JP2010527788A - How to make a solenoid housing - Google Patents

Abstract

The present invention relates to a method for providing a solenoid housing comprising providing a malleable material of a solid cylinder having a first portion and a second portion; Shrinking to be smaller than the diameter; compressing the second part towards the first part to produce a flattening disk that is generally perpendicular to the first part; at least a flattening disk to define a lifting wall A portion of the peripheral portion of the first portion is lifted in a direction toward the first portion; and the first portion, the second portion, and the lifting periphery are all joined together as a single piece.
[Selection] Figure 6

Description

Related applications

  The present invention claims the priority of Indian Patent Application No. 848 / CHE / 2007 filed on April 19, 2007. This application also claims benefit under 35 USC § 119 (e) of US Provisional Patent Application No. 60 / 987,649, filed Nov. 21, 2007. All prior applications are incorporated herein by reference in their entirety.

  The present invention relates to a method of making a solenoid housing.

  Solenoid housings are typically used in automotive control systems such as doors, windows, fluid controls, engine controls and the like. Other applications include refrigerators, washing machines and dryers. Still other applications include electrically operated valves / switches, door holders, speakers, and CRT monitors.

  The solenoid housing is typically assembled into parts, with the center pole 8 welded or otherwise attached to the cup 12, as shown in FIGS. 1a-1b, and the cup 12 is usually cut from sheet metal. And bent into the shape shown. The cup 12 typically starts as a flat disk cut from sheet metal and moves up around the periphery of the disk so as to form a lifting wall 14 or a lifting lip extending along its periphery. Bend to The base 16 of the disc, or the remaining flat portion of the disc, is usually welded or attached to the pole 8.

  Another way to create a solenoid housing is to add various parts or machine instead of assembling the parts. Some methods include machining at least the pole or cup portion.

  However, creating a solenoid housing in the manner described above presents several disadvantages. In the assembly of parts, such as welding the pole 8 to the base 16, weak points tend to be introduced, and generally any mechanical deficiency is located at the junction between the pole 8 and the base 16. .

  In addition, since the electromagnetic field typically flows from the pole 8 to the base 16 and finally to the lifting wall 14, the base 16 is formed of sheet metal and its thickness is a small cross section through which the electromagnetic field flows. Therefore, the joint between the base portion 16 and the pole 8 often fails. As a result, even though the pole 8 originally has a large diameter so that it can enter and pass downwards toward the base 16, the electromagnetic field is lifted from the pole 8 through the base 16 and thus the wall 14 When transmitted to the network, it is usually disturbed.

  In addition, the orientation of the grain structure of the base 16 and the lifting wall 14 can be claimed, but the grain structure interferes with the flow of the electromagnetic field because it is perpendicular or intersects with the radial motion of the electromagnetic field. Since the cup 12 is usually cut from sheet metal, the grain orientation is usually unknown and often cannot be predicted or adjusted.

  For machined parts of the cup 12 or pole 8, such an implementation is usually scraped by a few thousandths or hundredths of an inch at a time, and scraping material at this rate is the manufacture of the solenoid. Is time consuming, so it is a labor concentration and generally a waste of time. Furthermore, lathes used for machined parts are generally expensive and require a large amount of space for proper operation. Therefore, the costs associated with machined parts are more than the benefits gained from machined parts over assembled parts.

  U.S. Pat. No. 4,217,526 shows in its FIGS. 10 and 10A a single unit having a matching nose portion pressed like an interference fit in an outer hollow space formed by an inwardly extending pole portion 52. One soft iron plug or insert 75 is shown. The plug 75 has the effect of increasing the flux flow capacity across the gap defined by the wall 60 of the bobbin 55. A substantially similar effect can be achieved at a substantially lower cost, where the flux flow plug means includes one or more mild steel balls 76 pushed into the hollow outer cavity defined by the pole portion 52. Prepare.

  US Pat. No. 6,029,704 to Kuroda et al. Discloses a steel sheet and hollow cylindrical solenoid that are compression molded or cold extruded. However, because Kuroda's solenoid housing and pole are made and assembled from multiple parts, they do not effectively induce electromagnetic fields.

  U.S. Pat. No. 4,365,223 to Fichant et al. Relates to solenoid housings that are placed together.

  Therefore, what is desired is a method of making a solenoid housing that attenuates weaknesses without sacrificing manufacturing efficiency. Another desire is a method of making a solenoid housing that enhances the flow of the electromagnetic field.

United States Patent No. 4,217,526 United States Patent No. 4,365,223

  Accordingly, it is an object of the present invention to provide a method for making an integral solenoid housing.

  Another object is to provide a method of making a solenoid housing in which the entire housing is made of solid material.

  Another object is to provide a method of making a solenoid housing in which a central pole, base and rising sidewalls are formed from a single, solid, electromagnetically permeable material.

  Yet another object is to provide a method of making a solenoid housing in which the grain structure of the material is oriented to increase electromagnetic transmission.

  These and other objects of the present invention provide a solid cylindrical body of malleable material having a first part and a second part; the diameter of the first part of the cylindrical body is the diameter of the second part of the cylindrical body The second portion is compressed axially toward the first portion and is generally flattened perpendicular to the first portion (hereinafter referred to as the “flattened disc”). ) And none; including a step of lifting at least the peripheral portion of the flattened disk toward the first portion so as to form a lifting wall, wherein the first portion, the second portion, and the lifting periphery are all single. This is accomplished by a method of making a solenoid housing that is joined together as a part.

  In some embodiments, the diameter of the first portion is reduced by extruding the first portion of the cylinder through a die. In another embodiment, the method forms a first portion and a region defined by a connection between the first portion and a side of the planarizing disk facing the first portion.

  In another embodiment, the method provides a solid cylinder of malleable material having a first portion and a second portion; the diameter of the first portion of the cylinder is less than or equal to the diameter of the second portion of the cylinder. The second portion is axially compressed toward the first portion to form a flattened disc generally perpendicular to the first portion; and at least the peripheral portion of the flattened disc is the first portion. Annealing the housing after at least one of the steps of lifting in a direction toward the housing.

  In another embodiment, the method controls the cross-section of the planarizing disk relative to the cross-section of at least the raised peripheral portion. In some of these embodiments, the method reduces the thickness of the raised periphery to less than the thickness of the planarizing disk.

  In yet another embodiment, the method orients the plurality of grain structures of the planarizing disk in a direction that extends generally radially from the overall center of the planarizing disk. In some of these embodiments, the method further orients the plurality of grain lines of the first portion to be axially extending generally along the length of the first portion.

  In another embodiment, the method provides a third portion of a solid cylindrical body of malleable material on the side of the second portion opposite the first portion; and the cylinder by extruding the third portion. Reducing the diameter of the third portion of the second portion to less than or equal to the diameter of the second portion. In some of these embodiments, the method extrudes a third portion of the cylinder through a die so that the third portion is square, rectangular, triangular, pentagonal, hexagonal, octagonal, Having a cross-sectional shape selected from the group consisting of polygons and combinations thereof. In another embodiment, the method extrudes the third part through a die, whereby the diameter of the third part is different from the diameter of the first part.

  In an alternative embodiment, the method provides a flange in the upper portion of the lift periphery.

  In another aspect of the present invention, a method for making a solenoid housing comprises providing a solid cylindrical body of malleable material having a first portion and a second portion; Reduced to less than the diameter of the second part; the second part is axially compressed toward the first part to form a flattened disk generally perpendicular to the first part; so as to form a lifting wall Lifting at least the periphery of the planarizing disk in a direction toward the first portion; controlling at least the cross section of the planarizing disk relative to the section of the raised peripheral portion; Orienting in a radial direction extending outward from the center; and orienting the grain lines of the first portion in an axial direction extending along the length of the first portion.

  In some embodiments, the method provides a solid cylinder of malleable material having a first portion and a second portion; the diameter of the first portion of the cylinder is the diameter of the second portion of the cylinder. Reduced to the following: a second portion is axially compressed toward the first portion to form a flattened disc generally perpendicular to the first portion; at least of the flattened disc to form a lifting wall Lift the peripheral part in the direction towards the first part; control the cross section of the flattening disk relative to the cross section of at least the lifted peripheral part; remove the multiple grain lines of the flattening disk from the overall center of the flattening disk After at least one of the steps of orienting in a radial direction extending in the direction; and orienting the grain lines of the first portion in an axial direction extending along the length of the first portion C Annealed magnetically the Managing.

FIG. 1a shows a solenoid housing according to the prior art. FIG. 1b shows a solenoid housing according to the prior art. FIG. 2 illustrates a method of making a solenoid housing according to the present invention. FIG. 3 shows in more detail the starting process of making the solenoid housing by the method shown in FIG. FIG. 4a shows in more detail the intermediate steps of making the solenoid housing by the method shown in FIG. FIG. 4b shows in more detail the intermediate steps of making the solenoid housing by the method shown in FIG. FIG. 4c shows in more detail the intermediate steps of making the solenoid housing by the method shown in FIG. FIG. 5a shows in more detail the final step of making the solenoid housing by the method shown in FIG. FIG. 5b shows in more detail the final step of making the solenoid housing by the method shown in FIG. FIG. 5c shows in more detail the final step of making the solenoid housing by the method shown in FIG. FIG. 5d shows in more detail the final step of making the solenoid housing by the method shown in FIG. FIG. 6 shows a solenoid housing made by the method shown in FIG. FIG. 7 shows in more detail a compatible embodiment of creating a solenoid housing by the method shown in FIG. FIG. 8a shows a die used to perform the compatible embodiment shown in FIG. FIG. 8b shows the dies used to perform the compatible embodiment shown in FIG. FIG. 8c shows a die used to implement the compatible embodiment shown in FIG. FIG. 8d shows the dice used to perform the compatible embodiment shown in FIG. FIG. 8e shows the dice used to perform the compatible embodiment shown in FIG. FIG. 8f shows the dice used to perform the compatible embodiment shown in FIG. FIG. 8g shows the dice used to perform the compatible embodiment shown in FIG. FIG. 9a shows various shapes of the central pole shown in FIGS. FIG. 9b shows various shapes of the central pole shown in FIGS. FIG. 9c shows various shapes of the central pole shown in FIGS. FIG. 9d shows various shapes of the central pole shown in FIGS. FIG. 10a shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 10b shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 10c shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 10d shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 10e shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 10f shows an embodiment in which a flange is arranged on the lifting wall according to the method shown in FIG. FIG. 11a shows an embodiment in which the housing is formed by the method shown in FIG. FIG. 11b shows an embodiment in which the housing is formed by the method shown in FIG. FIG. 11c shows an embodiment in which the housing is formed by the method shown in FIG. FIG. 11d shows an embodiment in which the housing is formed by the method shown in FIG.

  FIG. 2 shows a method 20 for making a solenoid housing according to the present invention, in which the solenoid housing 102 (see FIG. 5d) is converted by the method 20 into a single solid cylinder of malleable material 106. FIG. Manufactured from the body. In some embodiments, material 106 is a low carbon steel such as SAE 1006, 1008, 1010 and the like.

  As shown in FIG. 2, the present method 20 includes a step 20 of preparing a solid cylindrical body of malleable metal having a first portion and a second portion, and the diameter of the first portion of the cylindrical body is set to the second of the cylindrical body. A step 26 of reducing to less than the diameter of the part and a step 28 of axially compressing the second part towards the first part.

  FIG. 3A shows the first portion 108 and the second portion 10 of the material 106, and FIG. 3D shows the diameter of the second portion 110 after the step of reducing the diameter 112 of the first portion 108. A diameter 112 of the first portion 108 that is 114 or less is shown. During the process of reducing the diameter 112 by receiving the material 106, a first die 115 is used, in which the first portion 108 is inserted into the first die 115 in the direction of arrow 118, followed by the first portion 108. In order to reduce the diameter 112 of the first portion, the first portion is pushed into or extruded through the orifice 117. The method 20 reduces the diameter of the first portion by step 29 of extruding the cylindrical first portion through a die.

  FIG. 4a shows the step 28 of compressing the second part 110 in the direction of the arrow 122, so that a flattened disk is formed which is generally perpendicular to the axis passing through the first part 108 in the longitudinal direction. As shown, during the compression step 28 of flattening the second portion 110 into a disk 126, the first portion 108 is chamfered or otherwise resulting in a chamfer and / or profile imparted to the first portion 108 after the compression step. Are securely held in place by a second die 119 made in a shape having the following shape. In another embodiment, the first portion 108 is held in place by the first die 115. In one embodiment of the method 20, the method 20 is defined by a first portion and a connection between the first portion and the side of the planarizing disk facing the first portion (reference 132 in FIG. 4a including chamfer). Forming a region to be formed.

  Referring to FIG. 2, the method 20 also includes a step 32 of lifting at least the periphery of the planarizing disk toward the first portion to define a lifting wall or lifting lip. FIG. 4 b shows a lifting wall 128 shown to extend along the entire circumference of the planarizing disk 126. In another embodiment, the lifting wall 128 extends along a portion of the entire circumference of the planarizing disk 126.

  As shown in FIG. 4 b, the third die 123 is formed with a cavity that bends the periphery of the disk 126 downward toward the first portion 108 when pushed down onto the planarizing disk 126. While the peripheral die 123 is lowered to form a raised wall 128, the first portion 108 is fixed to prevent the first die 108 from moving during at least the step 32 of lifting a portion of the peripheral portion. 115, the second die 119, or other die is held in place. FIG. 4 c shows the housing removed from the peripheral die 123, where the lifting wall 128 extends along the entire planarizing disk 126 to become a base 134.

  As described in FIGS. 3A-D, the material 106 is annealed or stress relieved between steps. In some embodiments, material 106 is magnetic annealed. In another embodiment, annealing is performed between steps of the method 20. Annealing is beneficial because it occurs each time the material 106 is pushed into a die, bent, or otherwise formed, and attenuates the stress introduced into the material 106 during the cooling operation or extrusion. Without annealing, material 106 becomes increasingly brittle after each low temperature processing step, and material 106 becomes increasingly difficult to form in subsequent low temperature processing steps and is prone to cracking or loss. More frequent annealing of the material 106 makes it easier to extrude or form the material 106 in subsequent steps.

  In one embodiment, the annealing heats material 106 to about 850 ° C., then allows material 106 to stay at that temperature before cooling to 720 ° C. and allows material 106 to stay at this temperature before cooling to room temperature. Including that.

  However, the cost and time associated with annealing can cause an operator to skip one or more annealing steps. In some embodiments, annealing is performed during the above-described steps of FIG. 3 (A) -5d or method 20 as indicated by the annealing or stress relief instructions described in FIGS. 3 (A) -4c. To be carried out. All that is required for annealing is that the method 20 is sufficient to make the housing 102. In another embodiment, annealing is performed at least once during the method 20 or during the steps of FIGS. 3A-5d described above.

  In yet another embodiment of the method 20, the method includes the step 34 of controlling the cross-section of the planarizing disk relative to the cross-section of the lifting periphery, at least a portion of the lifting wall. In other words, and referring to FIG. 5a, the cross section of the base 134 is controlled to be smaller, larger or the same as the cross section of the raised peripheral portion 128. In particular, the thickness 135 of the base 134 is controlled relative to the thickness 137 of the lifting wall 128.

  As shown, the method facilitates the flow of electricity, current, electrical energy, magnetic energy, and / or electromagnetic field as transmitted from the pole 142 to the lifting wall 128, as the larger thickness 135 facilitates the lifting periphery. The thickness of the planarizing disk is increased so as to be larger than the thickness of the portion or the lifting wall (step 36). In another embodiment, the method reduces the raised peripheral thickness 137 less than the planarizing disc thickness 135 (step 46). The larger thickness 135 is used to conduct the electromagnetic field, or to allow the flow of electromagnetic energy to flow through the thinner base 134, particularly when the electromagnetic field reaches a lifting wall 128 arranged outward. Is more important. As shown, the lifting wall 128 is made thinner than the base 134 by the die 125, where the base 134 is pushed against the wall 128 in a downward compressive motion as indicated by arrow 127 so that the thickness 137 is Less than the thickness 135 and the wall 128 extends or extends away from the base 134.

  Conventional solenoid housings that form the base and lifting walls from sheet metal and then weld the center pole cannot achieve adjustability (see FIG. 1b), and hence the electromagnetic field that flows from the pole 142 to the wall 128 The potential for promotion is limited.

  Optionally, the method 20 provides a flange in the upper portion of the lift periphery (step 58). The flange 146 is shown in more detail in FIGS. 5b-5c, and is formed after placing the raised periphery 128 between the dies 129, 131, where the dies 129, 131 are subsequently rotated to remove the raised periphery 128. The flange 146 is formed by bending into a desired shape. FIG. 5d shows the housing 102 prior to the final magnetic annealing process.

  In another embodiment and another advantage over the prior art, the method 20 includes the step 36 of orienting the plurality of grain lines of the planarizing disk 126 to be generally radial. As described above, the electromagnetic field is transmitted from the pole 142 to the lifting wall 128 via the planarizing disk 126. In addition to controlling the cross section of the planarizing disk, including thickness, to facilitate transmission of the electromagnetic field through the planarizing disk 126, the plurality of grain lines of the planarizing disk are generally radial. The orienting step 36 further facilitates the transmission of the electromagnetic field as the electromagnetic field passes generally along the radial grain lines as the energy moves up and moves toward the wall 128.

  In typical prior art housings in which the grain lines are not oriented, the grain lines are oriented in a random, vertical, or angular relationship with respect to the electromagnetic field movement, in which case the grain lines impose electromagnetic field flow. Rather than promoting, it inhibits.

  Since the present method 20 compresses the second end 110, the second end 110 extends outward or the diameter of the second end increases in size, thereby forming a planarizing disk 126. As the second end 110 widens outward, the grain lines in the disk 126 also move in the outward direction and automatically in a generally radial direction or in an outward direction in which the second end 110 widens. Oriented.

  In another embodiment and another advantage over the prior art, the method 20 orients the plurality of grain lines of the first portion 108 to be axially extending generally along the length of the first portion. Step 40 is included. As described above, the electromagnetic field is transmitted to the planarizing disk 126 through the length of the pole 142. Therefore, orienting the plurality of grain lines of the first portion 108 to be generally axial (step 40) means that the energy is generally grained as the energy moves toward the planarizing disk 126. Passing along the axial direction of the line facilitates transmission of the electromagnetic field through the first portion 108. See FIG. 6 which shows the housing 102 with the grain wires 104 oriented as described above.

  In a typical prior art housing in which the grain lines are not oriented, the grain lines are in a random, vertical, or angular relationship with respect to electromagnetic field movement, in which case the grain lines are said to facilitate energy flow. Rather inhibit.

  The method 20 extrudes the first end 108 by pushing the material 106 into the first die 105 in the longitudinal direction along the length of the first end 108 so that the grains in the first end 108 are also the same. The first end 108 is moved in the longitudinal direction along the length of the first end 108 or in the direction in which the first end 108 is pushed out.

  In another embodiment, the method 20 also includes providing a third portion of the solid cylindrical material 106 on the side of the second portion 110 opposite the first portion 108 and extruding the third portion. Reducing the diameter of the third portion of the cylindrical body so as to be smaller than the diameter of the second portion.

  In another embodiment shown in FIG. 7, a second pole 148 is provided in addition to the first pole 142. As shown in FIG. 8a, the third or second pole 148 is obtained by extruding the second portion 110 through the orifice 158 of the die 161, where the material 106 is a punch that is compatible with the die 161 being assembled. 163 is pushed into the orifice 158 (see FIG. 8b). When the punch 163 is released from the die 161, the ejector 159 enters the orifice 158 from the end facing the material 106 and removes the material 106 from the die 161.

  As a result, when the die 153 having the orifice 156 is pushed against the die 167, the third portion of the material 106 or the second pole 148 is held in place within the first 167 (see FIGS. 8d-8e), so that The first end 108 is extruded through an orifice 156 to provide a first pole 142 and a planarizing disk 126 (see FIGS. 8d-8e).

  When the planarizing disk 126 is completed, the die 153 is removed, and the ejector 155 takes out the material 106 provided with the second pole 148 on the side of the planarizing disk 126 facing the first pole 142 (step 44).

  It should be understood that the poles 142, 148 may be of different diameters or shapes based on the orifices 156, 158. As shown in FIGS. 8a-8e, the dimensions of the orifice 156 are independent of the diameter 112 of the first portion 108 (first pole 142), where the orifice 156 is larger or smaller than the diameter 112, or It may be the same diameter. Based on the operator's choice, the dimensions for the orifice 156 are determined and the second pole 148 is pushed through the die 161 such that the diameter of the second pole 148 is different from the diameter 112 of the first pole 142. (Step 54) or compressed.

  In addition, the shape of the orifice 158 is independent of the shape of the first pole 142 or the orifice 156. In some embodiments, the method provides a second pole 148 having a cross-sectional shape selected from the group consisting of a square, a rectangle, a triangle, a pentagon, a hexagon, an octagon, a polygon, and combinations thereof. The third portion or second pole 148 is pushed through the die 161 or the orifice 158 (step 56). As shown in FIGS. 9 a-9 d, some examples of the cross-section or shape of the second pole 148 are shown, which are attributed to the orifice 158. The limitations of orifice 117 and / or orifice 156 include the same limitations as orifice 158 as well as the shape of orifice 158.

  In order to complete the lifting wall 128 from the planarizing disk 126, FIG. 8f shows holding the first pole 142 by rigid means, in which the die 153 or another die (the first pole 142 is pushed out). If the die 153 used in this manner is inappropriate for fixing the first pole 142, another die is used.

  A die 157 having a channel 165 and an internal die 169 having an orifice 158 ′ (having the same dimensions as the orifice 158) are brought downwardly with respect to the planarizing disk 126 to provide a raised wall 128 (see FIG. 8g). Arise. Since the internal die 169 is spring loaded by the spring 171, the internal die 169 is pushed into the channel 165 and pushed between the dice 157 and the die 153 to form a lifting wall (see FIG. 8 g). Dice 153 is removed from channel 165 and ejector 173 removes material 106 from die 153.

  The method for providing the second pole 148 and the second pole 142 includes all the advantages and limitations of the method for providing the first pole 142 and the first pole 142, including the orientation of the grain line, the thickness of the second pole 148. Note that the control includes a second pole 148 integrally coupled with the remainder of the solenoid housing 102, and the second pole 148 formed by being extruded from a single material 106. Is important. In addition, annealing is introduced between at least one of the steps shown in FIGS. 8a-8g.

  As shown in FIGS. 10 a-10 f, another embodiment of the housing 200 is shown with a flange 204 attached to the outer wall 206. As shown in FIG. 10 a, the material with the first end 108 and the second end 110 is prepared by the same means as described above, and the flange 204 is the same material as the first end 108 and the second end 110. Where all the components described under FIGS. 10a-10f are joined together and annealing and / or stress relief is performed between at least one of the steps shown in FIGS. 10a-10f.

  As shown in FIG. 10 b, the second end 110 is placed in the die 207 and is restrained by the side wall 209 of the die 207. It should be understood that the sidewall 209 need not contact the second end 110 and that in some embodiments, there is a gap between the second end 10 and the die 207.

  When the punch 211 having the orifice 213 is moved downward relative to the material 106, the raised wall 228 is formed by the second end 110 that is pushed between the die 207 and the punch 228. Similar to the lifting wall 128 described above, the lifting wall 228 extends along the entire periphery of the second end 110 and in some embodiments includes similar limitations as the lifting wall 128. See FIG. The size and shape of the orifice 213 represents the size and shape of the first end 108 that will eventually become the pole 208 (see FIG. 10f).

  In another embodiment, when placed in a die 207 that pushes material into the orifice 213 to form the pole 208, the punch 211 is lowered over the material so that the first end 106 is placed before being placed in the die 207. There is no need to extrude. In these embodiments, the material is a single cylinder when placed on the die 207.

  FIG. 10 d shows the material 206 having the pole 208, the lifting wall 208 and the base 226 when removed from the die 207.

  As shown in FIG. 10e, the material 206 is turned upside down and placed in the die 215, where the pole 208 and the lifting wall 228 are fixed and the base 226 is exposed. As shown in FIG. 10 f, the punch 217 is lowered onto the second end 110 to form a flattened disk 232, where the outermost periphery of the disk 232 defines a raised wall 228. The flange 204 is extruded and / or extruded from the same material used to provide the lift wall 228, base 226 and pole 208.

  As shown in another embodiment, FIG. 11 a shows a housing 222 having a hexagonal shaped lifting wall 224. It should be understood that although the lifting wall 224 is shaped as a hexagon, other embodiments have walls that are shaped like an octagon, a square, a rectangle, a triangle, or any polygon. There are no restrictions on the variations as long as they are shaped. As shown in FIG. 2, the method 20 includes a step 39 of forming a lifting wall, thereby selected from the group consisting of squares, rectangles, triangles, pentagons, hexagons, octagons, polygons, and combinations thereof. It has a cross-sectional shape.

  Consistent with all descriptions of the previous embodiments, the variously shaped lifting walls 224 are integrally coupled with the housing, and in which all the components described with reference to FIGS. 11a-11d are integrally coupled, Then, annealing and / or stress reduction is performed between at least one of the steps shown in FIGS. 11a-11d.

  As shown in FIG. 11b, a pole 234 and a planarizing disk 236 are prepared as described with reference to FIG. 4a and placed against a punch 227 having a hexagonal shape around its periphery 236. A die 225 having an orifice 238 is lowered relative to the disk 236, where the punch 227 and the disk 236 fit within the orifice 238, and the orifice also has a hexagonal shape. This is shown in more detail in FIGS. 11c-11d.

  As shown in FIGS. 11c-11d, the punch 227 includes an orifice 239 to position or secure the pole 234.

Claims (16)

Preparing a solid cylindrical malleable material having a first portion and a second portion;
Reducing the diameter of the first portion of the cylindrical body to be smaller than the diameter of the second portion of the cylindrical body;
Compressing the second portion axially toward the first portion so as to produce a flattened disk generally perpendicular to the first portion;
Lifting at least a portion of the periphery of the planarizing disk toward the first portion so as to define a lifting wall;
A method of making a solenoid housing, wherein the first portion, the second portion, and the lifting periphery are all joined together as a single piece.   The method of claim 1, wherein the diameter of the first portion is reduced by extruding the first portion of the cylinder through a die.   The method of claim 1, further comprising forming a first portion and a region defined by a connection between the side of the planarizing disk facing the first portion and the first portion. Preparing a solid cylindrical malleable material having a first portion and a second portion;
Reducing the diameter of the first portion of the cylindrical body to be smaller than the diameter of the second portion of the cylindrical body;
Compressing the second portion axially toward the first portion to form a planarized disk generally perpendicular to the first portion;
The method of claim 1, further comprising magnetically annealing the housing after at least one of the steps of lifting at least a portion of the periphery of the planarizing disk toward the first portion.   The method of claim 1, further comprising the step of controlling a cross section of the planarizing disk relative to at least a partial cross section of the lifting periphery.   6. The method of claim 5, further comprising the step of reducing the thickness of the raised periphery less than the thickness of the planarizing disk.   The method of claim 1, further comprising orienting the plurality of grain lines of the planarizing disk such that the radial direction extends generally outward from a general center of the planarizing disk.   The method of claim 1, further comprising orienting the plurality of grain lines of the first portion to be axially extending generally along the length of the first portion. Providing a third portion of the malleable material of the solid cylindrical body on the side of the second portion opposite the first portion;
The method of claim 1, further comprising reducing the diameter of the third portion less than the diameter of the second portion by extruding the third portion of the cylinder.   Extrude the third part of the cylinder through the die so that the third part has a cross-sectional shape selected from the group consisting of squares, rectangles, triangles, pentagons, hexagons, octagons, polygons and combinations thereof. The method of claim 9, further comprising a step.   The method of claim 9, further comprising extruding the third portion of the cylindrical body through a die such that the diameter of the third portion is different from the diameter of the first portion.   The method of claim 1, further comprising providing a flange in an upper portion of the lift periphery.   The method of claim 1, further comprising providing a flange in a lower portion of the raised periphery.   Further extruding the second part through a die so that the second part has a cross-sectional shape selected from the group consisting of squares, rectangles, triangles, pentagons, hexagons, octagons, polygons and combinations thereof. The method of claim 4 comprising. Preparing a solid cylindrical malleable material having a first portion and a second portion;
Reducing the diameter of the first portion of the cylindrical body to be smaller than the diameter of the second portion of the cylindrical body;
Compressing the second portion axially toward the first portion so as to produce a flattened disk generally perpendicular to the first portion;
Lifting at least a portion of the periphery of the planarizing disk toward the first portion so as to define a lifting wall;
Controlling the cross section of the planarizing disk relative to at least a partial cross section of the raised peripheral edge;
Orienting a plurality of grain lines of the planarizing disk such that the radial direction extends outwardly from the general center of the planarizing disk;
A method for producing a solenoid housing, comprising the step of orienting the grain lines of the first part so as to be in an axial direction extending along the length direction of the first part. Preparing a solid cylindrical malleable material having a first portion and a second portion;
Reducing the diameter of the first portion of the cylindrical body to be smaller than the diameter of the second portion of the cylindrical body;
Compressing the second portion axially toward the first portion to form a planarized disk generally perpendicular to the first portion;
Lifting at least a portion of the peripheral edge of the planarizing disk in a direction toward the first portion to form a lifting wall;
Controlling the cross section of the planarizing disk relative to at least a partial cross section of the raised peripheral edge;
Orienting a plurality of grain lines of the planarizing disk such that the radial direction extends outwardly from the general center of the planarizing disk;
17. The method of claim 16, further comprising magnetically annealing the housing after at least one of the steps of orienting the grain lines of the first portion so as to be axial along the length of the first portion. Method.

Images