2020P00775US
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`THROTTLE PLATE
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`FIELD OF THE INVENTION
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`[0001]
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`The invention relates generally to a throttle plate which is
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`part of a throttle assembly, where the throttle plate includes at least one feature,
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`or material deformation area, such as a rib or a plurality of ribs, and the throttle
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`plate is made with reduced cost and weight, and is still able to be used with
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`existing manufacturing and assembly processes.
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`BACKGROUND OF THE INVENTION
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`[0002]
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`Throttle assemblies are generally known and are typically
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`used to control the flow of air into an engine. Most throttle assemblies typically
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`have a valve which is mounted to a shaft, where the shaft is rotated (by an
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`actuator) to change the position of the valve and therefore control the flow of air
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`into the engine. These types of valves must withstand exposure to certain
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`pressures and temperatures. These valves also must past a “backfire” test,
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`where the valve is exposed to a sudden burst of pressure from the engine.
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`In
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`order to passthis test, the valve must have a minimum structural robustness and
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`rigidity. For larger valves, there is an increase in cost of manufacture because of
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`the needed increased structural
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`rigidity to withstand the backfire test. The
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`required flat thickness also adds inertia loading to the actuator componentry,
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`impacting performance and durability of the throttle assembly.
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`
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`THROTTLE PLATE
`
`FIELD OF THE INVENTION
`
`[0001]
`
`The invention relates generally to a throttle plate which is
`
`part of a throttle assembly, where the throttle plate includes at least one feature,
`
`or material deformation area, such as a rib or a plurality of ribs, and the throttle
`
`plate is made with reduced cost and weight, and is still able to be used with
`
`existing manufacturing and assembly processes.
`
`BACKGROUND OF THE INVENTION
`
`[0002]
`
`Throttle assemblies are generally known and are typically
`
`used to control the flow of air into an engine. Most throttle assemblies typically
`
`have a valve which is mounted to a shaft, where the shaft is rotated (by an
`
`actuator) to change the position of the valve and therefore control the flow of air
`
`into the engine. These types of valves must withstand exposure to certain
`
`pressures and temperatures. These valves also must past a “backfire” test,
`
`where the valve is exposed to a sudden burst of pressure from the engine.
`
`In
`
`order to passthis test, the valve must have a minimum structural robustness and
`
`rigidity. For larger valves, there is an increase in cost of manufacture because of
`
`the needed increased structural
`
`rigidity to withstand the backfire test. The
`
`required flat thickness also adds inertia loading to the actuator componentry,
`
`impacting performance and durability of the throttle assembly.
`
`
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`2020P00775US
`
`[0003]
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`Accordingly,
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`there exists a need for a valve for a throttle
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`assembly, which uses a largervalve, that is able to withstand a backfire test,
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`is
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`also lightweight, and may be manufactured with minimal or no increased cost.
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`SUMMARYOF THE INVENTION
`
`[0004]
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`In one embodiment, the present invention is a valve, such as
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`a valve plate, which is suitable for use with a throttle assembly, and is able to
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`withstand a backpressure test. The valve plate of the present invention is also
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`able to be used as a replacementfor existing valve plates, without requiring any
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`changes to the other components of the throttle assembly, or the manufacturing
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`processesofthe throttle assembly.
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`In an embodiment, the valve is a valve plate
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`which includes a flat plate, and a plastic material overmolded onto the valve
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`plate. The plastic material
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`includes at least one rib, and in one embodiment
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`includes a plurality of rips, allowing for a thinner and lighter weight plate which is
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`manufactured as a lower cost.
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`[0005]
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`In an embodiment,
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`the valve of the present invention is a
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`two-piece valve plate having an overlap portion.
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`In this embodiment, the two
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`pieces of the throttle valve overlap at
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`the portion of the valve plate which
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`interfaces with the shaft of the throttle assembly. The remaining portion of the
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`plate surface includes at
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`least one ribbed feature, and in one embodiment
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`includes a plurality of ribbed features which reduce material usage and therefore
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`reduce weight and cost, but also provide the required strength and rigidity.
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`
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`2020P00775US
`
`[0006]
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`Further areas of applicability of the present
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`invention will
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`become apparent from the detailed description provided hereinafter.
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`It should be
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`understood that the detailed description and specific examples, while indicating
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`the preferred embodiment of
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`the invention, are intended for purposes of
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`illustration only and are not intended to limit the scope of the invention.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0007]
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`The present
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`invention will become more fully understood
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`from the detailed description and the accompanying drawings, wherein:
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`[0008]
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`Figure 1
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`is a perspective view of an embodiment of valve
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`plate, according to embodiments of the present invention;
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`[0009]
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`Figure 2 is a top view of an embodiment of a valve plate,
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`according to embodiments of the present invention;
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`[0010]
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`Figure 3A Is a perspective view of a first half of an
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`embodiment of a valve plate, according to embodiments of the present invention;
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`[0011]
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`Figure 3B is a perspective view of a second half of an
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`embodiment of a valve plate, according to embodiments of the present invention;
`
`[0012]
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`Figure 4A is a side view ofa first half of an embodimentof a
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`valve plate, according to embodiments of the present invention;
`
`[0013]
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`Figure 4B is a side view of a second half of an embodiment
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`of a valve plate, according to embodimentsof the present invention;
`
`
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`2020P00775US
`
`[0014]
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`Figure 5 is a side view of a first half and second half of valve
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`plate during assembly, according to embodiments of the present invention;
`
`[0015]
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`Figure 6 is a side view of an embodiment of valve plate,
`
`according to embodiments of the present invention;
`
`[0016]
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`Figure 7 is a perspective view of an alternate embodiment of
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`valve plate, according to embodiments of the present invention;
`
`[0017]
`
`Figure
`
`8
`
`is
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`a perspective view of another alternate
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`embodiment of a valve plate next to a shaft, according to embodiments of the
`
`present invention;
`
`[0018]
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`Figure 9A is a first sectional side view of another alternate
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`embodiment of valve plate, according to embodiments of the present invention;
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`and
`
`[0019]
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`Figure 9B is a second sectional side view of another
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`alternate embodiment of valve plate, according to embodiments of the present
`
`invention.
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`DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
`
`[0020]
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`The following description of the preferred embodiment(s) is
`
`merely exemplary in nature and is in no way intended to limit the invention,
`
`its
`
`application, or uses.
`
`[0021]
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`A throttle plate or valve plate according to the present
`
`invention is shownin the Figures generally at 10, where the throttle plate 10 may
`
`
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`2020P00775US
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`be used as part of a throttle assembly for controlling air flow into an engine. The
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`throttle plate 10 includes a first half 12 and a second half 14. Thefirst half 12 of
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`the throttle plate 10 and the second half 14 are of generally the same shape.
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`Each half 12,14 includes an assembly flange 16a,16b. The assembly flange 16a
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`includes two assembly apertures 18a,18b, and the other assembly flange 16b
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`also includes two assembly apertures 20a,20b.
`
`[0022]
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`The assembly flanges 16a,16b are each integrally formed
`
`with a flange portion 22a,22b, respectively, and each flange portion 22a,22b
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`includes at least one deformation area.
`
`In this embodiment,
`
`the deformation
`
`areas are a singular rib 24a integrally formed as part of the flange portion 22a of
`
`the first half 12, and a singular rib 24b integrally formed as part of the flange
`
`portion 22b of the second half 14.
`
`[0023]
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`In this embodiment, the thickness 26a,26b of the assembly
`
`flanges 16a,16b is substantially the same the thickness 28a,28b of the flange
`
`portions 22a,22b in the areas of
`
`the flange portions 22a,22b which are
`
`unoccupied by the ribs 24a,24b.
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`It may be seen in Figures 4A, 4B, 5, and 6 that
`
`the assembly flanges 16a,16b are also offset from the flange portions 22a,22b.
`
`[0024]
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`During assembly, the halves 12,14 are assembled such that
`
`the assembly flanges 16a,16b are in contact with one another, and the assembly
`
`apertures 18a,18b of the assembly flange 16a are in alignment with the assembly
`
`apertures 20a,20b of the assembly flange 16b.
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`Fasteners (not shown) are
`
`inserted through the apertures 18a,18b,20a,20b to attach the plate 10 to a shaft.
`
`
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`2020P00775US
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`Furthermore, the assembly flanges 16a,16b are offset from the flange portions
`
`22a,22b such that when the halves 12,14 are assembled to one another, the
`
`assembly flange 16a of the first half 12 is in general alignment with the flange
`
`portion 22b of the second half 14, and the assembly flange 16b of the second
`
`half 14 is in general alignment with the flange portion 22a of the first half 12.
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`Also, when the halves 12,14 are assembled, the ribs 24a,24b are on opposite
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`sides of the throttle plate 10 relative to one another.
`
`[0025]
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`Referring now to Figure 6, when the halves 12,14 are
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`assembled,
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`the combined overall thickness 30 of the rib 24a and the flange
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`portion 22a is less than the combined thickness 36 of the assembly flanges
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`16a,16b. Additionally, the combined overall thickness 32 of the rib 24b and the
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`flange portion 22b is also less than the combined thickness 36 of the assembly
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`flanges 16a,16b.
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`[0026]
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`Also the combined thickness 36 of the assembly flanges
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`16a,16b results in the throttle plate 10 fitting into the slot 60 such that air leaking
`
`through the slot 60 is prevented or at least minimized. The combined thickness
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`36 of the assembly flanges 16a,16b also allows for the throttle plate 10 to be
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`used with the shaft 42 and slot 60 without having to change the dimensions of
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`the slot 60, where the shaft 42 is used with existing throttle plate designs.
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`[0027]
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`An alternate embodiment of the throttle plate is shown in
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`Figure 7, with like numbers referring to like elements.
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`In this embodiment,
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`instead of there being a singular rib,
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`there is a first plurality of ribs, shown
`
`
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`2020P00775US
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`generally at 34a,
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`integrally formed as part of the flange portion 22a of the first
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`half 12, and a secondplurality of ribs 34b integrally formed as part of the flange
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`portion 22b of the second half 14.
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`[0028]
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`Another embodiment of the invention is shown in Figures 8
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`and 9A-9B.
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`In this embodiment, the throttle plate 10 is a single piece throttle
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`plate, and the throttle plate 10 includes a metal deformation area, shown
`
`generally at 38.
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`Integrally formed as part of the metal deformation area 38 is two
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`assembly apertures 40a,40b. When assembled,
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`the throttle plate 10 is
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`connected to a shaft 42, and integrally formed as part of the shaft 42 is a slot 60.
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`The throttle plate 10 is inserted into the slot 60 during assembly, such that the
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`assembly apertures 40a,40b are aligned with other assembly apertures 44a,44b
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`formed as part of the shaft 42. Two fasteners extend through the apertures
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`40a,40b,44a,44b to secure the throttle plate 10 to the shaft 42.
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`In one
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`embodiment, the metal deformation area 38 includes at least one rib portion, and
`
`in this embodiment,
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`includes several rib portions 46a,46b,46c,46d,46e,46f and
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`several of the rib portions 46a,46b,46c,46d,46e,46f are in contact with the inner
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`walls 48a,48b of the slot 60, as shown in Figures 9A and 9B,
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`to provide an
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`interference fit between the throttle plate 10 and the shaft 42, more specifically
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`the slot 60. This prevents air flow through the slot 60.
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`In one embodiment, a
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`plastic overmold material 50, shown in Figure 9B, may be used aswell to provide
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`a sealing function in the slot 60.
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`In one embodiment, a support ring, or stand off
`
`
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`2020P00775US
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`52,
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`is used to provide support and increase robustness to manage the clamping
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`load from the fasteners on the throttle plate 10.
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`[0029]
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`The width 54 of
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`the slot 60 in
`
`this embodiment
`
`is
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`approximately 2 mm. However, the thickness 56 of the throttle plate 10 may be
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`less than 2 mm, and the rib portions 46a,46b,46c,46d,46e,46f may be configured
`
`such that an overall width 58 of
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`the rib portions 46a,46b,46c,46d,46e,46f
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`corresponds to a width that providesthe interferencefit between the throttle plate
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`10 and the slot 60. This allows for less material to be used when manufacturing
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`the throttle plate 10, and the throttle plate 10 may be used with various existing
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`shafts having existing slot dimensions, such that no modifications to the existing
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`shaft, or manufacturing processes of the throttle assembly are necessary. The
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`throttle plate 10 may also be used with existing fixtures and grippers with only
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`minor modifications as part of an existing manufacturing process, such as a high-
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`volume automation assembly line, without making any significant changes to the
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`existing manufacturing process.
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`[0030]
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`Further understanding of the invention may be gleaned from
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`the attached Appendix A.
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`[0031]
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`The description of the invention is merely exemplary in
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`nature and, thus, variations that do not depart from the gist of the invention are
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`intended to be within the scope of the invention. Such variations are not to be
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`regarded as a departure from the spirit and scope of the invention.
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