EP1193391B1 - Coil system including a structure for preventing fluid from leaking therein - Google Patents
Coil system including a structure for preventing fluid from leaking therein Download PDFInfo
- Publication number
- EP1193391B1 EP1193391B1 EP01123048A EP01123048A EP1193391B1 EP 1193391 B1 EP1193391 B1 EP 1193391B1 EP 01123048 A EP01123048 A EP 01123048A EP 01123048 A EP01123048 A EP 01123048A EP 1193391 B1 EP1193391 B1 EP 1193391B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- coil system
- coil
- terminal
- resin coating
- bobbin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/06—Insulation of windings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M47/00—Fuel-injection apparatus operated cyclically with fuel-injection valves actuated by fluid pressure
- F02M47/02—Fuel-injection apparatus operated cyclically with fuel-injection valves actuated by fluid pressure of accumulator-injector type, i.e. having fuel pressure of accumulator tending to open, and fuel pressure in other chamber tending to close, injection valves and having means for periodically releasing that closing pressure
- F02M47/027—Electrically actuated valves draining the chamber to release the closing pressure
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M51/00—Fuel-injection apparatus characterised by being operated electrically
- F02M51/005—Arrangement of electrical wires and connections, e.g. wire harness, sockets, plugs; Arrangement of electronic control circuits in or on fuel injection apparatus
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M63/00—Other fuel-injection apparatus having pertinent characteristics not provided for in groups F02M39/00 - F02M57/00 or F02M67/00; Details, component parts, or accessories of fuel-injection apparatus, not provided for in, or of interest apart from, the apparatus of groups F02M39/00 - F02M61/00 or F02M67/00; Combination of fuel pump with other devices, e.g. lubricating oil pump
- F02M63/0012—Valves
- F02M63/0014—Valves characterised by the valve actuating means
- F02M63/0015—Valves characterised by the valve actuating means electrical, e.g. using solenoid
- F02M63/0017—Valves characterised by the valve actuating means electrical, e.g. using solenoid using electromagnetic operating means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M2200/00—Details of fuel-injection apparatus, not otherwise provided for
- F02M2200/16—Sealing of fuel injection apparatus not otherwise provided for
Definitions
- the present invention relates to a coil system.
- Document JP 06299929 describes a coil system comprising a bobbin made of resin, a coil nurapped around said bobbin, a terminal member which is connected to said coil and projects from said bobbin and a terminal portion which is made of resin and includes a conductive terminal connected to the terminal member.
- An electromagnetic valve system or a fuel injection system includes a coil system which receives power from a power source via a supply portion and thereby drives a valve member or the like.
- the coil system is connected with the supply portion via its terminal portion such as a connector.
- seal members such as O-rings are usually included for preventing fluid such as water or fuel from leaking into the interior of the coil system.
- a coil system 100 shown in Fig. 8 is proposed.
- an O-ring 103 prevents fluid leaking from the end of a coil 101 into the coil system 100 along a terminal member 102
- another 0-ring 105 prevents fluid leaking into the coil system 100 along the external surface of a bush 104.
- the conductive member such as the coil 101, the terminal member 102, or the terminal 107, the conductive member itself or a resin layer coating the conductive member would be corroded. As a result, a conductive failure would occur or the winding of the coil 101 would be short-circuited.
- a coil system includes a bobbin made of resin, a coil, terminal members, terminal portion made of resin, and a resin coating member.
- the coil is wrapped around the bobbin.
- the terminal members are connected to the coil, and project from the bobbin.
- the terminal portion includes conductive terminals therein.
- the resin coating member covers the bobbin and the terminal members.
- weld portions are formed on the resin coating member on the side of the terminal portion.
- the weld portions are welded to the terminal portion during a molding process of the terminal portion.
- seal members are disposed circumferentially on the external surface of the resin coating member.
- a coil system 50 according to a first embodiment of the present invention is incorporated in a fuel injection system 1 as shown in Fig. 1.
- the fuel injection system 1 injects high constant pressure fuel, which is supplied from a common rail via fuel piping, toward the combustion chamber of a diesel engine.
- the fuel injection system 1 includes an injection nozzle 10, a valve needle 11, a valve body 12, a control piston 13, a pressure control chamber 14 and an electromagnetic valve portion 30.
- Nozzle holes 10a are formed at the tip of the injection nozzle 10.
- the nozzle holes 10a are opened and closed as the valve needle 11 reciprocates vertically in Fig. 1.
- the injection nozzle 10 is connected to the valve body 12 via a bush 15 by a retaining nut 16.
- the control piston 13 for driving the valve needle 11 is disposed in the valve body 12. Further, the pressure control chamber 14 is formed in the valve body 12. The high-pressure fuel is accumulated in the pressure control chamber 14 for driving the valve needle 11 to close the nozzle holes 10a.
- the electromagnetic valve portion 30 is a two way type valve which intermittently passes the high-pressure fuel from the pressure control chamber 14 to a low-pressure passage 17.
- the electromagnetic valve portion 30 includes a valve seat member 31, a movable member 32, and the coil system 50.
- the valve seat member 31 is a plate-type member.
- a fuel passage 311 communicating with the pressure control chamber 14 is formed through the valve seat member 31.
- the fuel passage 311 has an opening at its end on the side of the coil system 50, and a valve seat 31a of the valve seat member 31 extends around the opening.
- the movable member 32 includes a valve member 321 and an armature 322.
- the valve member 321 includes a ball member 321a at its end. The opening of the fuel passage 311 is opened and closed as the ball member 321a is seated on and lifted up from the valve seat 31a.
- the armature 322 is disposed on the valve member 321 on the opposite side of the ball member 321a.
- the armature 322 is made of magnetic material, and driven by the coil system 50.
- the armature 322 When power is not supplied to the coil system 50, the armature 322 is pushed down (downward in Fig. 1) by a spring 33. Therefore the valve member 321 integrated with the armature 322 is also pushed down, and the ball member 321a is seated on the valve seat 31a. Accordingly the opening of the fuel passage 311 is blocked, and thereby the fuel is prevented from flowing from the pressure control chamber 14 into the low-pressure passage 17.
- the pressure of the fuel accumulated in the pressure control chamber 14 increases.
- the force due to the pressure of the fuel urges the valve needle 11 to close the nozzle holes 10a via the control piston 13.
- the nozzle holes 10a are blocked by the valve needle 11, and therefore the fuel injection is stopped.
- the armature 322 When power is supplied to the coil system 50, the armature 322 is pulled up (upward in Fig. 1) due to the electromagnetic attraction of the coil system 50 and thereby the armature 322 and the valve member 321 are also pulled up. Accordingly, the ball member 321a is lifted up from the valve seat 31a, and thereby the opening of the fuel passage 311 is opened. Then the fuel flows from the pressure control chamber 14 into the low-pressure passage 17. Therefore the pressure of the fuel accumulated in the pressure control chamber 14 decreases. Thereby the force which urges the valve needle 11 via the control piston 13 to close the nozzle holes 10a decreases.
- the coil system 50 includes a bobbin 51, a coil 52, a positive terminal member and a negative terminal member 53, a resin coating member 54, a stator 55, a housing 56, a connector 58 as a terminal portion, and small rings 59 and a large ring 60 as seal members.
- the bobbin 51 is formed of resin, and the coil 52 surrounds the bobbin 51.
- the terminal members 53 are formed of conductive material, and project from the bobbin 51 toward the connector 58.
- the terminal members 53 are connected to the coil 52 so as to supply power to the coil 52.
- the bobbin 51, the coil 52, and the terminal members 53 are coated with the resin coating member 54.
- the bobbin 51 is made as a primary molded product, and then the coil 52 is wrapped around the bobbin 51. Further the terminal members 53 are connected to the bobbin 51.
- the resultant structure including the bobbin 51, the coil 52 and the terminal members 53 is provided as an insert, and coated with resin so as to form the resin coating member 54.
- the structure coated with the resin coating member 54 is provided as a secondary molded product 70.
- the resin which forms the resin coating member 54 has a softening point close to that of the resin which forms the bobbin 51.
- a receptacle portion 551 and two through holes 552 are formed in the stator 55.
- the through holes 552 pass through the stator 55 along the axis of the coil system 50.
- the secondary molded product 70 is inserted into the stator 55.
- the bobbin 51 and the coil 52 rest in the receptacle portion 551, and the terminal members 53 penetrate the respective through holes 552.
- a magnetic circuit is formed in the stator 55 and thereby the armature 322 of the movable member 32 is pulled up (upward in Fig. 1).
- the length of the stator 55 along the axis of the coil system 50 and the size of the surface of the stator 55 corresponding to the armature 322 are determined based on the required magnetic attraction.
- the housing 56 is disposed on the stator 55 on the opposite side of the armature 322.
- Two holes 561 and two through holes 562 are formed in the housing 56.
- the holes 561 are arranged so as to face the stator 55.
- the through holes 562 pass through the housing 56 along the axis of the coil system 50, and communicate with the respective holes 561.
- a groove 563 is circumferentially formed on the external surface of the housing 56.
- the small rings 59 rest in the respective holes 561.
- the large ring 60 rests in the groove 563.
- the terminal members 53 are inserted into the housing 56 so as to penetrate the respective holes 561 and through holes 562.
- Each of the small rings 59 is an O-ring which has a short diameter.
- the small rings 59 rest in the respective holes 561 of the housing 56 as described above so as to wind around the resin coating member 54. Then the top surface and the external surface of each small ring 59 contact with the housing 56. The internal surface of each small ring 59 contacts with the resin coating member 54. The bottom surface of each small ring 59 contacts with the stator 55.
- the large ring 60 is an O-ring which has a relatively long diameter. The large ring 60 rests in the groove 563 so as to contact with both of the housing 56 and the casing 57.
- the casing 57 is provided for connecting the coil system 50 to the valve body 12 of the fuel injection system 1.
- An internal thread portion is formed on the end of the casing 57 corresponding to the valve body 12. Further an external thread portion is formed on the corresponding end of the valve body 12.
- the coil system 50 is fixed to the valve body 12 by engaging the thread portions each other.
- the connector 58 is disposed on the housing 56 on the opposite side of the stator 55.
- the connector 58 includes a connector cap 581 and two terminals 582 included in the connector cap 581.
- the connector cap 581 is formed of resin which has a softening point close to that of the resin which forms the resin coating member 54.
- one of the terminals 582 is a positive terminal which is connected to the positive terminal member 53, while the other of the terminals 582 is a negative terminal which is connected to the negative terminal member 53.
- the terminals 582 are welded to the respective terminal members 53 after the stator 55, the housing 56 and the rings 59, 60 are fixed to the secondary molded product 70. Thereafter the resultant structure including the secondary molded product 70, the stator 55, the housing 56, the rings 59, 60 and the terminals 582 is provided as an insert, and the connector cap 581 is molded onto the structure.
- weld portions 541 are formed at the ends of the resin coating member 54.
- Each of the weld portions 541 has an acute angle in its cross section along the axis of the coil system 50.
- the weld portions 541 melts at its interface with the connector cap 581. Thereby the weld portions 541 and the connector cap 581 are welded.
- the boundary portion between the resin coating member 54 and the connector cap 581 is completely sealed up.
- the resin coating member 54 isolates the coil 52 and the terminal members 53, which are conductive members, from the stator 55 and the housing 56 which are also conductive members. Accordingly, another insulating member such as a bush is not required in the coil system 50, and the space for disposing such an insulating member is also not required. Therefore the number of the components which constitute the coil system 50 is reduced, and the structure of the coil system 50 is simple. Moreover the length of the coil system 50 along its axis is also reduced, and thereby the coil system 50 can be miniaturized. Then the coil system 50 can be incorporated in various systems.
- the resin coating member 54 covers up to the end portion of the bobbin 51 corresponding to the armature 322. This construction is possible because the coil system 50 can be miniaturized as described above. The fuel in the space 34 is prevented from reaching the winding of the coil 52 or the terminal members 53 by the resin coating member 54.
- engine oil, water such as dew drops, or salt water from the external may leak from the boundary portion A between the housing 56 and the connector cap 581 into the coil system 50. Such fluid may reach the terminal members 53 or the terminals 582. However the fluid is blocked by the boundary portion between the resin coating member 54 and the connector cap 581, because the boundary portion is completely sealed up by welding the weld portions 541 and connector cap 58 as described above.
- the fuel in the space 34 may also leak into the coil system 50 along the external surface of the resin coating member 54. Then the fuel may reach the boundary portion between the resin coating member 54 and the connector cap 581, and thereafter reach the terminal members 53 and the terminals 582. However, in the present coil system 50, the fuel is blocked by the small rings 59 or the boundary portion.
- a coil system according to a second embodiment of the present invention includes a bobbin 81 different in shape from the bobbin 51 of the coil system 50 according to the first embodiment. Further, the coil system according to the second embodiment includes a resin coating member 84 which covers the bobbin 81 to a different degree from the resin coating member 54 of the coil system 50 according to the first embodiment.
- the bobbin 81 includes a small portion 811 and two large portions 812 .
- the small portion 811 is surrounded with a coil 82, and the large portions 812 define both ends of the coil 82.
- Weld projections 813 are formed at the edges of the respective large portions 812.
- the bobbin 81 is made as a primary molded product, and then the coil 82 is wrapped around the bobbin 81. Thereafter terminal members 83 are connected to the bobbin 81.
- the resultant structure including the bobbin 81, the coil 82 and the terminal members 83 is provided as an insert, and coated with resin so as to from the resin coating member 84.
- the weld projections 813 and the resin coating member 84 are welded.
- the structure coated with the resin coating member 84 is provided as a secondary molded product 80.
- the other portions of the coil system according to the second embodiment are similar to the first embodiment.
- Fluid such as fuel is prevented from leaking from the boundary portion between the bobbin 81 and the resin coating member 84 into the coil system 50, because the boundary portion is completely sealed up by welding the weld projections 813 and the resin coating member 84. Thereby the coil 82 is prevented from being corroded, and therefore prevented from being short-circuited.
- the resin coating member 84 is not required to cover up to the end portion of the bobbin 81 corresponding to the armature 322. Therefore the coil system can be miniaturized.
- a coil system according to a third embodiment of the present invention includes a resin coating member 54 which has weld portions 542 different in position and shape from the weld portions 541 of the coil system 50 according to the first embodiment.
- the weld portions 542 are circumferentially formed on the external surface of the resin coating member 54, and positioned so as to contact with the connector cap 581.
- Each of the weld portions 542 has a triangle cross section along the axis of the coil system.
- Fluid leaking from the boundary portion A between the connector cap 581 and the housing 56 into the coil system is blocked by the boundary portion between the resin coating member 54 and the connector cap 581, because the boundary portion is completely sealed up by welding the weld portions 542 and the connector cap 581. Accordingly the fluid is prevented from reaching conductive members such as the terminal members 53 or the terminals 582. Therefore the terminal members 53 and the terminals 582 are prevented from being corroded.
- a coil system according to a fourth embodiment of the present invention also includes a resin coating member 90 which has weld portions 91 different in position and shape from the weld portions 541 of the coil system 50 according to the first embodiment.
- the resin coating member 90 has small portions 901 at its ends corresponding to a connector 58.
- the small portions 901 have a diameter shorter than the other portions of the resin coating member 90. Therefore gaps are formed between the small portions 901 and the internal walls 562a of the through holes 562 of a housing 56.
- the weld portions 91 each of which has a triangle cross section along the axis of the coil system, are formed on the respective small portions 901 so as to project radially toward the internal walls 562a of the through holes 562. Accordingly, the gaps 92 narrower than the gaps between the small portions 901 and the internal walls 562a are formed between the weld portions 91 and the internal walls 562a of the through holes 562.
- the distance D between the small portions 901 and the internal walls 562a is set to 1-2mm, while the distance Ds between the weld portions 91 and the internal walls 562a is set to 0.5mm.
- resin passes the weld portions 91 at a relatively high speed and thereby relatively large quantity of heat is applied to the weld portions 91, when the connector cap 581 is molded.
- the welding efficiency that is, a ratio of the welded area to the surface area of the weld portions 91 is increased. Thereby the sealing performance is improved.
- the other portions of the coil system according to the fourth embodiment are similar to the first embodiment.
- the coil system according to the present invention is incorporated in the fuel injection system 1 of the diesel engine.
- the coil system may be incorporated in the fuel injection system of a gasoline engine.
- the coil system may be incorporated in other electrical components, for example, an MRE sensor.
- a coil system (50) includes a bobbin (51, 81), a coil (52, 82) wrapped around the bobbin, terminal members (53, 83), a resin coating member (54, 84), a stator (55), a housing (56), and a connector (58).
- the resin coating member covers the bobbin, the coil and the terminal members so as to seal up them. Further, the resin coating member insulates the coil and the terminal members from the stator and the housing.
- O-xings (59) are disposed circumferentially on the external surface of the resin coating member so as to prevent fluid from leaking into the coil system.
- weld portions (541, 542, 91) are formed on the resin coating member, and welded to a connector cap (581) of the connector- Thereby fluid leaking into the coil system from the boundary portion (A) of the resin coating member and the connector cap is blocked.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Fluid Mechanics (AREA)
- Power Engineering (AREA)
- Fuel-Injection Apparatus (AREA)
- Electromagnets (AREA)
Description
- The present invention relates to a coil system.
- Document JP 06299929 describes a coil system comprising a bobbin made of resin, a coil nurapped around said bobbin, a terminal member which is connected to said coil and projects from said bobbin and a terminal portion which is made of resin and includes a conductive terminal connected to the terminal member.
- An electromagnetic valve system or a fuel injection system includes a coil system which receives power from a power source via a supply portion and thereby drives a valve member or the like. The coil system is connected with the supply portion via its terminal portion such as a connector.
- In such a coil system, seal members such as O-rings are usually included for preventing fluid such as water or fuel from leaking into the interior of the coil system. For example, a
coil system 100 shown in Fig. 8 is proposed. In thecoil system 100, an O-ring 103 prevents fluid leaking from the end of acoil 101 into thecoil system 100 along aterminal member 102, and another 0-ring 105 prevents fluid leaking into thecoil system 100 along the external surface of abush 104. - However, fluid leaking from a boundary portion B between a
connector cap 106 and ahousing 108 into thecoil system 100 cannot be prevented. Therefore the fluid may leak into thecoil system 100 and reach theterminal member 102 or aterminal 107. Further, the fluid may reach the winding of thecoil 101 along theterminal member 102. - When the fluid reaches a conductive member such as the
coil 101, theterminal member 102, or theterminal 107, the conductive member itself or a resin layer coating the conductive member would be corroded. As a result, a conductive failure would occur or the winding of thecoil 101 would be short-circuited. - It is therefore an object of the present invention to provide a coil system which has a structure for preventing fluid from leaking therein.
- A coil system according to the present invention includes a bobbin made of resin, a coil, terminal members, terminal portion made of resin, and a resin coating member. The coil is wrapped around the bobbin. The terminal members are connected to the coil, and project from the bobbin. The terminal portion includes conductive terminals therein. The resin coating member covers the bobbin and the terminal members.
- Preferably, weld portions are formed on the resin coating member on the side of the terminal portion. The weld portions are welded to the terminal portion during a molding process of the terminal portion. Further, seal members are disposed circumferentially on the external surface of the resin coating member.
- The invention, together with additional objects, features and advantages thereof, will be best understood from the following description, the appended claims and the accompanying drawings in which:
- Fig. 1 is a longitudinal sectional view of a fuel injection system in which a coil system according to a first embodiment of the present invention is incorporated;
- Fig.2 is an enlarged longitudinal sectional view of a portion of the fuel injection system of Fig. 1;
- Fig. 3 is an exploded longitudinal sectional view of the coil system according to the first embodiment;
- Fig. 4 is a longitudinal sectional view of a portion of a coil system according to a second embodiment of the present invention;
- Fig. 5 is an enlarged longitudinal sectional view of a portion of a fuel injection system in which a coil system according to a third embodiment of the present invention is incorporated;
- Fig. 6 is an enlarged longitudinal sectional view of a portion of a fuel injection system in which a coil system according to a fourth embodiment of the present invention is incorporated;
- Fig. 7 is an enlarged longitudinal sectional view of the vicinity of a weld portion of the coil system according to the fourth embodiment; and
- Fig. 8 is a longitudinal sectional view of a system in which a coil system according to a related art is incorporated.
- The present invention will be described with reference to embodiments and modifications.
- A
coil system 50 according to a first embodiment of the present invention is incorporated in afuel injection system 1 as shown in Fig. 1. Thefuel injection system 1 injects high constant pressure fuel, which is supplied from a common rail via fuel piping, toward the combustion chamber of a diesel engine. - The
fuel injection system 1 includes aninjection nozzle 10, avalve needle 11, avalve body 12, acontrol piston 13, apressure control chamber 14 and anelectromagnetic valve portion 30.Nozzle holes 10a are formed at the tip of theinjection nozzle 10. Thenozzle holes 10a are opened and closed as thevalve needle 11 reciprocates vertically in Fig. 1. Theinjection nozzle 10 is connected to thevalve body 12 via abush 15 by aretaining nut 16. - The
control piston 13 for driving thevalve needle 11 is disposed in thevalve body 12. Further, thepressure control chamber 14 is formed in thevalve body 12. The high-pressure fuel is accumulated in thepressure control chamber 14 for driving thevalve needle 11 to close thenozzle holes 10a. - The
electromagnetic valve portion 30 is a two way type valve which intermittently passes the high-pressure fuel from thepressure control chamber 14 to a low-pressure passage 17. Theelectromagnetic valve portion 30 includes avalve seat member 31, amovable member 32, and thecoil system 50. - The
valve seat member 31 is a plate-type member. Afuel passage 311 communicating with thepressure control chamber 14 is formed through thevalve seat member 31. Thefuel passage 311 has an opening at its end on the side of thecoil system 50, and avalve seat 31a of thevalve seat member 31 extends around the opening. - The
movable member 32 includes avalve member 321 and anarmature 322. Thevalve member 321 includes aball member 321a at its end. The opening of thefuel passage 311 is opened and closed as theball member 321a is seated on and lifted up from thevalve seat 31a. Thearmature 322 is disposed on thevalve member 321 on the opposite side of theball member 321a. Thearmature 322 is made of magnetic material, and driven by thecoil system 50. - When power is not supplied to the
coil system 50, thearmature 322 is pushed down (downward in Fig. 1) by aspring 33. Therefore thevalve member 321 integrated with thearmature 322 is also pushed down, and theball member 321a is seated on thevalve seat 31a. Accordingly the opening of thefuel passage 311 is blocked, and thereby the fuel is prevented from flowing from thepressure control chamber 14 into the low-pressure passage 17. During the prevention of the fuel flow, the pressure of the fuel accumulated in thepressure control chamber 14 increases. The force due to the pressure of the fuel urges thevalve needle 11 to close thenozzle holes 10a via thecontrol piston 13. Thus thenozzle holes 10a are blocked by thevalve needle 11, and therefore the fuel injection is stopped. - When power is supplied to the
coil system 50, thearmature 322 is pulled up (upward in Fig. 1) due to the electromagnetic attraction of thecoil system 50 and thereby thearmature 322 and thevalve member 321 are also pulled up. Accordingly, theball member 321a is lifted up from thevalve seat 31a, and thereby the opening of thefuel passage 311 is opened. Then the fuel flows from thepressure control chamber 14 into the low-pressure passage 17. Therefore the pressure of the fuel accumulated in thepressure control chamber 14 decreases. Thereby the force which urges thevalve needle 11 via thecontrol piston 13 to close thenozzle holes 10a decreases. When the force become less than the force which urges thevalve needle 11 upward to open thenozzle holes 10a due to the pressure of the fuel accumulated in apressure chamber 10b, thevalve needle 11 is pushed up so that thenozzle holes 10a are opened. Then the fuel is injected from thenozzle holes 10a. - When a predetermined time elapses from the beginning of the fuel injection, the power supply to the
coil system 50 is stopped again. Then thearmature 322 is seated on thevalve seat 31a due to thespring 33, and thereby the opening of thefuel passage 311 is blocked. Therefore the pressure of the fuel in thepressure control chamber 14 increases again, and the force which urges thevalve needle 11 to close thenozzle holes 10a increases. When the force become larger than the force which urges thevalve needle 11 to open thenozzle holes 10a, thevalve needle 11 is pushed down and thereby thenozzle holes 10a are blocked. Thus the fuel injection is stopped. - Referring to Figs. 2 and 3, the
coil system 50 includes abobbin 51, acoil 52, a positive terminal member and anegative terminal member 53, aresin coating member 54, astator 55, ahousing 56, aconnector 58 as a terminal portion, andsmall rings 59 and alarge ring 60 as seal members. Thebobbin 51 is formed of resin, and thecoil 52 surrounds thebobbin 51. Theterminal members 53 are formed of conductive material, and project from thebobbin 51 toward theconnector 58. Theterminal members 53 are connected to thecoil 52 so as to supply power to thecoil 52. Thebobbin 51, thecoil 52, and theterminal members 53 are coated with theresin coating member 54. - First, the
bobbin 51 is made as a primary molded product, and then thecoil 52 is wrapped around thebobbin 51. Further theterminal members 53 are connected to thebobbin 51. The resultant structure including thebobbin 51, thecoil 52 and theterminal members 53 is provided as an insert, and coated with resin so as to form theresin coating member 54. Then the structure coated with theresin coating member 54 is provided as a secondary moldedproduct 70. The resin which forms theresin coating member 54 has a softening point close to that of the resin which forms thebobbin 51. - A
receptacle portion 551 and two throughholes 552 are formed in thestator 55. The throughholes 552 pass through thestator 55 along the axis of thecoil system 50. The secondary moldedproduct 70 is inserted into thestator 55. Thereby thebobbin 51 and thecoil 52 rest in thereceptacle portion 551, and theterminal members 53 penetrate the respective throughholes 552. When power is supplied to thecoil 52, a magnetic circuit is formed in thestator 55 and thereby thearmature 322 of themovable member 32 is pulled up (upward in Fig. 1). The length of thestator 55 along the axis of thecoil system 50 and the size of the surface of thestator 55 corresponding to thearmature 322 are determined based on the required magnetic attraction. - The
housing 56 is disposed on thestator 55 on the opposite side of thearmature 322. Twoholes 561 and two throughholes 562 are formed in thehousing 56. Theholes 561 are arranged so as to face thestator 55. The throughholes 562 pass through thehousing 56 along the axis of thecoil system 50, and communicate with therespective holes 561. Further, agroove 563 is circumferentially formed on the external surface of thehousing 56. The small rings 59 rest in therespective holes 561. Thelarge ring 60 rests in thegroove 563. Theterminal members 53 are inserted into thehousing 56 so as to penetrate therespective holes 561 and throughholes 562. - Each of the
small rings 59 is an O-ring which has a short diameter. The small rings 59 rest in therespective holes 561 of thehousing 56 as described above so as to wind around theresin coating member 54. Then the top surface and the external surface of eachsmall ring 59 contact with thehousing 56. The internal surface of eachsmall ring 59 contacts with theresin coating member 54. The bottom surface of eachsmall ring 59 contacts with thestator 55. Thelarge ring 60 is an O-ring which has a relatively long diameter. Thelarge ring 60 rests in thegroove 563 so as to contact with both of thehousing 56 and thecasing 57. - The
casing 57 is provided for connecting thecoil system 50 to thevalve body 12 of thefuel injection system 1. An internal thread portion is formed on the end of thecasing 57 corresponding to thevalve body 12. Further an external thread portion is formed on the corresponding end of thevalve body 12. Thecoil system 50 is fixed to thevalve body 12 by engaging the thread portions each other. - The
connector 58 is disposed on thehousing 56 on the opposite side of thestator 55. Theconnector 58 includes aconnector cap 581 and twoterminals 582 included in theconnector cap 581. Theconnector cap 581 is formed of resin which has a softening point close to that of the resin which forms theresin coating member 54. one of theterminals 582 is a positive terminal which is connected to thepositive terminal member 53, while the other of theterminals 582 is a negative terminal which is connected to thenegative terminal member 53. - The
terminals 582 are welded to the respectiveterminal members 53 after thestator 55, thehousing 56 and therings product 70. Thereafter the resultant structure including the secondary moldedproduct 70, thestator 55, thehousing 56, therings terminals 582 is provided as an insert, and theconnector cap 581 is molded onto the structure. As shown in Fig. 2,weld portions 541 are formed at the ends of theresin coating member 54. Each of theweld portions 541 has an acute angle in its cross section along the axis of thecoil system 50. During a molding process of theconnector cap 581, theweld portions 541 melts at its interface with theconnector cap 581. Thereby theweld portions 541 and theconnector cap 581 are welded. Thus the boundary portion between theresin coating member 54 and theconnector cap 581 is completely sealed up. - In the
coil system 50, theresin coating member 54 isolates thecoil 52 and theterminal members 53, which are conductive members, from thestator 55 and thehousing 56 which are also conductive members. Accordingly, another insulating member such as a bush is not required in thecoil system 50, and the space for disposing such an insulating member is also not required. Therefore the number of the components which constitute thecoil system 50 is reduced, and the structure of thecoil system 50 is simple. Moreover the length of thecoil system 50 along its axis is also reduced, and thereby thecoil system 50 can be miniaturized. Then thecoil system 50 can be incorporated in various systems. - When fuel flows from the
pressure control chamber 14 to the low-pressure passage 17 via thefuel passage 311, some of the fuel leaks into aspace 34, which includes thearmature 322, along the external surface of thevalve member 321. That is, thespace 34 is filled with the fuel. Therefore the fuel may leak from thespace 34 into thecoil system 50 and reach thecoil 52 or theterminal members 53. However, in thepresent coil system 50, theresin coating member 54 covers up to the end portion of thebobbin 51 corresponding to thearmature 322. This construction is possible because thecoil system 50 can be miniaturized as described above. The fuel in thespace 34 is prevented from reaching the winding of thecoil 52 or theterminal members 53 by theresin coating member 54. - Further, engine oil, water such as dew drops, or salt water from the external may leak from the boundary portion A between the
housing 56 and theconnector cap 581 into thecoil system 50. Such fluid may reach theterminal members 53 or theterminals 582. However the fluid is blocked by the boundary portion between theresin coating member 54 and theconnector cap 581, because the boundary portion is completely sealed up by welding theweld portions 541 andconnector cap 58 as described above. - Moreover, the fuel in the
space 34 may also leak into thecoil system 50 along the external surface of theresin coating member 54. Then the fuel may reach the boundary portion between theresin coating member 54 and theconnector cap 581, and thereafter reach theterminal members 53 and theterminals 582. However, in thepresent coil system 50, the fuel is blocked by thesmall rings 59 or the boundary portion. - Thus, fluid is prevented from reaching conductive members such as the winding of the
coil 52, theterminal members 53, or theterminals 582 in thepresent coil system 50. Accordingly the conductive member itself or a resin layer coating the conductive member is prevented from being corroded. Therefore the winding of thecoil 52 or theterminal members 53 are prevented from being short-circuited. - A coil system according to a second embodiment of the present invention includes a
bobbin 81 different in shape from thebobbin 51 of thecoil system 50 according to the first embodiment. Further, the coil system according to the second embodiment includes aresin coating member 84 which covers thebobbin 81 to a different degree from theresin coating member 54 of thecoil system 50 according to the first embodiment. - Referring to Fig. 4, the
bobbin 81 includes asmall portion 811 and twolarge portions 812 . Thesmall portion 811 is surrounded with acoil 82, and thelarge portions 812 define both ends of thecoil 82.Weld projections 813 are formed at the edges of the respectivelarge portions 812. First, thebobbin 81 is made as a primary molded product, and then thecoil 82 is wrapped around thebobbin 81. Thereafterterminal members 83 are connected to thebobbin 81. The resultant structure including thebobbin 81, thecoil 82 and theterminal members 83 is provided as an insert, and coated with resin so as to from theresin coating member 84. During the coating process of the structure, theweld projections 813 and theresin coating member 84 are welded. The structure coated with theresin coating member 84 is provided as a secondary moldedproduct 80. The other portions of the coil system according to the second embodiment are similar to the first embodiment. - Fluid such as fuel is prevented from leaking from the boundary portion between the
bobbin 81 and theresin coating member 84 into thecoil system 50, because the boundary portion is completely sealed up by welding theweld projections 813 and theresin coating member 84. Thereby thecoil 82 is prevented from being corroded, and therefore prevented from being short-circuited. - Moreover, in the second embodiment, the
resin coating member 84 is not required to cover up to the end portion of thebobbin 81 corresponding to thearmature 322. Therefore the coil system can be miniaturized. - Further, because it is easy to coat the structure with the
resin coating member 84 without coating the end portion of thebobbin 81, the production process of the coil system is simplified and therefore production costs are lowered. - A coil system according to a third embodiment of the present invention includes a
resin coating member 54 which hasweld portions 542 different in position and shape from theweld portions 541 of thecoil system 50 according to the first embodiment. - Referring to Fig. 5, the
weld portions 542 are circumferentially formed on the external surface of theresin coating member 54, and positioned so as to contact with theconnector cap 581. Each of theweld portions 542 has a triangle cross section along the axis of the coil system. When theconnector 58 is welded to a secondary molded product integrated with astator 55, ahousing 56 and rings 59, 60, theweld portions 54 melt at its interface with theconnector cap 581 and thereby theresin coating member 54 and theconnector cap 581 are welded. The other portions of the coil system according to the third embodiment are similar to the first embodiment. - Fluid leaking from the boundary portion A between the
connector cap 581 and thehousing 56 into the coil system is blocked by the boundary portion between theresin coating member 54 and theconnector cap 581, because the boundary portion is completely sealed up by welding theweld portions 542 and theconnector cap 581. Accordingly the fluid is prevented from reaching conductive members such as theterminal members 53 or theterminals 582. Therefore theterminal members 53 and theterminals 582 are prevented from being corroded. - A coil system according to a fourth embodiment of the present invention also includes a
resin coating member 90 which hasweld portions 91 different in position and shape from theweld portions 541 of thecoil system 50 according to the first embodiment. - Referring to Figs. 6 and 7, the
resin coating member 90 hassmall portions 901 at its ends corresponding to aconnector 58. Thesmall portions 901 have a diameter shorter than the other portions of theresin coating member 90. Therefore gaps are formed between thesmall portions 901 and theinternal walls 562a of the throughholes 562 of ahousing 56. Theweld portions 91, each of which has a triangle cross section along the axis of the coil system, are formed on the respectivesmall portions 901 so as to project radially toward theinternal walls 562a of the throughholes 562. Accordingly, thegaps 92 narrower than the gaps between thesmall portions 901 and theinternal walls 562a are formed between theweld portions 91 and theinternal walls 562a of the throughholes 562. - For example, the distance D between the
small portions 901 and theinternal walls 562a is set to 1-2mm, while the distance Ds between theweld portions 91 and theinternal walls 562a is set to 0.5mm. Then, resin passes theweld portions 91 at a relatively high speed and thereby relatively large quantity of heat is applied to theweld portions 91, when theconnector cap 581 is molded. Thus the welding efficiency, that is, a ratio of the welded area to the surface area of theweld portions 91 is increased. Thereby the sealing performance is improved. The other portions of the coil system according to the fourth embodiment are similar to the first embodiment. - Fluid leaking from the boundary portion A between the
connector cap 581 and thehousing 56 into the coil system is blocked by the boundary portion between theresin coating member 90 and theconnector cap 581, because the boundary portion is completely sealed up by welding theweld portions 91 and theconnector cap 581. Therefore conductive members such as theterminal members 53 or theterminals 582 are prevented from being corroded. - In the above embodiments, the coil system according to the present invention is incorporated in the
fuel injection system 1 of the diesel engine. However, the coil system may be incorporated in the fuel injection system of a gasoline engine. Further the coil system may be incorporated in other electrical components, for example, an MRE sensor. - A coil system (50) includes a bobbin (51, 81), a coil (52, 82) wrapped around the bobbin, terminal members (53, 83), a resin coating member (54, 84), a stator (55), a housing (56), and a connector (58). The resin coating member covers the bobbin, the coil and the terminal members so as to seal up them. Further, the resin coating member insulates the coil and the terminal members from the stator and the housing. O-xings (59) are disposed circumferentially on the external surface of the resin coating member so as to prevent fluid from leaking into the coil system. Further, weld portions (541, 542, 91) are formed on the resin coating member, and welded to a connector cap (581) of the connector- Thereby fluid leaking into the coil system from the boundary portion (A) of the resin coating member and the connector cap is blocked.
Claims (7)
- A coil system (50) comprising:a stator (55) having a bobbin (51, 81) made of resin;a coil (52, 82) wrapped around said bobbin (51, 81);a terminal member (53, 83) which is connected to said coil (52, 82) and projects from said bobbin (51, 81);a terminal portion (58) which is made of resin and is separated from said stator (55) by a housing (56); said terminal portion including a conductive terminal (582) connected to said terminal member (53, 83); anda resin coating member (54, 84) which continuously covers said bobbin (51, 81), said coil (52, 82), and said terminal member (53, 83)wherein said terminal member (53, 83) extends from said coil (52, 82) in the direction of the terminal portion (58.), extending beyond a boundary between the housing (56) and said terminal portion (58),
characterized in that
said resin coating member (54, 84) extends inside said terminal portion (58) and continuously covers the coil (52, 82) and said terminal member (53, 83), including portions of said terminal member (53, 83) around said boundaries, and has a weld portion (541, 542) inside said terminal portion (58),
welded to said terminal portion (58), said weld portion (541, 542) is formed by melting during the molding process of the terminal portion (58). - A coil system (50) according to claim 1, characterized in that said weld portion (541, 542) is formed on an end portion of said resin coating member (54).
- A coil system (50) according to claim 1, characterized in that said weld portion (541, 542, 91) is circumferentially formed on an external surface of said resin coating member (54, 84, 90).
- A coil system (50) according to any one of claims 1 to 3, further characterized by a seal member (59) which is disposed circumferentially on the external surface of said resin coating member (54, 84, 90).
- A coil system (50) according to any one of claims 1 to 4, characterized in that a weld projection (813) for being welded to said resin coating member (84) is formed on said bobbin (81).
- A coil system (50) according to any one of claims 1 to 5, characterized in that said resin coating member (54, 90) covers up to an end face of said bobbin (51) on an opposite side of said terminal portion (58).
- A coil system (50) according to claim 1 further characterized by a wall portion (562a) which faces an external surface of said resin coating member (90) at a predetermined distance (D),
wherein a weld portion (91) for being welded to said terminal portion (58) is formed on said resin coating member (90);
a gap (92) is formed between said weld portion (91) and said wall portion (562a); and
a width (Ds) of said gap (92) and said predetermined distance (D) are determined so that a speed at which resin for forming said terminal portion (58) passes said weld portion (91) during a molding process of said terminal portion (58) is increased.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2000295892A JP3669425B2 (en) | 2000-09-28 | 2000-09-28 | Coil device |
JP2000295892 | 2000-09-28 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1193391A1 EP1193391A1 (en) | 2002-04-03 |
EP1193391B1 true EP1193391B1 (en) | 2006-03-29 |
Family
ID=18778248
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP01123048A Expired - Lifetime EP1193391B1 (en) | 2000-09-28 | 2001-09-26 | Coil system including a structure for preventing fluid from leaking therein |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1193391B1 (en) |
JP (1) | JP3669425B2 (en) |
DE (1) | DE60118285T2 (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10049709A1 (en) * | 2000-05-25 | 2001-11-29 | Mannesmann Rexroth Ag | Magnetic coil arrangement |
JP4698876B2 (en) * | 2001-04-27 | 2011-06-08 | 豊興工業株式会社 | electromagnet |
ITBO20030678A1 (en) * | 2003-11-14 | 2005-05-15 | Magneti Marelli Powertrain Spa | FUEL INJECTOR WITH HYDRAULIC IMPLEMENTATION OF THE PIN |
DE102005013911B4 (en) * | 2005-03-24 | 2019-10-02 | Continental Automotive Gmbh | Actuator for actuating a fuel injection valve |
ATE479018T1 (en) | 2006-06-15 | 2010-09-15 | Fiat Ricerche | FUEL INJECTION VALVE |
CN101772878B (en) * | 2007-09-26 | 2012-08-29 | 三菱电机株式会社 | Electromagnet actuator |
DE102008040168A1 (en) * | 2008-07-04 | 2010-01-07 | Robert Bosch Gmbh | Solenoid valve for a fuel injector and fuel injector |
DE102011078423A1 (en) * | 2011-06-30 | 2013-01-03 | Robert Bosch Gmbh | Component of a fuel injection system |
FR3038008B1 (en) * | 2015-06-29 | 2017-08-04 | Electricfil Automotive | ELECTROMAGNETIC ACTUATOR FOR CONTROLLING AN INJECTOR COMPRISING A REAR SHIRT AND METHOD FOR MANUFACTURING THE SAME |
AT517926B1 (en) * | 2015-11-20 | 2017-09-15 | Egston System Electronics Eggenburg Gmbh | Coil carrier for an electrical coil arrangement and method for producing an electrical coil arrangement |
JP2019220616A (en) * | 2018-06-21 | 2019-12-26 | 株式会社鷺宮製作所 | Electromagnetic coil |
WO2020022076A1 (en) * | 2018-07-27 | 2020-01-30 | 日立オートモティブシステムズ株式会社 | Fuel pump |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0525442A1 (en) * | 1991-07-26 | 1993-02-03 | Orbital Fluid Technologies, Inc. | Solenoid winding case and protective overmold and method of making |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2618163C2 (en) * | 1976-04-26 | 1985-08-08 | Eckart Dr.Rer.Nat. 2300 Kiel Hiss | Coil arrangement for proximity switches |
JP3188979B2 (en) * | 1991-09-17 | 2001-07-16 | 株式会社ケーヒン | Fuel injection valve |
JPH06299929A (en) * | 1993-04-19 | 1994-10-25 | Hitachi Ltd | Electromagnetic fuel injection valve |
JPH10196488A (en) * | 1997-01-08 | 1998-07-28 | Aisan Ind Co Ltd | Electromagnetic fuel injection valve |
DE19756604C2 (en) * | 1997-12-18 | 2000-01-20 | Siemens Ag | Electric coil, in particular for a relay, and method for the production thereof |
-
2000
- 2000-09-28 JP JP2000295892A patent/JP3669425B2/en not_active Expired - Lifetime
-
2001
- 2001-09-26 EP EP01123048A patent/EP1193391B1/en not_active Expired - Lifetime
- 2001-09-26 DE DE2001618285 patent/DE60118285T2/en not_active Expired - Lifetime
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0525442A1 (en) * | 1991-07-26 | 1993-02-03 | Orbital Fluid Technologies, Inc. | Solenoid winding case and protective overmold and method of making |
Also Published As
Publication number | Publication date |
---|---|
DE60118285D1 (en) | 2006-05-18 |
EP1193391A1 (en) | 2002-04-03 |
DE60118285T2 (en) | 2006-11-09 |
JP2002110419A (en) | 2002-04-12 |
JP3669425B2 (en) | 2005-07-06 |
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