Distribution block for air distribution in compressed air systems of commercial vehicles

Abstract

A manifold block for air distribution in compressed air systems of commercial vehicles, comprising at least two interconnected modules (1, 9, 11) with bodies, at least one through-hole mounting (3), at least one through-hole (8), at least one screw (14), and seals (12) between the modules (1, 9, 11), wherein the manifold block includes two external modules: an upper module (1) and a lower module (9), each equipped with a central coaxial blind bore (2), with identical bores (2) in other modules (11), wherein each external module (1, 9) has at least two through-hole mounting (3) parallel to a central axis of the modules (1, 9, 11), in which screws (14) are fastened, which project beyond the external modules (1, 9) and terminate with threaded ends (15) on each side, serving for connection to a vehicle frame (19), wherein coupling sockets (5) with coupling parts inserted therein (20, 21,22) or coupling boxes (5) with closure caps are provided in each external module (1, 9) in its opposite side walls (4), wherein in the upper wall (10) of the external lower module (9) and the lower wall (6) of the external upper module (1) a recess (7) is provided along the edge of each side wall (4) with coupling boxes (5), equipped with three through holes (8) which interact with a locking element (23) having a transverse beam (24) with three vertical lower projections (25) and three vertical upper projections (25) set therein, and wherein the external modules (1, 9) are made of plastic with at least 30% glass fiber content.

Description

[0001] The subject of the invention is a distribution block for air distribution in compressed air systems of commercial vehicles, in particular for compressed air distribution to their individual receiving devices in pneumatic braking systems and suspensions of commercial vehicles.

[0002] From application description US 2011 / 0 168 285 A1, a modular distributor is known for distributing fluids to equipment such as a plastic injection molding machine, and in particular to the coolant line. The modular fluid distributor according to the invention comprises at least two modules. Each module has a body, openings, at least one mounting opening, at least one through-hole, and at least one fastening element in the form of screws. The body includes a pair of opposite end surfaces, a lower surface and an opposite upper surface, and a pair of opposite side surfaces. Openings in each opposite end surface are fluidly coupled to define the portion of the internal chamber extending beyond the body. Mounting ports are connected to the internal chamber. The through-hole traverses the body between the opposite end surfaces.At least one fastener can be inserted through at least one through-hole to permanently connect at least two modules in the modular fluid distributor.

[0003] Previously known manifolds for air distribution in commercial vehicle compressed air systems are monoliths made of aluminum alloys, requiring time-consuming machining from a homogeneous aluminum alloy block during the manufacturing process. These manifolds used coupling sockets, which were then fitted with brass couplings, causing leaks and air leaks. The previously used metal alloy manifolds corroded and were not resistant to mechanical stress, requiring additional protection in the form of protective coatings.

[0004] Another disadvantage of the solutions used so far is their weight and complicated assembly method.

[0005] Further prior art is disclosed in the documents DE 10 2017 116 417 A1 and DE 103 17 819 A1.

[0006] The commercial vehicle sector lacks solutions that improve functionality, reduce weight, improve functionality and configurability, and reduce manufacturing costs. To date, no modular distribution blocks have been used for air distribution in commercial vehicle compressed air systems, particularly for compressed air distribution to the individual receivers in pneumatic braking systems and commercial vehicle suspensions.

[0007] The invention aims to provide a solution that can be easily adapted to customer needs, is quick to connect and install, allows any combination desired by the customer, and represents a distributor with a fixed construction that saves the space required for block mounting in the vehicle, is lightweight, corrosion-resistant and does not require any additional protection.

[0008] The distribution block according to the invention for air distribution in compressed air systems of commercial vehicles has at least two interconnected modules with bodies, at least one assembly opening, at least one through-hole, at least one fastening element, and seals between modules, wherein the distribution block contains two external modules: an upper module and a lower module, each equipped with a central coaxial blind hole, with an identical hole in other modules, wherein each external module has at least two through-mounting holes parallel to a central axis of the modules, in which screws are fastened, which protrude beyond the external modules and have threaded ends on each side, which serve for connection to the vehicle frame, wherein coupling sockets with coupling parts inserted therein or coupling sockets with closure caps are designed in each external module in its opposite side walls,wherein in the upper wall of the external lower module and the lower wall of the external upper module, a recess is formed along the edge of each side wall with coupling sockets, equipped with three through holes, which cooperate with a locking element comprising a crossbar with three vertical lower projections and three vertical upper projections set therein, and wherein the external modules are made of plastic with at least 30% glass fiber content.

[0009] Preferably, the distribution block comprises at least one internal module, placed between the external modules, equipped with a central coaxial through-hole, with an identical hole in other modules, equipped with at least two through-mounting holes parallel to the central module axis, in which screws are fastened, and coupling sockets with coupling parts placed therein or coupling sockets with closing caps, which are made in two opposite side walls of the at least one internal module, wherein in the upper and lower wall of the at least one internal module a recess is made along the edge of each side wall with coupling sockets, equipped with three through-holes which cooperate with a locking element with crossbar with three vertical lower projections and three vertical upper projections placed therein, wherein the internal module is made of plastic with at least 30% glass fiber content.

[0010] In the manifold block, O-ring seals are set in a groove in the top wall of the lower external module, in the bottom wall of the upper external module, and in the top and bottom walls of each internal module.

[0011] Coupling parts are permanently installed in the coupling socket: plug-in sleeve, cutting ring, O-ring.

[0012] The lower projections of the locking element cooperate with the plug-in sleeve in the lower external module or internal module, and the upper projections of the locking element cooperate with openings in the top-mounted upper external module or internal module.

[0013] Each module is equipped with at least three coupling sockets.

[0014] The solution according to the invention is a modular plastic block characterized by its robust construction, compact dimensions, and lightweight, which makes it a perfect replacement for the previously used metal alloy distribution blocks. The distribution block in question consists of individual modules that can be easily and flexibly configured. This allows for the practical assembly of any desired combination by the customer using a few basic elements. Various combinations are possible, differing in the number of coupling sockets for connecting compressed air lines and their size. Variants of the target configurations of the distribution block are assembled like building blocks, which significantly reduces its assembly time. This solution also allows the customer to assemble it independently.The recipient can assemble any distribution block configuration – depending on the specific needs at the time – by purchasing a few components that differ in the number and size of the inlets. The solid construction of the distribution block saves the space required for block installation on the vehicle. The material from which the distribution block body is constructed is plastic, i.e., polyamide with the addition of at least 30% glass fiber. This material is approximately 60% lighter than previously used light alloys. This reduces the overall weight of the vehicle, which directly affects fuel consumption and, consequently, environmental pollution. The material used, in addition to being lightweight, does not corrode and is sufficiently resistant to mechanical stress. The material does not require additional protection such as protective coatings.It is a product that meets the requirements of standards applicable in the automotive industry that determine corrosion resistance, such as PN-EN ISO 9227, ASTM B-117-73, ASTM B368.

[0015] The subsequent advantage of the solution is a reduced number of connections that generate potential leaks. Previous manifold block solutions were constructed from aluminum alloys, in which coupling sockets were located, into which brass couplings were then inserted. Each such connection to the block is a potential source of leaks and air leaks. In the solution according to the invention, the number of such connections is at least half as the coupling socket is made directly from plastic. Each element of the compressed air system is connected directly to the manifold block via a single line, without the need for additional couplings, adapters, reducers, etc.

[0016] The invention was presented on the drawing on which the Fig. the upper external module in bottom view, Fig. - the upper external module in side view; Fig. the upper external module viewed from above; Fig. - the upper external module in perspective view; Fig. the lower external module in bottom view, Fig. - the lower external module in side view; Fig. the lower external module in top view; Fig. - the upper external module in perspective view; Fig. shows the internal module in bottom view, Fig. - the internal module in side view; Fig. the internal module viewed from above; Fig. - the internal module in section A - A; Fig. shows the upper external module in perspective view; Fig. shows the removed distribution block, consisting of the upper external module and lower external module with screw; Fig. shows the assembled distribution block, consisting of the upper external module and lower external module; Fig. shows the removed distribution block, consisting of the upper external module, one module and the lower external module with screw; Fig. shows the assembled distribution block, consisting of the upper external module, an internal module and the lower external module; Fig. shows an assembled distribution block containing the upper external module, two internal modules and the lower external module with wires in coupling sockets, mounted on the vehicle frame; Fig. shows the coupling socket structure with coupling parts in perspective partial section; Fig. shows the coupling socket structure with coupling parts in section BB; Fig. shows the removed locking element and the internal module; Fig. shows the locking element mounted to the internal module.

[0017] The Fig. The upper external module 1 shown is equipped with a central, coaxial through-hole 2, identical to the hole 2 in other modules, as well as two through-holes 3 parallel to the central module axis 1 for mounting. Two coupling sockets 5 are provided in each of the two opposite side walls 4, with coupling parts fixed therein (not visible in the drawing). In the lower wall 6 of the upper external module 1, two recesses 7 are provided along the edge of each side wall 4, containing coupling sockets 5, each equipped with three square through-holes 8. The module 1 is made of polyamide with an added content of at least 30% glass fibers.

[0018] The Fig. The lower external module 9 shown is equipped with a central, coaxial through-hole 2, identical to the hole in other modules, as well as two through-holes 3 parallel to the central module axis 9 for mounting. Three coupling sockets 5 are made in two opposite side walls 4, two with the coupling parts fixed therein (invisible in the drawing), and one with a closing cap (invisible in the drawing). In the upper wall 10 of the lower external module, two recesses 7 are made along the edge of each side wall 4 with coupling sockets 5, equipped with three square through-holes 8. The module 9 is made of polyamide with the addition of at least 30% glass fiber.

[0019] The Fig. The internal module 11 shown is equipped with a central, coaxial through-hole 2, identical to the hole 2 in other modules, as well as two through-holes 3 parallel to the central axis for mounting. One side wall 4 contains two connector sockets 5 with the connector parts fixed therein (invisible in the drawing). The opposite side wall 4 contains two connector sockets 5: one with the connector parts fixed therein (invisible in the drawing), and the other with a cover cap. In the upper wall 10 and the lower wall 6 of the internal module 11, two recesses 7 are provided along the edge of each side wall 4 with connector sockets 5, each equipped with three square through-holes 8. The module 11 is made of polyamide with 30% glass fiber added.

[0020] The block tightness among its individual modules 1, 9, 11 is determined by the Fig. and Fig. illustrated O-ring seal 12, set in the groove 13 on the upper wall 10 of the lower external module 9, the lower wall 6 of the upper external module 1 and the upper wall 10 and the lower wall 6 of each internal module 11.

[0021] On the Fig. The disassembled and assembled distribution block, consisting of the upper external module 1 and the lower external module 9, is shown. Two mounting screws 14, which secure the modules 1, 9, extend through two through holes 3 parallel to the central axis of the modules 1, 9 for mounting each module 1, 9. The screws 14 protrude beyond the external modules 1, 9 and have threaded ends 15 on each side for connection to the vehicle frame. The modules 1, 9 of the block are secured with nuts 16 and spring washers 17.

[0022] On the Fig. The disassembled and assembled distribution block, consisting of the upper external module 1, an internal module 11, and the lower external module 9, is shown. Two mounting screws 14, which secure the modules 1, 9, 11, extend through two through holes 3 parallel to the central axis of the modules 1, 9, 11 for mounting each module 1, 9, 11. The screws 14 protrude beyond the external modules 1, 9 and end on each side with a threaded end 15 for connection to the vehicle frame. The modules 1, 9, 11 of the block are secured with nuts 16 and spring washers 17.

[0023] On the Fig. the assembled distribution block was shown, consisting of the upper external module 1, two internal modules 11 and the lower external module 9. Two mounting screws 14, which fasten the modules 1, 9, 11, extend through two through holes 3 parallel to the central axis of the modules 1, 9, 11 for mounting each module 1, 9, 11. The screws 14 protrude beyond the external modules 1, 9 and have a threaded end 15 on each side. Cables 18 are mounted in the coupling sockets 5 of the modules 1, 9, 11. The modules 1, 9, 11 of the block are secured with nuts 16 and spring washers 17. The entire distribution block is attached to the vehicle support frame 19 with screws 14 with a threaded end 15, onto which mounting nuts 16 and spring washers 17 are placed.

[0024] The technically known solutions have coupling sockets, usually with threads, into which couplings are screwed, which allow the connection of compressed air lines. Fig. As shown, the block according to the invention has no couplings set in the coupling socket 5, which can represent independent elements. In each of the modules 1, 9, 11 of the block, coupling sockets 5 are provided, in which coupling parts are permanently set: plug-in sleeve 20, cutting ring 21, O-ring 22.

[0025] The elements inserted into individual coupling sockets 5 are secured against failure. The cutting ring 21 is automatically secured against failure after insertion into the plug-in sleeve 20 by its own construction - cone with longitudinal cuts that expand when pressed into the plug-in sleeve 20. The O-ring 21 is pressed into the coupling socket 5 by the plug-in sleeve 20. On the other hand, the plug-in sleeve 20 is protected from failure from the coupling socket 5 by the Fig. The locking element 23 is secured by a crossbar 24 with three vertical lower projections 25 and three vertical upper projections 25. The lower projections 25 of the locking element 23 act with the Fig. shown plug-in sleeve 20 in the lower external module 9 or in the internal module 11, and the upper projections 25 of the locking element 23 cooperate with openings 8 in the top-mounted, upper external module 1 or in the internal module 11. As the Fig. As shown, the plug-in sleeve 20 has a special circumferential notch 26. After inserting the plug-in sleeve 20 into the coupling socket 5, projections 25 of the locking element 23 are pressed into the square openings 8. The projections 25 interlock the notches 26 in the plug-in sleeve 20 and form a secure protection against the plug-in sleeve 20 falling out of the coupling socket 5.

Claims

[1] A distribution block for air distribution in compressed air systems of commercial vehicles, comprising at least two interconnected modules (1, 9, 11) with bodies, at least one through-mounting bore (3), at least one through-bore (8), at least one screw (14), and seals (12) between the modules (1, 9, 11), wherein the distribution block contains two external modules: an upper module (1) and a lower module (9), each equipped with a central coaxial blind bore (2), with an identical bore (2) in other modules (11), wherein each external module (1, 9) has at least two through-mounting bores (3) parallel to a central axis of the modules (1, 9, 11), in which screws (14) are fastened, which project beyond the external modules (1, 9) and end with threaded ends (15) on each side, which serve for connection to a vehicle frame (19), wherein coupling sockets (5) with set coupling parts (20, 21,22) or coupling sockets (5) with closure caps are provided in each external module (1, 9) in its opposite side walls (4), wherein in the upper wall (10) of the external lower module (9) and the lower wall (6) of the external upper module (1) a recess (7) is provided along the edge of each side wall (4) with coupling sockets (5), equipped with three through holes (8) which cooperate with a locking element (23) with a crossbar (24) with three vertical lower projections (25) and three vertical upper projections (25) set therein, and wherein the external modules (1, 9) are made of plastic with at least 30% glass fibre content. [2] The distribution block according to claim 1, characterized in that it additionally comprises at least one internal module (11), placed between the external modules (1, 9), equipped with a central coaxial through-hole (2), with an identical hole (2) in other modules (1, 9), equipped with at least two through-mounting holes (3) parallel to the central axis of the modules (1, 9, 11), in which screws (14) are fastened, and coupling sockets (5) with coupling parts (20, 21, 22) placed therein or coupling sockets (5) with closure caps, which are made in two opposite side walls (4) of the at least one additional internal module (11), wherein in the upper wall (10) and the lower wall (6) of the at least one additional internal module (11) a recess (7) is made along the edge of each side wall (4) with coupling sockets (5) equipped with three through-holes (8),which cooperate with a locking element (23) with crossbars (24) with three vertical lower projections (25) and three vertical upper projections (25) set therein, wherein the at least one additional internal module (11) is made of plastic with at least 30% glass fiber content. [3] The distribution block according to claim 2, characterized in that O-ring seals (12) are placed in a groove (13) in the upper wall (10) of the lower external module (9), in the lower wall (6) of the upper external module (1) and in the upper wall (10) and the lower wall (6) of each internal module (11). [4] The distribution block according to any one of claims 1 to 3, characterized in that the coupling parts (20, 21, 22) are permanently set in the coupling socket (5): a plug-in nozzle (20), a cutting ring (21), an O-ring (22). [5] The distribution block according to claim 4, characterized in that the lower projections (25) of the locking element (23) cooperate with the plug-in sleeve (20) in the lower external module (9) or in the at least one additional internal module (11), and the upper projections (25) of the locking element (23) cooperate with openings (8) in the top-mounted upper external module (1) or in the at least one additional internal module (11). [6] The distribution block according to any one of claims 1 to 5, characterized in that each module (1, 9, 11) is equipped with at least three coupling sockets (5).

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