Patent Application
20170292623
The present invention relates to solenoid actuator assemblies, and in particular to solenoid actuated valve assemblies.
Solenoid valves are known in the art and are used in various applications for controlling a fluid flow. A solenoid valve includes a combination of two functional units: a solenoid and a valve. The solenoid includes an electrical coil, a core or armature that is actuated by the magnetic flux generated by the coil upon energization, a spring which returns the armature to a de-energized position, and a housing in which these components are located. The valve includes a valve housing typically including one or more valve ports, and a poppet which is moveable within the valve housing in order to open or close the one or more ports. Typically the valve housing is a metal part and requires machining at least at the sealing surfaces and valve seats. The coil is typically a wound copper wire that, upon energization, creates the magnetic flux. The core or armature is made of a magnetic material and upon energization of the coil is moved via the magnetic flux to an actuating position. The spring acts on the armature or the poppet to return the armature to its de-energized position. Typically, the armature is located in a tube that is closed at one end that is located within the coil and acts as a guide for the armature.
Since the solenoid valve is a combination of two functional parts, one issue that is always faced is the need to make a strong, reliable, and low cost physical connection between the solenoid housing, which is typically a metallic component, and the valve housing. There is also the need to reduce costs to the extent possible while maintaining the same functionality and reliability for the overall solenoid valve assembly.
In one aspect, a method of assembling a solenoid valve assembly is provided. The method includes providing a polymeric valve housing having a plurality of housing posts extending from one end, and inserting the posts through corresponding openings on a metallic intermediate plate. The housing posts are then at least one of heat or ultrasonically staked over the openings to connect the metallic intermediate plate to the polymeric valve housing. A metallic solenoid housing with solenoid components therein is then placed over the metallic intermediate plate and the metallic housing is crimped onto the metallic intermediate plate. This type of assembly ensures that the metallic elements are crimped onto other metallic elements rather than onto a polymeric element to avoid damage to the polymeric element as well as provide a firm assembly with sufficient structural integrity for the overall solenoid valve assembly.
In one preferred arrangement, the metallic intermediate plate is a mounting flange.
The method may further include inserting a poppet as well as the valve plunger or rocket into the polymeric valve housing.
In one preferred aspect, a groove is located on the top of the polymeric valve housing in an area of the housing posts in a region of the metallic intermediate plate. The method further includes inserting an O-ring into the groove with the O-ring extending above the groove.
In a further aspect, the metallic intermediate plate includes an actuator opening, the method further comprises placing a metallic tube having a tube flange at one end through the actuator opening, with an armature of the solenoid being located in the metallic tube for contacting the valve plunger or rocket, locating the flange over the O-ring and installing the metallic intermediate plate with the tube flange on the valve housing with the housing posts extending through corresponding openings, and compressing the O-ring during the staking of the ends of the housing posts over the openings.
In another aspect, the method further includes inserting poles and a coil into the metallic solenoid housing prior to placing the metallic solenoid housing over the metallic intermediate plate and crimping the metallic solenoid housing onto the metallic intermediate plate.
In another aspect, a solenoid valve assembly that is assembled according to the method is provided. The solenoid valve assembly preferably includes the polymeric valve housing with the plurality of housing posts that extend from one end as well as the metallic intermediate plate having openings corresponding to the housing posts, with the housing posts being staked over the openings. A metallic solenoid housing is located on the metallic intermediate plate on an opposite side from the polymeric valve housing and has crimped portions that engage the metallic intermediate plate. Preferably, the poppet is located in the polymeric valve housing and a solenoid armature actuates the poppet.
Further, as noted above, preferably a groove is provided on the top of the polymeric valve housing in an area of the housing posts in a region of the metallic intermediate plate, and an O-ring is located in and extends above the groove. Preferably, an actuator opening is provided in the metallic intermediate plate. A metallic tube is provided with a tube flange at one end, and an armature is located the metallic tube that contacts the rocket for moving the poppet. The tube flange is located on the top of the polymeric valve housing with the tube flange located between the O-ring and the metallic intermediate plate. The metallic tube extends through the actuator opening and acts as a guide for the armature as well.
The O-ring provides a vertical force against the tube flange of the metallic tube in order to press it tightly against the bottom of the metallic intermediate plate providing a pre-load against the heat-staked ends of the housing post as well as its normal sealing function.
Poles and a coil for the solenoid are located in the metallic solenoid housing surrounding the armature.
The foregoing Summary and the following detailed description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the invention. In the drawings:
Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “rear,” “upper,” and “lower” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from the parts referenced in the drawings. “Axially” refers to a direction along an axis of the valve plunger or rocket or the solenoid armature. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terminology includes the words specifically noted above, derivatives thereof and words of similar import.
Referring to
Preferably, a plurality of O-rings 34 are located on the outside of the polymeric valve housing 22 in a plurality of grooves in order to allow the housing 22 to be sealed within a receiving opening, for example in a cylinder head, engine block, or other component in which fluid lines that deliver or receive fluid from or to the valve ports 25, 26 are located.
The valve housing 22 is preferably made of a thermoplastic material and in one preferred embodiment is formed of a glass-fiber reinforced PPS. This can include 30%, 40% or more of glass-fiber in order to improve the tensile strength of the valve housing 22 and the posts 24. This allows the valve housing 22 to be molded to a near net shape, reducing both cost and machining time in comparison to metal valve housings. Other suitable polymeric materials can also be used, for example a glass-fiber reinforced PEEK material.
A metallic intermediate plate 36 with corresponding openings 38 is located over the housing posts 24. In a preferred embodiment, the metallic intermediate plate 36 is a mounting flange that can be used to mount the solenoid valve assembly 10. The metallic intermediate plate 36 preferably also includes an actuator opening 39 in which a metallic tube 46 having a closed end at one end and an annular flange 47 at the other end is located. Preferably, the flange 47 is located between the metallic intermediate plate 36 and the polymeric valve housing 22, as shown in
Preferably, the solenoid 40 includes an armature 42 located within the metallic tube 46 and in the assembled position, the armature 42 contacts the valve rocket or plunger 31. Annular solenoid poles 44a, 44b, are located around the metallic tube 46 and preferably include a resilient spacer or crush ring 45 there-between. As shown in detail in
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While two tabs 50 are shown in
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Referring now to
While one valve configuration is illustrated, those skilled in the art will recognize that different valve configurations for different operations can be provided.
The present assembly allows for lower cost and easier assembly of a solenoid valve 10 due to the drop in assembly of the components and crimping of the metallic solenoid housing 48 to the metallic intermediate plate 36 after the polymeric valve housing 22 has been at least one of heat or ultrasonically staked to the metallic intermediate plate 36.
It is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.
