METHOD FOR MANUFACTURING A SEALING ELEMENT, SEALING ELEMENT AND USE OF A SEALING ELEMENT MANUFACTURED BY SUCH A METHOD

Description

[0001] The present invention relates to a sealing element with a substantially rectangular basic shape having a first extension direction and a second extension direction as well as a plurality of openings, a method for manufacturing such a sealing element and the use of a sealing element manufactured according to such a method.

[0002] Such a sealing element is known, for example, from EP 3 385 583 A1 or WO 2021 / 087106. US2020 / 180187A1 discloses a sealing element according to the characterizing portion of claim 1.

[0003] In many "old" technology fields, such as the established automotive industry in Germany, the focus today is no longer solely on developing new products. Instead, the improvement of existing technologies to increase efficiency and reduce costs has taken center stage. This applies to all levels, from the engine to the washer. In addition to the aforementioned requirements, the increasing number of functions presents the further challenge of solving these tasks in ever-shrinking installation spaces.

[0004] An example of the problem described above is the thermal management module of a motor vehicle. Due in part to the increasing electrification of the powertrain, a multitude of coolant flows, sometimes at different temperature levels, now need to be regulated. For this reason, rotary valves with multiple internal channels and ports are increasingly being used. These are very compact and, thanks to their various positions, are able to simultaneously implement and control different coolant flows as needed. Such a rotary valve requires a special seal that creates a tight seal between the housing, which has multiple ports, and the rotary valve located inside the housing, ensuring that only the intended flow patterns through the valve body are possible.

[0005] The aforementioned EP 3 385 583 A1 was identified as the closest prior art. It describes such a multi-way valve, consisting of a housing with an inner cavity and several ports, a rotatable cylindrical valve body with internal channels, which is arranged within the cavity of the housing, and a sealing element. The sealing element has a substantially sleeve-like shape and features several openings. It is arranged such that it surrounds the cylindrical valve body within the cavity of the housing.

[0006] The WO 2021 / 087106, also mentioned at the beginning, features a sealing element similar to EP 3 385 583 A1. It differs from the latter in that it does not have a complete sleeve shape, but rather this is interrupted along a certain section of its entire axial length.

[0007] Chinese utility model CN ​​212 564 523 U describes a liquid distributor consisting of a housing, a rotating shaft, and a flange connector. By rotating the shaft, the flange connector can select different liquids. The parts can be manufactured using plastic injection molding, resulting in a simple structure and low manufacturing costs.

[0008] US patent application US 2010 / 319796 A1 relates to a multi-way valve comprising a valve body, a directional component, and an elastomeric seal. The directional component inside the body creates a channel through rotation, which connects different opening combinations depending on its orientation. The elastomeric seal between the directional component and the body ensures a fluid-tight seal and low friction.

[0009] The sealing elements described in the first two documents mentioned above share the characteristic that their basic shape, even when not installed, corresponds at least partially to that of a hollow cylinder or sleeve. This complex, three-dimensional shape places high demands on the manufacturing of the sealing element. Such an injection molding process requires a complex injection mold with multiple slides or at least a subsequent stamping or cutting operation. This results in high production costs for the manufacturer, which in turn leads to a high price per unit for the customer.

[0010] The object of the invention is therefore to describe a sealing element and a manufacturing process for a sealing element that is technically simpler and thus more cost-effective to produce than sealing elements known from the prior art. The use of a sealing element produced according to such a process is a further aspect of the invention.

[0011] This problem is solved by a sealing element with a substantially rectangular basic shape in its unfolded state, comprising a first extension direction and a second extension direction, as well as a plurality of openings and a nearly cylindrical end contour, characterized in that the sealing element is made of at least two materials, wherein a second material completely or partially covers a first material in a third extension direction, which is arranged orthogonally to the first and second extension directions. Advantageous embodiments are the subject of further dependent claims 2 to 16.

[0012] The remaining aspects are addressed by a method for manufacturing such a sealing element according to claim 17 and its use according to claim 22. Advantageous embodiments of the manufacturing method are the subject of dependent claims 18 to 21, while advantageous embodiments of the use are the subject of dependent claims 23 to 25.

[0013] In its most general form, the present invention provides for the first time a manufacturing process for a sealing element in which the initial forming is carried out using injection molding or compression molding in a developed mold before a nearly cylindrical final contour is formed. Compared to the prior art, such a process represents a cost-effective and easy-to-control way to produce a nearly cylindrical sealing element that can be used in this way. This eliminates the need for complex three-dimensional geometries of the vulcanization tool, additional slides, or further processing steps for post-treatment and / or further treatment.

[0014] For the initial forming process, an elastomeric material is heated and molded under pressure in a vulcanization tool. The correct combination of temperature, pressure, and other parameters is crucial to achieving the viscosity of the elastomeric material required for vulcanization. Besides the described embodiment using a single elastomeric material, embodiments are also conceivable in which at least two elastomeric materials are used. These can be either homogeneously mixed or heterogeneously arranged. The latter, for example, offers the possibility of creating a core made of one elastomeric material and a coating made of a second elastomeric material.

[0015] The cavity of the vulcanization tool corresponds to the developed shape of the sealing element to be produced. In a first embodiment of the manufacturing process according to the invention, the cavity has a substantially rectangular basic shape with a first extension direction and a second extension direction arranged orthogonally to it. The first and second extension directions thus define a substantially rectangular frame that surrounds a plurality of openings. The openings are separated from one another by webs that are connected to the frame and are also pre-formed during the injection molding or compression molding process.

[0016] If the goal is to obtain a sealing element with properties that cannot be achieved solely with elastomeric materials, it is also possible to insert an additional component, such as a film, into the vulcanization tool and chemically or mechanically bond the sealing element to it. The bond with the additional component is thus established during the formation of the sealing element itself.

[0017] Following the injection molding or compression molding process, the resulting sealing element is rolled into an almost cylindrical final contour. The first direction of extension corresponds to the circumferential direction of the cylindrical final contour, while the second direction of extension runs coaxially to the imaginary central axis. Consequently, elastic deformation occurs through bending in the first direction of extension, but not in the second direction.

[0018] To reduce the prestress introduced by elastic deformation, an advantageous embodiment proposes giving individual segments of the sealing element a partially cylindrical shape during the injection molding or compression molding process. For this purpose, the vulcanization tool is designed such that all sections of the frame aligned along the first direction of extension, as well as any webs extending in the same direction, have correspondingly curved geometries. This excludes those points in the first direction of extension where the webs extending in the second direction meet the frame. In simplified terms, the cavity of the vulcanization tool, and thus also the sealing element produced with it, has a wave-like shape after the injection molding or compression molding process.The points where the webs running in the second direction of extension meet the frame represent the wave crests, while the centers of the pre-formed segments represent the wave troughs.

[0019] In a further embodiment of the invention, one or more starting materials of an elastomer and / or a polymer are used as the material. In particular, variants are also conceivable in which some sections of the sealing element consist of an elastomer and other sections of a polymer. Both elastomers and polymers, in their final form, exhibit a good ratio of flexibility to frictional resistance and are frequently used as sealing materials.

[0020] In an advantageous embodiment, the sealing element is tempered after the shaping vulcanization process. This increases the bonds between the molecules and improves the elastic properties of the sealing element.

[0021] In another advantageous embodiment, the sealing element is partially or completely coated. For example, a PTFE coating could be applied to all sections that will form a dynamic sealing surface during operation. Such a coating reduces the frictional resistance of the corresponding sliding pair without negatively affecting the sealing properties.

[0022] According to one or more of the claims described in more detail below, the sealing element according to the invention serves to seal a cylindrical rotary valve of a media distributor against its housing. Such media distributors are used particularly in applications where several, essentially independent, fluid flows must be controlled simultaneously. The various fluid flows can differ, among other things, in their temperature, pressure, and volumetric flow rate. The latter, in particular, may require differently sized connections in the housing as well as channels in the cylindrical rotary valve. Consequently, further embodiments of the sealing element according to the invention are conceivable in which one or more of the openings have different sizes.Of course, variations are also conceivable in which several openings have the same size and one or more additional openings have a different size.

[0023] Based on the potentially different sizes described above, further embodiments are conceivable in which the openings of the sealing element have different shapes. Depending on suitability for the individual application, the openings can, for example, have rectangular, round, or elliptical shapes, and of course, other geometric shapes are also conceivable. This includes, in particular, asymmetrical shapes. A single sealing element can also have openings of different shapes.

[0024] The size, shape, and arrangement of the majority of openings depend on the application. In both the first and second directions of extension, one or more openings can be arranged side by side. A recurring pattern or symmetry in the arrangement is possible, but asymmetrical arrangements are also conceivable.

[0025] The frames and webs of the sealing element can have a substantially rectangular cross-sectional profile. It is also possible for the cross-sectional profile to be round, triangular, curved, or another shape. The selection is made on a case-by-case basis depending on the specific requirements.

[0026] In one application of the sealing element according to the invention, it provides a static seal against the housing of a media distributor and a dynamic seal against the cylindrical rotary valve. To ensure that the sealing element cannot rotate relative to the housing of the media distributor during operation, in one embodiment it has one or more grooves on the radially outer side of the nearly cylindrical end contour. One or more corresponding springs, provided on the radially inner side of the housing of the media distributor, engage in this groove or these grooves.

[0027] It is also possible to reverse the tongue-and-groove connection described above. According to a further embodiment, one or more springs are provided on the radially outer side of the nearly cylindrical end contour of the sealing element. These, in turn, engage in one or more corresponding grooves, which are arranged on the radially inner side of the housing of the medium distributor. The springs are an integral part of the sealing element, which are formed during the vulcanization process.

[0028] In particular, with the embodiments described above, which incorporate a tongue-and-groove connection between the sealing element and the surrounding housing of a media distributor, the sealing element can also function as a bearing shell for the cylindrical rotary valve. Radial forces can thus be absorbed by the sealing element if its stiffness is sufficiently high. This offers the possibility of eliminating one or more bearings on the shaft driving the cylindrical rotary valve, which in turn can lead to advantages in terms of installation space and cost. Furthermore, overdeterminations and axial misalignments between the cylindrical rotary valve and the housing of the media distributor can be better compensated for via the dynamic sealing surface between the sealing element and the cylindrical rotary valve.

[0029] According to an alternative embodiment, the sealing element can be rotationally fixed relative to the cylindrical rotary valve, thus forming a static sealing surface with it. In this case, the dynamic sealing surface is located between the sealing element and the housing of the media distributor, which radially surrounds the sealing element. To ensure this relationship, the sealing element can have one or more grooves on the radially inner side of its cylindrical contour. One or more corresponding springs, provided on the radially outer side of the cylindrical rotary valve of the media distributor, engage in this groove or these grooves.

[0030] It is also possible to reverse the tongue-and-groove connection described above. According to a further embodiment, one or more springs are provided on the radially inner side of the nearly cylindrical end contour of the sealing element. These, in turn, engage in one or more corresponding grooves, which are arranged on the radially outer side of the cylindrical rotary valve.

[0031] The present invention is described in more detail below with reference to the drawings. These show: Fig. 1a a first embodiment of a sealing element according to the invention in top view; Fig. 1b the sealing element according to the invention Fig. 1a in side view; Figs. 2a to 2g different cross-sectional profiles of a section of the sealing element according to the invention; Fig. 3a a second embodiment of the sealing element according to the invention in top view; Fig. 3b the sealing element according to the invention Fig. 3a in side view; Fig. 4 the sealing element according to the Fig. 3a und 3b in its nearly cylindrical end contour in the installed state; Fig. 5a a third embodiment of the sealing element according to the invention in top view; Fig. 5b the sealing element according to Fig. 5a in side view; Fig. 6 the sealing element according to the Fig. 5a und 5b in its almost cylindrical end contour in the installed state; and Fig. 7 a fourth embodiment of the sealing element according to the invention in the installed state.

[0032] The Fig. 1a bis 7 The figures show various embodiments and states of a sealing element according to the invention. The method required to manufacture such a sealing element is explained with reference to these figures, without illustrating the individual process steps with separate drawings.

[0033] Fig. 1a Figure 1 shows a first embodiment of a sealing element 10 according to the invention in a top view. As can be seen from the combined view with Fig. 1b , which shows a side view of that sealing element 10 of the Fig. 1a As shown, it is essentially a flat and planar structure. The sealing element 10 comprises a first extension 12 and a second extension 14 arranged essentially orthogonally to it, by which a frame 16 of the sealing element 10 is spanned, which essentially has the shape of a rectangle. In addition, the sealing element 10 includes several openings, some of which are in Fig. 1a The openings 18 and 20 are provided as examples. They are each separated from one another by webs 22, which connect either to further webs 22 or to the frame 16.

[0034] The Fig. 1a und 1b Figure 1 shows a sealing element 10 as it exists before the final step of a manufacturing process according to the invention. To obtain such an element, the sealing element 10 is preformed using an injection molding or compression molding process. The cavity of the associated vulcanization tool therefore has exactly the shape of the sealing element 10 to be produced, but in its unfolded form. In the final process step, the preformed sealing element 10 is rolled up by bringing the two sections of the frame 16, which are located in the second extension direction 14, towards each other. This creates an almost cylindrical end contour in which the original first extension direction 12 runs along the circumference, while the original second extension direction 14 is arranged coaxially to an imaginary central axis of the cylindrical end contour. The process discussed in detail below... Fig. 4 Figure 10 shows such a rolled-up sealing element in its almost cylindrical end contour in the installed state.

[0035] In the Fig. 2a bis 2g Possible cross-sectional profile shapes of the frame 16 and / or the webs 22 are shown. As in Fig. 2a As shown, such a cross-sectional profile can have a rectangular shape, with the inner and outer corners and edges exhibiting a less or more pronounced rounding depending on the individual application. According to Fig. 2c This can also be coated on one or more sides, preferably on the side that forms a dynamic sealing surface during operation. A PTFE coating, for example, is suitable for this purpose. It is also possible that the sealing element 10 consists of two materials that are bonded together during the vulcanization process. Furthermore, a round cross-sectional shape is conceivable ( Fig. 2b ), as well as a triangular cross-sectional shape, which can be oriented in different ways ( Fig. 2d bis 2f Furthermore, a cross-shaped or X-shaped cross-sectional shape is also conceivable ( Fig. 2g ), as well as others, not in the Fig. 2a bis 2g The forms shown are examples. Preferably, all sections of the frame 16 and webs 22 of a sealing element 10 have the same cross-sectional shape. However, embodiments are also conceivable in which individual sections of the frame 16 and / or one or more webs 22 have a different cross-sectional shape. The appropriate selection is made in each individual case based on the specific operating conditions.

[0036] The Fig. 3a und 3b show a further embodiment of the sealing element 10 according to the invention. The in Fig. 3a The top view shown corresponds exactly to the one from Fig. 1a As can be seen from the corresponding side view in Fig. 3b As can be seen, individual sections of the sealing element 10, located in the first extension direction 12, are partially pre-formed cylindrically. This applies on the one hand to the sections of the frame 16 located in the first extension direction 12, but can also include the webs 22, which are likewise located in the first extension direction 12. The radius of these partial shells 24 corresponds approximately to the radius of the sealing element 10 in its nearly cylindrical end contour. Similar to how the sealing element 10 is formed from the Fig. 1a und 1b can the sealing element 10 of the Fig. 3a und 3b They can be produced with a comparatively simple vulcanization tool. To manufacture a sealing element 10 with such a shape, complex slides during the injection molding process can be dispensed with, as can complex post-processing, such as stamping or cutting.

[0037] One advantage of such an embodiment of the sealing element 10, pre-formed with partial shells 24, is that less bending stress is exerted on some parts of the sealing element 10 when forming the nearly cylindrical final contour. This promotes more reliable performance of its sealing function. Furthermore, it reduces friction and the resulting section modulus, which can be taken into account in the design of the drive.

[0038] According to an advantageous embodiment, the sealing element 10 according to the invention is designed such that its circumference contains one or more grooves 26 in the nearly cylindrical end contour. These are already provided during the primary forming process by a corresponding design of the vulcanization tool. In the installed state, which in Fig. 4 As illustrated, these grooves, together with corresponding springs in the housing of a media distributor which surrounds the sealing element 10 on its radially outer side, form a positive-locking connection. This connection prevents rotation and thus ensures the correct position of the sealing element 10 in the housing.

[0039] The Fig. 5a und 5b show a further embodiment of the sealing element 10 according to the invention, in which, compared to the exemplary embodiment of the Fig. 3a und 3b The tongue-and-groove connection has been inverted. Accordingly, one or more springs 28 protrude in a radially outward direction from the nearly cylindrical end contour of the sealing element 10. This shape is also already provided for in the design of the vulcanization tool for the primary forming process.

[0040] As in Fig. 6 As shown, these one or more springs 28 correspond, in the installed state, to one or more corresponding grooves in the housing of the media distributor. Analogous to the previous example, such a design prevents the sealing element 10 from rotating relative to the housing of the media distributor.

[0041] Fig. 7 In contrast, Figure 1 shows an embodiment of the sealing element 10 that requires only a single spring 28. The desired anti-rotation feature is achieved through its interaction with a corresponding spring in the housing. The selection of an appropriate number of spring-groove connections and their orientation is determined on a case-by-case basis according to the specific operating conditions.

[0042] The last-mentioned embodiment, in which the springs 28 are formed as part of the sealing element 10, allows for less local reduction in the height of the cross-sectional profile. The overall stability and stiffness of the sealing element 10 can thus be increased. Since the grooves in this embodiment are provided in the housing of the media distributor, the housing diameter increases to maintain a minimum wall thickness. It can therefore be deduced that the selection of the design of the tongue-and-groove connection must be made for each individual application and based on the operating conditions. Bezugszeichenliste

[0043] 10 Sealing element 12 First extension direction 14 Second extension direction 16 Frame 18 Opening 20 Opening 22 Web 24 Partial shell 26 Groove 28 Spring

Claims

1. Sealing element (10) having, in the unwound state, a substantially rectangular basic shape with a first direction of extension (12) and a second direction of extension (14), as well as a plurality of openings (18, 20) and an almost cylindrical final contour, said sealing element (10) being subjected to primary shaping by means of injection molding or compression molding, characterized in that said sealing element (10) is made of at least two materials, with a second material completely or partially covering a first material in a third direction of extension, which is arranged orthogonally to the first direction of extension (12) and the second direction of extension (14).

2. Sealing element (10) according to claim 1, characterized in that the first direction of extension (12) runs along the periphery of the approximately cylindrical final contour and the second direction of extension (14) runs parallel to an imaginary center axis of the approximately cylindrical end contour.

3. Sealing element (10) according to claim 1 or 2, characterized in that at least one portion of the sealing element (10) has a partially cylindrical shape in the unwound state.

4. Sealing element (10) according to claim 3, characterized in that the at least one portion of the sealing element (10), which, in the unwound state, has a partially cylindrical shape, is aligned along the first direction of extension (12).

5. Sealing element (10) according to one of claims 1 to 4, characterized in that for forming a twist lock, the sealing element (10) has, in its nearly cylindrical final contour, either one or more grooves (26) or one or more springs (28) on its radially outer side.

6. Sealing element (10) according to one of claims 1 to 4, characterized in that for forming a twist lock, the sealing element (10) has, in its nearly cylindrical final contour, either one or more grooves (26) or one or more springs (28) on its radially inner side.

7. Sealing element (10) according to one of claims 3 to 6, characterized in that an area between at least two portions of the sealing element (10), which have a partially cylindrical shape when being unwound, is designed as a predetermined bending point which particularly includes a reduced wall thickness and / or is made of only one material.

8. Sealing element (10) according to one of claims 1 to 7, characterized in that at least one of the at least two materials is an elastomeric material.

9. Method for manufacturing a sealing element (10) according to one of claims 1 to 8, characterized in that the sealing element (10), in the unwound state, is subjected to primary shaping by means of injection molding or compression molding, and subsequently a nearly cylindrical final contour is formed.

10. Method according to claim 9, characterized in that the sealing element (10) is manufactured from at least two materials, said at least two materials being distributed homogeneously or heterogeneously during injection molding or compression molding.

11. Method according to claim 9 or 10, characterized in that the sealing element (10) is tempered after primary shaping in the unwound state or in the nearly cylindrical final contour.

12. Method according to one of claims 9 to 11, characterized in that the sealing element (10) is partially or completely coated before the formation of the nearly cylindrical final contour.

13. Method according to one of claims 9 to 12, characterized in that the sealing element (10) is chemically or mechanically bonded with an additional component during injection molding or compression molding.

14. Use of a sealing element (10) according to one of claims 1 to 8, manufactured by a method according to one of claims 9 to 13, for sealing a cylindrical rotary valve of a medium distributor against a housing of the medium distributor.

15. Use according to claim 14, characterized in that the sealing element (10) is either rotationally fixed relative to the housing and forms a dynamic sealing surface with the cylindrical rotary valve, or is rotationally fixed relative to the cylindrical rotary valve and forms a dynamic sealing surface with the housing.