Information
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Patent Grant
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6680666
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Patent Number
6,680,666
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Date Filed
Monday, October 7, 200221 years ago
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Date Issued
Tuesday, January 20, 200420 years ago
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Inventors
-
Original Assignees
-
Examiners
Agents
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CPC
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US Classifications
Field of Search
US
- 336 65
- 336 83
- 336 90
- 336 92
- 336 107
- 336 192
- 336 198
- 439 874
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International Classifications
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Abstract
A coil assembly includes a spool having a wire wound therearound to establish a coil. A spool terminal extends from the spool and the end of the wire is wound around the spool terminal. A connector housing is coupled to the spool and a connector terminal extends therefrom. A portion of the connector terminal is adjacent to a portion of the spool terminal. Thus, the connector terminal can be relatively easily resistance welded or soldered to the spool terminal.
Description
TECHNICAL FIELD
The present invention relates to solenoids and actuators.
BACKGROUND OF THE INVENTION
Modern motor vehicles are equipped with numerous vehicle subsystems that are designed to increase the comfort and safety of drivers and passengers. For example, a vehicle can include an anti-lock braking system, a traction control system, a speed control system, and/or a vehicle stability enhancement control system. In turn, each subsystem can include numerous electromagnetic sensors and/or actuators that utilize electric coil assemblies to move plungers when energized or to provide control signals in response to changes in magnetic flux around the sensing coils.
In general, these coil assemblies include a plastic “I” shaped spool having a winding bay established around it. A coil of wire is formed within the winding bay. The spool is mated with a connector housing having one or more terminals to which the coil is electrically connected. Typically, during manufacturing, the spool is loaded into a winding machine that automatically winds a thin wire around the spool within the winding bay in order to form the coil. The ends of the wire are manually stripped and wrapped around connector terminals. Thereafter, the ends of the wire are manually soldered to the connector terminals. It can be appreciated that the manual steps increase manufacturing time and costs.
The present invention has recognized the prior art drawbacks, and has provided the below-disclosed solutions to one or more of the prior art deficiencies.
SUMMARY OF THE INVENTION
A coil assembly includes a spool having a wire wound around it to establish a coil. A spool terminal extends from the spool and a portion of the wire is wound around the spool terminal. A connector housing is coupled to the spool and a connector terminal extends from the connector housing. A portion of the connector terminal is adjacent to a portion of the spool terminal and is electrically connected thereto.
In one aspect of the present invention, a first arm extends from the connector terminal such that it flanks the spool terminal. Moreover, a second arm extends from the connector terminal such that flanks the spool terminal. Thus, the spool terminal is between the first and second arms.
In another aspect of the present invention, the spool defines a top and the spool terminal extends perpendicularly from the top of the spool. Also, the connector housing defines a top and the connector terminal includes a lower connector terminal portion that extends perpendicularly from the top of the connector housing. A lateral connector terminal portion extends perpendicularly from the lower connector terminal portion toward the spool. Also, an upper connector terminal portion extends perpendicularly from the lateral connector terminal portion such that it is parallel and adjacent to the spool terminal. In this aspect, the first arm and the second arm extend perpendicularly from the upper connector terminal portion around the spool terminal and the spool terminal is electrically connected to the connector terminal by resistance welding or soldering.
In yet another aspect of the present invention, the spool defines a top and the spool terminal includes a lower spool terminal portion that extends perpendicularly from the top of the spool. Moreover, an upper spool terminal portion extends perpendicularly from the lower spool terminal portion toward the connector housing. The connector housing defines a top and the connector terminal includes a lower connector terminal portion that extends perpendicularly from the top of the connector housing. Also, an upper connector terminal portion extends perpendicularly from the lower connector terminal portion such that it is parallel and adjacent to the spool terminal. In this aspect the first arm and the second arm extend perpendicularly from the upper connector terminal portion around the spool terminal. Also, the spool terminal is electrically connected to the connector terminal by resistance welding or soldering.
In still another aspect of the present invention, the spool defines a top and the spool terminal extends perpendicularly from the top of the spool. Also, the connector housing defines a top and the connector terminal comprises a lower connector terminal portion extends perpendicularly from the top of the connector housing. A lateral connector terminal portion extends perpendicularly from the lower connector terminal portion toward the spool and an upper connector terminal portion extends perpendicularly from the lateral connector terminal portion such that it is parallel and adjacent to the spool terminal. Thus, the spool terminal can be resistance welded or soldered to the connector terminal.
In yet still another aspect of the present invention, a terminal assembly includes an electrical device. An electrical device terminal extends from the electrical device. A portion of a wire is wound around the electrical device terminal. A connector device is coupled to the electrical device and a connector device terminal extends from the connector device. A portion of the connector device terminal is adjacent to a portion of the electrical device terminal and is electrically connected thereto.
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1
is a side plan view of a coil assembly;
FIG. 2
is a top plan view of the coil assembly shown in
FIG. 1
;
FIG. 3
is a side plan view of an alternative coil assembly;
FIG. 4
is a top plan view of the coil assembly shown in
FIG. 3
; and
FIG. 5
is a side plan view of a second alternative coil assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to
FIGS. 1 and 2
, a coil assembly is shown and generally designated
10
.
FIGS. 1 and 2
show that the coil assembly
10
includes a preferably “I” shaped spool
12
around which a relatively thin, preferably copper wire
14
is wound to form a coil
16
. As shown, at least one, but preferably two spool terminals
18
extend perpendicularly from the top of the spool
12
such that they are parallel to a longitudinal axis
20
defined by the coil assembly. In a preferred embodiment, the spool terminals
18
have a cross-section that is square. The wire
14
defines two ends
22
and each end
22
of the wire
14
is wrapped around a respective spool terminal
18
.
FIGS. 1 and 2
show that the coil assembly
10
also includes a connector housing
24
that is mechanically coupled to the spool
12
. As shown, the connector housing
24
forms an internal cavity
26
that is sized and shaped to receive a male electrical connector that can be electrically connected to a vehicle control system. Moreover, the connector housing
24
includes at least one, but preferably two connector terminals
28
.
It is to be understood that the connector terminals
28
are identical to each other and that each includes a lower connector terminal portion
30
that extends from within the cavity
26
through the connector housing
24
and beyond the top thereof. As shown, the lower connector terminal portion
30
of each connector terminal
28
is parallel to the longitudinal axis
20
of the coil assembly
10
. A lateral connector terminal portion
32
extends perpendicularly from the lower connector terminal portion
30
toward the spool
12
. Moreover, an upper connector terminal portion
34
extends perpendicularly from the lateral connector terminal portion
32
in an upward direction such that it is parallel to the longitudinal axis
20
. It is to be understood that when the connector housing
24
is coupled to the spool
12
, the upper connector terminal portion
34
of each connector terminal
28
is slightly spaced from a respective spool terminal
18
.
FIGS. 1 and 2
show that a first arm
36
and a second arm
38
extend perpendicularly from the upper connector terminal portion
34
of each connector terminal
28
such that the arms
36
,
38
of each connector terminal
28
flank a respective spool terminal
18
when the connector housing
24
is mechanically coupled to the spool
12
. It can be appreciated that the arms
36
,
38
of each connector terminal
28
are spaced a distance, d, from each other that is slightly larger that the width of a spool terminal
18
plus twice the diameter of the wire end
22
that is wound around the spool terminal
18
. Accordingly, during assembly, when the spool
12
is coupled to the connector housing
24
the arms
36
,
38
of each connector terminal
28
fit around a respective spool terminal
18
and are preferably resistance welded thereto.
Referring now to
FIGS. 3 and 4
, an alternative coil assembly is shown and generally designated
50
.
FIGS. 3 and 4
show that the coil assembly
50
includes a preferably “I” shaped spool
52
around which a relatively thin, preferably copper wire
54
is wound to form a coil
56
. As shown, at least one, but preferably two spool terminals
58
extend from the top of the spool
52
. As shown, each spool terminal
58
includes a lower spool terminal portion
59
that extends from the top of the spool
52
such that it is parallel to a longitudinal axis
60
defined by the coil assembly
50
. Also, each spool terminal
58
includes an upper spool terminal portion
61
that extends radially from the lower spool terminal portion
59
such that it is perpendicular to the longitudinal axis
60
. It is to be understood that the wire
54
defines two ends
62
and each end
62
of the wire
54
is wrapped around a respective spool terminal
58
.
FIGS. 3 and 4
show that the coil assembly
50
also includes a connector housing
64
that is mechanically coupled to the spool
52
. As shown, the connector housing
64
forms an internal cavity
66
that is sized and shaped to receive a male electrical connector leading to and from a vehicle control system. Moreover, the connector housing
64
includes at least one, but preferably two connector terminals
68
.
It is to be understood that the connector terminals
68
are identical to each other and that each includes a lower connector terminal portion
70
that extends from within the cavity
66
through the connector housing
64
and beyond the top thereof. As shown, the lower connector terminal portion
70
of each connector terminal
68
is parallel to the longitudinal axis
60
of the coil assembly
50
. An upper connector terminal portion
74
extends perpendicularly from the lower connector terminal portion
70
toward the spool
52
. It is to be understood that when the connector housing
64
is coupled to the spool
52
, the upper connector terminal portion
74
of each connector terminal
68
is beneath and slightly spaced from a respective spool terminal
58
.
FIGS. 3 and 4
show that a first arm
76
and a second arm
78
extend perpendicularly from the upper connector terminal portion
74
of each connector terminal
68
such that the arms
76
,
78
of each connector terminal
68
flank a respective spool terminal
58
when the connector housing
64
is mechanically coupled to the spool
52
. It can be appreciated that the arms
76
,
78
of each connector terminal
68
are spaced a distance, d, from each other that is slightly larger that the width of a spool terminal
58
plus twice the diameter of the wire end
62
wound therearound. Accordingly, during assembly, when the spool
52
is coupled to the connector housing
64
the arms
76
,
78
of each connector terminal
76
fit around a respective spool terminal
58
and are preferably resistance welded thereto.
Referring to
FIG. 5
, a coil assembly is shown and generally designated
100
.
FIG. 5
shows that the coil assembly
100
includes a preferably “I” shaped spool
102
around which a relatively thin, preferably copper wire
104
is wound to form a coil
106
. As shown, at least one, but preferably two spool terminals
108
extend perpendicularly from the top of the spool
102
such that they are parallel to a longitudinal axis
110
defined by the coil assembly. The wire
104
defines two ends
112
and each end
112
of the wire
104
is wrapped around a respective spool terminal
108
.
FIG. 5
shows that the coil assembly
100
also includes a connector housing
114
that is mechanically coupled to the spool
102
. As shown, the connector housing
114
forms an internal cavity
116
that is sized and shaped to receive a male electrical connector leading to and from a vehicle control system. Moreover, the connector housing
114
includes at least one, but preferably two connector terminals
118
.
It is to be understood that the connector terminals
118
are identical to each other and that each includes a lower connector terminal portion
120
that extends from within the cavity
116
through the connector housing
114
and beyond the top thereof. As shown, the lower connector terminal portion
120
of each connector terminal
118
is parallel to the longitudinal axis
110
of the coil assembly
100
. A lateral connector terminal portion
122
extends perpendicularly from the lower connector terminal portion
120
toward the spool
102
. Moreover, an upper connector terminal portion
124
extends perpendicularly from the lateral connector terminal portion
122
in an upwards direction such that it is parallel to the longitudinal axis
110
. It is to be understood that when the connector housing
114
is coupled to the spool
102
, the upper connector terminal portion
124
of each connector terminal
118
is slightly spaced from a respective spool terminal
108
. Accordingly, during assembly, when the spool
102
is coupled to the connector housing
114
each connector terminal
118
can be preferably soldered to a respective spool terminal
108
.
While the particular SOLENOID COIL ASSEMBLY as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it is to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
Claims
- 1. A coil assembly, comprising:a spool; at least one wire wound around the spool; a coil established around the spool by the wire; at least one spool terminal extending from the spool, at least a portion of the wire being wound around the spool terminal; a connector housing coupled to the spool; and at least one connector terminal extending from the connector housing, at least a portion of the connector terminal being adjacent to at least a portion of the spool terminal and electrically connected thereto, the connector terminal including a lower connector terminal portion extending from within the housing, a lateral connector terminal portion extending perpendicularly from the lower connector terminal portion, and an upper connector terminal portion extending perpendicularly from the lateral connector terminal portion away from the lower connector terminal portion and housing.
- 2. The coil assembly of claim 1, further comprising: at least a first arm extending from the connector terminal such that it flanks the spool terminal.
- 3. The coil assembly of claim 2, further comprising: at least a second arm extending from the connector terminal such that it flanks the spool terminal.
- 4. The coil assembly of claim 3, wherein the spool terminal is between the first and second arms.
- 5. The coil assembly of claim 4, wherein the spool defines a top and the spool terminal extends perpendicularly from the top of the spool.
- 6. The coil assembly of claim 5, wherein the connector housing defines a top and the connector terminal comprises:a lower connector terminal portion extending perpendicularly from the top of the connector housing; a lateral connector terminal portion extending perpendicularly from the lower connector terminal portion toward the spool; and an upper connector terminal portion extending perpendicularly from the lateral connector terminal portion such that it is parallel and adjacent to the spool terminal.
- 7. The coil assembly of claim 6, wherein the first arm and the second arm extend perpendicularly from the upper connector terminal portion at least partially around the spool terminal.
- 8. The coil assembly of claim 7, wherein the spool terminal is electrically connected to the connector terminal by one of the following: resistance welding and soldering.
- 9. The coil assembly of claim 4, wherein the spool defines a top and the spool terminal comprises:a lower spool terminal portion that extends perpendicularly from the top of the spool; and an upper spool terminal portion that extends perpendicularly from the lower spool terminal portion toward the connector housing.
- 10. The coil assembly of claim 9, wherein the connector housing defines a top and the connector terminal comprises:a lower connector terminal portion that extends perpendicularly from the top of the connector housing; and an upper connector terminal portion that extends perpendicularly from the lower connector terminal portion such that it is parallel and adjacent to the spool terminal.
- 11. The coil assembly of claim 10, wherein the first arm and the second arm extend perpendicularly from the upper connector terminal portion at least partially around the spool terminal.
- 12. The coil assembly of claim 11, wherein the spool terminal is electrically connected to the connector terminal by one of the following: resistance welding and soldering.
- 13. The coil assembly of claim 1, wherein the spool defines a top and the spool terminal extends perpendicularly from the top of the spool.
- 14. The coil assembly of claim 11, wherein the connector housing defines a top and the connector terminal comprises:a lower connector terminal portion extending perpendicularly from the top of the connector housing; a lateral connector terminal portion extending perpendicularly from the lower connector terminal portion toward the spool; and an upper connector terminal portion extending perpendicularly from the lateral connector terminal portion such that it is parallel and adjacent to the spool terminal.
- 15. The coil assembly of claim 14, wherein the spool terminal is electrically connected to the connector terminal by one of the following: resistance welding and soldering.
US Referenced Citations (1)
Number |
Name |
Date |
Kind |
4954801 |
Urbanski et al. |
Sep 1990 |
A |