Method for producing a throttle valve unit in a two-component injection molding process

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising the following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transfer of the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) demolding the molded housing part at very high temperatures and maintenance of this temperature to reduce stresses and permit secondary crystallization processes to occur.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising including the following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) demolding of the molded housing part from the first cavity and execution of an intermediate treatment of the resulting premolded part to selectively reduce stresses in the premolded part.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transfer of the molded housing part of the housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) demolding the valve flap part obtained according to process step c) inside the premolded part in a position of the valve flap part inside the molded housing part that produces an extremely narrow gap geometry or in a sealed position of the valve flap part inside a gas passage of the molded housing part, which position is defined during the injection of the second plastic material for the valve flap part.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) applying a third material after process step a) onto molding surfaces for the second plastic material of the valve flap part to be subsequently injection molded in the molded housing part.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising including the following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring of the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) inserting bushes into openings of the molded housing part so that the bushes are rotationally fixed in relation to the molded housing part, before or during the transfer of the molded housing part to the second cavity.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, the flap part having shaft parts, and
• d) inserting bushes and reverse injection with rotational fixing in relation to the flap shaft parts of the valve flap part before or during the transfer of the premolded part to the second cavity.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the molded housing part in the second cavity, and
• d) introducing a third material into the gap geometries of the two-component injection molded throttle valve unit where the gap geometries lie outside the tightness specification before the introduction of the third material and then—after the possibly partial removal of the third material—lie within the tightness specification.

A method for manufacturing a throttle valve unit having a housing part and a valve flap part that is able to move in relation to the housing part, the method comprising following process steps:

• a) injection molding the housing part out of a first plastic material in a first cavity,
• b) transferring the molded housing part obtained according to process step a) to a second cavity spatially separate from the first cavity,
• c) injection molding the movable valve flap part out of a second plastic material inside the mold housing part in the second cavity,
• d) providing bushes between the molded housing part and the flap part, and
• e) introducing a fourth material into the gap geometries of the two-component injection throttle valve unit with bushes where the gap geometries lie outside the tightness specification before the introduction of the fourth material and then—after the possibly partial removal of the fourth material—lie within the tightness specification.