This application relates to the field of gas proportional valve technology, specifically to a gas proportional valve and its application in gas appliances. Background Technology

[0002] Gas proportional valves are key actuators in household gas appliances such as gas water heaters and gas boilers, primarily used to precisely adjust the gas supply according to actual heat load requirements. As the core component for achieving proportional regulation, the electromagnetic coil assembly in the gas proportional valve plays a crucial role in converting electrical signals into mechanical actions. When control current passes through the coil, the generated electromagnetic force drives the proportional valve core to move, thereby adjusting the valve opening and achieving precise control of the gas flow.

[0003] Currently, these electromagnetic coil assemblies are generally made of copper wire due to their excellent conductivity and stable electrical characteristics. However, the continuous fluctuations in raw material market prices have brought significant uncertainty to manufacturers' cost budgets and weakened the price competitiveness of their products in the low-to-mid-end market.

[0004] Therefore, aluminum wire, as an alternative material, has significant potential for reducing material costs due to its relatively low price and good conductivity.

[0005] However, the surface of aluminum wire readily reacts with oxygen in the air, forming a dense but poorly conductive aluminum oxide insulating layer. This oxide layer significantly increases the contact resistance and overall resistance of the coil, leading to increased heating of the electromagnetic coil, decreased energy efficiency, and directly affecting the response accuracy and long-term operational stability of the gas proportional valve.

[0006] Furthermore, even when using copper wire, an oxide layer may still form on the surface of the coil during winding, welding, and long-term operation, which can also adversely affect its electrical performance.

[0007] Therefore, how to effectively suppress the oxidation of electromagnetic coils (especially aluminum wire or copper-clad aluminum wire) during manufacturing, storage and long-term service, and improve their electrical stability, has become a technical problem that urgently needs to be solved to improve the safety of gas proportional valves, extend their service life and promote the application of low-cost materials. Summary of the Invention

[0008] To address the aforementioned problems, this application proposes a gas proportional valve and a gas appliance using it. The aim is to effectively prevent oxidation of the gas proportional valve's electromagnetic coil by optimizing the structure of the injection-molded shell of the electromagnetic coil formed by injection molding the skeleton of the gas proportional valve's winding electromagnetic coil.

[0009] To achieve the above objectives, the present application adopts the following technical solution:

[0010] In a first aspect, this application proposes a gas proportional valve, including a valve mechanism and a coil assembly fixed at the lower end of the valve mechanism. The lower end of the valve mechanism is provided with a magnet and a valve cover, and the coil assembly is fixed to the valve cover and drives the magnet.

[0011] The coil assembly includes a frame, an electromagnetic coil wound around the outer periphery of the frame, and an injection-molded shell encapsulating the electromagnetic coil. The frame extends axially and has a hollow inner cavity, and an adjusting bolt is provided inside the hollow inner cavity.

[0012] It also includes a bracket, which includes a support portion supporting the lower end of the injection-molded housing and a mounting portion extending upward from the outer periphery of the support portion and fixedly connected to the valve cover, such that the injection-molded housing is clamped and fixed between the bracket and the valve cover.

[0013] In this way, by encapsulating the entire frame after the electromagnetic coil is wound with an injection-molded shell, the insulation, moisture resistance and mechanical protection performance of the electromagnetic coil are effectively improved, preventing oxidation and enhancing its long-term reliability in high temperature and high humidity environments.

[0014] Meanwhile, the support part of the bracket supports the injection-molded shell from below, and the mounting part is fixedly connected to the valve cover, forming an "upper and lower clamping" constraint on the injection-molded shell, which improves the sealing performance of the injection-molded shell.

[0015] In some possible implementations, the injection-molded housing is an integral structure formed by injection molding the skeleton in the state of the wound electromagnetic coil.

[0016] In some possible implementations, the electromagnetic coil is a copper-clad aluminum wire or an aluminum wire.

[0017] In some possible implementations, the frame includes an upper coil winding portion and a lower wiring mounting portion, the wiring mounting portion being provided with lead wire ends.

[0018] In some possible implementations, the injection-molded housing encloses the coil winding portion and the wiring mounting portion.

[0019] In some possible implementations, the injection-molded housing extends centrally from the bottom of the wiring mounting portion and is held between the bottom of the wiring mounting portion and the support portion of the bracket.

[0020] In some possible implementations, the injection-molded housing extends centrally from the top of the skeleton and is held between the top of the skeleton and the bottom of the valve cover.

[0021] In some possible implementations, a solenoid valve assembly capable of opening and closing the gas intake is also included.

[0022] Secondly, this application also proposes gas appliances that utilize the solenoid valve described above. Attached Figure Description

[0023] Figure 1 This is an overall schematic diagram of the gas proportional valve of this application;

[0024] Figure 2 This is a cross-sectional view of the gas proportional valve in this application from the direction of the air inlet;

[0025] Figure 3 This is a cross-sectional view of the gas proportional valve in this application, showing the direction of the gas outlet.

[0026] Figure 4 This is an overall schematic diagram of the coil assembly in this application;

[0027] Figure 5 This is an exploded view of the coil assembly in this application;

[0028] Figure 6 This is an exploded schematic diagram of the skeleton, electromagnetic coil, and injection-molded shell in this application;

[0029] Figure 7 This is a cross-sectional view of the coil assembly in this application;

[0030] Figure 8 A schematic diagram of a gas water heater in which the gas proportional valve of this application is used. Detailed Implementation

[0031] The following examples further illustrate the features of this application and other related features in detail, so as to facilitate understanding by those skilled in the art:

[0032] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions in the attached diagrams, while the terms “bottom surface,” “top surface,” “inner,” and “outer” refer to the directions toward or away from the geometric center of a specific component, respectively.

[0033] Furthermore, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this case based on the specific circumstances.

[0034] Please refer to Figure 1 and Figure 8The gas proportional valve 100 of this application is used in gas appliances. In this embodiment, a gas water heater is used as an example for illustration. It can also be applied to gas-consuming products such as gas wall-hung boilers. The gas water heater has a water inlet 110, a water outlet 120, and a gas inlet 130 at its lower end. The gas proportional valve 100 of this application is located at the rear end of the gas inlet 130 and installed inside the gas water heater. The working principle of the gas water heater is a conventional technical means in the industry and will not be described in detail in this case.

[0035] Please refer to Figures 1 to 3 The gas proportional valve 100 of this application includes a valve mechanism 10 and a coil assembly 20 at its lower end. In some embodiments, a solenoid valve assembly 30 for opening and closing gas intake and the gas proportional valve 100 for regulating gas intake are sequentially arranged between the gas source inlet 1 and the gas source outlet 2. The solenoid valve assembly 30 and the gas proportional valve 100 are designed as an integrated valve body 11. The electromagnetic force generated by energizing the coil assembly 20 drives the proportional valve core 12 of the valve mechanism 10 to move, thereby adjusting the valve opening and achieving precise control of gas flow.

[0036] The working principle of valve mechanism 10 is a conventional technology used in existing gas water heaters. To better illustrate the gas proportional valve 100 of this application, valve mechanism 10 will be further described. It includes a valve body 11, and is provided with a gas source inlet 1, a gas source outlet 2, and a valve port 13. The lower end of valve port 13 is connected to the gas source inlet 1, and the upper end of valve port 13 is connected to the gas source outlet 2. In the non-working state, valve port 13 is blocked by proportional valve seat 14 and piston cup 15, isolating the connection between gas source inlet 1 and gas source inlet 2. At the lower end of valve port 13, a proportional valve core 12 pushes the proportional valve seat 14 upward, causing the piston cup 15 to disengage from valve port 13, thereby adjusting the gas flow.

[0037] Furthermore, a base plate 16 is provided at the upper end of the proportional valve seat 14, and a return spring 17 is provided between the base plate 16 and the proportional valve seat 14 to support the proportional valve seat 14 in resetting. A magnet 18 is fixed to the lower end of the proportional valve core 12, and a valve cover 19 is provided. A support spring 121 is provided between the lower end of the valve core 12 and the bottom of the valve cover 19 to prevent the magnet 18 and the proportional valve core 12 from falling due to their own weight. That is, the lower end of the valve mechanism 10 is provided with a magnet 18 and a valve cover 19, and the coil assembly 20 is fixed to the valve cover 19 and drives the magnet 18. The magnet 18 drives the proportional valve core 12 to push the proportional valve seat 14 upward.

[0038] Furthermore, a diaphragm 191 is provided at the connection between the valve cover 19 and the valve body 11 to isolate the proportional valve core 12 and the proportional valve seat 14, and a vent 192 is provided on the valve cover 19 to communicate with the space at the lower end of the diaphragm 191.

[0039] Please refer to Figures 4 to 7 The coil assembly 20 is described in detail below. The coil assembly 20 includes a frame 21, an electromagnetic coil 22 wound around the outer periphery of the frame 21, and an injection-molded shell 23 enclosing the electromagnetic coil 22. The frame 21 extends axially and has a hollow inner cavity, and an adjusting bolt 24 is provided in the hollow inner cavity for adjusting the distance with the magnet 18.

[0040] In conventional applications, copper wire is commonly used for electromagnetic coils 22. However, as mentioned above, the price of copper wire fluctuates significantly. Aluminum wire can be used instead, which not only reduces costs but also provides a larger heat dissipation area, thus reducing temperature rise. Alternatively, copper-clad aluminum wire can be used, replacing it with copper-clad aluminum wire or aluminum wire. By changing the wire diameter of the copper-clad aluminum wire or aluminum wire, the resistance remains the same. Simultaneously, the current and ampere-turns remain essentially unchanged, and the opening and closing voltages meet the usage requirements.

[0041] Specifically, the injection-molded outer shell 23 is an integral structure formed by injection molding the skeleton 21 in the state of the wound electromagnetic coil 22. This isolates the electromagnetic coil 22 from the air and prevents oxidation. Suitable injection molding materials include polyamide (PA, nylon), polyphenylene sulfide (PPS), polyoxymethylene (POM), etc., without specific limitations.

[0042] Furthermore, it also includes a bracket 25, which includes a support portion 251 supporting the lower end of the injection-molded housing 23 and a mounting portion 252 extending upward from the outer periphery of the support portion 251 and fixedly connected to the valve cover 19. In this case, the injection-molded housing 23 is clamped and fixed between the bracket 25 and the valve cover 19. The outer side of the support portion 251 can be adjusted by adjusting the adjusting bolt 26 via an adjusting nut 27.

[0043] Further, the frame 21 includes an upper coil winding portion 211 and a lower wiring mounting portion 212. The wiring mounting portion 212 is provided with a lead-out end 26, which is connected to an external power source. The injection-molded housing 23 encloses the coil winding portion 211 and the wiring mounting portion 212. Preferably, the injection-molded housing 23 extends from the bottom of the wiring mounting portion 212 towards the center, forming a lower extension portion 231, and is thus clamped by the bottom of the wiring mounting portion 212 and the support portion 251 of the bracket 25.

[0044] Preferably, the injection-molded housing 23 extends from the top of the frame 21 toward the center to form an upper extension 232, and is held by the top of the frame 21 and the bottom of the valve cover 19.

[0045] In this way, by encapsulating the skeleton 21 after the electromagnetic coil 22 is wound around the injection-molded shell 23, the insulation, moisture resistance and mechanical protection performance of the electromagnetic coil 22 are effectively improved, its oxidation is prevented, and its long-term reliability in high temperature and high humidity environments is enhanced.

[0046] Meanwhile, the support portion 251 of the bracket 25 supports the injection-molded housing 23 from below, and the mounting portion 252 is fixedly connected to the valve cover 19, forming an "upper and lower clamping" constraint on the injection-molded housing, which improves the sealing performance of the injection-molded housing 23.

[0047] As stated above, this case protects a gas proportional valve and gas appliances using it. All technical solutions that are the same as or similar to this case should be considered to fall within the scope of protection of this case.

Claims

1. A gas proportional valve, characterized in that, Includes a valve mechanism (10) and a coil assembly (20) fixed to the lower end of the valve mechanism (10). The lower end of the valve mechanism (10) is provided with a magnet (18) and a valve cover (19). The coil assembly (20) is fixed to the valve cover (19) and drives the magnet (18). The coil assembly (20) includes a frame (21), an electromagnetic coil (22) wound around the outer periphery of the frame (21), and an injection-molded shell (23) enclosing the electromagnetic coil (22). The frame (21) extends axially and has a hollow inner cavity, and an adjusting bolt (24) is provided in the hollow inner cavity. It also includes a bracket (25), which includes a support portion (251) supporting the lower end of the injection-molded housing (23) and a mounting portion (252) extending upward from the outer periphery of the support portion (251) and fixedly connected to the valve cover (19), such that the injection-molded housing (23) is clamped and fixed between the bracket (25) and the valve cover (19).

2. A gas proportional valve as described in claim 1, characterized in that, The injection-molded outer shell (23) is an integral structure formed by injection molding the skeleton (21) in the state of the wound electromagnetic coil (22).

3. A gas proportional valve as described in claim 1, characterized in that, The electromagnetic coil (22) is made of copper-clad aluminum wire or aluminum wire.

4. A gas proportional valve as described in claim 1, characterized in that, The frame (21) includes an upper coil winding part (211) and a lower wiring mounting part (212), the wiring mounting part (212) being provided with lead wire end (26).

5. A gas proportional valve as described in claim 4, characterized in that, The injection-molded housing (23) encloses the coil winding portion (211) and the wiring mounting portion (212).

6. A gas proportional valve as described in claim 5, characterized in that, The injection-molded housing (23) extends from the bottom of the wiring mounting part (212) toward the center and is held by the bottom of the wiring mounting part (212) and the support part (251) of the bracket (25).

7. A gas proportional valve as described in claim 1, characterized in that, The injection-molded housing (23) extends from the top of the frame (21) toward the center and is held between the top of the frame (21) and the bottom of the valve cover (19).

8. A gas proportional valve as described in claim 1, characterized in that, It also includes a solenoid valve assembly (30) that can open and close the gas intake.

9. A gas appliance, characterized in that, The gas proportional valve as described in any one of claims 1 to 8 is used.

Images