Throttle Valve Filler Material Positioning and Sealing
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Solution Overview
Problem
Existing flap connectors in internal combustion engines face challenges in minimizing leakage, ensuring precise positioning, and maintaining a secure mechanical connection between the flap and the flap shaft, while also being complex and material-restrictive.
Innovation Solution
A flap connector design featuring a filling material between the flap and the flap shaft, with irregularities on both surfaces to ensure a permanent, torque-proof connection, allowing for precise alignment and secure positioning without the need for liquid or pasty materials, and enabling the use of various materials for the flap and flap shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a slot is used in the flap shaft to attach the flap, then the flap can be secured to the shaft, but leakage occurs between the flap and the gas duct
Solution Approach 1:
The connection between flap and shaft is segmented into two independent functions: mechanical attachment (via slot and projection) and sealing (via separate sealing element). This separates the leakage problem from the mechanical connection, allowing each to be optimized independently.
Solution Approach 2:
A sealing element is introduced as an intermediary component between the flap and the gas duct. This sealing element fills the gap created by the slot in the flap shaft, preventing leakage without interfering with the mechanical connection function.
2Object-generated harmful factors
If the flap is positioned precisely within the gas duct, then leakage is reduced, but the positioning is not permanently guaranteed
Solution Approach 1:
The sealing element is pre-positioned in the flap shaft slot before the flap is installed. This preliminary placement ensures that when the flap is positioned, the sealing is already in place, permanently guaranteeing the positioning and preventing future leakage.
Solution Approach 2:
The sealing element acts as an intermediary that permanently fixes the relative position between the flap and the gas duct wall, maintaining precise positioning over time and preventing leakage that would occur with simple mechanical attachment.
3Manufacturing precision
If transverse holes and stub shafts are used to position the flap, then precise positioning is achieved, but the manufacturing process becomes complex
Solution Approach 1:
The complex positioning function (transverse holes and stub shafts) is extracted and replaced by a simpler system using a slot in the flap shaft combined with a sealing element. The slot provides both mechanical attachment and positioning, while the sealing element ensures precise fit without requiring additional holes or shafts.
Solution Approach 2:
The mechanical attachment function and the positioning function are merged into a single slot structure in the flap shaft. This eliminates the need for separate transverse holes and stub shafts, reducing manufacturing complexity while maintaining precise positioning capability.
Data Source
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AI summary
Throttle valves often have the problem that the throttle must be precisely positioned with and fixed to the throttle shaft. In the throttle valve (2) proposed by the invention, hardening filler material (10) is inserted into the intermediate space (22) between the throttle (6) and the throttle shaft (8). After said filler material (10) has hardened, the throttle (6) is precisely positioned relative to the throttle shaft (8) and fixed in a torque-proof manner. The throttle valve may be used for controlling the output of an internal combustion engine. (Fig. 1)