Throttle Valve Housing Half-Shell Assembly for Thermal Insulation
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Solution Overview
Problem
The production and assembly of existing throttle valve devices for internal combustion engines are complex and cost-intensive due to the use of tubular semi-finished products that require complex forming processes, making them expensive to manufacture and assemble.
Innovation Solution
The throttle valve device is designed with an outer housing element made from two half-shells and an inner housing element formed from two half-shells, which are produced from sheet metal blanks and assembled by welding, reducing manufacturing costs and simplifying the process. The air gap is maintained through a labyrinth seal and a cohesive connection between the housing elements, preventing thermal leakage and ensuring insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tubular semi-finished products are used for manufacturing the throttle valve housing, then the structural integrity is maintained, but the manufacturing complexity and cost increase due to complex forming processes
Solution Approach 1:
The throttle valve housing is divided into two separate half-shells that are manufactured independently and then joined together. This segmentation allows each half-shell to be produced using simpler forming processes from sheet metal blanks, avoiding the need for complex forming of complete tubular structures, while maintaining structural integrity through proper joining of the segments
Solution Approach 2:
The inner housing element is inserted into the outer housing element, creating a nested structure with an air gap between them. This nested design allows both housing elements to be manufactured separately using simpler processes, then assembled together to achieve the desired thermal insulation and structural properties without requiring complex integrated forming
2Shape
If the inner housing element is formed by pressing elastic base material into the tubular semi-finished product, then the predefined shape is achieved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The housing is segmented into half-shells that can be formed from flat sheet metal blanks using standard deep-drawing processes, which are more economical and simpler than pressing elastic base material into tubular forms. The segmentation allows each piece to be formed independently using conventional, cost-effective manufacturing methods
3Shape
If the outer housing element is deformed into final shape by external force after inner housing element insertion, then the final shape is achieved, but the assembly process becomes more complex
Solution Approach 1:
Both the inner and outer housing elements are pre-formed into their final shapes using deep-drawing processes before assembly. This preliminary forming eliminates the need for complex post-assembly deformation operations, simplifying the assembly process to merely joining the pre-shaped components together
4Temperature
If the air gap is provided between outer and inner housing elements, then thermal insulation is improved, but the risk of thermal leakage through gaps increases
Solution Approach 1:
A labyrinth seal is introduced as an intermediary element between the inner and outer housing elements. This seal prevents direct thermal leakage paths through the air gap while maintaining the insulating air space, thus preserving thermal insulation performance while eliminating thermal leakage risks
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 design simplifies the manufacturing and assembly of the throttle valve housing, reduces costs, and enhances thermal insulation, while preventing gas leakage and extending the service life of the device by avoiding overlapping weld seams that can be weakened by thermal expansion.
Implementation Method 1
Such an air gap leads to air gap insulation, thereby reducing heat transfer between the flow channel and the external environment
Implementation Method 2
The two inner housing half-shells are joined together to form the inner housing element, wherein the two outer housing half-shells are slipped over the inner housing element and joined together
Data Source
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AI summary
The invention relates to a throttle valve device for an exhaust gas tract or an air intake tract of an internal combustion engine, comprising a throttle valve housing (30) which has an inner housing element (34) and an outer housing element (32) radially surrounding the inner housing element (34), an air gap (80) being provided between the outer housing element (32) and the inner housing element (34), and the inner housing element (34) radially delimiting a flow channel (36) and having a valve stop (38) projecting into the flow channel (36), said throttle valve device also comprising a throttle valve (40) which is arranged pivotably in the flow channel (36). In order to produce the throttle valve device simply and cost-effectively, the outer housing element (32) is produced from two outer housing half-shells (90, 92) and the inner housing element (34) is produced from two inner housing half-shells (94, 96).