The present disclosure relates to a solenoid assembly. The present invention relates more particularly to an improved solenoid assembly having embedded magnets.
A solenoid is a type of electromagnet that can include a coil that operable to form magnetic fields. In operation, solenoids typically allow a current to pass through their coil thereby creating a magnetic field within the immediate vicinity of the coil. Solenoids can be used in valves that are integrated devices having an electromechanical solenoid operable to actuate a valve.
In view of the foregoing, it is an object of the present disclosure to provide a method and apparatus.
A first exemplary embodiment of the present disclosure provides a solenoid assembly. The solenoid assembly having a ferromagnetic core tube having a longitudinal axis, a radial exterior surface and a radial interior surface surrounding a cavity, the ferromagnetic core tube comprising a first channel and a second channel disposed on the radial exterior surface of the ferromagnetic core tube, the first channel and the second channel circumscribing the ferromagnetic core tube along a given portion of the longitudinal axis, wherein the first channel and the second channel are spaced from one another along the longitudinal axis, the first channel comprising a plurality of radial exterior surfaces, the second channel comprising a second plurality of radial exterior surfaces, wherein a first portion of the ferromagnetic core tube between the plurality of radial exterior surfaces of the first channel and the radial interior surface of the ferromagnetic core tube define a first thin wall portion of the ferromagnetic core tube, wherein a second portion of the ferromagnetic core tube between the second plurality of radial exterior surfaces of the second channel and the radial interior surface of the ferromagnetic core tube define a second thin wall portion of the ferromagnetic core tube, the first channel comprising a first magnetic ring radially spaced apart from the first thin wall, the second channel comprising a second magnetic ring radially spaced part from second thin wall. The solenoid assembly further includes a coil located radially outward of the ferromagnetic core tube, wherein the ferromagnetic core tube comprises a uniform single piece material.
A second exemplary embodiment of the present disclosure provides a solenoid assembly having a ferromagnetic core tube having a longitudinal axis, a radial exterior surface and a radial interior surface surrounding a cavity, the ferromagnetic core tube comprising a first channel and a second channel disposed on the radial exterior surface of the ferromagnetic core tube, the first channel and the second channel circumscribing the ferromagnetic core tube along a given portion of the longitudinal axis, wherein the first channel and the second channel are spaced from one another along the longitudinal axis, the first channel comprising a plurality of radial exterior surfaces, the second channel comprising a second plurality of radial exterior surfaces, wherein a first portion of the ferromagnetic core tube between the plurality of radial exterior surfaces of the first channel and the radial interior surface of the ferromagnetic core tube define a first thin wall portion of the ferromagnetic core tube, wherein a second portion of the ferromagnetic core tube between the second plurality of radial exterior surfaces of the second channel and the radial interior surface of the ferromagnetic core tube define a second thin wall portion of the ferromagnetic core tube, the first channel comprising a first magnetic ring radially spaced apart from the first thin wall, the second channel comprising a second magnetic ring radially spaced part from second thin wall. The solenoid assembly further includes an armature maintained with the cavity, the armature operable to move through the longitudinal axis of the cavity in response to a current passing through the coil. The solenoid assembly still further includes a coil located radially outward of the ferromagnetic core tube, wherein the ferromagnetic core tube comprises a uniform single piece material, wherein the first channel maintains a filler material between an inner radial surface of the first magnetic ring and the outer radial surface of the first thin wall, and wherein the second channel maintains a filler material between an inner radial surface of the second magnetic ring and the outer radial surface of the second thin wall.
A third exemplary embodiment of the present disclosure provides a method. The method includes providing a ferromagnetic core tube having a longitudinal axis, a radial exterior surface and a radial interior surface surrounding a cavity, the ferromagnetic core tube comprising a first channel and a second channel disposed on the radial exterior surface of the ferromagnetic core tube, the first channel and the second channel circumscribing the ferromagnetic core tube along a given portion of the longitudinal axis, wherein the first channel and the second channel are spaced from one another along the longitudinal axis, the first channel comprising a plurality of radial exterior surfaces, the second channel comprising a second plurality of radial exterior surfaces, wherein a first portion of the ferromagnetic core tube between the plurality of radial exterior surfaces of the first channel and the radial interior surface of the ferromagnetic core tube define a first thin wall portion of the ferromagnetic core tube, wherein a second portion of the ferromagnetic core tube between the second plurality of radial exterior surfaces of the second channel and the radial interior surface of the ferromagnetic core tube define a second thin wall portion of the ferromagnetic core tube, the first channel comprising a first magnetic ring radially spaced apart from the first thin wall, the second channel comprising a second magnetic ring radially spaced part from second thin wall. The method further includes providing a coil located radially outward of the ferromagnetic core tube, wherein the ferromagnetic core tube comprises a uniform single piece material.
The following will describe embodiments of the present disclosure, but it should be appreciated that the present disclosure is not limited to the described embodiments and various modifications of the disclosure are possible without departing from the basic principles. The scope of the present disclosure is therefore to be determined solely by the appended claims.
Embodiments of the present disclosure provide a solenoid assembly having a core tube that is circumscribed by a single coil, excitation coil, wound coil, or coil. Embodiments of the core tube include a ferromagnetic tube having a uniform tube thickness along its longitudinal axis except for a pair of channels that circumscribe the radial exterior surface of the core tube. Embodiments of the core tube include having a pair of channels that have a thinner cross section of the core tube. Within the core tube is a cavity that maintains a moveable armature operable to move through the longitudinal axis of the cavity in response to magnetic flux created by current passing through the coil. Embodiments include the core tube being a ferromagnetic tube having a uniform diameter across its longitudinal axis except for a pair of spaced apart channels circumscribing the radial exterior surface of the core tube. Each of the channels are located radially inward from the coil. The two channels are separated from one another along the longitudinal axis by a ferrous spacer. Within each of the channels along the inner radial portion of the channels are a non-magnetic filler material welded to the outer radial surface of the channels. Embodiments include the filler material being replaced by an air gap such that there is an air gap between the radial inner surface of the magnets and the outer radial surface of the core tube. Radially outwardly adjacent the filler material is a magnet or magnets that circumscribe the filler material. Each of the magnets are embedded within the core tube such that the radial exterior surface of the core tube and the radial exterior surface of the magnets are coextensive. A thin wall of the core tube separates the filler material from the inside cavity of the core tube. Embodiments of the magnets are removable from the channels and the core tube such that they can be replaced with new magnets in the instance that the magnets degrade or lose their magnetic force. Embodiments provide that a small gap may exist between the side edges of the magnets and the adjacent core tube surface.
Embodiments of the present disclosure include a solenoid assembly having a core tube that has a Teflon coated sleeve located or disposed along the inner radial surface of the cavity of the core tube. Embodiments provide that the Teflon coated sleeve is operable to reduce friction between the armature and the tube.
It should be appreciated that each magnet that circumscribes the core tube may include multiple curved magnets that are in contact with or close proximity to one another such that in combination they collectively circumscribe the core tube. One embodiment includes that the magnets be C-shaped such that two or more C-shaped magnets are operable to collectively circumscribe the core tube.
In one embodiment, the location of the magnets and the length of the magnets along the longitudinal axis are equal in length to the radially outer most surface of the filler material such that the magnets and the filler material are coextensive in the longitudinal direction. In another embodiment, the magnets are coextensive in the longitudinal direction with the filler material along the edge adjacent the spacer, but are not coextensive on the edge opposite from the spacer such that the magnets extend beyond the filler material. In yet another embodiment, the magnets are coextensive in the longitudinal direction with the filler material along the edge opposite from the spacer, but are not coextensive on the edge adjacent the spacer such that the magnets extend over the spacer. In yet a further embodiment, the magnets are located such that they are radially outward from the filler material. In this embodiment, the magnets are not coextensive with the filler material on either the edge adjacent the spacer or the edge opposite from the spacer. In other words, in this embodiment, the magnets are longer than the filler material in the longitudinal direction and extend past the edge of the filler material that is adjacent the spacer and opposite from the spacer.
Referring to
The first channel 106 and the second channel 108 each define a groove disposed on the radial exterior surface 116 of core tube 104. The first channel 106, spacer 105 and the second channel 108 are located radially inward from coil 102. The first channel 106 is spaced apart from the second channel 108 such that they each circumscribe the radial exterior surface 116 of core tube 104 along a set range along the longitudinal axis 118 of core tube 104. The first channel 106 is spaced apart and separated from the second channel 108 in the longitudinal direction by a ferrous spacer 105. Ferrous spacer 105 is integral with the core tube 104 and extends radially outward from the radial interior surface 114 of the cavity 115 to the radial exterior surface 114. Embodiments of ferrous spacer 105 include ferrous spacer 105 having the same uniform thickness as the radial interior surface 114 and radial exterior surface 116 of the remainder of core tube 104 (shown in
The first channel 106 is located such that along its cross-section along the longitudinal axis 118 of core tube 104, it has a uniform thickness in the radial direction. Similarly, the second channel 108 is located such that along its cross-section along the longitudinal axis 118 of core tube 104, it has a uniform thickness in the radial direction. Embodiments of the first channel 106 and the second channel 108 include them maintaining either (i) a filler material 111, or (ii) an air gap 117 (shown in
The first magnetic ring 107 is located radially outward from and in contact with either the filler material 111 or the air gap 117 within the first channel 106. The second magnetic ring 109 is located radially outward from either the filler material 111 or the air gap 117 within the second channel 106. Embodiments of the first magnetic ring 107 and the second magnetic ring 109 include two or a plurality of curved or C-shaped magnets (shown in
In other embodiments, the first magnetic ring 107 and the second magnetic ring 109 are not coextensive with the adjacent filler material 111 or air gap in the longitudinal axis 118 direction (shown in
It should be appreciated that both the first channel 106 and the second channel 108 can include two, three or more surfaces on their radial exterior surface. Referring to
Shown in
Reference is now made to the embodiment of second channel 108 illustrated in
Referring to
Referring to
Next, block 1206 recites wherein the first channel and the second channel are located radially inward from the coil, and wherein the first channel is spaced apart from the second channel along the longitudinal axis by a ferrous spacer. Block 1208 then states wherein the first channel maintains one of a filler material or an air gap between an inner radial surface of the first magnetic ring and the outer radial surface of the first thin wall, and wherein the second channel maintains one of a filler material or an air gap between an inner radial surface of the second magnetic ring and the outer radial surface of the second thin wall. Following block 1208, block 1210 recites wherein first magnetic ring and the second magnetic ring each include an outer radial surface that is coextensive with the radial exterior surface of the ferromagnetic core tube. Block 1212 then states wherein the first magnetic ring circumscribes the first channel, and wherein the second magnetic ring circumscribes the second channel. Finally, block 1214 states wherein the inner radial surface of the first magnetic ring is one of coextensive or not coextensive along the longitudinal axis with an outer radial surface of the filler material in the first channel, and wherein the inner radial surface of the second magnetic ring is one of coextensive or not coextensive along the longitudinal axis with an outer radial surface of the filler material in the second channel.
Embodiments of the present disclosure include a solenoid assembly having a core tube having a pair of channels that circumscribe the radial exterior surface. The channels include either a filler material or an air gap radially inward from magnetic rings. The solenoid assembly is operable to create a directional magnetic force operable to move an armature located within the core tube through its longitudinal axis. Embodiments include a solenoid having a core tube 104 and a pair of channels 106, 108 that each have a thin wall section with no welded material. This allows embodiments of the core tube 104 to be able to withstand low internal pressures and the ability to create high magnetic forces. Embodiments of the thin wall section of channels 106, 108 create a barrier between the fluids within the core tube 104, which improves the chemical resistance along the radial interior surface of core tube 104. One of the advantages of having a pair of channels that each have a thin wall portion that is integral with the core tube is to aid in the elimination of leaks without sacrificing the strength of the magnetic forces created by the solenoid.
It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used alone, or in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. The presently disclosed embodiments are therefore considered in all respects to be illustrative. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of this disclosure, which is defined in the accompanying claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/025702 | 4/5/2021 | WO |
Number | Date | Country | |
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63086123 | Oct 2020 | US |