JPH06215937A - Solenoid - Google Patents

Abstract

PURPOSE: To obtain a compact and strong solenoid by providing a bobbin which has a rectangular section and a core hole that is in the same shape as an outer surface with a round edge and winding the wire coil of the solenoid so that it has a rectangular section with a round edge. CONSTITUTION: A solenoid has a rectangular core hole 26 and a bobbin 22 where an armature 18 with a rectangular section is mounted inside and a magnetic pole piece 13 with a rectangular section. In the bobbin 22, a coil 30 of a magnet wire is wound around a bobbin tubular body 23 with a rectangular section. The bobbin has an upper flange 25 and a lower flange 24 and a tubular can 43 is embedded to the surrounding of the bobbin. Then, an upper magnetic flux plate 31 is sealed to the upper surface of the can 43 and a bottom magnetic flux plate 12 is sealed to the flange of each bobbin on the lower surface of the can 43. Also, to seal the coil 30, an electrically insulated, heat-dispersive material is provided inside the can 43, thus obtaining a compact and strong solenoid for electromagnetic valves.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The field of art to which this invention pertains is generally in the device category of valves.

The present invention relates to solenoids, and more particularly to solenoids adapted for use in operating components such as small valves.

[0003]

BACKGROUND OF THE INVENTION Conventionally, prior art solenoids have incorporated a round core construction with a cylindrical armature and mating cylindrical pole pieces. A drawback of such prior art solenoids is that the width of the solenoid with a round iron core configuration is significantly larger to make a solenoid with a given force at a given stroke. In small valve packages, the width of the valve and solenoid is of fundamental importance.
Length and height are important, but they are less critical than width. Currently, there is a need for a small, efficient solenoid for use in control circuits for operating industrial fabrication and assembly equipment that can be made to very thin dimensions.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a solenoid that is small, efficient and powerful, and that overcomes the aforementioned drawbacks and problems of prior art solenoids.

[0005]

SUMMARY OF THE INVENTION A solenoid made in accordance with the present invention includes a bobbin having a core hole that is rectangular in cross section and shaped similarly to the outer surface with rounded ends. The bobbin has an integral upper flange and an integral lower flange. The magnet wire coil of the solenoid is wound around the bobbin so as to make a solenoid coil having a rectangular cross section with a rounded end, and by using the rectangular cross section, the length of each turn of the coil wire is lengthened, As a result, the electric resistance per turn is increased, the ampere-turn of the coil is increased, and the force of the solenoid is increased. The bobbin is telescopically mounted in a tubular shell having a rectangular cross section and open at both ends. This can
It is a member that allows the magnetic flux of a thin wall to pass. A pole piece having a rectangular cross section with rounded ends is slidably attached to the lower end of the rectangular core hole of the bobbin. The pole piece has an integral bottom flux plate that engages the lower end of the can. The upper end of the can is closed with an upper plate which is flux permeable and the can is secured between the upper and lower flux plates by any suitable means such as thermoforming the flux plate to the flange of the bobbin. An armature bush is slidably mounted in the upper end of the bobbin, which has a rectangular cross section with rounded ends for slidable fit in a similarly shaped core hole in the bobbin. . An elongated armature having a rectangular cross section with rounded ends is slidably mounted in the armature bush. The inner end of the armature is engaged by a push pin slidably mounted through a shaft hole formed through the pole piece. An upper cover member is attached to the upper flux plate which secures the solenoid assembly described above to a valve or similar device.

The upper and lower ends of the armature are provided with radially shaped end faces to ensure that the solenoid moves completely when the armature is slightly cocked when the solenoid is energized. There is. The rectangular shape of the coil bobbin not only increases the ampere turns of the coil, but also increases the cross-sectional area and surface area of the armature and pole pieces that increase the force due to the increased ampere turns.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings, and in particular to FIGS. 1 and 2, the numeral 10 generally designates a solenoid made in accordance with the principles of the present invention. As shown in Figure 2,
The numeral 11 has a substantially T-shaped vertical cross section, and the bottom transverse flux plate 1
2 and 2 collectively show a magnetic pole piece having a magnetic pole plate 13. An axial hole 14 is formed through the pole piece 11 so as to slidably receive an ordinary push pin 15. The push pin 15 includes an enlarged head 16 that operates in engagement with a valve spool of a valve or other mechanism to be actuated by the solenoid 10. The number 17 is
Represents the inner end of the push pin 15, which operates by engaging a radially rounded lower end 20 of an armature 18 made of a suitable magnetic material such as powder metal. Number nineteen
Represents the upper end of the pole piece 11. The numeral 21 represents the upper end of the active member 18 which is rounded in the radial direction.

As shown in FIG. 2, the solenoid 10 has a coil bobbin, generally designated by the numeral 22, which comprises an elongated tubular body 23, an integral lower lateral flange, and an integral upper flange 25. As shown in FIGS. 4 and 5, the tubular body 23 of the coil bobbin has a rectangular cross section with rounded ends. An axial core hole 26 is formed through the tubular body 23 of the solenoid bobbin, the hole also being shaped as a rectangle with rounded ends. As shown in FIGS. 2, 4 and 5, numeral 30 represents a coil formed by wrapping a thin magnet wire in a conventional manner around the tubular body 23 of the solenoid bobbin. The bobbin 22 is made of a suitable plastic material. As shown in FIGS. 2 and 3, the solenoid 10 has an upper flux plate 31 mounted on the upper flange 25 of the bobbin and having rectangular holes 38 (FIG. 2) with rounded ends. .

As shown in FIG. 2, the bottom flux plate 1
2 comprises two or more holes as shown in the hole 33 with a dished outer edge. The lower flange 24 of the bobbin comprises an equal number of integral extensions 32 that extend axially outwardly through holes 33 in the bottom flux plate. The bobbin upper flange 25 also includes one or more pairs of extensions 35 extending axially outward through holes 36 formed through the upper flux plate 31. A thin-walled, open-ended can 43 is placed over the bobbin and coil assembly described above.
The pole piece structure 11 and the upper flux plate 31 are assembled to their respective bobbin flanges and the extensions (32, 35) of the bobbin flanges are thermoformed flatly in the same plane as the outer surface of the respective flux plates. It

An armature bush 40 is slidably mounted through a hole 38 in the upper flux plate 31 and into a core hole 26 in the tubular body 23 of the solenoid bobbin. Bushiyu 4
0 has a flange 41 formed around its upper end,
It sits around a hole 38 in the upper flux plate 31. The armature 18 is slidably attached to the armature bush 40. The armature bush 40 is made of any suitable magnetic material such as cold-rolled steel and is in motion.
8 to guide the magnetic flux from the upper magnetic flux plate 31 into the armature 18. As best seen in FIG. 3, the armature bushing 40 is formed through a rectangular inner surface 62 having rounded ends.

As shown in FIGS. 2, 4 and 5, the interior space between the coil 30 and the can 43 is filled with a suitable potting or encapsulating material 45, which materials are used to form the coil 30. Is an insulator and a sealant for protecting the inside of the solenoid from moisture and providing a good heat transfer material instead of air in the inner area of the solenoid. As shown in FIG. 3, two holes 44 are provided in the upper flux plate 31 for the injection of the sealing material 45. The solenoid assembly is placed in a fitting with appropriate pins extending through the assembly so that when the sealing material 45 is inserted into the can 43, the sealing material 45 will flow around the pins. Allow to make a hole for the bolt 49. Figure 1
And as shown in FIG. 6, the upper end cover, generally designated by numeral 48, is releasably secured to the aforementioned solenoid structure by a pair of suitable elongated bolts 49. The bolt 49 is attached to the upper end cover 4
8 through a hole (not shown) in the downward direction and then through a hole 47 (FIG. 3) in the upper flux plate 31 and then a suitable hole in the upper flange 25 of the bobbin and the lower flange 24 of the bobbin (not shown). ) And downwardly through a hole 46 in the lower flux plate 12 to threadably engage a threaded hole in the actuated valve body or device.

A suitable encapsulant material is silicone compound. As shown in FIG. 2, the solenoid 10 includes a hand-operated device 50 mounted in a stepped hole 51 formed in an axial position in the upper end cover 48. As shown in FIG. 6, the upper end cover 48 is
A pair of laterally extending conductor conduits 52 are attached. The two conduits 52 are spaced apart,
The outer edge is open. The interior 54 of the conduit 52 passes through the inner end of each conduit 52 and communicates with the coil through a pair of mating holes 53 (FIG. 2) formed through the can 43. A conductor column 55, which is connected to the coil 30 and operates, is provided in each conduit 52. A receptacle connector 56 (FIG. 2) is operably attached to each conductor post 55, and the connector 56 is operably connected to a lead wire 57. The receptacle connector 56 is
A detent member 59 is detachably fixed to an appropriate position of the conductor column 55. The detent member 59 is a spring arm that flexes downward into a detent hole 58 in the bottom wall of each conduit 52.

The solenoid 10 can be used as a straight DC solenoid when using the upper end cover 48, or can be used as a rectifying AC solenoid using conventional AC conversion means. The elongated, narrow configuration of the rectangular solenoid 10 provides advantages over conventional solenoids having a round core configuration. Solenoid 10 can be used when only a small space is available for mounting the solenoid. For example, solenoid 1
The 0 can be made to a very small width, eg 10 mm wide, for use where space is limited such that a wide solenoid cannot be used. The rectangular cross-section of the core area of the solenoid 10 optimizes the cross-sectional area and surface area of the iron core, and the circumference of the solenoid bobbin tubular body 23 around which the magnet wire for the coil 30 is wound is a circular solenoid bobbin tubular body. Since a solenoid structure having a longer length than that of the periphery can be formed, the resistance for the coil 30 to obtain the optimum ampere-turn number becomes large. With this coil construction, the coil 30 is used to create a very efficient low wattage, short stroke solenoid.
The amount of magnetic force that can be created by is significantly increased. Can 4
The spread of 3 throughout the coil 30 and the thin cross section provides a more efficient solenoid. Solenoid 1
The above-mentioned structure of 0 provides an efficient magnetic flux path, and in this structure, the upper magnetic flux plate 31 and the lower magnetic flux plate 12 are above the rod 43,
These parts, the bush 4
0, the magnetic flux path through the pole piece 13 and the armature 18 is made efficient. The encapsulation material 45 electrically insulates the coils from their inside and outside from the magnetic components and mounting screws 49. The rounded surfaces of the lower end 20 and the upper end 21 of the armature 18 are flat and curved along the long axes of both ends of the rectangular armature 18.

[Brief description of drawings]

1 is a plan view of a solenoid made in accordance with the principles of the present invention.

2 is a vertical cross-sectional view of the solenoid shown in FIG. 1 taken along line 2-2 of FIG. 1 and viewed in the direction of the arrows.

3 is a horizontal view of the removed portion of the solenoid shown in FIG. 2 taken along line 3-3 of FIG. 2 and viewed in the direction of the arrows.

4 is a horizontal cross-sectional view of the solenoid shown in FIG. 2 taken along line 4-4 of FIG. 2 and viewed in the direction of the arrows.

5 is a horizontal cross-sectional view of the solenoid shown in FIG. 2 taken along line 5-5 of FIG. 2 and viewed in the direction of the arrows.

6 is a right side view of the solenoid shown in FIG. 1 taken along line 6-6 of FIG. 1 and viewed in the direction of the arrows.

[Explanation of symbols]

 12 bottom magnetic flux plate 13 magnetic pole piece 18 armature 22 bobbin 23 tubular body 24 integrated lower flange 25 integrated upper flange 26 core hole 30 coil 31 upper magnetic flux plate 40 armature bush 43 tubular can 45 sealing material 48 upper end cover 57 lead wire

 ─────────────────────────────────────────────────── ─── Continued Front Page (72) Inventor Richard A. Faigary 48322, Michigan, USA, West Bloomfield, Dunbrook 7291 (72) Inventor Eric P. Jansen 48843, Michigan, USA, Howell, Oak Crest Drive 967 (72) Inventor Michael E. Robert Michigan, USA 48386, Union Lake, Allen Lake Drive 111

Claims (7)

[Claims] 1. A bobbin (2) wound with a coil (30).
2), and the bobbin (22) has an armature bush (4).
0) has a core hole (26) mounted therein, an armature (18) and an armature piece (13) operably mounted in the core hole (26), and (a) the above The bobbin (22) has a tubular body (23) having a rectangular cross section and forming a core hole (26) having an upper end and a lower end, and (b) the armature bush (40) is the core hole of the bobbin. It is attached to the upper end of (26) and has a rectangular cross section. (C) The armature (18) is the armature bush (4).
0) is movably mounted and has a rectangular cross section, and (d) the pole piece (13) is fixedly mounted at the lower end of the core hole (26) of the bobbin and has a rectangular cross section. (E) The bobbin (22) includes an upper flange (25) and a lower flange (24) that are integral with the coil (30) and surround the upper and lower ends of the coil (30). (F) The upper magnetic flux plate (31) ) Is the upper flange (25)
Mounted on the bobbin, a hole having a rectangular cross section is formed, the armature (40) is mounted through the hole, and (g) the bottom flux plate (12) is integral with the pole piece (13). (H) a tubular can (43) having a rectangular cross section and having open top and bottom ends extending below said lower flange (24) of said coil (30),
Is in contact with the upper flux plate (31) and the bottom flux plate (12) and held between both flux plates; (i) the upper flux plate (31) and the lower flux plate (1)
Fastening means (3) for fixing 2) to the flange of the bobbin
2, 35) are the bobbin (22) and the magnetic flux plates (31, 1).
2) and the tubular can (43) are joined together, (j) an electrically insulating and thermally conductive sealing material for sealing is placed in the tubular can (43), and the coil (30)
(K) The solenoid (10) comprises a detachably mounted upper end cover (48). 2. The upper end cover (48) comprises electrical connection means (52-59) for operably connecting the coil (30) to a lead wire (57). The solenoid according to Item 1. 3. The rectangular bobbin core hole (26), armature bush (40), armature (18) and pole piece (13).
The solenoid according to claim 1, wherein the solenoid has rounded ends. 4. At least the bottom end (20) of the armature (18) is rounded to compensate for cocking of the armature (18) when the solenoid (10) is energized. The solenoid according to claim 3, which is formed with a surface. 5. A method of making a solenoid (10), comprising: (a) a tubular body (2) having an outer surface with a rectangular cross section.
3) and a similarly shaped core hole with upper and lower ends (2
6), wherein the bobbin tubular body comprises a bobbin (10) having an integral upper flange (25) and an integral lower flange (24), and (b) a solenoid coil (30) having a rectangular cross section. ) Winding a magnet wire around the rectangular outer surface of the bobbin (22) to provide (b), (c) having a rectangular cross section at the lower end of the core hole (26),
Attaching a pole piece (13) having an integral bottom flux plate (12), (d) covering the bobbin (22) and having a rectangular cross section, the lower end of the bobbin resting on the bottom flux plate (12) Attaching the tubular can (43), and (e) contacting an upper flux plate (31) having a rectangular hole in the axial direction on the upper flange (25) of the bobbin and on the upper side of the tubular can (43). And (f) the upper magnetic flux plate (31) and the lower magnetic flux plate (1)
The bottom flux plate (12) for securely holding the tubular can between it and the lower flange (2) of the bobbin.
4) fixing and fixing the upper flux plate (31) to the upper flange (25) of the bobbin; and (g) attaching the armature bushing (40) having a rectangular cross section to the upper flux plate (31). Through the rectangular hole in the core hole (2
6) Sliding into the upper end of step 6),
(H) slidably mounting the armature (18) through the rectangular hole in the upper flux plate (31) into the rectangular armature bush (40); (i) the solenoid coil (30) To seal and electrically insulate the upper and lower flux plates (31, 12), tubular cans (43) and any solenoid mounting screws (49) used to attach the solenoid to the actuated device. Injecting an electrically insulating and heat-dissipating sealing material (45) for sealing into the tubular can (43). 6. The upper and lower flux plates (31, 12)
6. The method for manufacturing a solenoid according to claim 5, including the step of providing the rectangular hole, the armature bush (40), and the core hole (26) having rounded ends. 7. At least the bottom end (2) of the armature (18).
8. The method for manufacturing a solenoid according to claim 7, further comprising the step of providing a rounded surface in 0).