Throttle Valve Resin Bonding for Leakage Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional throttle valves for internal combustion engines often contain pinholes and micro bubbles formed during the high-temperature, high-pressure die-casting process, which are difficult to detect and can lead to fluid leakage and mechanical issues over time.
Innovation Solution
A method for manufacturing a throttle valve using a die-casting process for the valve body and a heat-conducting tube, with a structural and heat-conducting resin applied between the seat and the tube to secure and insulate the tube within the valve body, eliminating the need for mechanical locks and enhancing thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If die-casting process is used to manufacture the valve body, then productivity and manufacturing efficiency are improved, but pinholes and micro bubbles are formed in the valve body
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the valve body and the tube. This resin layer serves multiple functions: it compensates for pinholes and micro bubbles in the valve body, provides thermal insulation, and creates a secure mechanical bond. The resin acts as a mediator that transfers heat and structural load while masking the defects inherent in die-casting processes.
Solution Approach 2:
The invention creates a composite structure by combining the valve body (metal or polymer) with a resin layer and a tube. This composite approach allows the valve body to maintain its die-casting advantages for productivity while the resin layer addresses the reliability issues by compensating for internal defects and providing additional functional properties.
2Strength
If mechanical fixing is used to connect the tube to the valve body, then connection strength is improved, but device complexity increases
Solution Approach 1:
The invention replaces mechanical fixing systems (such as brackets, clips, or threaded connections) with a resin-based bonding system. The resin layer provides both mechanical attachment and thermal insulation properties, eliminating the need for separate mechanical fastening components and simplifying the overall structure while maintaining connection strength.
3Temperature
If heat-conducting paste is used between the tube and valve body, then thermal conduction is improved, but structural function is lost requiring mechanical fixing
Solution Approach 1:
The invention uses a resin layer that combines both structural and thermal conduction functions in a single material system. This composite approach eliminates the need for separate heat-conducting paste and mechanical fixing elements, as the resin itself provides both thermal management and structural bonding capabilities.
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
The method results in a cost-effective, lightweight throttle valve with improved thermal resistance and reduced risk of fluid leakage, as the resin provides a secure and uniform interface between the valve body and the tube, preventing fluid passage to the electric motor or outside environment.
Implementation Method 1
a substantially uniform layer of a structural and heat-conducting resin interposed between the seat and the tube
Data Source
AI summary
A method to manufacture a throttle valve for an internal combustion engine comprising a valve body having a seat and a tube for the passage of conditioning fluid; an actuating device, which controls the rotation of a throttle plate; and a substantially uniform layer of a structural and heat-conducting resin interposed between the seat and the tube and applied on the entire available surface of the seat; the method comprising the steps of manufacturing the valve body provided with the seat by causing a first metal material to undergo a die casting process; applying a trace of the structural and thermosetting resin on the bottom of the seat; and inserting the tube into the seat so as to obtain a substantially uniform layer of the structural and thermosetting resin, which is interposed between the seat and the tube.