Patent Description:
In the commercial vehicle industry, valve units are utilized in gearbox control units of automated manual transmission (AMT) devices. For connecting the valve unit to the gearbox control unit, flexible printed circuits are used. In state of the art valve units, such flexible printed circuits are, for example, directly soldered to the valve unit, are reinforced by plastic holders or are glued to the valve unit. This has been well proven to avoid vibrations and unwanted sound emissions. The described solutions, however, are often difficult to assemble, and are destroyed when the components need to be dissembled.

<CIT> shows a valve unit for a gearbox control unit, wherein said valve unit comprises a valve block and a flexible printed circuit and wherein said unit further comprises a fixation plate assembly including a fixation plate.

Further valve units are disclosed in <CIT> and <CIT>.

Therefore, it was an object of the invention to provide a valve unit for a gearbox control unit of a commercial vehicle that overcomes the above-mentioned issues as far as possible. In particular, it was an object of the invention to provide a valve unit that allows for an easy assembling and damage-free disassembling of the components while ensuring that the components form a durable and vibration free connection when assembled.

According to the invention the object is solved by a valve unit according to claim <NUM>.

Preferred embodiments are laid down in the dependent claims.

According to the invention, it is proposed that said valve unit comprises a fixation plate assembly comprising a fixation plate, wherein the flexible printed circuit is attached to the fixation plate, and wherein said fixation plate assembly is attached to said valve block.

The invention is based on the finding that the connectability of the flexible printed circuit to the valve block is significantly increased by utilizing a fixation plate assembly as defined above. It is ensured that the flexible printed circuit is safely attached to the structurally rigid fixation plate, which avoids vibrations at the flexible printed circuit and reduces noise. Furthermore, the fixation plate assembly can be releasably attached to the valve block allowing an easy assembling and disassembling of the components. Moreover, the number of required parts is low and the overall appearance of the valve unit is compact.

According to the invention, the valve unit comprises at least one receiving means arranged at the valve block, the receiving means being configured to couple pivotally with the fixation plate and limit its movement in a first direction. According to a preferred embodiment, the receiving means are configured to couple pivotally and releasably with the fixation plate. Preferably, the first direction extends along a longitudinal axis of the valve block. In this way, the fixation plate can be connected to the receiving means of the valve block at first, and thereafter hinged in the direction of the valve block. Additionally, the receiving means limits the movement of the fixation plate in a first direction.

According to a preferred embodiment, the receiving means comprises a first receiving hook, said first receiving hook protruding from said valve block and wherein said first receiving hook is configured to couple pivotally with the fixation plate. Such a first receiving hook has been found to be easy to manufacture and particularly suitable to provide the aspired function.

Preferably, the receiving means comprises a second receiving hook, said second receiving hook protruding from a top surface of said valve block and being spaced apart from the first receiving hook, wherein the first receiving hook and the second receiving hook are configured to couple pivotally with the fixation plate. With the help of such first receiving hook and second receiving hook, the overall guidance of the fixation plate is improved. Moreover, a tilting of the fixation plate is avoided.

According to another preferred embodiment, the fixation plate comprises a coupling section for coupling with the receiving means, wherein the coupling section comprises a cutout extending from an outer edge of the fixation plate inwardly. Such a coupling section comprising a cutout has been found to be beneficial to provide more compact valve unit. Preferably, the cutout may be rectangular extending from the outer periphery of the fixation plate inwardly.

According to yet another preferred embodiment, the valve block comprises at least one rail configured to support the fixation plate assembly when the fixation plate assembly is mounted to the valve block. Such a rail ensures that the contact area between the valve block and the fixation plate assembly is increased so that vibrations and noise emissions are inhibited. Furthermore, the structural integrity is increased. Preferably, the valve block comprises two rails that are arranged in parallel to one another. This configuration helps to further increase the structural integrity of the valve unit.

In a further aspect or in a further embodiment according to the first aspect, the valve block comprises at least one locking means protruding from the valve block, and wherein the fixation plate comprises at least one corresponding cutout for receiving the locking means. In other words, the at least one locking means is guided through at least one cutout arranged in the fixation plate when the fixation plate is attached to the valve block. After having inserted the locking means into the cutout, the locking means provides a locking functionality releasably attaching the fixation plate to the valve block.

According to a preferred embodiment, the locking means comprises at least one locking hook, said locking hook limiting a movement of the fixation plate assembly in a second direction, the second direction being opposite from the first direction. Such a locking hook has been found to be beneficial to provide a releasable locking functionality by also limiting the movement of the fixation plate in a second direction.

Preferably, said locking hook comprises a top section having a sloped surface, said sloped surface being configured to push the fixation plate towards the valve block when the fixation plate assembly is moved in the second direction. In this way, an elastic deformation is applied to the fixation plate, which generates a preload on both sides of the fixation plate. Thereby, it is ensured that the fixation plate does not vibrate or generate unwanted noise during operation.

Preferably, the valve block comprises a stopping means for limiting the movement of the fixation plate in the second direction. Such a stopping means has been found to be beneficial to further simplify the assembly process.

According to yet another preferred embodiment, the fixation plate comprises at least one centre hole and wherein the valve unit comprises a corresponding threaded bore configured for receiving a tensioning screw to be guided through the centre hole, for fixing the fixation plate assembly to the valve block. With the help of such centre hole, it is ensured that the fixation plate occupies its assigned position even if the fixation plate is not positioned exactly on the assigned position. Furthermore, the use of a tensioning screw ensures that the preload generated at the fixation plate is maintained to avoid any vibrations and unwanted noise emissions.

According to another preferred embodiment, said locking means comprises a plurality of locking hooks, wherein said locking hooks are arranged in a row, said row extending along the first direction. The use of a plurality of locking hooks arranged in a row further improves the durability of the connection between the valve block and the fixation plate assembly.

Preferably, said locking hooks are arranged in a first row and a second row, said rows extending along the first direction, and wherein the first row is parallel to the second row. Again, the quality of the connection between the valve block and the fixation plate assembly is improved. Furthermore, in case of a damage to one of said locking hooks, a durable connection between the mentioned components is maintained. Hence, a fail-safe design philosophy is incorporated.

According to yet another preferred embodiment, said first row is arranged at a first outer edge of the valve block and said second row is arranged at a second outer edge of the valve block, and wherein said first outer edge is opposite from the second outer edge. Preferably, the said first row and said second row are arranged perpendicular to a pivot axis of said fixation plate. The mentioned arrangement of said first row and said second row has been found to be beneficial to durably connect the components and also simplify the manufacturing of the components.

In a further aspect, the invention relates to a gearbox control unit for a commercial vehicle, said gearbox control unit comprising a bottom housing section configured to be attached to a gearbox of a vehicle, a top cover, the top cover being releasably attached to the bottom housing section, and a valve unit accommodated within said bottom housing section. According to the invention, the valve unit is a valve unit according to any of the embodiments mentioned above.

The gearbox control unit takes advantage of the same benefits and preferred embodiments as the valve unit according to the invention. In this regard, reference is made to the above explanations and their content is included herein.

In yet another aspect, which is not part of the present invention, it relates to a method for assembling a valve unit according to any of the above described embodiments, the method comprising the steps: providing a fixation plate assembly comprising a fixation plate and a flexible printed circuit attached thereto, providing a valve block, connecting the fixation plate assembly to the valve block while the fixation plate assembly is folded away from the valve unit, rotating the fixation plate assembly towards the valve block such that cutouts in the fixation plate receive locking means protruding from the valve block, and moving the fixation plate assembly to engage the locking means with the cutouts.

Preferably, the method, which is not part of the present invention, further comprises the step of fixing the fixation plate assembly to the valve block.

The method for assembling a valve unit takes advantage of the same benefits and preferred embodiments as the valve unit and the gearbox control unit according to the invention. In this regard, reference is made to the above explanations and their content is included herein.

The aspects of the present invention, which is defined by the appended claims, may best be understood from the following detailed description taken in conjunction with the accompanying figures. The figures are schematic and simplified for clarity, and they just show details to improve the understanding of the claims while other details are left out. The individual features of each aspect may each be combined with any or all features of other aspects.

These and other aspects, features and/or technical effects will be apparent from and elucidated with reference to the illustrations described hereafter, which show in:.

<FIG> shows a gearbox control unit <NUM> for a commercial vehicle. The gearbox control unit <NUM> comprises a bottom housing section <NUM>. The bottom housing section <NUM> is configured to be attached to a gearbox of a vehicle (not shown). The gearbox control unit <NUM> furthermore comprises a top cover <NUM>. The top cover <NUM> is releasably attached to the bottom housing section <NUM>. A valve unit <NUM> is accommodated within said bottom housing section <NUM>. In the top cover <NUM>, an electronic control unit <NUM> is accommodated.

The valve unit <NUM> comprises a valve block <NUM>. The valve unit <NUM> furthermore comprises a fixation plate assembly <NUM>. The fixation plate assembly <NUM> comprises a fixation plate <NUM>. Attached to the fixation plate <NUM> is a flexible printed circuit <NUM>. The gearbox control unit <NUM> furthermore comprises a second flexible printed circuit <NUM> connecting the top cover <NUM> with the bottom housing section <NUM>.

<FIG> show a valve unit <NUM> according to the invention. Referring to <FIG>, the valve unit <NUM> comprises the valve block <NUM> and the fixation plate assembly <NUM>. Attached to the fixation plate <NUM> is the flexible printed circuit <NUM>. The valve block <NUM> furthermore comprises a receiving area <NUM> for receiving said fixation plate assembly <NUM>. The valve block <NUM> comprises receiving means <NUM>. The receiving means <NUM> are configured to couple pivotally with the fixation plate <NUM>. Furthermore, the receiving means <NUM> limit the movement of the fixation plate <NUM> in a first direction <NUM>.

The receiving means <NUM> comprise a first receiving hook <NUM>. The receiving means <NUM> furthermore comprise a second receiving hook <NUM>. The first receiving hook <NUM> and the second receiving hook <NUM> protrude from said valve block <NUM>. The second receiving hook <NUM> is spaced apart from the first receiving hook <NUM>. The first receiving hook <NUM> and the second receiving hook <NUM> are configured to couple pivotally with the fixation plate <NUM>. This can best be seen in <FIG>.

The fixation plate <NUM> comprises a coupling section <NUM> for coupling with the receiving means <NUM>. The coupling section <NUM> comprises a cutout <NUM> extending from an outer edge <NUM> of the fixation plate <NUM> inwardly. The valve block <NUM> comprises two rails <NUM>, <NUM>'. The rails <NUM>, <NUM>' are configured to support the fixation plate assembly <NUM> when the fixation plate assembly <NUM> is mounted to the valve block <NUM>. The rails <NUM>, <NUM>' are arranged in parallel to one another.

The valve block <NUM> furthermore comprises locking means <NUM>. The locking means <NUM> protrude from the valve block <NUM>. The fixation plate <NUM> comprises corresponding cutouts <NUM> for receiving the locking means <NUM>. The locking means <NUM> comprise locking hooks <NUM>. Said locking hooks <NUM> limit a movement of the fixation plate assembly <NUM> in a second direction <NUM>, see <FIG>. The second direction <NUM> is opposite of the first direction <NUM>.

As shown in <FIG>, the locking hooks <NUM> are arranged in a first row <NUM> and a second row <NUM> extending along the first direction <NUM>. The first row <NUM> is parallel to the second row <NUM>. Said first row <NUM> is arranged at a first outer edge <NUM> of the valve block <NUM>. The second row <NUM> is arranged at a second outer edge <NUM> of the valve block <NUM>. The first outer edge <NUM> is opposite from the second outer edge <NUM>.

<FIG> shows a detailed perspective of said locking hook <NUM>. The locking hook <NUM> comprises a top section <NUM> having a sloped surface <NUM>. The sloped surface <NUM> is configured to push the fixation plate <NUM> towards the valve block <NUM> when the fixation plate assembly <NUM> is moved in the second direction <NUM>.

As shown in <FIG>, the valve block <NUM> comprises a stopping means <NUM>. The stopping means <NUM> limits the movement of the fixation plate <NUM> in the second direction <NUM>. The fixation plate <NUM> furthermore comprises a centring bore <NUM>. The valve unit <NUM> comprises a corresponding threaded bore <NUM>. The threaded bore <NUM> is configured for receiving a tensioning screw <NUM>. The tensioning screw <NUM> is guided through the centring bore <NUM> into the threaded bore <NUM>. With the help of the tensioning screw <NUM>, the fixation plate assembly <NUM> is secured to the valve block <NUM>.

As described in <FIG>, the fixation plate assembly <NUM> is mounted to the valve block <NUM> as follows: First of all, the fixation plate assembly <NUM> is connected to the receiving area <NUM> of the valve block <NUM> while the fixation plate assembly <NUM> is folded away from the valve unit <NUM>. Secondly, the fixation plate assembly <NUM> is rotated towards the valve block <NUM>, such that the cutouts <NUM> in the fixation plate <NUM> receive the locking means <NUM> that protrude from the valve block <NUM>. Finally, when the fixation plate assembly <NUM> abuts against the valve block <NUM>, the fixation plate assembly <NUM> is moved in the second direction <NUM> to engage the locking means <NUM> with the cutouts <NUM>. Finally, the fixation plate assembly <NUM> is fixed to the valve block <NUM> with the help of the tensioning screws <NUM>. To disassemble the fixation plate assembly <NUM> from the valve block <NUM>, the above described steps are carried out in reverse order.

Claim 1:
A valve unit (<NUM>) for a gearbox control unit (<NUM>) of a commercial vehicle, said valve unit (<NUM>) comprising a valve block (<NUM>) and a flexible printed circuit (<NUM>) for connecting the valve unit (<NUM>) to the gearbox control unit (<NUM>),
wherein said valve unit (<NUM>) comprises a fixation plate assembly (<NUM>) comprising a fixation plate (<NUM>), wherein the flexible printed circuit (<NUM>) is attached to the fixation plate (<NUM>), and wherein said fixation plate assembly (<NUM>) is attached to said valve block (<NUM>)
characterized by at least one receiving means (<NUM>) arranged at the valve block (<NUM>), the receiving means (<NUM>) configured to couple pivotally with the fixation plate (<NUM>) and limit its movement in a first direction (<NUM>).