Pressure regulator for a fuel supply unit and method for production of a pressure regulator

Disclosed is a pressure regulator for a fuel supply unit of a motor vehicle and method for production of a pressure regulator. The pressure regulator comprises a valve for producing a joining of a connection to an outlet above a designated pressure in the connection, a movable piston and a membrane, which is held on a fixed annular element, for sealing the piston in relation to the annular element, characterized in that the membrane is welded to the annular element.

BACKGROUND OF THE INVENTION

Pressure regulator for a fuel supply unit and method for production of a pressure regulator

The invention relates to a pressure regulator for a fuel supply unit of a motor vehicle, with a valve for producing a joining of a connection to an outlet above a designated pressure in the connection, with a movable piston and with a membrane, which is held on a fixed annular element, for sealing the piston in relation to the annular element. Furthermore, the invention relates to a method for production of a pressure regulator for a fuel supply unit of a motor vehicle, in which a piston of a valve is joined to a fixed annular element in a sealing manner via a membrane.

Pressure regulators of this type are frequently used in motor vehicles today to regulate a pressure in a forward flow line leading to an internal combustion engine, and are known from practice. The membrane is clamped between two annular elements of the housing and separates the region above the piston from the region below the piston. The connection opens into the region below the piston. The required tensioning force of the membrane is generally produced by flanging an edge of the annular element.

A drawback of the known pressure regulator is that the sealing of the membrane is insufficient, in particular in the temperature range below 0° C., in order to keep the designated pressure at which the pressure regulator is to open within an exacting tolerance range. The pressure regulator may frequently fail completely due to leakages at the outer edge.

The invention is based on the problem of developing a pressure regulator of the type mentioned at the beginning in such a manner that reliable tightness between the membrane and the annular element is ensured. Furthermore, the invention is based on the problem of designing a method for production of the pressure regulator in such a manner that it ensures particularly reliable sealing of the membrane in relation to the annular element.

BRIEF DESCRIPTION OF THE INVENTION

The problem mentioned first is solved according to the invention in that the membrane is welded to the annular element.

This design enables the membrane to be joined to the annular element with a cohesive material joint. This ensures reliable tightness in particular in the temperature range below 0° C. Settling gaps between the membrane and the annular element, which may result in leakages after a certain operating time of the pressure regulator according to the invention, are likewise reliably avoided. This ensures reliable tightness between the membrane and the annular element.

In the case of a pressure regulator according to the invention and designed as a throughflow valve, the tightness between the region below the piston and the region above the piston can be further increased if the membrane is welded to the piston.

Flow through the piston above the designated pressure can be ensured in a simple manner, according to another advantageous development of the invention, if the membrane has a recess for a valve seat arranged in the piston.

Welding the membrane to the piston and the annular element turns out to be particularly cost-effective, according to another advantageous development of the invention, if the annular element and the piston are manufactured from plastic.

Permanent tightness of the welded joint is ensured, according to another advantageous development of the invention, if the plastic of the membrane, the piston and the annular element is polyphenylene sulfide.

According to another advantageous development of the invention, the membrane, the annular element and the piston have a particularly high degree of stability if the plastic has inserts of glass fibers.

The welded joint of the membrane can be produced particularly cost-effectively, according to another advantageous development of the invention, if the membrane or the component to be welded to the membrane is manufactured from a material permeable to a laser beam and the respectively other component is manufactured from a material impermeable to a laser beam. This design enables the membrane to be welded by means of the laser beam. This results in particularly low manufacturing costs in particular in series manufacturing of the pressure regulator according to the invention. In addition, the manufacturing can be automated.

The annular element could be, for example, an edge of a housing guiding the piston. However, in order to set the prestressing force of the spring element against the piston, the housing of the pressure regulator according to the invention is preferably manufactured from an easily plastically deformable material. According to another advantageous development of the invention, the housing can be manufactured from an easily deformable steel sheet and the membrane from plastic if the annular element is clamped in a housing in a sealing manner.

The problem mentioned second, namely the provision of a method for production of the pressure regulator with particularly reliable sealing of the membrane in relation to the annular element, is solved according to the invention in that the membrane is welded to the annular element.

By this means, settling gaps which arise during the flanging operation, as in the case of the known annular element, are reliably avoided. Owing to the invention, the membrane is joined to the annular element with a cohesive material joint. This leads to particularly reliable sealing of the membrane in relation to the annular element in particular in the range below 0° C. In the case of a pressure regulator designed as a straight-way valve, the piston can be welded to the membrane in an analogous manner.

According to an advantageous development of the invention, the method according to the invention turns out to be particularly cost-effective if the welding takes place by a laser welding technique.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a pressure regulator according to the invention and designed as a throughflow valve with a housing1and a piston2arranged displaceably in the housing1. The pressure regulator serves to limit a maximum pressure in a forward flow line (not illustrated) of a fuel tank of a motor vehicle. The housing1has two housing parts4,5which are kept at a distance by an annular element3. The pressure regulator has a connection6for a pressure line, and an outlet7. The piston2is prestressed with a valve seat9against a valve body10by means of a spring8designed as a spiral spring.

A membrane11joined to the annular element3and the piston2seals the region below the piston2from the region above the piston2. This ensures that, at a pressure in the connection6, the piston2is loaded counter to the force of the spring8and, above a designated pressure, the piston2is moved such that the valve seat9lifts off from the valve body10. Above the designated pressure, fuel from the connection6can therefore escape through the outlet7. The housing parts4,5are manufactured from steel sheet and are joined to each other by flanging12. The flanging12prestresses a sealing ring13between the annular element3and the lower housing part5. An edge14of the upper housing part4, which edge holds the spring8, is of plastically deformable design and serves to calibrate the pressure regulator and therefore to set to the designated pressure at which the join between the connection6and the outlet7is produced. The annular element3, the piston2and the membrane11are manufactured from the plastic polyphenylene sulfide. The membrane11is joined to the annular element3and the piston2by a laser welding technique.

FIG. 2shows a pressure regulator designed as a cutoff valve. Said pressure regulator differs from that fromFIG. 1in particular by an outlet15being arranged on the same side as a connection16, as seen from a piston17. A membrane18is welded to an annular element19exclusively in the radially outer region and covers the entire cross section of the piston17. Furthermore, the membrane18forms a valve body21bearing against a valve seat20of the outlet15. At a designated pressure in the connection16, the piston17and the membrane18are pressed away from the valve seat20of the outlet15such that fuel can flow from the connection16to the outlet15.