Pneumatic Multi-Valve Venting Layout With Welded Housing Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pneumatic multi-valve devices for electronically controlled air spring systems in commercial vehicles have complex production processes, requiring multiple screwing steps, elastomeric ring seals, and a two-part overmolding process, which increases component count and copper usage.
Innovation Solution
The solution involves a welded connection between the housing cover and base body for airtight sealing, eliminating the need for elastomeric seals and reducing components, with a single overmolding process and a monolithic housing design that includes coil units directly overmolded with the yoke, and axially aligned ventilation channels within the housing base body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a two-part overmolding process with separate housing and coil carrier is used, then the housing can be manufactured with integrated ventilation channels, but the production process becomes complex and requires multiple assembly steps
Solution Approach 1:
The patent combines the housing and coil carrier into a single monolithic component manufactured through one-part overmolding. The coil elements are directly embedded in the housing material during the molding process, eliminating the need for separate housing and coil carrier parts. This integration maintains the ventilation channels while simplifying the production process to a single molding operation without complex assembly steps.
2Reliability
If a two-part overmolding process with carrier yoke is used, then the coil elements can be securely mounted, but the amount of copper required increases
Solution Approach 1:
The patent extracts the coil elements from the traditional carrier yoke structure and directly embeds them in the monolithic housing material. The housing itself provides the mounting function that previously required a separate carrier yoke, thereby reducing copper usage by eliminating the additional material needed for the carrier structure while maintaining secure coil element mounting through direct integration.
3Reliability
If multiple screw connections and elastomeric ring seals are used for housing cover fixation, then airtight sealing is achieved, but the manufacturing process becomes elaborate and time-consuming
Solution Approach 1:
The patent merges the housing cover fixation function into the monolithic housing structure. The airtight sealing is achieved through the integrated design where the housing material itself forms the sealing structure, eliminating the need for separate screw connections and elastomeric ring seals. This integration maintains reliability by providing inherent sealing through the molded structure while dramatically improving productivity by eliminating multiple assembly steps.
4Ease of manufacture
If a trough-shaped housing cover is used to form the vent collection channel, then the vent holes can be connected, but the component count and assembly complexity increase
Solution Approach 1:
The patent merges the vent collection channel function directly into the monolithic housing body. The ventilation channels are formed as integral features of the housing material during the one-part overmolding process, eliminating the need for a separate trough-shaped housing cover. This integration maintains ease of manufacture by forming the vent channels in a single molding operation while reducing device complexity by eliminating the additional housing cover component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies production, reduces copper usage, and allows for a compact design with fewer components, enhancing manufacturing efficiency and reducing installation space requirements.
Implementation Method 1
armature means adjustable along an adjustment axis in response to an energization of the coil means in the housing relative to the core
Implementation Method 2
The housing cover (17) is fixed to the housing base (13) via a welded joint (35)
Data Source
Figure 1a~1g
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to a pneumatic multi-valve device (valve block), comprising a housing (18), which has a housing main body and and a plurality of electromagnetic valve actuators (1), each having coil elements (2) arranged in the housing (18) in a stationary manner, a core (4) arranged in the housing (18), and armature elements (15), which can be displaced along a displacement axis (V) in the housing (18) in relation to the core (4) and in relation to a pneumatic connection (12) of the housing (18) in response to energizing of the coil elements (2), wherein the displacement axes (V) of the armature elements (15) of the valve actuators (1) are oriented parallel and the pneumatic connections (12) associated with the armature elements (15) are arranged adjacent to each other on a connection housing side (14), which is spaced apart from a housing back side (16) facing away therefrom along the displacement axes (V), wherein the cores (4) each have a venting bore (5), which is connected, for air conduction, to a venting collection channel (31) on the side of the cores (4) facing away from the connection housing side (14), which venting collection channel is bounded on the housing back side (16) by a housing cover (17) fastened to the housing main body (13), which venting collection channel is connected, for air conduction, to a venting opening of the housing (18), which venting opening is arranged on a housing side different from the housing back side (16), in particular on the connection housing side (14) having the pneumatic connections (12).